Lincoln Electric R3R-500, R3R-300 service manual SCR/Diode

Page 39

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F-5

F-5

 

TROUBLESHOOTING & REPAIR

 

TROUBLESHOOTING GUIDE

Observe Safety Guidelines

 

 

detailed in the beginning of this manual.

PROBLEMS

POSSIBLE AREAS OF

 

RECOMMENDED

 

 

(SYMPTOMS)

MISADJUSTMENT(S)

 

COURSE OF ACTION

 

 

 

 

 

 

 

 

 

 

 

OUTPUT PROBLEMS

 

 

 

 

 

 

 

The machine is dead – no output –

1. If the amber thermal protection

1. Check the leads and connec-

no fan. The input contactor does

light is on, the primary or sec-

 

tions between the thermostats,

not operate. The amber thermal

ondary thermostat is

open.

 

the input contactor (1CR) and

protection light is on. The pilot

Allow the machine to cool.

 

the power switch (SW1).

See

light is on.

Check the fan motor for proper

 

the Wiring Diagram.

 

 

 

operation. Make sure all case

2.

One of

the

(normally

closed)

 

openings are free for proper cir-

 

 

thermostats may be faulty.

 

 

culation of air. Operate the

 

 

 

 

 

 

 

 

 

 

 

machine at rated current and

 

 

 

 

 

 

 

 

duty cycle.

 

 

 

 

 

 

 

 

 

 

 

The input contactor (CR1) chatters.

1. Make certain the three-phase

1. Perform the Input Contactor

 

input voltage matches the rat-

 

Test.

 

 

 

 

 

 

ing plate and the reconnect

 

 

 

 

 

 

 

 

panel.

 

 

 

 

 

 

 

 

 

 

 

The machine has high welding out-

1. If the remote control is being

1. Check the Output Control

put and no control.

used, set the output control

 

Switch (SW2) and the Dial

 

switch (SW2) to the Machine or

 

Selector

Switch

(SW3)

and

 

Local position and control the

 

associated

wiring. See

the

 

weld output with the machine

 

Wiring Diagram.

 

 

 

 

Output Control (R1).

If the

2.

Check

the

feedback leads

 

problem is resolved, check the

 

 

#205, #206, #204 and #225 for

 

remote control unit and associ-

 

 

 

loose or faulty connections.

 

 

ated cable leads. If the Pocket

 

 

 

 

 

 

 

 

 

 

 

Amptrol option is being used,

3.

Perform

the

SCR/Diode

 

the Pocket Amptrol circuit may

 

Rectifier Bridge Test.

 

 

 

be faulty.

 

4. If the Pocket Amptrol is not

 

 

 

 

 

 

 

functioning

properly,

perform

 

 

 

 

the Pocket

Amptrol

Circuit

 

 

 

 

Test.

 

 

 

 

 

 

 

 

5. The control board may be

 

 

 

 

faulty. Replace.

 

 

 

 

 

 

 

 

 

 

 

 

 

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

Image 39
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 Tilting Safety PrecautionsSelect Suitable Location LiftingInput 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 Recommended Processes Design Features and AdvantagesOperation General DescriptionFigure B.1 Case Front Controls Controls and SettingsOperation Operating Steps Welding OperationTable of Contents Accessories Section Field Installed Options AccessoriesOPTIONS/ACCESSORIES Factory 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 MachineWelding Output Load Test Retest After Repair R3RInput Idle Amps and Watts Open Circuit VoltagesWelding 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