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

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F-32

F-32

TROUBLESHOOTING & REPAIR

POCKET AMPTROL CIRCUIT TEST (continued)

FIGURE F.21 – T3 TRANSFORMER AND LEADS (POCKET AMPTROL)

TRANSFORMER

T3

POCKET

AMTROL

TEST PROCEDURE

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1.Remove input power to the R3R machine.

2.Using the ohmmeter, check the resistance from one probe to the other probe at the Pocket Amptrol. Normal resistance is 700 ohms when the dial is at the “1” position. When the dial is rotated toward the “10” posi- tion, the resistance from probe to probe should decrease to approximately 200 ohms.

If the measured resistance is not correct, the Pocket Amptrol may be faulty.

3.Using the 5/16” nut driver, lower the front panel and locate the Pocket Amptrol trans- former T3 inside the control box compart- ment. See Figure F.21.

NOTE: If the machine is equipped with a polari- ty switch, the switch handle will have to be removed using a 1/8” Allen type wrench.

WARNING

Electric Shock can kill.

• With the input power on, there are high voltages inside the machine. Do not reach into the machine or touch any internal part of the machine while the power is on.

4.Apply the correct input power to the machine.

5.Check the T3 primary voltage at leads #201A to 203A. See Figure F.21. Normal voltage is approximately 120VAC. If the primary volt- age is missing or low, check the leads and associated connections.

6.Check the T3 secondary voltages at plug P7 located on the Pocket Amptrol board. See

Figure F.22.

Check pin 1 (green lead) to pin 2 (yellow lead). Normal is approximately 12VAC.

Check pin 3 (green lead) to pin 2 (yellow lead). Normal is approximately 12VAC.

If the correct primary voltage is applied to the T3 transformer and either of the secondary voltages are missing or low, the T3 trans- former may be faulty.

7.Turn off the R3R machine.

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 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 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 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 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