Contents
Main
SVM139-A
June 1998
Safety Depends on You
IDEALARC R3R-300, -400 and -500
i i
FOR ENGINE powered equipment.
WARNING
ELECTRIC AND MAGNETIC FIELDS may be dangerous
ii ii
IDEALARC R3R
ARC RAYS can burn.
ELECTRIC SHOCK can kill.
FUMES AND GASES can be dangerous.
iii iii
FOR ELECTRICALLY powered equipment.
CYLINDER may explode if damaged.
WELDING SPARKS can cause fire or explosion.
iv iv
PRCAUTIONS DE SRET
PRCAUTIONS DE SRET POUR LES MACHINES SOUDER TRANSFOR- MATEUR ET REDRESSEUR
MASTER TABLE OF CONTENTS FOR ALL SECTIONS
- INSTALLATION SECTION -
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SAFETY PRECAUTIONS
SELECT SUITABLE LOCATION
LIFTING
TILTING
STACKING
INPUT CONNECTIONS
GROUND CONNECTION
INPUT SUPPLY CONNECTIONS
INPUT WIRE AND FUSE SIZE
A-8 A-8
{
L2
{
INPUT
GND H3
FIGURE A.3 - INPUT CONNECTION DIAGRAM FOR 208, 208/230 and 230/460 VOLTS AC, 50/60 HZ
IMPORTANT: CHANGE LINK POSITIONS AND PILOT TRANSFORMER CONNECTIONS.
OUTPUT CONNECTIONS (STICK, TIG, AIR/CARBON ARC CUTTING)
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- OPERATION SECTION -
OPERATING INSTRUCTIONS
SAFETY INSTRUCTIONS
GENERAL DESCRIPTION
RECOMMENDED PROCESSES
DESIGN FEATURES AND ADVANTAGES
WELDING CAPABILITY
CONTROLS AND SETTINGS
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WELDING OPERATION
OPERATING STEPS
- ACCESSORIES SECTION -
ACCESSORIES
OPTIONS/ACCESSORIES
FACTORY INSTALLED OPTIONS
FIELD INSTALLED OPTIONS
TIG WELDING OPTIONS
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MAINTENANCE
SAFETY PRECAUTIONS
ROUTINE AND PERIODIC MAINTENANCE
MAINTENANCE
D-3 D-3
FIGURE D.1 GENERAL COMPONENT LOCATIONS
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Section E-1 Section E-1
- THEORY OF OPERATION SECTION -
FIGURE E.1 IDEALARC R3R BLOCK LOGIC DIAGRAM
GENERAL DESCRIPTION
INPUT LINE VOLTAGE, CONTACTOR AND MAIN TRANSFORMER
OUTPUT RECTIFICATION, CONTROL, AND FEEDBACK
E-4 E-4
FIGURE E.4 OPTIONAL POLARITY SWITCH AND POCKET AMPTROL CIRCUITS
OPTIONAL POLARITY SWITCH AND POCKET AMPTROL CIRCUITS
PROTECTIVE DEVICES AND CIRCUITS
SCR OPERATION
- TROUBLESHOOTING & REPAIR SECTION -
HOW TO USE TROUBLESHOOTING GUIDE
PC BOARD TROUBLESHOOTING PROCEDURES
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TROUBLESHOOTING GUIDE
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WELDING PROBLEMS
INPUT CONTACTOR TEST (FOR MODELS EQUIPPED WITH AC COIL ON INPUT CONTACTOR)
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TEST FOR CONTACT CONTINUITY
REMOVED)
INPUT CONTACTOR TEST (FOR R3R 300 EQUIPPED WITH DC COIL ON INPUT CONTACTOR)
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TEST FOR CONTACT CONTINUITY
REMOVED)
CONTROL TRANSFORMER (T2) VOLTAGE TEST
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CONTROL TRANSFORMER (T2) VOLTAGE TEST (continued)
MAIN TRANSFORMER (T1) VOLTAGE TEST
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PHASE ANGLE WINDING TEST
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STATIC SCR/DIODE RECTIFIER BRIDGE TEST
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STATIC SCR/DIODE RECTIFIER BRIDGE TEST(continued)
STATIC SCR/DIODE RECTIFIER BRIDGE TEST (continued)
ACTIVE SCR TEST
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ACTIVE SCR TEST (continued)
POCKET AMPTROL CIRCUIT TEST
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F-34 F-34
FIGURE F.23 SENSING RESISTOR R4
R4 SENSING RESISTOR
FIGURE F.24 POCKET AMPTROL SIMPLIFIED DRAWING
NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM
MAXIMUM OUTPUT SETTING NO LOAD
TYPICAL OUTPUT VOLTAGE WAVEFORM MACHINE LOADED
TYPICAL SCR GATE VOLTAGE WAVEFORM
MAXIMUM OUTPUT SETTING NO LOAD
ABNORMAL OUTPUT VOLTAGE WAVEFORM
ONE OUTPUT SCR NOT FUNCTIONING
INPUT CONTACTOR (CR1) CLEANING/REPLACEMENT
INPUT CONTACTOR (CR1) CLEANING/REPLACEMENT (continued)
CLEANING PROCEDURE
CONTACTOR REPLACEMENT
FAN MOTOR AND BLADE REMOVAL AND REPLACEMENT
FAN MOTOR AND BLADE REMOVAL AND REPLACEMENT (continued)
SCR/DIODE RECTIFIER ASSEMBLY REMOVAL AND REPLACEMENT
SCR/DIODE RECTIFICER ASSEMBLY REMOVAL AND REPLACEMENT (continued)
TROUBLESHOOTING
REASSEMBLY
SCR/DIODE RECTIFICER ASSEMBLY REMOVAL AND REPLACEMENT (continued)
SCR REMOVAL AND REPLACEMENT
SPECIAL INSTRUCTIONS
PROCEDURE FOR THE 1/2 INCH WIDE SPRING
CLAMPING PROCEDURE FOR 1/4-28 CAP SCREWS
FOR 1/4-20 CAP SCREWS
PROCEDURE FOR THE 5/8 INCH WIDE SPRING
CLAMPING PROCEDURE FOR 1/4-28 CAP SCREWS
AFTER REPLACING THE SCRs
FOR 1/4-20 CAP SCREWS
MOUNTING OF STUD TYPE DIODES TO ALUMINUM HEAT SINKS
MOUNTING OF STUD TYPE DIODES TO ALUMINUM HEAT SINKS (continued)
MAIN TRANSFORMER REMOVAL AND REPLACEMENT
REMOVAL OF LIFT BAIL
REMOVAL OF CHOKE AND TOP IRON ASSEMBLY
REASSEMBLY OF TRANSFORMER COILS
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REASSEMBLING THE MAIN TRANSFORMER INTO THE MACHINE
REASSEMBLE THE LIFT BAIL
RETEST AFTER REPAIR (R3R 300)
RETEST AFTER REPAIR (R3R 400)
RETEST AFTER REPAIR (R3R 500)
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G-3
-
INPUT CONTACTOR BRIDGE
TP1 TRANSIENT PROTECTOR
D8
ICR INPUT STARTER
-
COLORS
SINGLE, 346V AND ABOVE (EXCEPT 380V.)
380V OR TRIPLE VOLTAGE
SINGLE, BELOW 346V OR DUAL VOLTAGE
IDEALARC R3R-400, 500-I, 500 & 600-I WIRING DIAGRAM
-
230/400V
(60 Hz ONLY)
OPTIONAL POLARITY SWITCH
G-6
Pocket Amptrol Schematic
2-82 2-82 4-82
3-8-91J
R54
G-6
G-7
Snubber Board Schematic & Layout
M15370-3
INDUCTANCE = HENRYS
ITEM REQD PART NO.
G-7
IDENTIFICATION
RESISTORS = OHMS CAPACITORS = MFD/VOLTS
SNUBBER
G-8
R3R-300 Control PC Board
IDENTIFICATION
PART No. REQD. ITEM
G-8
G-9
R3R-400 Control PC Board
IDENTIFICATION
PART No. REQD. ITEM
G-9
G-10
R3R-500 Control PC Board
IDENTIFICATION
PART No. REQD. ITEM
G-10