Lincoln Electric R3R-300, R3R-500 service manual Troubleshooting Guide, Output Problems

Page 38

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F-4

 

 

 

F-4

TROUBLESHOOTING & REPAIR

 

Observe Safety Guidelines

 

 

TROUBLESHOOTING GUIDE

detailed in the beginning of this manual.

 

 

 

 

 

 

PROBLEMS

POSSIBLE AREAS OF

RECOMMENDED

(SYMPTOMS)

MISADJUSTMENT(S)

COURSE OF ACTION

 

 

 

 

 

 

 

OUTPUT PROBLEMS

 

 

Major physical or electrical dam-

1. Contact your local authorized

1. Contact the Lincoln Electric

age is evident when the sheet

 

Lincoln Electric Field Service

Service Department, 216-383-

metal cover(s) are removed.

 

Facility for technical assistance.

2531 or 1-800-833-9353

 

 

 

(WELD).

 

 

 

 

 

Machine is dead – no output – no

1.

Make sure that the input power

1. Check the input power switch

fan – no pilot light.

 

switch is in the “ON” position.

(S1) for proper operation. See

 

2. Check the three-phase input

the Wiring Diagram.

 

 

 

 

 

voltage at the machine. Input

2. Check the leads associated

 

 

voltage must match the rating

with the power switch (S1) and

 

 

plate and the reconnect panel.

the control transformer (T2) for

 

3.

Check for blown or missing

loose or

faulty connections.

 

See the Wiring Diagram.

 

 

fuses in the input lines.

 

 

 

 

 

 

 

3. Perform the Control Trans-

 

 

 

former Test.

 

 

 

 

The machine is dead - not output -

1.

Check the three-phase voltage

1. Perform the Input Contactor

no fan - the pilot light is on. The

 

at the machine. Input voltage

Test.

 

amber temperature light is NOT on.

 

must match the rating plate and

2. Check the associated leads for

 

 

the reconnect panel.

 

 

loose or

faulty connections

 

 

 

 

2. Check for blown or missing

between

the input contactor

 

 

fuses in the input lines.

(CR1), the reconnect panel and

 

 

 

the main transformer. See the

 

 

 

Wiring Diagram.

 

 

 

3. Perform the Main Transformer

 

 

 

Test.

 

 

 

 

 

 

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.

IDEALARC 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 Lifting Safety PrecautionsSelect Suitable Location TiltingInput Supply Connections Input ConnectionsGround Connection 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 Operating Instructions Safety InstructionsOPERATIONB-2 General Description Design Features and AdvantagesOperation Recommended ProcessesControls and Settings Figure B.1 Case Front ControlsOperation Welding Operation Operating StepsTable of Contents Accessories Section Factory Installed Options AccessoriesOPTIONS/ACCESSORIES 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 Normal Open Circuit Voltage Waveform Maximum Output Setting no LoadScope Settings Typical Output Voltage Waveform Machine Loaded Typical SCR Gate Voltage Waveform CH1Abnormal Output Voltage Waveform ONE Output SCR not FunctioningInput Contactor CR1 CLEANING/REPLACEMENT Contactor Replacement Procedure Input Contactor CR1 CLEANING/REPLACEMENTCleaning 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 BailOpen Circuit Voltages Retest After Repair R3RInput Idle Amps and Watts 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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