Lincoln Electric R3R-300 service manual R3R-500 Control PC Board

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G-10

ELECTRICAL DIAGRAMS

R3R-500 Control PC Board

 

R9

R6

R8

R5

R7

R4

DZ1

C1

C12

COMMON

 

 

 

 

 

 

 

 

 

+15V

 

C11

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

D6

 

 

 

 

D14

 

 

 

 

 

D5

 

 

 

 

R90

 

 

 

 

 

D4

 

 

 

R10

D15

 

 

 

 

 

 

 

 

 

R11

 

ITEM

REQÕD.

PART No.

IDENTIFICATION

C1

1

S13490-8

50/25

C2,C30

2

S13490-35

50/15 OR 16

C3

1

S13490-4

.022/200

C4,C9

2

S16668-3

100pF/100

C5,C10,C27,C28,C29

5

S16668-5

.022/50

C6

1

S13490-62

.0033/200

C7,C12,C14,C15,C24,C25,C26

7

T11577-38

.02/600

C11

1

S13490-73

20/50

C18,C19,C20

3

T11577-62

1/200

C21,C22,C23

3

S13490-102

.047/100

C31

1

T11577-57

0.1/400

D1,D2,D3

3

T12199-2

1N4007

D4,D5,D6,D7,D8,D9,D10 ,D11,D12,D13,D14,

 

 

 

D15,D16,D17,D18,D19,D20,D21,D22,D23,

30

T12199-1

1N4004

D24,D25,D26,D27,D28 ,D29,D30,D34,D35,

D36

 

 

 

D31,D32,D33

3

T12199-4

IN4005

DZ1

1

T12702-23

1N5352B

DZ2

1

T12702-33

1N5347B

DZ3

1

T12702-9

1N5234B

DZ4

1

T12702-40

1N4735

DZ5,DZ6,DZ7,DZ8

4

T12702-29

1N4744A

G-10

R3

R2

D3

G

D2

F

D1

E

 

 

 

 

 

 

 

 

 

 

C20

R64

R97

R58

D23

C26

R88

QU3

 

 

SCR3

 

 

 

D20

 

 

 

 

 

 

 

R61

R70

R73

DZ8

R76

C23

D36

R85

C29

R79 R82

 

 

 

 

 

 

 

 

 

 

R67

 

 

 

 

 

 

 

 

 

 

C19

R63

R96

R57

D22

C25

R87

QU2

 

 

SCR2

 

 

 

D19

 

 

 

 

 

 

 

R60

R69

R72

DZ7

R75

C22

D35

R84

C28

R78 R81

 

 

 

 

 

 

 

 

 

 

R66

 

 

 

 

 

 

 

 

 

 

C18

D7

D8

D9

DZ2

C2

 

 

 

 

 

1

-10V

 

 

 

R3R-500 CONTROL G2206-

 

 

 

L

 

 

 

 

K

TP1

A H

D10

 

 

 

R52

R14

 

 

 

R13

 

 

 

 

DZ5

 

 

 

X3

 

 

 

 

R32

R33

 

R29

 

 

 

 

R34

 

D11

B

R53

D24

R28

 

 

 

OCI1

 

D17

 

 

 

 

 

 

 

OCI3

 

 

 

 

J

R25

R26

C10

R20

R19

R103

R102

R18

R17

R30

 

 

 

 

X1

 

 

D30

C

 

R12

 

R15

 

R27

 

DZ3

 

D26

 

R54

 

R46

 

R99

 

R98

 

R47

 

R101

 

R100

 

R89

 

R36

D13

R22

R41

R45

R38

R40

D12

R37

D27

R48

R50

R35

R42

Q2

Q1

OCI2

C3

C6

R91

 

R24

 

X2

C9

DZ9

1

T12702-8

1N5240B

OCI1

1

S15000-1

4N28

OCI2,OCI3

2

S15000-5

 

Q1, Q2

2

T12704-69

2N4403

QU1,QU2,QU3

3

T12707-4

 

R1,R2,R3

3

T12300-73

250 20W

R4,R5,R6,R7,R8,R9

6

T14648-12

1500 5W

R10,R29,R52

3

T10812-67

100K 1/2W

R11,R48

2

S19400-1503

 

R12,R15,R21,R27

4

S19400-2672

 

R13,R14,R32,R35,R37,R39 R80,R81,R82

9

S19400-1003

 

R16

1

T10812-62

500 1/2W

R17,R18,R47,R89

4

S19400-6813

 

R19,R20,R22,R98,R99,R100

9

S19400-1004

 

R101,R102,R103

 

 

 

R23,R65,R66,R67

4

T10812-39

50K 1/2W

R24

1

S19400-6811

 

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R62

R95

R56

D21

C24

R86

 

SCR1

TP2

R94

R49

 

C15

C7

C14

C31

C4

 

D28

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

C5

 

D29

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

QU1

 

TP3

 

 

 

 

 

 

 

R44

 

D25

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

D18

 

 

 

 

 

N

 

 

 

 

 

 

 

 

R55

R1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

R23

R16

R21

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

D16

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

R59

R68 R71

DZ6

R74

C21

D34

R83 C27 R77 R80

 

 

R93

R92

 

 

D32

 

R31

 

DZ9

 

 

 

 

 

 

 

C30

 

 

 

 

 

 

 

 

 

 

 

 

 

 

R51

 

DZ4

 

R39

 

 

 

 

 

 

 

 

R65

 

 

 

 

 

D31

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

D M

 

 

D33

 

R43

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

J4

 

 

 

J3

 

 

J2

 

 

J1

 

 

 

R25,R26,R41,R77,R78,R79

6

S19400-4751

 

R28,R45,R74,R75,R76

5

S19400-2213

 

R30,R31,R91

3

T14230-23

5.0 MEG

R33

1

S19400-5622

 

R34,R95,R96,R97

4

T14231-12

150 1/2W

R36,R42,R59,R60,R61

5

S19400-1002

 

R38

1

S19400-2673

 

R40,R83,R84,R85

4

S19400-2670

 

R43,R49

2

T14231-16

 

R44

1

S19400-1301

 

R46

1

T14231-2

10M 1/2W

R50

1

S19400-3321

 

R51

1

T14231-15

68 5W

R53

1

S19400-1501

 

R54

1

S19400-2211

 

R55

1

S19400-3323

 

R56,R57,R58,R62,R63,R64 R92,R93,R94

9

T14231-11

100 1/2W

R68,R69,R70,R71,R72,R73

6

S19400-2671

 

R86,R87,R88

3

S19400-1001

 

R90

1

T10812-41

10K 1/2W

SCR1,SCR2,SCR3

3

S15161-19

 

TP1,TP2,TP3

3

T13640-12

38J

X1,X2

2

S15128-9

 

X3

1

S15128-4

 

R92,R93,R94

 

 

 

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

R3R

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Contents Idealarc R3R-300, -400 Safety California Proposition 65 WarningsElectric Shock can kill Cylinder may explode if damaged Précautions DE Sûreté Master Table of Contents for ALL Sections Table of Contents Installation Section Installation Technical Specifications Idealarc R3R-300Technical Specifications Idealarc R3R-400 Technical Specifications Idealarc R3R-500 Safety Precautions Select Suitable LocationLifting TiltingInput Connections Ground ConnectionInput Supply Connections Input Wire and Fuse Size Figure A.2 Input Power Supply ConnectionsReconnect Procedure Input Supply Connection DiagramOutput Connections STICK, TIG, AIR/CARBON ARC Cutting Return to SectionIdealarc R3R Table of Contents Operation Section Safety Instructions OPERATIONB-2Operating Instructions Design Features and Advantages OperationGeneral Description Recommended ProcessesControls and Settings Figure B.1 Case Front ControlsOperation Welding Operation Operating StepsTable of Contents Accessories Section Accessories OPTIONS/ACCESSORIESFactory Installed Options Field Installed OptionsTable of Contents Maintenance Section Maintenance Routine and Periodic MaintenanceFigure D.1 General Component Locations Idealarc R3R Table of Contents Theory of Operation Section Theory of Operation Input Line Voltage Contactor and Main TransformerOutput Rectification CONTROL, and Feedback Figure E.3 Output RECTIFICATION, CONTROL, and FeedbackOptional Polarity Switch and Pocket Amptrol Circuits Protective Devices and Circuits SCR Operation Figure E.5 SCR OperationTable of Contents Troubleshooting & Repair Section Troubleshooting & Repair HOW to USE Troubleshooting GuidePC Board Troubleshooting Procedures PC Board can be damaged by static electricityTroubleshooting Guide Output ProblemsSCR/Diode Pocket Amptrol Circuit Input Contactor Output Problems Welding Problems Description Materials NeededTest Procedure Input Contactor TestRemoved Test for Contact Continuity Description Figure F.3 DC Coil Input Contactor Connections Removed Control Transformer T2 Voltage Test Control Transformer T2 Voltage Test Figure F.5 Control Transformer and Lead LocationsTroubleshooting & Repair Main Transformer T1 Voltage Test Main Transformer T1 Voltage Test Figure F.8 Main Secondary Lead Test Points Phase Angle Winding Test Table F.1Figure F.9 Control Board G2206 Test Points Static SCR/DIODE Rectifier Bridge Test Static SCR/DIODE Rectifier Bridge Test Static SCR/DIODE Rectifier Bridge Test Figure F.13 Snubber Board M15370 Plug P5 LocationSCR Test Active SCR Test Active SCR Test Active SCR Test Figure F.20 SCR Tester Circuit and SCR ConnectionsPocket Amptrol Circuit Test Pocket Amptrol Circuit Test Figure F.21 T3 Transformer and Leads Pocket AmptrolFigure 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 Typical SCR Gate Voltage Waveform CH1Abnormal Output Voltage Waveform ONE Output SCR not FunctioningInput Contactor CR1 CLEANING/REPLACEMENT Input Contactor CR1 CLEANING/REPLACEMENT Cleaning ProcedureContactor Replacement Procedure FAN Motor and Blade Removal and Replacement FAN Motor and Blade Removal and Replacement ProcedureSCR/DIODE Rectifier Assembly Removal and Replacement SCR/DIODE Rectificer Assembly Removal and ReplacementTroubleshooting ReassemblySCR Removal and Replacement SCR Removal and Replacement Special InstructionsProcedure for the 1/2 Inch Wide Spring Figure F.29 1/2 Wide Leaf SpringClamping Procedure For 1/4-28 CAP Screws Clamping Procedure For 1/4-20 CAP ScrewsProcedure for Inch Wide SpringAfter Replacing the SCRs Mounting of Stud Type Diodes to Aluminum Heat Sinks Mounting of Stud Type Diodes to Aluminum Heat SinksMain Transformer Removal and Replacement Main Transformer Removal & Replacement Removal of Lift BailRemoval of Choke and TOP Iron Assembly Figure F.34 Choke RemovalReassembly of Transformer Coils Figure F.35 Epoxy MIX Application AreasFigure F.36 Coil Lead Placement Figure F.38 Secondary Lead Trim and Weld Detail Reassembling the Main Transformer Into the Machine Reassemble the Lift BailRetest After Repair R3R Input Idle Amps and WattsOpen 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
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