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IDEALARC ®
IM410-D
R3R 375-I, 500-I AND 600-I
For use with machine Code Numbers above:
June, 2009
9535
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.
OPERATOR’S MANUAL
Copyright © Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
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SAFETY
WARNING
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 Above For Diesel Engines
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 Gasoline Engines
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.
FOR ENGINE
powered equipment.
1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
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 welding 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.
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.
Mar ‘95
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SAFETY
ELECTRIC SHOCK can kill.
ARC RAYS can burn.
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.
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.
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.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
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.
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.
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 within applicable OSHA PEL and
ACGIH TLV limits 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. The operation of welding fume control equipment is affected
by various factors including proper use and positioning of the
equipment, maintenance of the equipment and the specific
welding procedure and application involved. Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable OSHA PEL
and ACGIH TLV limits.
5.c. 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.d. 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.e. 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.f. Also see item 1.b.
Jan ‘09
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SAFETY
WELDING and CUTTING
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.
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.
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.
6.h. Also see item 1.c.
6.I. Read and follow NFPA 51B “ Standard for Fire Prevention
During Welding, Cutting and Other Hot Work”, available from
NFPA, 1 Batterymarch Park, PO box 9101, Quincy, Ma
022690-9101.
6.j. Do not use a welding power source for pipe thawing.
Refer to http://www.lincolnelectric.com/safety for additional safety information.
Jan ‘09
IDEALARC® R3R 375-I, 500-I AND 600-I
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SAFETY
PRÉCAUTIONS DE SÛRETÉ
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
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:
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.
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 tension
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.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
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
enrouler le câble-électrode autour de n’importe quelle partie du
corps.
8. S’assurer que la masse est connectée le plus prés possible de
la zone de travail qu’il est pratique de le 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 autres 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 fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations 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 toxique)
ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté, voir
le code “Code for safety in welding and cutting” CSA Standard
W 117.2-1974.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
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 rayonnement de 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 laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des 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.
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, I’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 dispositifs de sûreté à leur place.
Mar. ‘93
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Thank You
for selecting a QUALITY product by Lincoln Electric. We want you
to take pride in operating this Lincoln Electric Company product •••
as much pride as we have in bringing this product to you!
CUSTOMER ASSISTANCE POLICY
The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equipment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln Electric
for advice or information about their use of our products. We respond to our customers based on the best information in our possession at that
time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or
advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customer’s particular purpose, with respect
to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or correcting any
such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any warranty with
respect to the sale of our products.
Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control
of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service requirements.
Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com
for any updated information.
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the time
the shipment is received.
Please record your equipment identification information below for future reference. This information can be found
on your machine nameplate.
Product _________________________________________________________________________________
Model Number ___________________________________________________________________________
Code Number or Date Code_________________________________________________________________
Serial Number____________________________________________________________________________
Date Purchased___________________________________________________________________________
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially important when identifying the correct replacement parts.
On-Line Product Registration
- Register your machine with Lincoln Electric either via fax or over the Internet.
• For faxing: Complete the form on the back of the warranty statement included in the literature packet
accompanying this machine and fax the form per the instructions printed on it.
• For On-Line Registration: Go to our WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then
“Product Registration”. Please complete the form and submit your registration.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.
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TABLE OF CONTENTS
Page
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A
Input Power Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Output Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section B
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section C
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section D
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section E
Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-7 – E-10
Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section F
Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P206 Series
IDEALARC® R3R 375-I, 500-I AND 600-I
A-1
A-1
INSTALLATION
INSTALLATION
WARNING
FALLING EQUIPMENT can cause
injury.
• Do not lift this machine using lift
bail if it is equipped with a heavy
• accessory such as trailer or gas cylinder.
• Lift only with equipment of adequate lifting
capacity.
Remove the rear access panel. Connect the three
phase input power to the three line terminals on the
input contactor, and the earth ground lead to the
ground stud marked with the
symbol. Install the
reconnect panel for the proper input voltage per the
diagram pasted inside the access panel cover.
Copper Wire Size
Type 75°C in Conduit
Input
R3R
Volts
Amps 3 Input
1 Ground
Welder 50/60 Hz Input
Wires
Wire
375-I
220
380
440
67
39
34
8
10
10
8
10
10
80
60
40
500-I
220
380
415-440
90
52
45
6
8
10
6
8
10
125
80
60
600-I
220
380
440
103
60
52
4
8
8
6
8
8
150
90
70
• Be sure machine is stable when lifting.
The machine should be located in a clean, dry place
where there is free circulation of clean air, such that air
movement entering the front and exiting the back will
not be restricted. Dirt and dust that can be drawn into
the machine should be kept to a minimum. Failure to
observe these precautions can result in excessive
operating temperatures and nuisance shutdown of the
machine.
The Idealarc R3R welders can be stacked three high
when the following precautions are observed:
1. Be sure the bottom machine is on a firm, level surface suitable for the total weight [up to 1340 pounds
(608 kg)] of the stacked machines.
2. Stack the machines with the fronts flush. Be certain
the pins on the top front corners of the lower
machines fit through the holes in the base rails of
the upper machines.
3. No unit heavier than the bottom unit should be
stacked on top of it. For example, an R3R 500-I
shall not be slacked on top of an R3R 400-I, but an
R3R 400-I may be stacked on top of an R3R 500-I.
INPUT POWER CONNECTION
WARNING
ELECTRIC SHOCK can kill.
• Have an electrician install and service this equipment.
• Turn the input power off at the fuse
box before working on equipment.
• Do not touch electrically hot parts.
Super Lag
Fuse Size
in Amps
DUTY CYCLE
The maximum output rating of this welder is at a 35%
duty cycle. Duty cycle is based on a ten minute period.
Therefore, the welder can be operated at the maximum
rated output for 3.5 minutes out of every 10 minute
period without overheating.
CAUTION
Failure to follow these instructions can cause immediate failure of components within the machine.
When powering welder from a generator be sure to
turn off welder first, before generator is shut down,
in order to prevent damage to welder!
------------------------------------------------------------------------
OUTPUT CONNECTIONS
With the machine power switch off, the output leads
are connected to the Magnum™ Twist-Mate™ output
terminals marked “–” and “+”. They are located at the
lower right and lower left corners of the front panel.
Strain relief for the electrode and work cables is provided by routing the leads through the rectangular
holes in the base before the connections to the output
terminals are made. Twist-Mate Lead plugs must be
installed to the output cables before connections can
be made to the power source. See S18737 instructions
included with the plugs.
Theommended output cable sizes can be found in the
Table below.
Machine Up to 100 ft. 100 to 150 ft. 150 to 200 ft. 200 to 250 ft.
Size
(30 m)
(30 – 46 m)
(46 – 61 m)
(61 – 76 m)
375-I
500-I
600-I
1/0 (54 mm2) 1/0 (54 mm2)
2/0 (68 mm2) 2/0 (68 mm2)
2/0 (68 mm2) 3/0 (86 mm2)
IDEALARC® R3R 375-I, 500-I AND 600-I
2/0 (68 mm2) 3/0 (86 mm2)
3/0 (86 mm2) 4/0 (108 mm2)
3/0 (86 mm2) 4/0 (108 mm2)
B-1
B-1
OPERATION
OPERATION
OUTPUT CONTROL
WARNING
The “current control” dial (labeled “I”) on the front of the
machine indicates the output current.
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts
or electrode with skin or wet clothing.
• Insulate yourself from 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.
On the R3R 375-I, there is only one dial. On the R3R
500-I, and 600-I, there are two dials. The “A” range
controls the current over about 1/2 of the “B” range. A
toggle switch on the control panel allows selection of
the desired range. The output control can be adjusted
while welding.
MACHINE OR REMOTE CURRENT
CONTROL SWITCH
Provisions for remote control are standard on each
power source. A current control switch on the machine
control panel labeled “
“or “ I “ is provided for
selecting the desired mode of operation, either remote
(
)or at the machine ( I ).
• Keep flammable material away.
• Do not weld on containers that
have held combustibles.
ARC RAYS can burn.
• Wear eye, ear and body protection.
STARTING THE MACHINE
The “power on-off” switch on the machine control panel
energizes the three phase line contactor from a small
115 volt pilot transformer. This in turn energizes the
main power transformer.
NOTE: All PC boards are protected by a moisture
resistant coating. When the welder is operated, this
coating will “bake off” of certain power resistors that
normally operate at high temperatures, emitting some
smoke and odor for a short time. These resistors and
the PC board beneath them may become blackened.
This is a normal occurrence and does not damage the
component or affect the machine performance.
ARC FORCE CONTROL
The arc force control, located on the right side of the
front control panel, is calibrated from one to ten. For
most welding, the dial should be set at approximately
mid-range, 5-6. Adjustments up or down can then be
made depending on the electrode, procedures, and
operator preference. Lower settings will provide less
short circuit current and a softer arc. A setting that is
too low may cause the electrode to stick in the puddle.
Higher settings will provide a higher short circuit current and a more forceful arc. Excessive spatter may
result if the control setting is too high. For most TIG
welding applications, adjust this control to minimum for
best operating characteristics.
INTERNATIONAL SYMBOLOGY
REFERENCE
The R3R nameplates feature international symbols in
describing the function of the various components.
Below are the symbols used and an explanation of
what each represents.
A. POWER ON-OFF SWITCH
PILOT LIGHT
On
The while light on the machine control panel indicates
when The line contactor is energized.
NOTE: If the amber High Temperature Warning Light is
lit, it indicates that one or both of the protective thermostats has opened the line contactor.
IDEALARC® R3R 375-I, 500-I AND 600-I
Off
Power Input
B-2
B-2
OPERATION
B. ARC FORCE CONTROL DIAL
G. RATING PLATE
Arc Force
Three Phase
Power
Increase/Decrease of
Arc Force
Transformer
C. OUTPUT CURRENT CONTROL DIAL
Rectifier
Output Current
D. OUTPUT CURRENT CONTROL RANGE SWITCH
(R3R 500-I and R3R 600-I only)
Rectified DC
Output
Output Current
Control Dial Range A
Constant Current
Characteristics
Output Current
Control Dial Range B
Shielded Metal Arc
Welding
E. OUTPUT CURRENT CONTROL “MACHINEREMOTE” SWITCH
Line Connection
Remote Output
Current Control
H. HIGH TEMPERATURE WARNING LIGHT
F. POLARITY SWITCH (Factory installed option on
domestic models only)
High Temperature
Limit
Electrode Polarity
Positive
I. WARNING
Electrode Polarity
Negative
Do Not Switch While
Welding
Warning
Identification
J. GROUND
Signifying the Earth
(Ground)
Connection
IDEALARC® R3R 375-I, 500-I AND 600-I
C-1
ACCESSORIES
OPTIONAL EQUIPMENT
K857 – REMOTE CURRENT CONTROL
The K857 consists of a control box with 8.5 m (28 ft) of
four conductor cable and a 6 pin Amphenol for easy
connection to the front of the power source.
The K857 will give the same control as the current control on the machine depending on the position of the
current dial selector switch. (Current dial selector
switch not used on the R3R 375-I.)
C-1
b. Turn the welder power switch on.
c. Insert one end of the probe into the electrode holder and hold the other end on the work for approximately five seconds.
AMMETER AND VOLTMETER – (factory installed
only)
CAUTION
Extreme care must be observed when installing or
extending the wiring of a remote control. The
Remote Control cord can be lengthened to any
length by splicing four wires to the standard 28 ft
(8.5 m) cord before connecting to the R3R receptacle. Only the green lead can and should be
grounded to the machine case.
K817, K817R – UNDERCARRIAGE
For easy moving of the machine, optional undercarriages are available with either steel or rubber tire
wheels.
K963 – HAND AMPTROL AND K870 FOOT
AMPTROL
Connect directly to the 6 pin Amphenol on the front of
the power source.
POCKET AMPTROL – (factory installed only)
The Pocket Amptrol option provides a remote current
control for the R3R welders. This “wireless” control
requires no control cable connection to the welder.
a. On the R3R 500-I and R3R 600-I the welder Current
Control (labeled “ I “ switch must be in the Remote
(
) position and the Current Dial Selector switch
in the “B” range. The R3R 375-I has only one
Current Dial Selector and no selector switch. With
the Current Control switch in the Remote position,
the current control potentiometer on the welder is
removed from the circuit and its setting has no
effect on the output. With the Current Dial Selector
switch in the “B” range position, the Pocket Amptrol
provides total control of the welder’s output.
IDEALARC® R3R 375-I, 500-I AND 600-I
D-1
MAINTENANCE
WARNING
ELECTRIC SHOCK can kill.
• Have an electrician install and service this equipment.
• Turn the input power off at the fuse
box before working on equipment.
• Do not touch electrically hot parts.
ROUTINE MAINTENANCE
1. The fan motor has sealed bearings which require no
service.
2. In extremely dusty locations, dirt may clog the air
channels causing the welder to run hot. Blow out
the machine at regular intervals.
POCKET AMPTROL
Routine cleaning should be the only maintenance
required. The probe tip should be kept in condition to
provide sharp edges at the ends to assure penetration
of heavy oxide coatings on the work piece. A blunted
tip could result in giving different welding currents for a
given dial setting.
POWER RECTIFIER REPLACEMENT
Refer to the troubleshooting section “Power Rectifier
Bridge Assembly Checking Procedure” if a rectifier failure is suspected
NOTE: Since proper material and correct assembly
procedures are critical, field disassembly of the power
rectifier bridge sections can do more harm than good.
Return a defective rectifier bridge section (or the entire
bridge) to the factory for repairs.
IDEALARC® R3R 375-I, 500-I AND 600-I
D-1
E-1
TROUBLESHOOTING
E-1
HOW TO USE TROUBLESHOOTING GUIDE
WARNING
Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
and machine operator and will invalidate your factory warranty. For your safety and to avoid
Electrical Shock, please observe all safety notes and precautions detailed throughout this
manual.
__________________________________________________________________________
This Troubleshooting Guide is provided to
help you locate and repair possible machine
malfunctions. Simply follow the three-step
procedure listed below.
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled “PROBLEM
(SYMPTOMS)”. This column describes possible symptoms that the machine may exhibit. Find the listing that best describes the
symptom that the machine is exhibiting.
Step 2. POSSIBLE CAUSE.
The second column labeled “POSSIBLE
CAUSE” lists the obvious external possibilities that may contribute to the machine
symptom.
Step 3. RECOMMENDED COURSE OF
ACTION
This column provides a course of action for
the Possible Cause.
If you do not understand or are unable to
perform the Recommended Course of Action
safely, contact you local Lincoln Authorized
Field Service Facility.
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically hot parts.
• Have an electrician install and service this equipment.
• Turn the input power off at the fuse box before
working on equipment.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local
Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
IDEALARC® R3R 375-I, 500-I AND 600-I
E-2
E-2
TROUBLESHOOTING
Observe all Safety Guidelines detailed througout this manual
PROBLEMS
(SYMPTOMS)
RECOMMENDED
COURSE OF ACTION
POSSIBLE CAUSE
FUNCTION PROBLEMS
A. Input contactor chatters.
B. Machine input contactor does not
operate.
1.Faulty input contactor.
1.Repair or replace.
2.Low line voltage.
2.Check with Power Company.
1.Supply line fuse blown.
1.Replace (look for reason for
blown fuse first).
2.Power circuit dead.
2.Check voltage.
3.Broken or loose power lead.
3.Repair.
4.Wrong voltage.
4.Check voltage against
instructions.
5.Thermostats tripped. (High
Temperature Warning Light
should be lit.) (Welder
overheated.)
5.a. Make sure the fan is operating
and that there are no obstructions to free flow of air.
b. Operate at normal current
and duty cycle.
c. Replace High Temperature
Warning Light if defective.
6.Input contactor coil open.
6.Replace.
7.Open winding on 115V pilot
transformer.
7.Replace.
8.Power ON-OFF switch not
closing.
8.Replace.
9.Lead broken or loose connection in 115V starter circuit.
9.Replace.
10.Thermostats defective. (High
Temperature Warning Light
should be lit.)
10.Turn input power off (115V circuit is hot when input power is
connected). Check thermostats
with continuity meter – should
read short-circuit when machine
is cool. Replace if defective.
There are two thermostats; one
on the secondary lead and one
on the choke. Replace High
Temperature Warning Light if
defective.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local
Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
IDEALARC® R3R 375-I, 500-I AND 600-I
E-3
E-3
TROUBLESHOOTING
Observe all Safety Guidelines detailed througout this manual
PROBLEMS
(SYMPTOMS)
RECOMMENDED
COURSE OF ACTION
POSSIBLE CAUSE
FUNCTION PROBLEMS
C. Machine input contactor closes
1. Electrode or work lead loose or
but has no or low output. Open
broken.
circuit voltage should be 67 to 71
volts.
2. Open transformer primary or
secondary circuit.
D. Machine has maximum output
but no control.
1. Repair connections.
2. Repair.
3. Supply line fuse blown.
3. Replace blown fuse – check fuse
size.
4. Input line grounded causing
single phase input.
4. Repair input to machine.
5. Input leads not connected to
contactor.
5. Connect input lead.
6. Latching resistor, R3, open.
6. a. Replace.
b. Check leads to the resistor
and repair if defective.
7. Control circuit problems.
7. See Troubleshooting Procedures
– Power Silicon Controlled
Rectifier.
1. Possible defective power SCR.
1. Remove all gate leads G1, G2
and G3 at PC board connector
J4. If welder has any open circuit
voltage, power SCR is defective.
See Troubleshooting Procedures
Section J.
2. Possible defective control board.
2. See PC board Troubleshooting
Procedures Section A
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local
Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
IDEALARC® R3R 375-I, 500-I AND 600-I
E-4
E-4
TROUBLESHOOTING
Observe all Safety Guidelines detailed througout this manual
PROBLEMS
(SYMPTOMS)
RECOMMENDED
COURSE OF ACTION
POSSIBLE CAUSE
FUNCTION PROBLEMS
E. Machine does not have
1. Input fuse blown. Machine is
maximum output (67 to 71 volts).
single phased.
2. One phase of main transformer
windings open.
2. Repair.
3. Defective power bridge.
3. Check bridge per
Troubleshooting Procedures
Section J and check snubber per
Section F.
F. Machine comes on but soon trips 1. Improper ventilation.
off while under load and High
Temperature Warning Light
glows. (Thermostat tripped)
2. Loaded beyond rating.
G.Machine comes on but reduces
to low output under load and
remains there until the load is
broken and arc restarted. See
Fault Protection Troubleshooting
Section E.
1. Replace fuse or repair input line.
Check reason for fault.
1. Make sure all case openings are
free for proper circulation of air.
2. Operate at rated current and
duty cycle.
3. Fan inoperative.
3. Check leads and motor bearings.
Fan can be tested on 115 volt
line.
4. Shorted diode or SCR in power
rectifier bridge.
4. Refer to Troubleshooting
Procedures Section J and
Snubber, Section F.
1. Excessive load causing the over- 1. Reduce load.
load protection on control board
to operate.
2. Machine output shorted causing
overload protection on control
board to operate.
2. Turn machine off and remove
short.
3. Control circuit defective.
3. Replace per PC board,
Troubleshooting, Section A.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local
Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
IDEALARC® R3R 375-I, 500-I AND 600-I
E-5
E-5
TROUBLESHOOTING
Observe all Safety Guidelines detailed througout this manual
PROBLEMS
(SYMPTOMS)
RECOMMENDED
COURSE OF ACTION
POSSIBLE CAUSE
FUNCTION PROBLEMS
H. Machine trips off when under no
load or makes excessive noise
like it is loaded.
1. Power bridge rectifier may have
a shorted diode or SCR.
1. Refer to Power Hybrid,
Troubleshooting Procedures,
Section J and Snubber, Section
F.
2. Short in the transformer.
2. Repair.
3. Fan hitting vertical baffle.
3. Clear the fan.
1. Poor work or electrode cable
connection.
1. Check and clean cable connections.
2. Current too low.
2. Check recommended currents
for rod type and size.
3. Welding leads too small.
3. See Table in Output Connection
Section.
4. Open SCR or diode in power
rectifier bridge.
4. Check per Power Rectifier
Bridge Troubleshooting
Procedures, Section J and
Snubber, Section F.
5. Control circuit problems.
5. See SCR Troubleshooting,
Section K.
J. Welder will not shut off.
1. Input contactor contacts frozen.
1. Replace input contactor.
K. Current control on machine not
functioning.
1. Current control switch in wrong
position.
1. Place switch in “machine” ( I )
position.
2. Current control switch defective.
2. Check per Section H.
3. Current control potentiometer
defective.
3. Check per Section G.
4. Lead or connection in control
circuit open.
4. Repair or connect.
5. Defective control or circuit
boards.
5. See SCR Troubleshooting,
Section K.
I. Variable or sluggish welding arc.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local
Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
IDEALARC® R3R 375-I, 500-I AND 600-I
E-6
E-6
TROUBLESHOOTING
Observe all Safety Guidelines detailed througout this manual
PROBLEMS
(SYMPTOMS)
RECOMMENDED
COURSE OF ACTION
POSSIBLE CAUSE
FUNCTION PROBLEMS
L. Optional remote current control
not functioning. See
Troubleshooting , Section C
before connecting.
1. Current control switch in the
wrong position.
1. Place switch in “remote” (
position.
)
2. Leads 75, 76 and 77 not connected to correct numbers on
models with terminal strip.
2. Correct connection.
3. Remote control leads broken.
3. Repair broken leads.
4. Remote control potentiometer
open.
4. See Troubleshooting, Section C.
5. Lead or connection in current
control circuit open.
5. Connect or repair.
6. Control PC board plug disconnected or loose.
6. Connect plug.
7. Control circuit problems.
7. See SCR Troubleshooting,
Section K.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local
Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
IDEALARC® R3R 375-I, 500-I AND 600-I
IDEALARC® R3R 375-I, 500-I AND 600-I
If removing each gate lead
one at a time changes OCV
If amphenol OK, possible
defective PC board.
If resistance is OK, possible
defective PC board.
If not, clear terminal strip
and leads, and also check
SW2 and R1 for dirt.
If resistance is OK,
possible defective
PC board.
Check resistance of each
terminal on this terminal
strip to ground. Resistance
must be as follows:
75-GND 2K minimum
76-GND 2K minimum
77-GND 12K minimum
Possible intermittent
or loose connections
in control circuit.
Check PC board connector, switches,
potentiometers, etc.
If removing and replacing
each gate lead one at a
time does NOT change OCV
Retighten
leads
Loose lead
connections
on shunt
Rated OCV but
erratic welding
Replace
Defective power SCR
If voltage OK
Replace.
Possible defective
PC board
If voltage is
not correct
Identify gate lead that, when
removed, OCV did not change.
Remove gate lead. Voltage
between gate lead and 204 must be 13-17V.
Replace
Possible
defective
PC board
OCV is 0
Check leads 76, 77,
212, 213, 210, 211
& SW2 for open
Remove and replace Gate leads
G-1, G-2, G-3 from PC board
one at a time.
Possible machine
is being
single phased
Codes below 9500
with power off, remove leads from
75, 76, 77 terminal strip and
welding leads from output terminals
If aux. voltages
are OK
OCV 35-45V
OCV is 40-45V
Replace
Possible
defective
PC board
See wiring diagram
and correct
Possible wrong connection
of gate leads if recent
PC board or rectifier
stack change.
Replace
Possible defective
PC board
OCV less than rated
but more than 55V
TROUBLESHOOTING
If fault found, repair or
replace amphenol assembly.
If not, examine amphenol
assembly for faults.
Check the following pins
for resistance to ground.
Resistance must be as
follows:
GND 2K min.
GND 2K min.
GND 12K min.
Codes above 9500
with power off, disconnect
remote control amphenol
and welding leads from
output terminals.
If aux. voltages
are incorrect,
check & repair.
201-202 = 120V ± 10%
201-202 = 120V ± 10%
202-203 = 120V ± 10%
Check aux. voltages
on PC board
OCV 45-55V
OCV is 35-55V
Check OCV
Turn control dial to minimum
Low output, low OCV, or erratic welding
E-7
E-7
CONTROL CIRCUIT
TROUBLESHOOTING CHART
E-8
E-8
TROUBLESHOOTING
C. CONNECTING THE REMOTE CONTROL
TO THE MACHINE
TROUBLESHOOTING
PROCEDURES
A. PROCEDURE FOR REPLACING PC
BOARDS
When a PC board is to be replaced, the following
procedure must be followed:
1. Visually inspect PC board in question. Are any of
the components damaged? Is a conductor on
the back side of the board damaged?
a. If there is no damage to the PC board, insert
a new one and see if this remedies the problem. If the problem is remedied replace the
old PC board and see if the problem still
exists with the old PC board.
1. If the problem does not exist with the old
board, check the PC board harness plug
and PC board plug for corrosion, contamination, or oversize.
2. Check leads in the harness for loose connections.
b. If there is damage to the PC board, refer to
the Troubleshooting Guide.
B. PROCEDURE FOR CHECKING DIODES
1. Isolate the diode
in
question.
(Electrically disconnect
from
other circuits.)
Extreme caution must be observed when installing
or extending the wiring of a remote control.
Improper connection of this unit can Lead to failure
of the current control rheostat or the control circuit.
Only the green lead can and should be grounded to
the machine case. When extending the standard
remote control make sure the leads are the same
and the splice is waterproof. Be very careful not to
ground the cable when in use and do not let these
connections touch against the case.
D. OUTPUT VOLTAGE
The open circuit voltage of the machine should be
66 to 71 volts and should not vary when the rheostat is varied unless the machine is welding. If any
other condition exists, refer to the Troubleshooting
Guide.
E. FAULT PROTECTION OPERATION
The overload protection circuit, in the control board,
will reduce the welding current (heat) to some safe
value if the machine is overloaded for 2 to 3 seconds. The overload values are as appears in the following table.
Machine Name
f
Load Current ±5%
R3R 375-I
R3R 500-I
R3R 600-I
50 Hz
100 A
F. CHECKING SNUBBER CIRCUIT
2. Use an ohmmeter X10 scale.
Connect
the
meter across the
diode and note
the resistance
value. Reverse the ohm-meter leads and note
the resistance value.
In case of an SCR malfunction or failure, the snubber assembly should be checked. Turn the machine
off and disconnect one lead of the snubber assembly. (Either 221, 222 or 223 depending on the SCR
in question. See wiring diagram.) The sides of the
machine have to be removed to do this. (See the
instruction manual parts list for the exact location.)
Shorted diode – Low resistance readings in both
directions.
1. Visually inspect the snubber assembly for overheated components.
Open diode – High or infinite resistance in both
directions.
2. Using a VOM meter on the X10 scale, connect
the positive lead to the lead removed. Touch the
negative lead to the other lead still connected to
the SCR bridge. The indicating needle on the
meter will move quickly to the right (low resistance value) and then slowly return to the left
Good diode – One reading will be high or infinite
and the other reading will be low.
IDEALARC® R3R 375-I, 500-I AND 600-I
E-9
E-9
TROUBLESHOOTING
(high resistance value). This indicates that the
capacitor in the snubber circuit is taking a
charge.
3. If the needle stays to the right, the capacitor is
shorted and the assembly is defective.
5. If either step (3) or step (4) fails, replace the
switch.
I. REMOTE CONTROL CHECK
For codes above 9500, the remote control
Amphenol pin assignments are: pin C-75, pin B-76,
and pin A-77. Disconnect the remote field control
and connect an ohmmeter across 75 and 76 and
rotate the rheostat in the remote control. The resistance reading should go from zero to 10K ohms.
Repeat with triplet across 77 and 76 with same
results. Connect ohmmeter across 75 and 77. The
reading should be 10K ohms. A lower reading will
indicate a shorted or partially shorted rheostat. A
very high reading will indicate an open rheostat. In
either of the last two cases, replace rheostat. Check
cable for any physical damage.
4. If the needle does not move, the capacitor is
open and the assembly is defective.
G.CHECKING CURRENT CONTROL
RHEOSTAT ON MACHINE
1. Turn machine off.
2. Remove the control panel screws and open the
front cover.
3. Turn the current control switch to remote.
4. Disconnect the harness plug from the control
board.
J. POWER RECTIFIER BRIDGE ASSEMBLY CHECKING PROCEDURE
5. Put current range switch to B range.
6. With an ohmmeter on X1K, connect it to lead
210 and 211 on SW #2. Rotate the current control rheostat. The resistance reading should be
from around zero to 10K ohms. Check the resistance reading between 75 on the terminal strip
(codes below 9500) or Amphenol (codes above
9500), and 211 on SW #2. The reading must be
10K ohms. No reading will indicate an open
rheostat and low reading will indicate a shorted
or partially shorted rheostat; in either case,
replace.
CAUTION
The rectifier bridge tests outlined below will identify the most common effects found in power
diodes or power silicon controlled rectifiers. If a
bridge problem still exists after test, please call a
Lincoln Field Service Shop. Further evaluation of
diodes or silicon controlled rectifiers may require
laboratory equipment.
1. DEVICE ISOLATION (see the instruction manual Parts List for the exact location)
Disconnect the following leads from the bridge,
shown in Diagram 1:
H. TOGGLE SWITCH CHECK
1. Turn off the machine power input. SW-1 has 110
volts across it when the input power is connected.
a. Wiring harness gate leads (G1, G2, G3) from
the gate lead terminals(1) on the Control PC
board.
2. Isolate the switch to be tested by removing all
connecting leads.
b. AC leads X1, X2 and X3 from the anodes of
the SCR’s and cathodes of the diodes.
3. Check to make sure the switch is making connections with a VOM meter. The meter should
read zero resistance.
c. The 220, 221 and 223 leads from the
Snubber PC board.
d. Lead 220 that connects to the latching resistor (R3).
4. Put the ohmmeter on X1K scale and measure
the resistance between the terminal and the
case of the machine (touch a self-tapping
screw). Reading should be infinite.
e. The cathode of each diode (4 total).
(1)
Connector J4 on latest control board.
IDEALARC® R3R 375-I, 500-I AND 600-I
E-10
TROUBLESHOOTING
E-10
DIAGRAM 1
DIAGRAM 2
2. POWER DIODE TEST
K. POWER SILICON CONTROLLED RECTIFIER TEST
a. Establish the polarity of the ohmmeter leads
and set to X10 scale.
b. Connect the ohmmeter positive lead to anode
and negative lead to the cathode.
c. Reverse the leads of the ohmmeter from Step
b.
d. A shorted diode will indicate zero or an equally low resistance in both directions. An open
diode will have an infinite or high resistance in
both directions, and a good diode will have a
low resistance in Step b and a much higher
resistance in Step c.
The SCR must be mounted in the heat sink when
making this test.
a. Connect the ohmmeter (set to the X10 scale)
leads to the anode and cathode.
b. Reverse the leads of the ohmmeter from Step a.
c. A shorted SCR will indicate zero or an equally
low resistance in one or both directions.
d. Establish the polarity of the ohmmeter. Connect
the positive lead to the gate and the negative
lead to the cathode.
e. An open gate circuit will have an infinite or high
resistance. A good gate circuit will read a low
resistance, but not zero ohms.
IDEALARC® R3R 375-I, 500-I AND 600-I
F-1
F-1
WIRING DIAGRAMS
IDEALARC R3R-400, 500-I, 500 & 600-I WIRING DIAGRAM
3
18
2
17
1
16
T2
X1
L3
X1
H2
H1
H3
H2
L3
3
9
6
L2
2
8
5
L1
1
7
4
L2
ICR
TO PRIMARY
COILS
233
PRIMARY CONNECTIONS 1-7, 2-8 AND 3-9
ARE MADE AT THE MAIN TRANSFORMER
TO SUPPLY LINES
H2 L2
2
L1
1
H3
H2
H1
9
5
L3
3
8
4
L2
2
7
6
L1
232
233
231
TO PRIMARY
COILS
H3 L3
3
L2
2
H2
X1
LIFT BALE
AND FRAME
233
232
BONDED GROUNDING LEADS
INPUT BOX
6
10
8
5
12
7
4
FLEX
LEAD
1
L1
231
JUMPER
TO PRIMARY COILS
ICR
233
220/380/415-440
TO PRIMARY
COILS
AND
220-230/380400/440-460
REMOTE
RECEPTACLE
CONTROL
PANEL
CONTROL
BOX
HIGH TEMP LIGHT
BASE
A
11
233
FAN MOTOR
10
SECONDARY
THERMOSTAT
CHOKE
THERMOSTAT
12
232
235
234
231
235
1
ICR
232
TO PRIMARY
COILS
SINGLE, 346V AND ABOVE
(EXCEPT 380V.)
115 V
A
231
T2
ICR
(R3R-600-I ABOVE CODE 11200 ONLY)
RECONNECT PANEL SHOWN
CONNECTED FOR 230V
X1
3
H1
SINGLE, BELOW 346V OR
DUAL VOLTAGE
380/500 OR 460/575
T2
X2
L3
H1
231
X2
H4
11 9
L1
232
TO GROUND
PER
NATIONAL
ELECTRICAL
CODE
X1
H1
ICR
231
H3
X2
T2
RECONNECT PANEL
A
X2
H3
RECONNECT PANEL SHOWN
CONNECTED FOR LOW VOLTAGE
RECONNECT PANEL SHOWN
CONNECTED FOR 220V
TO SUPPLY LINES
TO GROUND
PER
NATIONAL
ELECTRICAL
CODE
A
X2
T2
RECONNECT PANEL SHOWN
CONNECTED FOR LOW VOLTAGE
TO GROUND
PER
NATIONAL
ELECTRICAL
CODE
A
TO GROUND
PER
NATIONAL
ELECTRICAL
CODE
PRIMARY CONNECTIONS
4-7, 5-8 AND 6-9
ARE MADE AT THE
MAIN TRANSFORMER
TO SUPPLY LINES
TO SUPPLY LINES
TO GROUND
PER
NATIONAL
ELECTRICAL
CODE
A
PRIMARY CONNECTIONS 4-7, 5-8 AND 6-9
ARE MADE AT THE MAIN TRANSFORMER
TO SUPPLY LINES
233
230/400V
AUXILIARY COILS
(ON BOTTOM PRI.
COIL ASSEMBLIES)
ELECTRICAL SYMBOLS PER E1537
A
202
201
TO PRIMARY
COILS
66V
66V
8
7
203
66V
9
S
S
S
204
TOP PRIMARY
11
10
LEGEND
16, 17, & 18 ARE PRESENT
ON 380/500 OR 460/575
MACHINES ONLY.
D5
D6
D7
L1
DC OUTPUT FILTER
R1
R2
R3
R4
10K OHM POT., OUTPUT CONTROL
10K OHM POT., ARC FORCE CONTROL
40 OHM
.4 OHM POCKET AMPTROL SENSING RESISTOR
SW1
SW2
SW3
SW4
POWER SWITCH
MACHINE/REMOTE SWITCH
DIAL SELECTOR SWITCH
OPTIONAL POLARITY SWITCH
(60 Hz ONLY)
THERE IS NO 10-11-12
CONNECTION ON 380,
220/380/415-440 OR
230/400V MACHINES.
12
16
17
18
1
2
3
POCKET AMPTROL SENSING BRIDGE
4
5
T1
L1
R4
223
221
SHUNT
-
D6
219
G
G1 G2 G3
4
1
5
2
6
5
1
6
2
7
3
8
4
204
115V
201A
G
1 2
G
Y
G
THESE LEADS ARE
PRESENT ONLY WITH
OPTIONAL METER
KIT.
206
G1 G2 G3 204
203A
Y
205
204
204
224
2
3 4 5 6 7 8
T3
1
3
4
2
1
J2
J4
J3
J5
SNUBBER BOARD
226
218
219
75
76
77
CONTROL
P.C.
BOARD
J1
OPTIONAL METER KIT
AM
- +
VM
- +
217
2
SCR3
204
220
225
OPTIONAL POCKET
AMPTROL P.C.
BOARD
1
2
J7
3
4
1
2
3
J6
4
5
6
1
1
D5
D7
222
( DASHED ITEMS ON WIRING
DIAGRAM ARE OPTIONAL )
3
204
R3
SCR2
SCR1
SCR AND DIODE
RECTIFIER BRIDGE
COLORS
A = AMBER
G = GREEN
W = WHITE
Y = YELLOW
4
D3
D4
RECTIFIER
BRIDGE
INPUT STARTER
2
218
204
220
D2
D1
MAIN TRANSFORMER
CONTROL TRANSFORMER
POCKET AMPTROL OPTION
TRANSFORMER
ICR
X3
SEC
X2
SEC
226
T1
T2
T3
219
6
X1
SEC
+
SCR1-D1
SCR2-D2
SCR3-D3
D4
BOTTOM PRIMARY
205
206
217
6
3
2
1
5
4
1
2
3
4
5
6
7
8
201A
201
202
203
203A
204
204
209
208
214
75
212
213
217
232
235
W
PILOT LIGHT
235
231
235
SW1
217
210
75
3
212 76
CAVITY NUMBERING SEQUENCE
(COMPONENT SIDE OF BOARD)
77
76
75
75
76
77
211
210
211
214 204
208
204
77
R2
R1
213
204
209
224
SW3
SW2
(SWITCH SHOWN IN LOCAL POSITION)
TO CONTROL BOX
GROUNDING STUD
CONNECTOR AND THESE THREE
LEADS ARE NOT USED WHEN
OPTIONAL POCKET AMPTROL
IS PROVIDED.
A
B
C
D
E
F
REMOTE CONTROL RECEPTACLE
-
SW4
+
F
L9376
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The
specific diagram for a particular code is pasted inside the machine on one of the enclosure panels.
IDEALARC® R3R 375-I, 500-I AND 600-I
F-2
WIRING DIAGRAMS
F-2
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The
specific diagram for a particular code is pasted inside the machine on one of the enclosure panels.
IDEALARC® R3R 375-I, 500-I AND 600-I
F-3
F-3
WIRING DIAGRAMS
R3R 375-I, 500-I and 600-I
K817 or K817R
(K841 not shown)
Part No.
Type
M12244-7
R3R
A
B
32.00 15.39
C
D
3092
1.44
F
G
30.02±.11 33.07±.06
M12244-7
7-7-78
IDEALARC® R3R 375-I, 500-I AND 600-I
H
.94
● Do not touch electrically live parts or
WARNING
Spanish
AVISO DE
PRECAUCION
French
ATTENTION
German
WARNUNG
Portuguese
ATENÇÃO
● Keep flammable materials away.
● Wear eye, ear and body protection.
● Mantenga el material combustible
● Protéjase los ojos, los oídos y el
electrode with skin or wet clothing.
● Insulate yourself from work and
ground.
● No toque las partes o los electrodos
bajo carga con la piel o ropa mojada.
● Aislese del trabajo y de la tierra.
● Ne laissez ni la peau ni des vête-
ments mouillés entrer en contact
avec des pièces sous tension.
● Isolez-vous du travail et de la terre.
● Berühren Sie keine stromführenden
fuera del área de trabajo.
● Gardez à l’écart de tout matériel
inflammable.
● Entfernen Sie brennbarres Material!
Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!
● Isolieren Sie sich von den
Elektroden und dem Erdboden!
● Não toque partes elétricas e elec-
trodos com a pele ou roupa molhada.
● Isole-se da peça e terra.
cuerpo.
● Protégez vos yeux, vos oreilles et
votre corps.
● Tragen Sie Augen-, Ohren- und Kör-
perschutz!
● Mantenha inflamáveis bem guarda-
dos.
● Use proteção para a vista, ouvido e
corpo.
Japanese
Chinese
Korean
Arabic
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO
BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HERSTELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
IDEALARC® R3R 375-I, 500-I AND 600-I
● Keep your head out of fumes.
● Use ventilation or exhaust to
● Turn power off before servicing.
● Do not operate with panel open or
guards off.
remove fumes from breathing zone.
● Los humos fuera de la zona de res-
piración.
● Mantenga la cabeza fuera de los
humos. Utilice ventilación o
aspiración para gases.
● Gardez la tête à l’écart des fumées.
● Utilisez un ventilateur ou un aspira-
● Desconectar el cable de ali-
mentación de poder de la máquina
antes de iniciar cualquier servicio.
● Débranchez le courant avant l’entre-
Schweibrauch!
● Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
● Mantenha seu rosto da fumaça.
● Use ventilação e exhaustão para
remover fumo da zona respiratória.
guardas quitadas.
● N’opérez pas avec les panneaux
ouverts ou avec les dispositifs de
protection enlevés.
tien.
teur pour ôter les fumées des zones
de travail.
● Vermeiden Sie das Einatmen von
● No operar con panel abierto o
● Strom vor Wartungsarbeiten
● Anlage nie ohne Schutzgehäuse
abschalten! (Netzstrom völlig öffnen; Maschine anhalten!)
oder Innenschutzverkleidung in
Betrieb setzen!
● Não opere com as tampas removidas.
● Desligue a corrente antes de fazer
● Mantenha-se afastado das partes
serviço.
● Não toque as partes elétricas nuas.
moventes.
● Não opere com os paineis abertos
ou guardas removidas.
WARNING
Spanish
AVISO DE
PRECAUCION
French
ATTENTION
German
WARNUNG
Portuguese
ATENÇÃO
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
IDEALARC® R3R 375-I, 500-I AND 600-I
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com