Lincoln Electric R3R-500, R3R-300 service manual Active SCR Test

Page 63

 

 

F-29

 

 

 

F-29

 

 

 

TROUBLESHOOTING & REPAIR

 

 

TOC

TOC

ACTIVE SCR TEST (continued)

 

 

Section

Master

 

 

P1 AND P3 LOCATIONS

 

G1575 LEAD LOCATIONS

 

 

 

FIGURE F.16 – CONTROL BOARD PLUG

 

FIGURE F.17 – CONTROL BOARD

 

to

to

 

 

 

 

 

 

 

 

 

R3R CONTROL

 

Return

Return

 

 

G1

 

 

 

 

 

G2

G3

 

 

 

 

 

 

G1575 - [

]

 

TOC

TOC

 

Plug P3

 

R3R CONTROL

 

Section

Master

 

G2206 - [

]

 

 

 

 

to

to

Plug P4 (Removed)

 

 

 

 

 

Return

Return

FIGURE F.18 – SNUBBER BOARD PLUG

FIGURE F.19 – RESISTOR R3 LOCATION

 

 

 

 

P5 LOCATION

 

 

 

 

Plug P5

 

 

 

 

 

RESISTOR R3

Section TOC

Master TOC

M15370-[ ] SNUBBER

 

Return to

Return to

 

TEST PROCEDURE

 

 

 

1.

Disconnect the main input supply power to

5.

Locate and remove molex plug P5 from

 

 

 

the machine.

 

snubber board M15370. See Figure F.18. If

 

 

2.

With the 5/16” nut driver, remove the case

 

the machine has snubber board M14215, it

 

 

 

will be necessary to label and disconnect

 

 

 

top and sides. Remove the screws holding

 

 

 

 

 

lead #204 from the output shunt. Be sure to

 

 

 

the front panel and lower the panel.

 

 

 

 

 

disconnect the #204 lead that runs

 

 

 

 

 

TOC

TOC

3.

Disconnect the welding cables from the

 

between the snubber board and the out-

 

welding output terminals.

 

put shunt.

 

 

 

 

Section

Master

4.

Locate and remove molex plug P4 from con-

6.

Locate and remove lead #204 from resistor

 

If the machine has control board G1575, dis-

 

R3 (40 ohms, 50 Watts). See Figure F.19.

 

 

 

trol board G2206. See Figure F.16.

 

to

to

 

connect the individual gate leads G1, G2,

 

 

Return

Return

 

and G3 and also lead #204. See Figure F.17.

 

 

 

 

 

 

 

 

 

 

IDEALARC R3R

 

Image 63
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