Lincoln Electric R3R-300, R3R-500 service manual Pocket Amptrol Circuit

Page 40

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F-6

 

 

 

 

 

 

 

 

 

F-6

 

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

 

 

 

 

 

 

 

 

The machine has minimum (or very

1. Make certain the three-phase

1.

Check the Output Control (R1)

 

low) welding output and no con-

input voltage is correct and

 

and associated wiring. See the

 

trol.

matches the rating plate and

 

Wiring Diagram.

 

 

 

 

 

the reconnect panel.

 

2. Check the Output Control

 

 

 

 

 

 

 

 

2. Make certain the Dial Control

 

Switch

(S2)

and

associated

 

 

Switch (SW3) is in the correct

 

wiring.

See

the

Wiring

 

 

position.

(Not present on R3R

 

Diagram.

 

 

 

 

 

 

300).

 

 

 

3. Perform the Main Transformer

 

 

 

 

 

 

 

 

3. If the remote control is being

 

Test.

 

 

 

 

 

 

 

used, set the Output

Control

4.

Perform

the

SCR/Diode

 

 

Switch (SW2) to the Machine or

 

 

 

Rectifier Bridge Test.

 

 

 

 

Local position and control the

 

 

 

 

 

 

 

 

 

 

 

 

 

 

weld output with the machine

5. If the Pocket Amptrol is not

 

 

Output Control (R1).

If the

 

functioning

properly,

perform

 

 

problem is resolved, check the

 

the Pocket

Amptrol

Circuit

 

 

remote control unit and associ-

 

Test.

 

 

 

 

 

 

 

ated cable leads. If the Pocket

6.

The control

board

may be

 

 

Amptrol option is being used,

 

 

 

faulty. Replace.

 

 

 

 

 

the Pocket Amptrol circuit may

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

be faulty.

 

 

 

 

 

 

 

 

 

 

 

 

4. Make sure the remote control

 

 

 

 

 

 

 

 

 

leads (#75, #76, #77) are not

 

 

 

 

 

 

 

 

 

grounded or shorted to the

 

 

 

 

 

 

 

 

 

positive

or negative

welding

 

 

 

 

 

 

 

 

 

output.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

The input contactor operates - the

1. Make certain the output control

1.

Check for loose or faulty con-

 

fan runs - the pilot light is on - but

switch (SW2) is in the Machine

 

nections on the heavy current

 

the machine has no welding out-

or Local position.

If the prob-

 

carrying leads between the out-

 

put. The open circuit voltage is not

lem is resolved, check the

 

put terminals, the shunt, the

 

present at the output terminals.

remote control and associated

 

choke

and

the

SRC/Diode

 

 

circuitry.

See

the

Wiring

 

Bridge.

See

the

Wiring

 

 

Diagram.

 

 

 

 

Diagram.

 

 

 

 

 

 

 

 

 

 

2.

Perform

the

SCR/Diode

 

 

 

 

 

 

 

Rectifier Bridge Test.

 

 

 

 

 

 

 

 

3. Perform the Main Transformer

 

 

 

 

 

 

 

Test.

 

 

 

 

 

 

 

 

 

 

 

4. 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

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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 TiltingGround Connection Input ConnectionsInput 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 OPERATIONB-2 Safety InstructionsOperating 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 Scope Settings Maximum Output Setting no LoadNormal 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 Cleaning Procedure Input Contactor CR1 CLEANING/REPLACEMENTContactor 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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