Lincoln Electric R3R-500, R3R-300 service manual Snubber Board Schematic & Layout

Page 105

TOC

TOC

G-7

ELECTRICAL DIAGRAMS

G-7

Snubber Board Schematic & Layout

 

 

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Return to Master

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TP4

320V

160J

 

TP6C5TP5 150V.05320V 80J600V160J

 

 

 

 

 

 

 

 

 

FILENAME: S19687 3EA

IDEALARCDC400

SNUBBERSCHEMATIC

 

19687

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

S

 

 

 

 

600V

 

 

 

 

 

RESISTORS = OHMS,1/4 WATT (UNLESS OTHERWISE SPECIFIED)

DIODES = 1 AMP/400 VOLT (UNLESS OTHERWISE SPECIFIED)

OP AMPS = LM124 (UNLESS OTHERWISE SPECIFIED)

 

 

SHT. NO.

 

223220225224

41576

J5

C4 .05

 

 

 

ELECTRICAL SYMBOLS PER E1537

 

= COMMON CONNECTION

EQUIP. THE LINCOLN ELECTRIC CO.TYPE

 

SUBJECT

 

 

SUPÕSÕDÕG.

 

J5

 

 

GENERAL INFORMATION

CAPACITORS = MFD/VOLTS

 

 

 

 

 

 

J5J5J5

 

 

 

 

 

 

CHK.

 

 

 

CLEVELAND, OHIO U.S.A.

NONE

 

26-90

 

 

 

SCALE

3-

 

 

 

DATE

 

 

 

MCW

 

 

 

DR.

 

 

 

 

C3

.68

400V

 

5W

10

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

R3

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

TP2

130V

38J

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

222

3

J5

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

C2

.68

400V

 

5W

10

 

TP3

130V 38J

 

 

 

 

 

 

 

ChÕge.Sht.No.

3-8-91G

12-20-96F

 

 

 

 

 

 

 

 

R2

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

221204

28

J5J5

 

 

 

 

 

10

130V

38J

 

 

 

 

 

 

 

 

UNLESS OTHERWISE SPECIFIED TOLERANCE

 

 

 

 

 

 

 

 

 

 

 

 

R1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

19687S

C1

.68

400V

 

5W

TP1

 

 

 

 

 

 

 

 

ON HOLES SIZES PER2056E-

ON 2 PLACE DECIMALS ISO2+.

ON 3 PLACE DECIMALS ISOO2+.

ON ALL ANGLES IS + .5 DEGREEOF A

MATERIAL TOLERANCE ("t")AGREETO

WITH PUBLISHEDSTANDARDS

REQD PART NO. IDENTIFICATION

ITEM

SNUBBER

J5

 

TP1

 

R2

 

 

R3

TP2

TP3

 

C3

 

R1

C2

C1

TP4

C4

C5

TP5

TP6

M15370-3

CAPACITORS = MFD/VOLTS RESISTORS = OHMS INDUCTANCE = HENRYS

NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not

 

available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result

R3R

in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.

 

Image 105
Contents Idealarc R3R-300, -400 California Proposition 65 Warnings SafetyElectric Shock can kill Cylinder may explode if damaged Précautions DE Sûreté Master Table of Contents for ALL Sections Table of Contents Installation Section Technical Specifications Idealarc R3R-300 InstallationTechnical Specifications Idealarc R3R-400 Technical Specifications Idealarc R3R-500 Select Suitable Location Safety PrecautionsLifting TiltingInput Connections Ground ConnectionInput Supply Connections Figure A.2 Input Power Supply Connections Input Wire and Fuse SizeInput Supply Connection Diagram Reconnect ProcedureReturn to Section Output Connections STICK, TIG, AIR/CARBON ARC CuttingIdealarc R3R Table of Contents Operation Section Safety Instructions OPERATIONB-2Operating Instructions Operation Design Features and AdvantagesGeneral Description Recommended ProcessesFigure B.1 Case Front Controls Controls and SettingsOperation Operating Steps Welding OperationTable of Contents Accessories Section OPTIONS/ACCESSORIES AccessoriesFactory Installed Options Field Installed OptionsTable of Contents Maintenance Section Routine and Periodic Maintenance MaintenanceFigure D.1 General Component Locations Idealarc R3R Table of Contents Theory of Operation Section Input Line Voltage Contactor and Main Transformer Theory of OperationFigure E.3 Output RECTIFICATION, CONTROL, and Feedback Output Rectification CONTROL, and FeedbackOptional Polarity Switch and Pocket Amptrol Circuits Protective Devices and Circuits Figure E.5 SCR Operation SCR OperationTable of Contents Troubleshooting & Repair Section HOW to USE Troubleshooting Guide Troubleshooting & RepairPC Board can be damaged by static electricity PC Board Troubleshooting ProceduresOutput Problems Troubleshooting GuideSCR/Diode Pocket Amptrol Circuit Input Contactor Output Problems Welding Problems Materials Needed DescriptionInput Contactor Test Test ProcedureRemoved Test for Contact Continuity Description Figure F.3 DC Coil Input Contactor Connections Removed Control Transformer T2 Voltage Test Figure F.5 Control Transformer and Lead Locations Control Transformer T2 Voltage TestTroubleshooting & Repair Main Transformer T1 Voltage Test Main Transformer T1 Voltage Test Figure F.8 Main Secondary Lead Test Points Table F.1 Phase Angle Winding TestFigure F.9 Control Board G2206 Test Points Static SCR/DIODE Rectifier Bridge Test Static SCR/DIODE Rectifier Bridge Test Figure F.13 Snubber Board M15370 Plug P5 Location Static SCR/DIODE Rectifier Bridge TestSCR Test Active SCR Test Active SCR Test Figure F.20 SCR Tester Circuit and SCR Connections Active SCR TestPocket Amptrol Circuit Test Figure F.21 T3 Transformer and Leads Pocket Amptrol Pocket Amptrol Circuit TestFigure F.22 Pocket Amptrol Board Plug P6 and P7 Location Figure F.23 Sensing Resistor R4 Maximum Output Setting no Load Scope SettingsNormal Open Circuit Voltage Waveform Typical Output Voltage Waveform Machine Loaded CH1 Typical SCR Gate Voltage WaveformONE Output SCR not Functioning Abnormal Output Voltage WaveformInput Contactor CR1 CLEANING/REPLACEMENT Input Contactor CR1 CLEANING/REPLACEMENT Cleaning ProcedureContactor Replacement Procedure FAN Motor and Blade Removal and Replacement Procedure FAN Motor and Blade Removal and ReplacementSCR/DIODE Rectifier Assembly Removal and Replacement Removal and Replacement SCR/DIODE Rectificer AssemblyReassembly TroubleshootingSCR Removal and Replacement Special Instructions SCR Removal and ReplacementFigure F.29 1/2 Wide Leaf Spring Procedure for the 1/2 Inch Wide SpringClamping Procedure For 1/4-20 CAP Screws Clamping Procedure For 1/4-28 CAP ScrewsInch Wide Spring Procedure forAfter Replacing the SCRs Mounting of Stud Type Diodes to Aluminum Heat Sinks Heat Sinks Mounting of Stud Type Diodes to AluminumMain Transformer Removal and Replacement Removal of Lift Bail Main Transformer Removal & ReplacementFigure F.34 Choke Removal Removal of Choke and TOP Iron AssemblyFigure F.35 Epoxy MIX Application Areas Reassembly of Transformer CoilsFigure F.36 Coil Lead Placement Figure F.38 Secondary Lead Trim and Weld Detail Reassemble the Lift Bail Reassembling the Main Transformer Into the MachineInput Idle Amps and Watts Retest After Repair R3ROpen Circuit Voltages Welding Output Load TestWelding Output Terminals 63/69VDC 61/66VDC Welding Output Terminals 64/72VDC 61/69VDC Idealarc R3R Electrical Diagrams Idealarc R3R Electrical Diagrams DIAGRAMSELECTRICALG-4 Idealarc R3R-400, 500-I, 500 & 600-I Wiring Diagram Pocket Amptrol Schematic Snubber Board Schematic & Layout R3R-300 Control PC Board R3R-400 Control PC Board R3R-500 Control PC Board