RETURN TO MAIN MENU Operator’s Manual IDEALARC ®R3R-300, -400 & -500 For use with machines having Code Numbers: 9534 thru 10471, 10857, 10858, 10881, 10882, 11043, 11044, 11045, 11046, 11342, 11344 Register your machine: www.lincolnelectric.com/registration Authorized Service and Distributor Locator: www.lincolnelectric.com/locator Save for future reference Date Purchased Code: (ex: 10859) Serial: (ex: U1060512345) IM409-E | Issue Date Nov-09 © Lincoln Global, Inc. All Rights Reserved.
i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. The Above For Diesel Engines The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS.
ii ii SAFETY ELECTRIC SHOCK can kill. ARC RAYS can burn. 3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards. 3.b.
iii iii SAFETY WELDING and CUTTING SPARKS can cause fire or explosion. 6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily available. 6.b.
iv SAFETY iv PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque dʼincendie dû aux étincelles. Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes: 7. Quand on ne soude pas, poser la pince à une endroit isolé de la masse.
v Thank You v for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you! CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equipment. Our challenge is to meet the needs of our customers and to exceed their expectations.
vi vi TABLE OF CONTENTS Page ____________________________________________________________________________ Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A Location and Stacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 Input Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-1 A-1 INSTALLATION LOCATION AND STACKING WARNING FALLING EQuIPMENT can cause injury. • Do not lift this machine using lift bail if it is equipped with a heavy • accessory such as trailer or gas cylinder. • Lift only with equipment of adequate lifting capacity. • be sure machine is stable when lifting. Install the welder in a dry location where there is a free circulation of air in through the front louvers and out the back of the case.
A-2 INSTALLATION A-2 OUTPUT CONNECTIONS TIG WELDING OUTPUT STUDS The R3R is shipped with proper R.F. By-pass circuitry installed to protect the control circuit when TIG welding with a Hi-Freq™ unit. To provide protection, the welder frame grounding stud must be connected to ground. With the machine off, run electrode and work cables of the appropriate sizes (see the following table) up through the rectangular holes in the machine base located below the output studs.
B-1 OPERATION WARNING ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrode with skin or wet clothing. • Insulate yourself from work and ground. • Always wear dry insulating gloves. FUMES AND GASES can be dangerous. • Keep your head out of fumes. • Use ventilation or exhaust to • remove fumes from breathing zone. WELDING SPARKS can cause fire or explosion. • Keep flammable material away. • Do not weld on containers that have held combustibles. ARC RAYS can burn.
B-2 OPERATION The solid state circuitry within the welder senses this change in probe setting and automatically resets the welding current to the new level. Each time the welder is turned off, the output goes to minimum and must be reset when the welder is turned on again. 115VAC DUPLEX RECEPTACLE AND CIRCUIT BREAKER (60 Hertz Models for Code Numbers 10857, 10858, 10881, 10882, 11043, 11044, 11045, 11046 only ) • This receptacle provides up to 15 Amps of 115VAC auxiliary power.
C-1 MAINTENANCE WARNING ELECTRIC SHOCK can kill. • Have an electrician install and service this equipment. • Turn the input power off at the fuse box before working on equipment. • Do not touch electrically hot parts. GENERAL MAINTENANCE 1. The fan motor has sealed bearings which require no service. 2. In extremely dusty locations, dirt may clog the air channels causing the welder to run hot. Blow out the welder at regular intervals. The side panels can be removed even when the machines are stacked.
D-1 TROUBLESHOOTING D-1 HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
D-2 D-2 TROUBLESHOOTING Observe all Safety Guidelines detailed througout this manual PROBLEMS (SYMPTOMS) POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION FUNCTION PROBLEMS Input contactor chatters. 1.Faulty input contactor. 2.Low line voltage. Machine input contactor does not operate. 1.Supply line fuse blown. 2.Power circuit dead. 3.Broken or loose power lead. 4.Wrong voltage. 5.Thermostats tripped. (High Temperature Warning Light should be lit.) (Welder overheated.) 6.Input contactor coil open.
D-3 D-3 TROUBLESHOOTING Observe all Safety Guidelines detailed througout this manual PROBLEMS (SYMPTOMS) POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION FUNCTION PROBLEMS Machine input contactor closes but has no or low output. Open circuit voltage should be 67 to 71 volts. 1. Electrode or work lead loose or broken. 2. Open transformer primary or secondary circuit. 3. Supply line fuse blown. 4. Input line grounded causing single phase input. 5. Input leads not connected to contactor. 6.
D-4 D-4 TROUBLESHOOTING Observe all Safety Guidelines detailed througout this manual PROBLEMS (SYMPTOMS) POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION FUNCTION PROBLEMS Machine does not have maximum output (67 to 71 volts). 1. Input fuse blown. Machine is single phased. 2. One phase of main transformer windings open. 3. Defective power bridge. Machine comes on but soon trips off while under load and High Temperature Warning Light glows. (Thermostat tripped) 1. Improper ventilation. 2.
D-5 D-5 TROUBLESHOOTING Observe all Safety Guidelines detailed througout this manual PROBLEMS (SYMPTOMS) POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION FUNCTION PROBLEMS Machine trips off when under no load or makes excessive noise like it is loaded. 1. Power bridge rectifier may have a shorted diode or SCR. 2. Short in the transformer. 3. Fan hitting vertical baffle. Variable or sluggish welding arc. 1. Poor work or electrode cable connection. 2. Current too low. 3. Welding leads too small. 4.
D-6 D-6 TROUBLESHOOTING Observe all Safety Guidelines detailed througout this manual PROBLEMS (SYMPTOMS) POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION FUNCTION PROBLEMS Current control on machine not functioning. 1. Current control switch in wrong position. 2. Current control switch defective. 3. Current control potentiometer defective. 4. Lead or connection in control circuit open. 5. Defective control or circuit boards. Optional remote current control not functioning.
IDEALARC® R3R, -300, -400, -500 If removing each gate lead one at a time changes OCV If amphenol OK, possible defective PC board. If not, clear terminal strip and leads, and also check SW2 and R1 for dirt. If resistance is OK, possible defective PC board. Check resistance of each terminal on this terminal strip to ground. Resistance must be as follows: 75-GND 2K minimum 76-GND 2K minimum 77-GND 12K minimum Possible intermittent or loose connections in control circuit.
D-8 TROUBLESHOOTING TROUBLESHOOTING PROCEDURES PROCEDURE FOR REPLACING P.C. BOARD (The P.C. Board is located behind the front control panel. Remove the nameplate screws to loosen the control panel.) When the P.C. Board is to be replaced, follow this procedure: Visually inspect P.C. Board in question. Are any of the components damaged? Is a conductor on the back side of the board damaged? 1. If there is no damage to the P.C. Board, insert a new one and see if this remedies the problem.
D-9 TROUBLESHOOTING No reading will indicate an open rheostat and a low reading will indicate a shorted or partially shorted rheostat; in either case, replace. TOGGLE SWITCH CHECK D-9 1. Wiring harness gate leads (G1, G2, G3) from gate lead connector J4 on control P.C. Board 2. AC leads X1, X2, and X3 from the anodes of the SCRs and cathodes of the diodes. 1. Turn off the machine power input. SW #1 has 115 volts across it when the input power is connected. 2.
D-10 TROUBLESHOOTING D-10 DIAGRAM 1 DIAGRAM 2 BATTERY TEST Check the batteries by shorting leads (A) and (C), then close switch SW-1. Replace batteries if voltage is less than 3 volts. SCR TEST 1. Isolate SCR to be tested by disconnecting gate leads from the terminals on the P. C. Board. (Do not remove SCR from the heat sink.) 2. Connect SCR into the test circuit as shown (A) lead to anode (C) lead to cathode and (G) lead to the gate. 4.
E-1 WIRING DIAGRAMS E-1 IDEALARC R3R-400, 500-I, 500 & 600-I WIRING DIAGRAM (Codes 9874, 9876, 9878, 9879, 9880,9884 9884, 9886, 9888, 9889, 9890, 9891, 10052, 10053, 10285, 10286, 10288, 11341, 11342 & 11344) L9376 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels.
E-2 E-2 WIRING DIAGRAMS IDEALARC R3R WIRING DIAGRAM (230/460/575 V) (FOR CANADA ONLY) TO SUPPLY LINES RECONNECT PANEL SHOWN CONNECTED FOR 230V TO GROUND PER NATIONAL ELECTRICAL CODE 13 3 H4 X2 T2 H2 L3 8 2 L2 X1 L1 H1 TAPE UP SEPARATELY TO PROVIDE AT LEAST 600 VOLTS INSULATION 14 9 H3 4 6 5 15 16 7 17 1 18 ICR TO PRIMARY COILS HIGH TEMP LIGHT A 233 FAN MOTOR ELECTRICAL SYMBOLS PER E1537 234 LEGEND 202 201 13 POCKET AMPTROL SENSING BRIDGE D7 231 235 115 V D5 D6 232 23
E-3 E-3 WIRING DIAGRAMS IDEALARC R3R WIRING DIAGRAM (230/460/575V) (FOR CANADA ONLY CODES 10857, 10858, 10881, 10882) TO SUPPLY LINES 2 1 3 1 4 2 4 1 5 2 6 5 1 6 2 7 3 H4 X2 4 H2 X1 H1 CAVITY NUMBERING SEQUENCE (COMPONENT SIDE OF BOARD) HIGH TEMP LIGHT 32 SILVER A 233 FAN MOTOR SW1 SW2 SW3 SW4 POWER SWITCH MACHINE/REMOTE SWITCH DIAL SELECTOR SWITCH OPTIONAL POLARITY SWITCH (60 Hz ONLY) 201 13 AUXILIARY COILS 66V 7 BOTTOM PRIMARY SCR AND DIODE RECTIFIER BRIDGE 231 2
E-4 E-4 WIRING DIAGRAMS IDEALARC R3R WIRING DIAGRAM (230/460/575V) (FOR CODES 11043, 11044, 11045, 11046) IDEALARC R3R WIRING DIAGRAM (230/460/575 V) 2 1 3 1 4 2 4 1 5 2 6 5 1 6 2 7 3 8 4 H4 X2 H2 X1 H1 HIGH TEMP LIGHT 32A 32 A 233 FAN MOTOR T1 T2 AUXILIARY COILS TO PRIMARY COILS 231 235 203 15 8 7 232 A 202 14 66V TAPE UP SEPARATELY TO PROVIDE AT LEAST 600 VOLTS INSULATION 66V 9 S 10 POWER SWITCH MACHINE/REMOTE SWITCH DIAL SELECTOR SWITCH OPTIONAL POLARITY S
E-5 E-5 WIRING DIAGRAMS Part No. Type M12244-7 R3R A B 32.00 15.39 C D 3092 1.44 F G 30.02±.11 33.07±.06 M12244-7 7-7-78 IDEALARC® R3R, -300, -400, -500 H .
NOTES IDEALARC® R3R, -300, -400, -500
NOTES IDEALARC® R3R, -300, -400, -500
WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENÇÃO Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection.
Keep your head out of fumes. Use ventilation or exhaust to remove Turn power off before servicing. Do not operate with panel open or Los humos fuera de la zona de res- Desconectar el cable de alimentación No operar con panel abierto o Gardez la tête à l’écart des fumées.
CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equipment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln Electric for advice or information about their use of our products. We respond to our customers based on the best information in our possession at that time.
