Lincoln Electric R3R-500, R3R-300 service manual Clamping Procedure For 1/4-28 CAP Screws

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F-49

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TROUBLESHOOTING & REPAIR

SCR REMOVAL AND REPLACEMENT (continued)

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CLAMPING PROCEDURE

FOR 1/4-28 CAP SCREWS

NOTE: This procedure can only be used with 1/4-28 cap screws.

Do not use cap screws with any other type thread or new SCR will be damaged.

Do not over tighten cap screws. The leaf spring will apply the required clamping force to the SCR.

1.Do not turn the nuts. While holding the nuts stationary, turn the cap screws only with the following procedure.

2.Tighten first cap screw 1/4 turn.

3.Tighten second cap screw 1/2 turn.

4.Tighten first cap screw 1/2 turn.

5.Tighten second cap screw 1/2 turn.

6.Tighten first cap screw 1/4 turn. Stop.

7.Assembly now has the proper clamping force.

8.Perform the Active SCR Test.

CLAMPING PROCEDURE

FOR 1/4-20 CAP SCREWS

NOTE: This procedure can only be used with 1/4-20 cap screws.

Do not use cap screws with any other type thread or new SCR will be damaged.

Do not over tighten cap screws. The leaf spring will apply the required clamping force to the SCR.

1.Do not turn the nuts. While holding the nuts stationary, turn the cap screws only with the following procedure.

2.Tighten first cap screw 1/4 turn.

3.Tighten second cap screw 1/2 turn.

4.Tighten first cap screw 1/2 turn.

5.Tighten second cap screw 1/4 turn. STOP.

6.Assembly now has the proper clamping force.

7.Perform the Active SCR Test.

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IDEALARC R3R

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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 Supply Connections Input ConnectionsGround Connection 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 Operating Instructions Safety InstructionsOPERATIONB-2 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 Normal Open Circuit Voltage Waveform Maximum Output Setting no LoadScope Settings Typical Output Voltage Waveform Machine Loaded CH1 Typical SCR Gate Voltage WaveformONE Output SCR not Functioning Abnormal Output Voltage WaveformInput Contactor CR1 CLEANING/REPLACEMENT Contactor Replacement Procedure Input Contactor CR1 CLEANING/REPLACEMENTCleaning 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 Troubleshooting SCR 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