Lincoln Electric R3R-500, R3R-300 User Manual

SVM139-A
June 1998
Safety Depends on You
Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation . . . and thoughtful operation on your part. DO NOT INSTALL,
OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READ­ING THIS MANUAL AND THE SAFETY PRECAUTIONS CON­TAINED THROUGHOUT. And,
most importantly, think before you act and be careful.
SERVICE MANUAL
World’s Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors
Sales and Service through subsidiaries and Distributors Worldwide
22801 St. Clair Ave. Cleveland, Ohio 44117-1199 U.S.A. Tel. (216) 481-8100
For use with machine code numbers 9534, 9537, 9874 and 9884
IDEALARC
®
R3R-300, -400 and -500
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
View Safety Info View Safety Info View Safety Info View Safety Info
RETURN TO MAIN INDEX
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

SAFETY

i i
IDEALARC R3R
FOR ENGINE powered equipment.
1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running.
____________________________________________________
1.b.Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors.
____________________________________________________
1.c. Do not add the fuel near an open flame weld-
ing arc or when the engine is running. Stop the engine and allow it to cool before refuel­ing to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting. Do not spill fuel when filling tank. If fuel is spilled, wipe it up and do not start engine until fumes have been eliminated.
____________________________________________________
1.d. Keep all equipment safety guards, covers
and devices in position and in good repair.Keep hands, hair, clothing and tools away from V-belts, gears, fans and all other moving parts when starting, operating or repairing equipment.
____________________________________________________
1.e. In some cases it may be necessary to remove safety guards to perform required maintenance. Remove guards only when necessary and replace them when the maintenance requiring their removal is complete. Always use the greatest care when working near moving parts.
___________________________________________________
1.f. Do not put your hands near the engine fan. Do not attempt to override the governor or idler by pushing on the throttle con­trol rods while the engine is running.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work, disconnect the spark plug wires, distributor cap or magneto wire as appropriate.
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society , P.O. Box 351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
WARNING
ELECTRIC AND MAGNETIC FIELDS may be dangerous
2.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines
2.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physician before welding.
2.c. Exposure to EMF fields in welding may have other health effects which are now not known.
2.d. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:
2.d.1.
Route the electrode and work cables together - Secure them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
2.d.5. Do not work next to welding power source.
1.h. To avoid scalding, do not remove the radiator pressure cap when the engine is hot.
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents are known to the State of California to cause can­cer, birth defects, and other reproductive harm.
The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.
The Above For Diesel Engines
The Above For Gasoline Engines
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
SAFETY
ii ii
IDEALARC R3R
ARC RAYS can burn.
4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant material to protect your skin and that of your helpers from the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammable screening and/or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal.
ELECTRIC SHOCK can kill.
3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands.
3.b. Insulate yourself from work and ground using dry insulation. Make certain the insulation is large enough to cover your full area of physical contact with work and ground.
In addition to the normal safety precautions, if welding must be performed under electrically hazardous conditions (in damp locations or while wearing wet clothing; on metal structures such as floors, gratings or scaffolds; when in cramped positions such as sitting, kneeling or lying, if there is a high risk of unavoidable or accidental contact with the workpiece or ground) use the following equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head, nozzle or semiautomatic welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical connection with the metal being welded. The connection should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical (earth) ground.
3.f.
Maintain the electrode holder, work clamp, welding cable and welding machine in good, safe operating condition. Replace damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders.
3.i. When working above floor level, use a safety belt to protect yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
FUMES AND GASES can be dangerous.
5.a.Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases.When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
welding with electrodes which require special ventilation such as stainless or hard facing (see instructions on container or MSDS) or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes, keep exposure as low as possible and below Threshold Limit Values (TLV) using local exhaust or mechanical ventilation. In confined spaces or in some circumstances, outdoors, a respirator may be required. Additional precautions are also required when welding on galvanized steel.
5.b.
Do not weld in locations near chlorinated hydrocarbon
vapors coming from degreasing, cleaning or spraying operations. The heat and rays of the arc can react with solvent vapors
to form phosgene, a highly toxic gas, and other irritating products.
5.c. Shielding gases used for arc welding can displace air and cause injury or death. Always use enough ventilation, especially in confined areas, to insure breathing air is safe.
5.d. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the material safety data sheet (MSDS) and follow your employer’s safety practices. MSDS forms are available from your welding distributor or from the manufacturer.
5.e. Also see item 1.b.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
SAFETY
iii iii
IDEALARC R3R
FOR ELECTRICALLY powered equipment.
8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment.
8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations.
8.c. Ground the equipment in accordance with the U.S. National Electrical Code and the manufacturer’s recommendations.
CYLINDER may explode if damaged.
7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely chained to an undercarriage or fixed support.
7.c. Cylinders should be located:
•Away from areas where they may be struck or subjected to
physical damage.
•A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use.
7.g. Read and follow the instructions on compressed gas cylinders, associated equipment, and CGA publication P-l, “Precautions for Safe Handling of Compressed Gases in Cylinders,” available from the Compressed Gas Association 1235 Jefferson Davis Highway, Arlington, VA 22202.
WELDING SPARKS can cause fire or explosion.
6.a.
Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
the welding sparks from starting a fire.
Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily available.
6.b. Where compressed gases are to be used at the job site, special precautions should be used to prevent hazardous situations. Refer to “Safety in Welding and Cutting” (ANSI Standard Z49.1) and the operating information for the equipment being used.
6.c. When not welding, make certain no part of the electrode circuit is touching the work or ground. Accidental contact can cause overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside. They can cause an explosion even
though
they have been “cleaned”. For information, purchase “Recommended Safe Practices for the
Preparation
for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances”, AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or welding. They may explode.
6.f.
Sparks and spatter are thrown from the welding arc. Wear oil free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes and a cap over your hair. Wear ear plugs when welding out of position or in confined places. Always wear safety glasses with side shields when in a welding area.
6.g. Connect the work cable to the work as close to the welding area as practical. Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains, crane cables or other alternate circuits. This can create fire hazards or overheat lifting chains or cables until they fail.
6.h. Also see item 1.c.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
SAFETY
iv iv
IDEALARC R3R
PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv­antes:
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter tou­jours tout contact entre les parties sous tension et la peau nue ou les vétements mouillés. Porter des gants secs et sans trous pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand
on soude dans des endroits humides, ou sur un planch­er metallique ou des grilles metalliques, principalement dans les positions assis ou couché pour lesquelles une grande partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état defonctionnement.
d. Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous ten-
sion des porte-électrodes connectés à deux machines à souder parce que la tension entre les deux pinces peut être le total de la tension à vide des deux machines.
2. Dans le cas de travail au dessus du niveau du sol, se protéger contre les chutes dans le cas ou on recoit un choc. Ne jamais enroule le câble-électrode autour de n’importe quelle partie du corps.
3. Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du rayonnement de l’arc et des projections quand on soude ou quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnementde l’arc.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflamma­bles.
4. Des gouttes de laiter en fusion sont émises de l’arc de soudage. Se protéger avec es vêtements de protection libres de l’huile, tels que les gants en cuir, chemise épaisse, pan­talons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de sécurité dans la zone de soudage. Utiliser des lunettes avec écrans lateraux dans les zones où l’on pique le laitier.
6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir ttout risque d’incendie dû étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de la masse. Un court-circuit accidental peut provoquer un échauffement et un risque d’incendie.
8. S’assurer que la masse est connectée le plus prés possible de la zone de travail qu’il est pratique de la faire. Si on place la masse sur la charpente de la construction ou d’autres endroits éloignés de la zone de travail, on augmente le risque de voir passer le courant de soudage par les chaines de levage, câbles de grue, ou atres circuits. Cela peut provoquer des risques d’incendie ou d’echauffement des chaines et des câbles jusqu’à ce qu’ils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage. Ceci est particuliérement important pour le soudage de tôles galvanisées plombées, ou cadmiées ou tout autre métal qui produit des fumées toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant d’opéerations de dégraissage, nettoyage ou pistolage. La chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs du solvant pour produire du phosgéne (gas forte­ment roxique) ou autres produits irritants.
PRÉCAUTIONS DE SÛRETÉ POUR LES MACHINES À SOUDER À TRANSFOR­MATEUR ET À REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code de l’électricité et aux recommendations du fabricant. Le dis­positif de montage ou la piece à souder doit être branché à une bonne mise à la terre.
2. Autant que possible, l’installation et l’entretien du poste seront effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la debrancher à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispostifis de sûreté à leur place.
MASTER TABLE OF CONTENTS FOR ALL SECTIONS
v v
IDEALARC R3R
Page
Safety.................................................................................................................................................i-iv
Installation.............................................................................................................................Section A
Technical Specifications .............................................................................................................A-2
Safety Precautions......................................................................................................................A-5
Select Suitable Location (Stacking, Tilting, Lifting) ....................................................................A-5
Input Connections.......................................................................................................................A-6
Reconnect Procedure .................................................................................................................A-8
Output Connections (Stick, TIG, Air/Carbon Arc Cutting)..........................................................A-9
Operation...............................................................................................................................Section B
Safety Instructions ......................................................................................................................B-2
General Description ....................................................................................................................B-3
Controls and Settings.................................................................................................................B-4
Welding Operation ......................................................................................................................B-6
Accessories...........................................................................................................................Section C
Maintenance .........................................................................................................................Section D
Safety Precautions......................................................................................................................D-2
Routine and Periodic Maintenance ............................................................................................D-2
General Component Locations...................................................................................................D-3
Theory of Operation .............................................................................................................Section E
Troubleshooting and Repair.................................................................................................Section F
How To Use Troubleshooting Guide ...........................................................................................F-2
Troubleshooting Guide ................................................................................................................F-4
Test Procedures ........................................................................................................................F-10
Oscilloscope Waveforms ..........................................................................................................F-35
Replacement Procedures..........................................................................................................F-39
Retest After Repair....................................................................................................................F-61
Electrical Diagrams..............................................................................................................Section G
Parts Manual................................................................................................................................P-206
RETURN TO MAIN INDEX
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
Section A-1 Section A-1
IDEALARC R3R
TABLE OF CONTENTS
- INSTALLATION SECTION -
Installation.............................................................................................................................Section A
Technical Specifications, Idealarc R3R-300 ...............................................................................A-2
Technical Specifications, Idealarc R3R-400 ...............................................................................A-3
Technical Specifications, Idealarc R3R-500 ...............................................................................A-4
Safety Precautions......................................................................................................................A-5
Select Suitable Location.............................................................................................................A-5
Lifting .................................................................................................................................A-5
Tilting .................................................................................................................................A-5
Stacking................................................................................................................................A-5
Input Connections.......................................................................................................................A-6
Ground Connection ..............................................................................................................A-6
Input Supply Connections....................................................................................................A-6
Input Wire and Fuse Size ...............................................................................................A-7
Reconnect Procedure .................................................................................................................A-8
Output Connections (Stick, TIG, Air/Carbon Arc).......................................................................A-9
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
INSTALLATION
A-2 A-2
IDEALARC R3R
TECHNICAL SPECIFICATIONS - IDEALARC R3R-300
INPUT - THREE PHASE ONLY
Standard Voltage Input Current @ Rated Output
230V 56A 460V 28A
RATED OUTPUT
Duty Cycle Amps Volts at Rated Amps
100% 230 29
60% 300 32 35% 375 35
OUTPUT
Current Range Maximum Open Circuit Voltage
45 to 375 Amps 67 VDC
RECOMMENDED INPUT WIRE AND FUSE SIZES AT 60% DUTY CYCLE
Input Wire Size Ground Wire Size
Input Voltage / Fuse Input Ampere Type 75°C Type 75°C
Frequency (Super Lag) Rating on Copper Wire in Copper Ground
or Breaker Size Nameplate Conduit Wire in Conduit
Volts/Hz AWG (IEC) Sizes AWG (IEC) Sizes
230/60 80 56 8 (10 mm2) 8 (10 mm2) 460/60 40 28 10 (6 mm2) 10 (6 mm2)
PHYSICAL DIMENSIONS
Height Width Depth Weight
27.50 in. 22.25 in. 33.10 in. 350 lbs.
(700 mm) (565 mm) (840 mm) (159 kg)
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
INSTALLATION
A-3 A-3
IDEALARC R3R
TECHNICAL SPECIFICATIONS - IDEALARC R3R-400
INPUT - THREE PHASE ONLY
Standard Voltage Input Current @ Rated Output
230V 74A 460V 37A
RATED OUTPUT
Duty Cycle Amps Volts at Rated Amps
100% 300 32
60% 400 36 35% 500 40
OUTPUT
Current Range Maximum Open Circuit Voltage
60 to 500 Amps 67 VDC
RECOMMENDED INPUT WIRE AND FUSE SIZES AT 60% DUTY CYCLE
Input Wire Size Ground Wire Size
Input Voltage / Fuse Input Ampere Type 75°C Type 75°C
Frequency (Super Lag) Rating on Copper Wire in Copper Ground
or Breaker Size Nameplate Conduit Wire in Conduit
Volts/Hz AWG (IEC) Sizes AWG (IEC) Sizes
230/60 125 74 6 (16 mm2) 6 (16 mm2) 460/60 60 37 10 (6 mm2) 10 (6 mm2)
PHYSICAL DIMENSIONS
Height Width Depth Weight
27.50 in. 22.25 in. 33.10 in. 402 lbs.
(700 mm) (565 mm) (840 mm) (182 kg)
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
INSTALLATION
A-4 A-4
IDEALARC R3R
TECHNICAL SPECIFICATIONS - IDEALARC R3R-500
INPUT - THREE PHASE ONLY
Standard Voltage Input Current @ Rated Output
230V 88A 460V 44A
RATED OUTPUT
Duty Cycle Amps Volts at Rated Amps
100% 600 44
60% 500 40 35% 375 35
OUTPUT
Current Range Maximum Open Circuit Voltage
75 to 625 Amps 67 VDC
RECOMMENDED INPUT WIRE AND FUSE SIZES AT 60% DUTY CYCLE
Input Wire Size Ground Wire Size
Input Voltage / Fuse Input Ampere Type 75°C Type 75°C
Frequency (Super Lag) Rating on Copper Wire in Copper Ground
or Breaker Size Nameplate Conduit Wire in Conduit
Volts/Hz AWG (IEC) Sizes AWG (IEC) Sizes
230/60 150 88 4 (25 mm2) 6 (16 mm2) 460/60 70 44 8 (10 mm2) 8 (10 mm2)
PHYSICAL DIMENSIONS
Height Width Depth Weight
27.50 in. 22.25 in. 33.10 in. 446 lbs.
(700 mm) (565 mm) (840 mm) (202 kg)
Read this entire installation section before you start installation.
SAFETY PRECAUTIONS
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or electrodes with your skin or wet clothing.
• Insulate yourself from the work and ground.
• Always wear dry insulating gloves.
Only qualified personnel should install, use, or ser­vice this equipment.
SELECT SUITABLE LOCATION
Place the Idealarc R3R in a dry location where clean cooling air can flow freely in through the front louvers and out through the rear louvers. Keep dust, dirt, and other foreign materials that can be drawn into the machine to a minimum. Failure to observe these pre­cautions can lead to excessive operating temperatures and nuisance shut-downs.
LIFTING
FALLING EQUIPMENT can cause injury.
• Do not lift this machine using the lift bail if it is equipped with a heavy accessory such as a trailer or a gas cylinder.
• Lift only with equipment of adequate lifting capacity.
• Be sure the machine is stable when lifting.
• Do not stack more than three high.
• Do not stack the R3R on top of any other machine.
A permanent lift bail is located at the top of the machine, positioned at the center of gravity for stable lifting. R3R weights are as follows:
R3R-300 350 pounds (159 kilograms) R3R-400 402 pounds (182 kilograms) R3R-500 446 pounds (202 kilograms)
TILTING
Place the machine on a secure, level surface. Any sur­faces you place it on other than the ground must be firm, non-skid, and structurally sound.
STACKING
Idealarc R3Rs may be stacked three high. The bottom machine must be on a stable, hard, level surface capa­ble of supporting the weight of up to three machines (1350 pounds/1608 kilograms). Be sure that the two pins in the roof of the bottom machine fit into the holes in the base of the machine above. The lift bail is posi­tioned so that it fits without interference under the base of the second machine.
Do not stack heavier machines on top of lighter machines. For example, do not place an R3R-500 on top of an R3R-400 or an R3R-400 on top of an R3R-300.
INSTALLATION
A-5 A-5
IDEALARC R3R
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
WARNING
WARNING
INPUT CONNECTIONS
ELECTRIC SHOCK can kill.
• Have a qualified electrician install and service this equip­ment.
• Turn the input power off at the fuse box before working on this equipment.
• Do not touch electrically hot parts.
• Insulate yourself from the work and ground.
• Always wear dry insulating gloves.
Be sure the voltage, phase, and frequency of the input power is as specified on the rating plate, located on the case front control panel. See Figure A.1. Also see appropriate Technical Specifications page for input and ground wire requirements.
Input supply line ground lead entry is through a hole located at the top of the case rear panel. A removable door covers the input connection box, which contains the input contactor (CR1) and reconnect panel assem­bly for multiple voltage machines.
GROUND CONNECTION
The welder frame must be grounded. A stud marked with the symbol located on the floor of the input box is provided for this purpose. See the U.S. National Electrical Code for details on proper ground­ing methods.
INPUT SUPPLY CONNECTIONS
Input power is connected to the three line terminals on the input contactor. See Figure A.2. Be sure the volt­age, phase, and frequency of the input power is as specified on the rating plate.
INSTALLATION
A-6 A-6
IDEALARC R3R
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
FIGURE A.1 – RATING PLATE LOCATION
1
WARNING
1. RATING PLATE
Have a qualified electrician connect the input power leads to the L1, L2, and L3 terminals of the input con­tactor. Follow all national and local electrical codes. Use a three-phase line. Refer to the connection dia­gram located on the inside of the access panel cover for proper input voltage connection. Also see Figure
A.3.
INPUT WIRE AND FUSE SIZE
Fuse the input circuit with super lag fuses or delay type circuit breakers as recommended on the Technical Specifications page. Choose an input and grounding wire size according to local or national codes; also see the appropriate Technical Specifications page. Using fuses or circuit breakers smaller than recommended may result in “nuisance” shut-offs from welder inrush currents, even if you are not welding at high currents.
INSTALLATION
A-7 A-7
IDEALARC R3R
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
FIGURE A.2 – INPUT POWER SUPPLY CONNECTIONS
1. INPUT SUPPLY LINE
2. INPUT CONTACTOR CR1
3. RECONNECT PANEL
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
INSTALLATION
A-8 A-8
IDEALARC R3R
FIGURE A.3 - INPUT CONNECTION DIAGRAM FOR 208, 208/230 and 230/460 VOLTS AC, 50/60 HZ
THE LINCOLN ELECTRIC CO., CLEVELAND OHIO U.S.A.
1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX.
CONNECTION FOR LOWEST RATING PLATE VOLTAGE, 50 OR 60 HZ.
CONNECTION FOR HIGHEST RATING PLATE VOLTAGE, 50 OR 60 HZ.
CODES.
4. CONNECT TERMINAL MARKED TO GROUND PER LOCAL AND NATIONAL ELECTRIC
LEAST 600 VOLT INSULATION.
2. DISCONNECT AND INSULATE THE H2 LEAD TERMINAL WITH TAPE TO PROVIDE AT
5. MOUNT THE LINKS IN THE POSITIONS SHOWN WITH THE PROVIDED HEX NUTS.
USE. SECURE THE REMAINING HEX NUTS IN PLACE.
DOUBLE UP THE LINKS IN TWO OF THE POSITIONS TO SAVE THEM FOR FUTURE
5. MOUNT THE LINKS IN THE POSITIONS SHOWN WITH THE PROVIDED HEX NUTS.
M15009
3-17-95E
LINK
1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX.
CODES.
4. CONNECT TERMINAL MARKED TO GROUND PER LOCAL AND NATIONAL ELECTRIC
LEAST 600 VOLT INSULATION.
2. DISCONNECT AND INSULATE THE H3 LEAD TERMINAL WITH TAPE TO PROVIDE AT
3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES AND H2 TRANSFORMER LEADS TO THE INPUT SIDE OF THE CR1 CONTACTOR AS SHOWN.
3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES AND H3 TRANSFORMER LEADS TO THE INPUT SIDE OF THE CR1 CONTACTOR AS SHOWN.
INPUT SUPPLY CONNECTION DIAGRAM
Do not touch electrically live parts
Only qualified persons should install, use or service this equipment
removed
servicing
Do not operate with covers
Disconnect input power before
NOTE: MACHINES ARE SHIPPED FROM FACTORY CONNECTED FOR OVER 300 VOLTS
DUAL VOLTAGE MACHINE
GND
H2
INPUT
LINES
L1
H1
L2
L3
{
CR1
V
U
W
CONTACTOR
H3
PILOT
TRANSF.
LINK
GND
H3
INPUT
LINES
L1
H1
L2
L3
{
CR1
V
U
W
CONTACTOR
H2
PILOT
TRANSF.
IMPORTANT: CHANGE LINK POSITIONS AND PILOT TRANSFORMER CONNECTIONS.
RECONNECT PROCEDURE
Multiple input voltage welders are shipped connected for the highest voltage listed on the machine’s rating plate. Before installing the welder, be sure the recon­nect panel is connected for the proper voltage.
Failure to follow these instructions can cause immedi­ate failure of components in the welder.
To reconnect a multiple voltage machine to a different voltage, remove input power. Follow the input con­nection diagram, located on the inside access panel cover, appropriate for your machine’s input voltage. These same connection diagrams are shown below.
For 208, 208/230 & 230/460 volts AC - see Figure A.3.
CAUTION
The output (welding) cables are connected to the out­put terminals marked “+” and “-”. See Table A.1 for recommended cable sizes for the combined lengths of electrode and work cables. The output terminals are located at the lower right and lower left corners of the front panel. Strain relief for the cables is provided by routing them through the rectangular holes in the base before connecting them to the output terminals. See Figure A.4.
NOTE: If the welder comes equipped with the polarity
switch option, the output terminals are labeled “electrode” and “to work.”
The output terminals are energized at all times.
INSTALLATION
A-9 A-9
IDEALARC R3R
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
FIGURE A.4 - OUTPUT TERMINAL CONNECTIONS
1
2
3
1. NEGATIVE (-) WELDING CABLE CONNECTION
2. POSITIVE (+) WELDING CABLE CONNECTION
3. CABLE STRAIN RELIEF HOLES
OUTPUT CONNECTIONS (STICK, TIG, AIR/CARBON ARC CUTTING)
WARNING
TABLE A.1 - CABLE SIZES FOR COMBINED LENGTHS OF COPPER ELECTRODE
AND WORK CABLES
Up to 100 ft 100 - 150 ft 150 - 200 ft 200 - 250 ft
Machine Size (30 m) (30 - 46 m) (46 - 61 m) (67 - 76 m) 300 Amp 1/0 1/0 2/0 3/0
(60% Duty 54 mm
2
54 mm
2
68 mm
2
86 mm
2
Cycle) 400 Amp 2/0 2/0 3/0 4/0
(60% Duty 68 mm
2
68 mm
2
86 mm
2
108 mm
2
Cycle) 500 Amp 2/0 3/0 3/0 4/0
(60% Duty 68 mm
2
86 mm
2
86 mm
2
108 mm
2
Cycle)
NOTES
A-10 A-10
IDEALARC R3R
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
Section B-1 Section B-1
IDEALARC R3R
TABLE OF CONTENTS
- OPERATION SECTION -
Operation...............................................................................................................................Section B
Safety Instructions ......................................................................................................................B-2
General Description ....................................................................................................................B-3
Recommended Processes ...................................................................................................B-3
Design Features and Advantages ........................................................................................B-3
Welding Capability................................................................................................................B-3
Controls and Settings ................................................................................................................B-4
Welding Operation ......................................................................................................................B-6
Operating Steps ...................................................................................................................B-6
Local Control..................................................................................................................B-6
Remote Control..............................................................................................................B-6
Pocket Amptrol ..............................................................................................................B-6
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
B-2
B-2
IDEALARC R3R
OPERATING INSTRUCTIONS
Read and understand this entire section of operating instructions before operating the machine.
SAFETY INSTRUCTIONS
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or electrodes with your skin or wet cloth­ing.
• Insulate yourself from the work and ground.
• Always wear dry insulating gloves.
FUMES AND GASES can be dangerous.
• Keep your head out of fumes.
• Use ventilation or exhaust to remove fumes from breathing zone.
WELDING SPARKS can cause fire or explosion.
• Keep flammable material away.
• Do not weld on containers that have held com­bustibles.
ARC RAYS can burn.
• Wear eye, ear, and body protection.
Observe additional Safety Guidelines detailed in the beginning of this manual.
WARNING
OPERATION
GENERAL DESCRIPTION
The Idealarc R3R is an SCR controlled constant cur­rent DC output power source for welding and cutting. The R3R-300 uses a single range potentiometer con­trol. The R3R-400 and R3R-500 have separate low and high range controls. The welder’s unique combi­nation of 3 phase transformer, SCR/Diode bridge rec­tifier, arc control choke, and solid state control system deliver outstanding arc characteristics. For stick weld­ing, an Arc Force Control enables the Idealarc-R3R to create a soft welding arc for critical applications or a forceful driving arc for heavy duty applications.
RECOMMENDED PROCESSES
The Idealarc R3R is recomended for stick and DC TIG welding and air/carbon arc gouging.
DESIGN FEATURES AND ADVANTAGES
• Input line voltage compensation keeps output con­stant for fluctuations of ± 10%.
• Hinged front control panel provides easy access to printed circuit boards and other control circuitry.
• Fully enclosed fan motor with permanently lubri­cated, sealed ball bearings needs no maintenance.
• Fully recessed control panel protects controls and minimizes accidental contact.
• Recessed output terminals reduces chance of acci­dental contact.
• Low profile case permits installation under a work­bench.
• Removable rear access panel provides easy access to input contactor and input lead connections.
• Removable case sides provide easy access for ser­vice or inspection, even when machines are stacked.
• Dripproof enclosure design permits outdoor operation.
• Double-dipped transformer, SCR bridge, and choke resist corrosion.
WELDING CAPABILITY
The Idealarc R3R has the following duty cycle ratings. If the duty cycle is exceeded, a thermal protector will shut off the machine output until it cools to normal operating temperature. The amber thermal protection indicator light will turn on until the machine cools.
60% Duty Cycle* Amps Volts
R3R-300 300 32 R3R-400 400 36 R3R-500 500 40
*Based on a 10 minute time period. For example, a 60% duty cycle means 6 minutes on and 4 minutes off.
OPERATION
B-3 B-3
IDEALARC R3R
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
CONTROLS AND SETTINGS
All operator controls and settings are located on the case front assembly. See Figure B.1 for their loca­tions.
FIGURE B.1 – CASE FRONT CONTROLS
1. POWER SOURCE PILOT LIGHT: This light indi-
cates that input power is applied to the R3R and that the on/off switch is in the ON position.
2. ON/OFF POWER TOGGLE SWITCH: Energizes
or de-engergizes the input contactor which is pow­ered by the 115 volt auxiliary transformer. The switch turns the machine ON or OFF. Position “I” is ON; position “0” is OFF.
3. ARC FORCE SELECTOR: Allows you to select
the ideal arc force according to the procedure and electrode being used for CC stick. It controls the amount of current added to the welding current when the electrode shorts to the work. At mini­mum setting, no extra short circuit current is added. The arc will be softer and have less spat­ter but may be more prone to sticking. At maxi­mum setting, the arc will be more forceful and less prone to sticking but will produce more spatter. For TIG welding applications, this control should usually be set to minimum.
4. CURRENT RANGE SELECTOR SWITCH (R3R- 400 and R3R-500 only): “A” position selects lower range current control. “B” position selects higher range current control.
5. OUTPUT CONTROL SWITCH (R3R OR REMOTE POSITIONS): Selects the mode of control. In the “R3R” position, control is by the machine control panel. In the “Remote” position, control is through an optional remote control device.
6. OUTPUT CONTROL POTENTIOMETER: Con- trols current.
7. REMOTE CONTROL CONNECTION: The 6-pin amphenol receptacle provides remote control con­nections. Machines below code 9500 use a termi­nal strip instead of the amphenol. A strain relief connector is provided for cable entry.
OPERATION
B-4 B-4
IDEALARC R3R
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
1. Power Source Pilot Light
2. ON/OFF Power Toggle Switch
3. Arc Force Control
4. Current Range Selector Switch (not on R3R-300)
5. Output Control Potentiometer
6. Output Control Switch (with R3R or Remote positions)
7. Remote Control Connections (6-pin amphenol or terminal strip)
8. Polarity Switch (optional)
9. DC Ammeter (optional)
10. DC Voltmeter (optional)
11. Thermal Protection Indicator Light
9
8
10
7
11
6
5
4
1
3
2
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
OPERATION
B-5 B-5
IDEALARC R3R
8. POLARITY SWITCH (optional): Permits chang-
ing the electrode polarity of the output terminals between DC+ and DC-.
9. DC AMMETER (optional): Displays output cur-
rent when welding.
10. DC VOLTMETER (optional): Displays output
voltage.
11. THERMAL PROTECTION INDICATOR LIGHT:
This amber light indicates that either of the two protective thermostats has opened. Output power is removed, but input power is still being applied to the machine.
WELDING OPERATION
OPERATING STEPS
LOCAL CONTROL
The following procedures are for using the Idealarc R3R in the local (“R3R”) control mode of operation. For remote control of the machine, see the REMOTE CONTROL section.
Before operating the machine, make sure you have all materials needed to complete the job. Be sure you are familiar with and have taken all possible safety pre­cautions before starting work. It is important that you follow these operating steps each time you use the machine.
1. Turn on the main AC input power to the machine.
2. Set the ELECTRODE POLARITY switch to the appropriate position (optional if equipped).
3. Set the OUTPUT CONTROL switch to “R3R.”
4. Set the ARC FORCE CONTROL to midrange, 5-6, for CC stick or TIG welding. Adjust for best char­acteristics as necessary.
5. Set the ON/OFF POWER toggle switch to the ON position (1).
• The white power source pilot light glows.
• The fan starts.
6. Set the CURRENT RANGE SELECTOR switch to the appropriate position (“A” for higher range, “B” for lower range).
7. Set OUTPUT CONTROL potentiometer to desired current.
8. Make the weld.
REMOTE CONTROL
The toggle switch on the control panel labeled “Output Control Remote” gives you the option of controlling the machine output from a remote location. In the “Remote” position a remote control device such as a K857 must be connected to the Idealarc R3R. Refer to the Accessories section for available remote control information.
POCKET AMPTROL (Optional)
The pocket amptrol option provides a remote current control for the R3R welders. This “wireless” control requires no control cable connection to the welder. Use it as follows:
a. On the R3R-400 and -500 the welder CURRENT
CONTROL switch must be in the “Remote” posi­tion and the CURRENT RANGE SELECTOR switch in the “B” range. The R3R-300 does not have a CURRENT RANGE SELECTOR switch. With the CURRENT CONTROL switch in the “Remote” posi­tion, the OUTPUT CONTROL potentiometer on the welder is removed from the circuit and its setting has no effect on the ouput. With the CURRENT RANGE SELECTOR switch in the “B” range posi­tion, the pocket amptrol provides total control from minimum to maximum output of the welder.
b. Turn the welder POWER switch ON.
c. Insert one end of the probe into the electrode hold-
er and hold the other end on the work for approxi­mately five seconds.
d. To change current, change the probe dial setting
and repeat the five second procedure of placing the probe between electrode and work.
The solid state circuitry within the welder senses this change in probe setting and automatically resets the welding current to the new level. Each time the welder is turned off, the output goes to minimum and must be reset when the welder is turned on again.
OPERATION
B-6 B-6
IDEALARC R3R
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
TABLE OF CONTENTS
- ACCESSORIES SECTION -
Accessories...........................................................................................................................Section C
Options/Accessories...................................................................................................................C-2
Factory Installed Options .....................................................................................................C-2
Polarity Switch ...............................................................................................................C-2
Meters ............................................................................................................................C-2
Pocket Amptrol ..............................................................................................................C-2
Field Installed Options .........................................................................................................C-2
Remote Output Adapter Cable (K857)...........................................................................C-2
Accessory Kits (K703, K704) .........................................................................................C-2
Undercarriages (K817P, K841) .......................................................................................C-2
TIG Welding Options............................................................................................................C-2
TIG Module (K930-1)......................................................................................................C-2
Water Valve Kit (K844-1) ................................................................................................C-2
Amptrols (K870, K812, K963-1, K963-2) .......................................................................C-2
Contactor Kit (K938-1) ...................................................................................................C-2
Docking Kit (K939-1)......................................................................................................C-2
Control Cable (K936-3) ..................................................................................................C-2
Control Cable Extensions (K937-22.5, K937-45)...........................................................C-2
Section C-1 Section C-1
IDEALARC R3R
OPTIONS/ACCESSORIES
FACTORY INSTALLED OPTIONS
POLARITY SWITCH
Permits changing polarity at the machine output ter­minals.
METERS
Ammeter and Voltmeter.
POCKET AMPTROL
Provides a wireless remote current control for R3R welders. See the Operation section for details.
FIELD INSTALLED OPTIONS
The following options/accessories are available for your Idealarc R3R from your local Lincoln Distributor.
Remote Current Control (K857) - Portable current control provides the same dial range as the current control on the welder. Consists of a 6-pin Amphenol connector which plugs into the remote control Amphenol.
Accessory Kits (For R3R-300 and R3R-400) ­Consists of electrode and work cables, headshield, electrode holder and work clamp.
R3R-300 - K703 R3R-400 - K704
Undercarriage (K817P) - A mounting frame with
wheels for hand moving. Undercarriage (K841) - Platform undercarriage with
mountings for two gas cylinders at rear of welder.
TIG WELDING OPTIONS
TIG Module (K930-2) - Portable, high frequency unit
with gas valve for TIG welding. Rated at 300 amps/60% duty cycle. (Request publication E3.205)
Water Valve Kit (K844-1) - For use with a water­cooled TIG torch. Controlled by the preflow and after­flow timers. Installs inside the TIG module.
Amptrol™ - Provides 25 ft. (7.6m) of remote current control for TIG welding. (6 pin MS-type plug connec­tion).
Foot Amptrol - K870 Hand Amptrol - K963-1 Hand Amptrol - K963-2
Contactor Kit (K938-1) - For use with the TIG Module. Docking Kit (K939-1) - Secures TIG Module on top of
R3R machines, or any flat surface at least 10 in x 15 in (254mm x 381mm). Mounts using strong grip adhe­sive pad or fasteners. Includes latch and provisions for a user-supplied padlock.
Control Cable (K936-3) - Connects the TIG Module to the R3R machine (9 to 6 plus 115V plug).
Control Cable Extensions - Allows the TIG Module to be operated at distances up to 200 ft. (61m) from the power source. Two lengths are available: 22.5ft.(6.9m) or 45ft. (13.7m).
22.5 ft. - K937-22.5 45 ft. - K937-45
ACCESSORIES
C-2 C-2
IDEALARC R3R
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
Section D-1 Section D-1
IDEALARC R3R
TABLE OF CONTENTS
- MAINTENANCE SECTION -
Maintenance .........................................................................................................................Section D
Safety Precautions......................................................................................................................D-2
Routine and Periodic Maintenance ............................................................................................D-2
General Component Locations...................................................................................................D-3
SAFETY PRECAUTIONS
ELECTRIC SHOCK can kill.
• Only qualified personnel should perform this mainte­nance.
• Turn the input power OFF at the disconnect switch or fuse box before working on this equipment.
• Do not touch electrically hot parts.
ROUTINE AND PERIODIC MAINTENANCE
Perform the following daily:
1. Check that no combustible materials are around the machine or in the welding or cutting area.
2. Remove any debris, dust, dirt, or materials that could block cooling air flow to the machine.
3. Inspect the electrode cables for any slits or punc­tures in the cable jacket. Also check for any other condition that could affect the proper operation of the machine.
Perform periodically:
1. In extremely dusty conditions, dirt may clog the cooling air channels, causing the machine to run hot. Blow out the machine at regular intervals with low pressure air. Clean the following parts. See
Figure D.1.
• Main transformer and choke
• SCR/diode bridge
• Control PC board
• Electrode and work cable connections
• Fan assembly
NOTE: The fan motor has sealed bearings that require no service.
• Remote control terminal strip TS1 (in machines
below code 9500).
NOTE: Keeping remote control terminal strip TS1 clean is especially important in damp locations.
2. Pocket Amptrol Maintenance - Clean and maintain the optional Pocket Amptrol (if equipped). Keep the probe tip in good condition. It requires sharp edges to penetrate heavy oxide coatings on the work piece. A blunted tip could result in different welding currents for a given dial setting.
MAINTENANCE
D-2 D-2
IDEALARC R3R
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
WARNING
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
MAINTENANCE
D-3 D-3
IDEALARC R3R
11
12
10
9
8
7
65
4
3
2
1
13
FIGURE D.1 – GENERAL COMPONENT LOCATIONS
1. CONTROL PANEL
2. SCR/DIODE BRIDGE
3. MAIN TRANSFORMER
4. CHOKE
5. RECONNECT PANEL (LOCATION)
6. INPUT CONTACTOR (LOCATION)
7. FAN ASSEMBLY
8. CONTROL TRANSFORMER (LOCATION)
9. PC BOARDS (LOCATION)
10. CASE FRONT
11. OUPUT TERMINALS (LOCATION BENEATH HINGED PANEL)
12. POCKET AMPTROL (OPTIONAL)
13. POLARITY SWITCH (OPTIONAL)
NOTES
D-4 D-4
IDEALARC R3R
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
Section E-1 Section E-1
IDEALARC R3R
TABLE OF CONTENTS
- THEORY OF OPERATION SECTION -
Theory of Operation .............................................................................................................Section E
General Description ....................................................................................................................E-2
Input Line Voltage, Contactor and Main Transformer.................................................................E-2
Output Mode and Control, Rectification and Feedback ............................................................E-3
Optional Polarity Switch and Amptrol Circuits ...........................................................................E-4
Protective Devices and Circuits..................................................................................................E-5
SCR Operation............................................................................................................................E-6
CONTROL BOARD
OUTPUT
CONTROL
ARC FORCE
CONTROL
CONTROL
TRANSFORMER
POWER
SWITCH
R E C O N N E C T
INPUT
CONTACTOR
TRANSFORMER
MAIN
SCR DIODE
HYBRID BRIDGE
/
SHUNT
OUTPUT
CHOKE
NEGATIVE
OUTPUT
TERMINAL
POSITIVE
OUTPUT
TERMINAL
G
A T E
S
I G N A L
S
FEEDBACK
F E E D B A C K
THERMOSTATS
FAN
MOTOR
TERMINAL
STRIP
REMOTE
SWITCH
DIAL
SELECTOR
SWITCH
SNUBBER
BOARD
AMPHENOL
POLARITY
SWITCH
OPTIONAL
OPTIONAL
POCKET
AMPTROL
PC BOARD
OPTIONAL POCKET AMPTROL
TRANSFORMER
FIGURE E.1 – IDEALARC R3R BLOCK LOGIC DIAGRAM
GENERAL DESCRIPTION
The Idealarc R3R welder is a three-phase transformer rectifier type constant current power source designed for DC manual welding and air carbon arc cutting. Its power system is SCR controlled with solid state elec­tronic circuitry. Minimum to maximum output is obtained with a single potentiometer control.
INPUT LINE VOLTAGE, CONTACTOR AND MAIN TRANSFORMER
The desired three-phase input power is connected to the R3R through an input contactor, located in the input box at the rear of the machine. Two phases of the input line are also connected to the primary of the
control transformer. The secondary of the control transformer supplies 120VAC power, via the power switch and thermostats, to activate the input contac­tor.
A reconnect panel allows the user to configure the machine for the desired input voltage. This AC input voltage is applied to the primary of the main trans­former.
The transformer changes the high voltage, low current input power to a lower voltage, higher current output. The finishes or “neutrals” of the main secondary coils are connected together, and the three starts of the secondary windings are connected to the rectifier bridge assembly. In addition, three 66VAC phase angle windings are housed in the main transformer assembly. These windings provide power and “timing” for the control board. Two of these coils provide 120VAC for the fan motor.
THEORY OF OPERATION
E-2 E-2
IDEALARC R3R
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
FIGURE E.2 – INPUT LINE VOLTAGE, CONTACTOR AND MAIN TRANSFORMER
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.
CONTROL BOARD
OUTPUT
CONTROL
ARC FORCE
CONTROL
CONTROL
TRANSFORMER
POWER
SWITCH
R E C O N N E C T
INPUT
CONTACTOR
TRANSFORMER
MAIN
SCR DIODE
HYBRID BRIDGE
/
SHUNT
OUTPUT
CHOKE
NEGATIVE
OUTPUT
TERMINAL
POSITIVE
OUTPUT
TERMINAL
G
A T E
S I G N A L S
FEEDBACK
F E E D B A C K
THERMOSTATS
FAN
MOTOR
TERMINAL
STRIP
REMOTE
SWITCH
DIAL
SELECTOR
SWITCH
SNUBBER
BOARD
AMPHENOL
POLARITY
SWITCH
OPTIONAL
OPTIONAL
POCKET
AMPTROL
PC BOARD
OPTIONAL POCKET AMPTROL
TRANSFORMER
Loading...
+ 78 hidden pages