idealarc r3r-500

IDEALARC ® R3R-300, -400 AND -500

OPERATOR’S MANUAL

IM409-ENovember, 2006

Safety Depends on YouLincoln arc welding and cuttingequipment is designed and builtwith safety in mind. However,your overall safety can beincreased by proper installation... and thoughtful operation onyour part. DO NOT INSTALL,OPERATE OR REPAIR THISEQUIPMENT WITHOUT READ-ING THIS MANUAL AND THESAFETY PRECAUTIONS CON-TAINED THROUGHOUT. And,most importantly, think before youact and be careful.

For use with machine Code Numbers: 9500 thru 10500,10857, 10858, 10881, 10882,11043, 11044, 11045, 1104611342, 11347

• 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

• World's Leader in Welding and Cutting Products •

Copyright © 2006 Lincoln Global Inc.

iSAFETYi

FOR ENGINEpowered equipment.

1.a. Turn the engine off before troubleshooting and maintenancework 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. Stopthe engine and allow it to cool before refuel-ing to prevent spilled fuel from vaporizing oncontact with hot engine parts and igniting. Donot spill fuel when filling tank. If fuel is spilled,wipe it up and do not start engine until fumeshave been eliminated.

____________________________________________________1.d. Keep all equipment safety guards, covers

and devices in position and in goodrepair.Keep hands, hair, clothing and toolsaway from V-belts, gears, fans and all othermoving parts when starting, operating orrepairing equipment.

____________________________________________________

1.e. In some cases it may be necessary to remove safetyguards to perform required maintenance. Removeguards only when necessary and replace them when themaintenance requiring their removal is complete.Always use the greatest care when working near movingparts.

___________________________________________________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 con-trol rods while the engine is running.

___________________________________________________1.g. To prevent accidentally starting gasoline engines while

turning the engine or welding generator during maintenancework, disconnect the spark plug wires, distributor cap ormagneto 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 youpurchase 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 theLincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES AREPERFORMED ONLY BY QUALIFIED INDIVIDUALS.

WARNING

Mar ‘95

ELECTRIC AND MAGNETIC FIELDSmay 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, andwelders having a pacemaker should consult their physicianbefore welding.

2.c. Exposure to EMF fields in welding may have other healtheffects which are now not known.

2.d. All welders should use the following procedures in order tominimize exposure to EMF fields from the welding circuit:

2.d.1. Route the electrode and work cables together - Securethem 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 andwork 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 aspossible to the area being welded.

2.d.5. Do not work next to welding power source.

1.h. To avoid scalding, do not remove theradiator pressure cap when the engine ishot.

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituentsare known to the State of California to cause can-cer, birth defects, and other reproductive harm.

The engine exhaust from this product containschemicals known to the State of California to causecancer, birth defects, or other reproductive harm.

The Above For Diesel Engines The Above For Gasoline Engines

iiSAFETYii

ARC RAYS can burn.4.a. Use a shield with the proper filter and cover

plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistantmaterial to protect your skin and that of your helpers fromthe arc rays.

4.c. Protect other nearby personnel with suitable, non-flammablescreening and/or warn them not to watch the arc nor exposethemselves 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 bareskin or wet clothing. Wear dry, hole-freegloves to insulate hands.

3.b. Insulate yourself from work and ground using dry insulation.Make certain the insulation is large enough to cover your fullarea of physical contact with work and ground.

In addition to the normal safety precautions, if weldingmust be performed under electrically hazardousconditions (in damp locations or while wearing wetclothing; on metal structures such as floors, gratings orscaffolds; when in cramped positions such as sitting,kneeling or lying, if there is a high risk of unavoidable oraccidental contact with the workpiece or ground) usethe 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 semiautomaticwelding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electricalconnection with the metal being welded. The connectionshould 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 andwelding machine in good, safe operating condition. Replacedamaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically “hot” parts ofelectrode holders connected to two welders because voltagebetween the two can be the total of the open circuit voltageof both welders.

3.i. When working above floor level, use a safety belt to protectyourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

FUMES AND GASEScan be dangerous.5.a. Welding may produce fumes and gases

hazardous to health. Avoid breathing thesefumes and gases. When welding, keepyour head out of the fume. Use enoughventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. Whenwelding with electrodes which require specialventilation such as stainless or hard facing (seeinstructions on container or MSDS) or on lead orcadmium plated steel and other metals or coatingswhich produce highly toxic fumes, keep exposure aslow as possible and below Threshold Limit Values (TLV)using local exhaust or mechanical ventilation. Inconfined spaces or in some circumstances, outdoors, arespirator may be required. Additional precautions arealso required when welding on galvanized steel.

5. b. The operation of welding fume control equipment is affectedby various factors including proper use and positioning of theequipment, maintenance of the equipment and the specificwelding procedure and application involved. Worker expo-sure level should be checked upon installation and periodi-cally thereafter to be certain it is within applicable OSHA PELand ACGIH TLV limits.

5.c. Do not weld in locations near chlorinated hydrocarbon vaporscoming from degreasing, cleaning or spraying operations.The heat and rays of the arc can react with solvent vapors toform phosgene, a highly toxic gas, and other irritating prod-ucts.

5.d. Shielding gases used for arc welding can displace air andcause 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 thisequipment and the consumables to be used, including thematerial safety data sheet (MSDS) and follow youremployer’s safety practices. MSDS forms are available fromyour welding distributor or from the manufacturer.

5.f. Also see item 1.b.

AUG 06

iiiSAFETYiii

FOR ELECTRICALLYpowered equipment.

8.a. Turn off input power using the disconnectswitch at the fuse box before working onthe equipment.

8.b. Install equipment in accordance with the U.S. NationalElectrical Code, all local codes and the manufacturer’srecommendations.

8.c. Ground the equipment in accordance with the U.S. NationalElectrical Code and the manufacturer’s recommendations.

CYLINDER may explodeif damaged.7.a. Use only compressed gas cylinders

containing the correct shielding gas for theprocess used and properly operatingregulators designed for the gas and

pressure used. All hoses, fittings, etc. should be suitable forthe application and maintained in good condition.

7.b. Always keep cylinders in an upright position securelychained to an undercarriage or fixed support.

7.c. Cylinders should be located:• Away from areas where they may be struck or subjected tophysical damage.

• A safe distance from arc welding or cutting operations andany other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any otherelectrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outletwhen opening the cylinder valve.

7.f. Valve protection caps should always be in place and handtight except when the cylinder is in use or connected foruse.

7.g. Read and follow the instructions on compressed gascylinders, associated equipment, and CGA publication P-l,“Precautions for Safe Handling of Compressed Gases inCylinders,” available from the Compressed Gas Association1235 Jefferson Davis Highway, Arlington, VA 22202.

Mar ‘95

WELDING SPARKS cancause fire or explosion.6.a. Remove fire hazards from the welding area.

If this is not possible, cover them to preventthe welding sparks from starting a fire.Remember that welding sparks and hot

materials from welding can easily go through small cracksand openings to adjacent areas. Avoid welding nearhydraulic 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 hazardoussituations. Refer to “Safety in Welding and Cutting” (ANSIStandard Z49.1) and the operating information for theequipment being used.

6.c. When not welding, make certain no part of the electrodecircuit is touching the work or ground. Accidental contact cancause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until theproper steps have been taken to insure that such procedureswill not cause flammable or toxic vapors from substancesinside. They can cause an explosion even though they havebeen “cleaned”. For information, purchase “RecommendedSafe Practices for the Preparation for Welding and Cutting ofContainers and Piping That Have Held HazardousSubstances”, AWS F4.1 from the American Welding Society(see address above).

6.e. Vent hollow castings or containers before heating, cutting orwelding. They may explode.

6.f. Sparks and spatter are thrown from the welding arc. Wear oilfree protective garments such as leather gloves, heavy shirt,cuffless trousers, high shoes and a cap over your hair. Wearear plugs when welding out of position or in confined places.Always wear safety glasses with side shields when in awelding area.

6.g. Connect the work cable to the work as close to the weldingarea as practical. Work cables connected to the buildingframework or other locations away from the welding areaincrease the possibility of the welding current passingthrough lifting chains, crane cables or other alternate circuits.This can create fire hazards or overheat lifting chains orcables until they fail.

6.h. Also see item 1.c.

ivSAFETYiv

PRÉCAUTIONS DE SÛRETÉPour votre propre protection lire et observer toutes les instructions etles précautions de sûreté specifiques qui parraissent dans cemanuel aussi bien que les précautions de sûreté générales suiv-antes:

Sûreté Pour Soudage A L’Arc1. Protegez-vous contre la secousse électrique:

a. Les circuits à l’électrode et à la piéce sont sous tensionquand la machine à souder est en marche. Eviter toujourstout contact entre les parties sous tension et la peau nue oules vétements mouillés. Porter des gants secs et sans trouspour isoler les mains.

b. Faire trés attention de bien s’isoler de la masse quand onsoude dans des endroits humides, ou sur un plancher met-allique ou des grilles metalliques, principalement dans les positions assis ou couché pour lesquelles une grandepartie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câble desoudage et la machine à souder en bon et sûr état defonc-tionnement.

d.Ne jamais plonger le porte-électrode dans l’eau pour lerefroidir.

e. Ne jamais toucher simultanément les parties sous tensiondes porte-électrodes connectés à deux machines à souderparce que la tension entre les deux pinces peut être le totalde la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source decourant pour soudage semi-automatique, ces precautionspour le porte-électrode s’applicuent aussi au pistolet desoudage.

2. Dans le cas de travail au dessus du niveau du sol, se protégercontre les chutes dans le cas ou on recoit un choc. Ne jamaisenrouler le câble-électrode autour de n’importe quelle partie ducorps.

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 ainsiqu’un verre blanc afin de se protéger les yeux du rayon-nement de l’arc et des projections quand on soude ou quandon regarde l’arc.

b. Porter des vêtements convenables afin de protéger la peaude soudeur et des aides contre le rayonnement de l‘arc.

c. Protéger l’autre personnel travaillant à proximité au soudageà 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 sansrevers, et chaussures montantes.

5. Toujours porter des lunettes de sécurité dans la zone desoudage. Utiliser des lunettes avec écrans lateraux dans les

zones où l’on pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin deprévenir tout risque d’incendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé dela masse. Un court-circuit accidental peut provoquer unéchauffement et un risque d’incendie.

8. S’assurer que la masse est connectée le plus prés possible dela zone de travail qu’il est pratique de le faire. Si on place lamasse sur la charpente de la construction ou d’autres endroitséloignés de la zone de travail, on augmente le risque de voirpasser le courant de soudage par les chaines de levage,câbles de grue, ou autres circuits. Cela peut provoquer desrisques d’incendie ou d’echauffement des chaines et descâbles 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 tôlesgalvanisées plombées, ou cadmiées ou tout autre métal quiproduit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenantd’opérations de dégraissage, nettoyage ou pistolage. Lachaleur ou les rayons de l’arc peuvent réagir avec les vapeursdu solvant pour produire du phosgéne (gas fortement toxique)ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté, voirle code “Code for safety in welding and cutting” CSA StandardW 117.2-1974.

PRÉCAUTIONS DE SÛRETÉ POURLES MACHINES À SOUDER ÀTRANSFORMATEUR ET ÀREDRESSEUR

1. Relier à la terre le chassis du poste conformement au code del’électricité et aux recommendations du fabricant. Le dispositifde montage ou la piece à souder doit être branché à unebonne mise à la terre.

2. Autant que possible, I’installation et l’entretien du poste seronteffectués par un électricien qualifié.

3. Avant de faires des travaux à l’interieur de poste, la debranch-er à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leurplace.

Mar. ‘93

IDEALARC R3R, -300, -400, -500

vv

Thank You for selecting a QUALITY product by Lincoln Electric. We want youto take pride in operating this Lincoln Electric Company product •••as much pride as we have in bringing this product to you!

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep ithandy 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:

WARNINGThis statement appears where the information must be followed exactly to avoid serious personal injury orloss of life.

This statement appears where the information must be followed to avoid minor personal injury or damage tothis equipment.

CAUTION

Please Examine Carton and Equipment For Damage ImmediatelyWhen this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claimsfor material damaged in shipment must be made by the purchaser against the transportation company at the timethe shipment is received.

Please record your equipment identification information below for future reference. This information can be foundon 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 youhave 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 packetaccompanying 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.

viTABLE OF CONTENTS

IDEALARC R3R, -300, -400, -500

vi

Page

____________________________________________________________________________Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A

Location and Stacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1Input Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1Output Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2

____________________________________________________________________________Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section B____________________________________________________________________________Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section C____________________________________________________________________________Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section D

Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-7 – D-10____________________________________________________________________________Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section E____________________________________________________________________________Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-206 SERIES____________________________________________________________________________

A-1INSTALLATION

IDEALARC R3R, -300, -400, -500

A-1

LOCATION AND STACKING

FALLING EQUIPMENT can causeinjury.

• Do not lift this machine using liftbail if it is equipped with a heavy

• accessory such as trailer or gas cylinder.

• Lift only with equipment of adequate liftingcapacity.

• Be sure machine is stable when lifting.

Install the welder in a dry location where there is a freecirculation of air in through the front louvers and out theback of the case. A location which minimizes theamount of smoke and dirt drawn into the front louversreduces the chance of dirt accumulation that can blockair passages, causing overheating and nuisance shut-down of the machine.

The Idealarc® R3R welders can be stacked three highwhen the following precautions are observed:

1. Be sure the bottom machine is on a firm, level sur-face suitable for the total weight {up to 1350 pounds(608 Kg)} of the stacked machines.

2. Stack the machines with the fronts flush. Be certainthe pins on the top front corners of the lowermachines fit through the holes in the base rails ofthe upper machines.

3. No unit heavier than the bottom unit should bestacked on top of it. For example, an R3R-500 shallnot be stacked on top of an R3R-400, but an R3R-400 may be stacked on top of an R3R-500.

INPUT WIRING

ELECTRIC SHOCK can kill.

• Have an electrician install and ser-vice this equipment.

• Turn the input power off at the fusebox before working on equipment.

• Do not touch electrically hot parts.

Dual or triple voltage (eg: 230/460, 220/380/440, etc.)models are shipped connected for highest voltage. Tochange the connection, see the wiring or connectiondiagram pasted to the inside of the access panel in thecase back.

Be sure the voltage, phase and frequency of the inputpower is as specified on the welder nameplate.

Have a qualified electrician remove the access panel inthe case back and connect the three phase AC powerto terminals L1, L2, L3 of the input contactor in accor-dance with the U. S. National Electrical Code, all localcodes, and the wiring diagram located inside themachine.

The welder frame must be grounded. A stud markedwith the symbol located on the floor of the inputbox is provided for this purpose. See the U.S. NationalElectrical Code for details on proper groundingmethods.

Recommended Input Wire, Ground Wire and Fuse Sizes

Based on U.S. National Electrical Code.For 60 hertz, 3 phase Welders at 60% Duty Cycle.

This welder is rated for 60% duty cycle. Duty cycle isbased on a ten minute period. Therefore, the weldercan be operated at nameplate rated output for 6 min-utes of every 10 minute period without overheating.An amber high temperature warning light provides avisual indication of an over temperature condition.

Failure to follow these instructions can causeimmediate failure of components within themachine.

When powering welder from a generator be sure toturn off welder first, before generator is shut down,in order to prevent damage to welder!

WARNING

WARNING

Copper Wire SizeType 75°C in Conduit

Input Amps 3 Input 1 Ground Super Lag FuseWelder Volts Input Wires Wire Size in Amps

300 230 56.0 8 8 80460 28.0 10 10 40

400 230 82.0 6 6 125460 41.0 10 10 60

500 230 100.0 4 6 150460 50.0 8 8 70

CAUTION

A-2INSTALLATIONA-2

OUTPUT CONNECTIONS

OUTPUT STUDS

With the machine off, run electrode and work cables ofthe appropriate sizes (see the following table) upthrough the rectangular holes in the machine baselocated below the output studs. Connect the cable lugsto the output terminals marked (+) and (-) or, if thewelder comes equipped with the polarity switch option“electrode” and “to work”. Tighten the holding nuts witha wrench.

Cable Sizes for Combined Length of Electrodeand Work Cable (Copper) at 60% Duty Cycle

CONNECTION OF OPTIONAL REMOTE CONTROL– K857

Turn the machine off. The K857 consists of a controlbox with 28 feet (8.5m) of four conductor cable and a 6pin connector for easy connection to the power source.This control will give the same control as the currentcontrol on the machine depending on the position ofthe current dial selector switch. (There is no currentdial selector switch on the R3R-300.)

Extreme care must be observed when installing orextending the wiring of a remote control. Theremote control cord can be lengthened to anylength by splicing four wires to the standard 28 ft.(8.5m) cord before connecting to the R3R terminalstrip. Only the green lead can and should begrounded to the machine case.

When extending the standard remote control makesure the leads are the same and the splice is water-proof. Don’t let the lugs touch against the case.

OPTIONAL K963 HAND AMPTROL AND K870FOOT AMPTROL

These amptrols connect directly to the 6 pin connectoron the front of the power source.

TIG WELDING

The R3R is shipped with proper R.F. By-pass circuitryinstalled to protect the control circuit when TIG weldingwith a Hi-Freq™ unit. To provide protection, thewelder frame grounding stud must be connected toground.

IDEALARC R3R, -300, -400, -500

CAUTION

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)

300 1/0 (54 mm2) 1/0 (54 mm2) 2/0 (68 mm2) 3/0 (86 mm2)400 2/0 (68 mm2) 2/0 (68 mm2) 3/0 (86 mm2) 4/0 (108 mm2)500 2/0 (68 mm2) 3/0 (86 mm2) 3/0 (86 mm2) 4/0 (108 mm2)

B-1OPERATIONB-1


• Do not touch electrically live partsor electrode with skin or wet cloth-ing.

• Insulate yourself from work and ground.

• Always wear dry insulating gloves.

FUMES AND GASES can be danger-ous.

• Keep your head out of fumes.

• Use ventilation or exhaust to • remove fumes from breathing zone.

WELDING SPARKS can cause fire orexplosion.

• Keep flammable material away.

• Do not weld on containers thathave held combustibles.

ARC RAYS can burn.

• Wear eye, ear and body protection.

NOTE: The P.C. Board is protected by a moistureresistant coating. When the welder is operated, thiscoating will “bake off” of certain power resistors thatnormally operate at high temperatures, emitting somesmoke and odor for a short time. These resistors andthe P.C. Board beneath them may become blackened.This is a normal occurrence and does not damage thecomponent or affect the machine performance.

1. To Start the Welder, move the “Power” switch to“On”. This starts the welder and lights the white pilotlight on the machine control panel. This light indi-cates that the line contactor is energized).

2. Setting Welding Current

a. The “Current Control” dial on the front of themachine indicates the output current at theNEMA arc voltage.

On R3R-300, one dial covers the completerange. On the R3R-400 and -500, two dials areused, The “A” range controls the current overabout 1/2 of the range of the “B” range. A toggleswitch on the control panel allows selection ofthe desired range. The output control can beadjusted while welding.

b. Provisions for remote control are standard oneach power source. A current control switch onthe machine control panel labeled “CurrentControl at R3R” or “Current Control Remote” isprovided for selecting the desired mode of oper-ation, either at the machine or remote, Be certainthe machine remote switch is in the machineposition, unless a remote control is connected,or the R3R is equipped with optional pocketamptrol.

c. The “Arc Force Control”, located on the right sideof the front control panel, is calibrated from oneto ten. Lower settings will provide less short cir-cuit current and a softer arc. A setting that is toolow may cause the electrode to stick in the pud-dle. Higher settings will provide a higher shortcircuit current, a more forceful arc, and possiblymore spatter. For most welding, the dial shouldbe set at approximately mid range (5 – 6).Adjustment up or down can then be madedepending on the electrode, procedures, andoperator preference. For most TIG welding appli-cations adjust this control to minimum for bestoperating characteristics.

3. Pocket Amptrol (Optional)

The pocket amptrol option provides a remote cur-rent control for the R3R welders. This “wireless”control requires no control cable connection to thewelder.

a. On the R3R-400 and -500 the welder “CurrentControl” switch must be in the “Remote” positionand the “Current Dial Selector” switch in the “B”range. The R3R-300 has only one dial and noselection switch. The R3R-300 does not have a“Current Dial Selector” switch. With the “CurrentControl” switch in the “Remote” position, the cur-rent control potentiometer on the welder isremoved from the circuit and its setting has noeffect on the output. With the “Current DialSelector” switch in the “B” range position, thepocket amptrol provides total control from NEMAminimum to NEMA maximum output of thewelder.

b. Turn the welder power switch on.

c. Insert one end of the probe into the electrodeholder and hold the other end on the work forapproximately five seconds.

d. To change current, change the probe dial settingand repeat the five second procedure of placingthe probe between electrode and work.

IDEALARC R3R, -300, -400, -500

WARNING

B-2OPERATIONB-2

The solid state circuitry within the welder senses thischange in probe setting and automatically resets thewelding current to the new level. Each time the welderis turned off, the output goes to minimum and must bereset when the welder is turned on again.

115VAC DUPLEX RECEPTACLE AND CIRCUITBREAKER (60 Hertz Models for Code Numbers10857, 10858, 10881, 10882, 11043, 11044, 11045,11046 only )

• This receptacle provides up to 15 Amps of 115VACauxiliary power.

• 15 Amp circuit breaker protects the 115VAC recepta-cle.

• The receptacle and the circuit breaker are located inthe output panel between the output studs.

OPTIONAL EQUIPMENT

1. Remote Current Control – See “Operation”.

2. Amptrol – See “Operation”.

3. Polarity Switch (Factory Installed Only). Permitschanging polarity at the machine output terminals.(See also “Output Connections”.)

4. Meters – Ammeter and Voltmeter (Factory InstalledOnly)

5. Pocket Amptrol – (Factory Installed Only) See“Operation”.

6. Undercarriage – (K817, K817R) includes a springloaded handle for hand towing and a choice ofwheels.

RATINGS

Transformer insulation class 155(F)IP21 enclosure protection

IDEALARC R3R, -300, -400, -500

C-1MAINTENANCEC-1


• Have an electrician install and ser-vice this equipment.

• Turn the input power off at the fusebox before working on equipment.

• Do not touch electrically hot parts.

GENERAL MAINTENANCE

1. The fan motor has sealed bearings which require noservice.

2. In extremely dusty locations, dirt may clog the airchannels causing the welder to run hot. Blow outthe welder at regular intervals. The side panels canbe removed even when the machines are stacked.

POCKET AMPTROL MAINTENANCE

Routine cleaning should be the only maintenancerequired. The probe tip should be kept in condition toprovide sharp edges at the ends to assure penetrationof heavy oxide coatings on the work piece. A bluntedtip could result in giving different welding currents for agiven dial setting.

POWER RECTIFIER REPLACEMENT

Refer to the troubleshooting section “Power RectifierBridge Assembly Checking Procedure” if a rectifier fail-ure is suspected.

NOTE: Since proper material and correct assemblyprocedures are critical, field disassembly of the powerrectifier bridge sections can do more harm than good.Return a defective rectifier bridge section (or the entirebridge) to the factory for repairs.

IDEALARC R3R, -300, -400, -500

WARNING

D-1TROUBLESHOOTINGD-1

IDEALARC R3R, -300, -400, -500

WARNINGELECTRIC SHOCK can kill.• Do not touch electrically hot parts.• Have an electrician install and service this equip-

ment.• Turn the input power off at the fuse box before

working on equipment.

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your LocalLincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

CAUTION

This Troubleshooting Guide is provided to help youlocate and repair possible machine malfunctions.Simply follow the three-step procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).Look under the column labeled “PROBLEM (SYMP-TOMS)”. This column describes possible symptomsthat the machine may exhibit. Find the listing that bestdescribes the symptom that the machine is exhibiting.

Step 2. POSSIBLE CAUSE.The second column labeled “POSSIBLE CAUSE” liststhe obvious external possibilities that may contribute tothe machine symptom.

Step 3. RECOMMENDED COURSE OF ACTION

This column provides a course of action for thePossible Cause, generally it states to contact yourlocal Lincoln Authorized Field Service Facility.

If you do not understand or are unable to perform theRecommended Course of Action safely, contact yourlocal Lincoln Authorized Field Service Facility.

HOW TO USE TROUBLESHOOTING GUIDE

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 machineoperator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, pleaseobserve all safety notes and precautions detailed throughout this manual.

__________________________________________________________________________

WARNING


IDEALARC R3R, -300, -400, -500

Observe all Safety Guidelines detailed througout this manual


CAUTION

FUNCTION PROBLEMS

PROBLEMS(SYMPTOMS)

POSSIBLECAUSE

RECOMMENDEDCOURSE OF ACTION

Input contactor chatters.

Machine input contactor does notoperate.

1.Faulty input contactor.

2.Low line voltage.

1.Supply line fuse blown.

2.Power circuit dead.

3.Broken or loose power lead.

4.Wrong voltage.

5.Thermostats tripped. (HighTemperature Warning Lightshould be lit.) (Welderoverheated.)

6.Input contactor coil open.

7.Open winding on 115V pilottransformer.

8.Power ON-OFF switch notclosing.

9.Lead broken or loose connec-tion in 115V starter circuit.

10.Thermostats defective. (HighTemperature Warning Lightshould be lit.)

If all recommended possible areasof misadjustment have beenchecked and the problem persists,Contact your local LincolnAuthorized Field Service Facility.


IDEALARC R3R, -300, -400, -500



CAUTION

FUNCTION PROBLEMS

PROBLEMS(SYMPTOMS)

POSSIBLECAUSE


Machine input contactor closes buthas no or low output. Open circuitvoltage should be 67 to 71 volts.

Machine has maximum output butno control.

1. Electrode or work lead loose orbroken.

2. Open transformer primary orsecondary circuit.

3. Supply line fuse blown.

4. Input line grounded causingsingle phase input.

5. Input leads not connected tocontactor.

6. Latching resistor, R3, open.

7. Control circuit problems.

1. Possible defective power SCR.

2. Possible defective control board.



IDEALARC R3R, -300, -400, -500



CAUTION

FUNCTION PROBLEMS

PROBLEMS(SYMPTOMS)

POSSIBLECAUSE


Machine does not have maximumoutput (67 to 71 volts).

Machine comes on but soon tripsoff while under load and HighTemperature Warning Light glows.(Thermostat tripped)

Machine comes on but reduces tolow output under load and remainsthere until the load is broken andarc re-started. See Fault ProtectionOperation Section.

1. Input fuse blown. Machine issingle phased.

2. One phase of main transformerwindings open.

3. Defective power bridge.

1. Improper ventilation.

2. Loaded beyond rating.

3. Fan inoperative.

4. Shorted diode or SCR in powerrectifier bridge.

1. Excessive load causing the over-load protection on control boardto operate.

2. Machine output shorted causingoverload protection on controlboard to operate.

3. Control circuit defective.



IDEALARC R3R, -300, -400, -500



CAUTION

FUNCTION PROBLEMS

PROBLEMS(SYMPTOMS)

POSSIBLECAUSE


Machine trips off when under noload or makes excessive noise likeit is loaded.

Variable or sluggish welding arc.

Welder will not shut off.

115VAC Receptacle not working.

1. Power bridge rectifier may havea shorted diode or SCR.

2. Short in the transformer.

3. Fan hitting vertical baffle.

1. Poor work or electrode cableconnection.

2. Current too low.

3. Welding leads too small.

4. Open SCR or diode in powerrectifier bridge.


1. Input contactor contacts frozen.

1. Circuit Breaker Tripped.2. Defective Cicuit Breaker.3. Broken connectionin wiring.



IDEALARC R3R, -300, -400, -500



CAUTION

FUNCTION PROBLEMS

PROBLEMS(SYMPTOMS)

POSSIBLECAUSE


Current control on machine notfunctioning.

Optional remote current control notfunctioning. See TroubleshootingProcedures before connecting.

1. Current control switch in wrongposition.

2. Current control switch defective.

3. Current control potentiometerdefective.

4. Lead or connection in controlcircuit open.

5. Defective control or circuitboards.

1. Current control switch in thewrong position.

2. Leads 75, 76 and 77 not con-nected to correct numbers onmodels with terminal strip.

3. Remove control leads broken.

4. Remote control potentiometeropen.

5. Lead or connection in currentcontrol circuit open.

6. Control PC board plug discon-nected or loose.




IDEALARC R3R, -300, -400, -500

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TROUBLESHOOTINGPROCEDURES

PROCEDURE FOR REPLACING P.C.BOARD

(The P.C. Board is located behind the front controlpanel. Remove the nameplate screws to loosen thecontrol panel.)

When the P.C. Board is to be replaced, follow this pro-cedure:

Visually inspect P.C. Board in question. Are any ofthe components damaged? Is a conductor on theback side of the board damaged?

1. If there is no damage to the P.C. Board, insert anew one and see if this remedies the problem. Ifthe problem is remedied, re-insert the old P.C.Board and see if the problem still exists with theold P.C. Board.

a. If the problem does not exist with the oldboard, check the harness plug and P.C.Board plug for corrosion, contamination, oroversize.

b. Check leads in the harness for loose connec-tions.

2. If there is damage to the P.C. Board, refer to theTroubleshooting Guide.

OUTPUT VOLTAGE

The open circuit voltage of the machine should be 67to 71 volts and should not vary when the rheostat isvaried. If any other condition exists, refer to theTroubleshooting Guide.

OVERLOAD PROTECTION

All IDEALARC R3R, -300, -400, -500s have built-inprotective thermostats. If the rectifier or transformerreaches the maximum safe operating temperaturebecause of frequent overload or high room tempera-ture plus overload, the line contactor drops out stop-ping the welder. The thermostats automatically resetand the line contactor pulls in when the temperaturereaches a safe operating level.

The power rectifier bridge is also protected againstshort term, high current overloads generally caused bypoor operating techniques.

For example, if an arc gouging carbon or the electrodeis allowed to touch – or almost touch – the work for acouple of seconds or more, the overload protectionP.C. Board automatically reduces the output to mini-mum and keeps it there until the overload is removedor the machine is turned off.

CHECKING SNUBBER CIRCUIT

In case of an SCR malfunction or failure, the snubberassembly should be checked. Turn the machine offand disconnect one lead of the snubber assembly.(Either 221, 222, or 223 depending on the SCR inquestion. See wiring diagram.) The sides of themachine have to be removed to do this. (See parts listfor the exact location.)

1. Visually inspect the snubber assembly for overheat-ed components.

2. Using a V.O.M meter on the X10 scale connect thepositive lead to the lead removed. Touch the nega-tive lead to the shunt. The indicating needle on themeter will move quickly to the right (low resistancevalue) and then slowly return to the left (high resis-tance value). This indicates that the capacitor in thesnubber circuit is taking a charge.

3. If the needle stays to the right, the capacitor isshorted and the assembly is defective.

4. If the needle does not move, the capacitor or resis-tor on the snubber assembly is open and theassembly is defective.

CHECKING CURRENT CONTROLRHEOSTAT ON MACHINE

Turn the machine off.

Remove the control panel screws and open the frontcover.

Turn the current control switch to remote.

Disconnect the harness plug from the control board.

Put current range switch to “B” range.

With an ohmmeter on X1K, connect it to lead 210 and211 on SW #2.

Rotate the current control rheostat. The resistancereading should be from around zero to 10K ohms.Check the resistance reading between 75 on the ter-minal strip and 211 on SW #2. The reading must be10K ohms.

IDEALARC R3R, -300, -400, -500


No reading will indicate an open rheostat and a lowreading will indicate a shorted or partially shorted rheo-stat; in either case, replace.

TOGGLE SWITCH CHECK

1. Turn off the machine power input. SW #1 has 115volts across it when the input power is connected.

2. Isolate the switch to be tested by removing all con-necting leads.

3. Check to make sure the switch is making connec-tions with a V.O.M. meter. The meter should readzero resistance.

4. Put the ohmmeter on X1K scale and measure theresistance between the terminal and the case of themachine (touch a self tapping screw). Readingshould be infinite.

5. If either step (3) or step (4) fails, replace the switch.

REMOTE CONTROL CHECK

Disconnect the remote field control and connect anohmmeter across 75 and 76 and rotate the rheostat inthe remote control. The resistance reading should gofrom zero to 10K ohms. Repeat with ohmmeter across77 and 76 with same results. Connect ohmmeteracross 75 and 77. The reading should be 10K ohms. Alower reading will indicate a shorted or partially short-ed rheostat. A very high reading will indicate an openrheostat. In either of the last two cases, replace therheostat. Check for any physical damage.

CHECKING POWER RECTIFIER BRIDGEASSEMBLYPrecise evaluation of diodes or SCRs require

laboratory equipment. If a bridge problem stillexists after test, please call a Lincoln FieldService Shop.

Equipment Needed:

1. V.O.M. or ohmmeter for diodes

2. Circuit Diagram 1 for SCRs

DEVICE ISOLATION (See the instruction manualparts list for the exact location.)Disconnect the following leads from the bridge,shown in Diagram 2:

1. Wiring harness gate leads (G1, G2, G3) fromgate lead connector J4 on control P.C. Board

2. AC leads X1, X2, and X3 from the anodes of theSCRs and cathodes of the diodes.

3. The 200, 221, 222, and 223 leads from theSnubber P.C. Board.

4. Lead 220 that connects to the latching resistor(R3).

5. The cathode of each diode (4 total).

POWER DIODE TEST

1. Establish the polarity of the ohmmeter leads andset to the X10 scale.

2. Connect the ohmmeter positive led to anode andnegative lead to the cathode.

3. Reverse the leads of the ohmmeter from Step 2.

4. A shorted diode will indicate zero or an equallylow resistance in both directions. An open diodewill have an infinite or high resistance in bothdirections; and a good diode will have a lowresistance in Step 2 and a much higher resis-tance in Step 3.

POWER SILICON CONTROLLEDRECTIFIER TEST

The SCR must be mounted in the heat sink when mak-ing this test.

1. Connect the ohmmeter (set to the X10 scale) leadsto the anode and cathode.

2. Reverse the leads of the ohmmeter from Step 1.

3. A shorted SCR will indicate zero or an equally lowresistance in one or both directions.

4. Establish the polarity of the ohmmeter. Connect thepositive lead to the gate and the negative lead tothe cathode.

5. An open gate circuit will have an infinite or highresistance. A good gate circuit will read a low resis-tance, but not zero ohms.

IDEALARC R3R, -300, -400, -500

CAUTION


BATTERY TEST

Check the batteries by shorting leads (A) and (C), thenclose switch SW-1. Replace batteries if voltage is lessthan 3 volts.

SCR TEST

1. Isolate SCR to be tested by disconnecting gateleads from the terminals on the P. C. Board. (Do notremove SCR from the heat sink.)

2. Connect SCR into the test circuit as shown (A) leadto anode (C) lead to cathode and (G) lead to thegate.

3. Close switch SW #1 (switch SW#2 should be open);voltmeter should read zero. If the voltmeter readshigher than zero, the SCR is shorted.

4. With switch SW #1 closed, close switch SW #2 fortwo seconds and release. The voltmeter shouldread 2 to 2.5 volts before and after switch SW #2 isreleased. If the voltmeter does not read, or readsonly while SW #2 is depressed, the SCR is open orbatteries are defective (repeat Battery TestProcedure).

5. Open switch SW #1, disconnect the gate lead (G)and reverse the (A) and (C) leads on the SCR.Close switch SW #1. The voltmeter should readzero. If the voltage is higher than zero, the SCR isshorted.

IDEALARC R3R, -300, -400, -500

DIAGRAM 1

DIAGRAM 2

E-1WIRING DIAGRAMSE-1

IDEALARC R3R, -300, -400, -500

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. Thespecific diagram for a particular code is pasted inside the machine on one of the enclosure panels.

ELECTRICAL SYMBOLS PER E1537

LEGEND

D5D6D7

POCKET AMPTROL SENSING BRIDGE

L1 DC OUTPUT FILTER

R1R2R3R4

16

TO SUPPLY LINES

TO GROUNDPER

NATIONALELECTRICAL

CODE

1

2

3

L1

L2

L3

ICR233232231

H3

H2

H1

X2

X1T2

RECONNECT PANEL SHOWNCONNECTED FOR LOW VOLTAGE

4

5

6

7

8

9

1

2

3

232231

H3

H2

H1

X2

X1T2

233

TO GROUNDPER

NATIONALELECTRICAL

CODE

ICR

L1

L2

L3

TO SUPPLY LINESTO GROUND

PERNATIONAL

ELECTRICALCODE

H3

H2

H1

X2

X1

T2

TO SUPPLY LINES

TO GROUNDPER

NATIONALELECTRICAL

CODE

232231

H3

H2

H1

X2

X1T2

TO SUPPLY LINES

ICR233

TO PRIMARYCOILS

PRIMARY CONNECTIONS

MAIN TRANSFORMER

1

2

3

L1

L2

L3

DIAL SELECTOR SWITCH

SCR1-D1SCR2-D2SCR3-D3D4

SCR AND DIODERECTIFIER BRIDGE

T1T2T3

MAIN TRANSFORMERCONTROL TRANSFORMERPOCKET AMPTROL OPTION

TRANSFORMER

ICR INPUT STARTER

( DASHED ITEMS ON WIRINGDIAGRAM ARE OPTIONAL )

CAVITY NUMBERING SEQUENCE(COMPONENT SIDE OF BOARD)

A B C D E F

10K OHM POT., OUTPUT CONTROL10K OHM POT., ARC FORCE CONTROL40 OHM

SW1SW2SW3SW4

POWER SWITCHMACHINE/REMOTE SWITCH

L1

D4D1 D2 D3

SCR1 SCR2 SCR3

R3

204

204

204

205

206

SHUNT

218

R4

D5

D6

D7

219

219

201202203

204

204209208

217

CONTROLP.C.

BOARD

SW1

PILOT LIGHT

231

235

235

232

W

THESE LEADS AREPRESENT ONLY WITHOPTIONAL METERKIT.

220225

115V

G

G

Y

T3G

OPTIONAL POCKETAMPTROL P.C.BOARD

77 76

75

75

217 206205

204

204

21475 210 211

R1

SW2

R2

204208

209

224

OPTIONAL METER KIT

VM AM+ +--

FRAME GROUND

- +

217

217

A A115 V

201 202 203

7S S

10

1

4 5 6

66V

BOTTOM PRIMARY

TOP PRIMARY

T1X1 X2 X3SEC SEC SEC

16, 17, & 18 ARE PRESENTON 380/500 OR 460/575MACHINES ONLY.

THERE IS NO 10-11-12CONNECTION ON 380,

A

CHOKETHERMOSTAT

SECONDARYTHERMOSTAT

233231

204

ICR

1

2

3

L1

L2

L3

RECONNECT PANEL SHOWNCONNECTED FOR 220V

H4

234 235

FAN MOTOR

HIGH TEMP LIGHT

221222 223

G1 G2 G3

204

+

-

G1 G2 G3 204

226

220

204

211

210

213

77

212 76

SW3

A = AMBERG = GREENW = WHITEY = YELLOW

COLORS

235232

ARE MADE AT THE

SINGLE, 346V AND ABOVE(EXCEPT 380V.)

220/380/440SINGLE, BELOW 346V ORDUAL VOLTAGE380/500 OR 460/575

7677

SW4

RECONNECT PANEL SHOWNCONNECTED FOR LOW VOLTAGE

1234123456

777675

GY

218219

J6

J712345678

21475

213212

201A

203A

J2J4

201A

203AJ3

63215

1

8

5

6

7

4

3

21

5

6

4

3

2

1

24

3

12

J1

.4 OHM POCKET AMPTROL SENSING RESISTOR

CONNECTOR AND THESE THREELEADS ARE NOT USED WHENOPTIONAL POCKET AMPTROLIS PROVIDED.

4

2 1 3 4 2 1

RECTIFIERBRIDGE

1 2 3 4 5 6 7 8

J5SNUBBER BOARD

226

224204

235

TO PRIMARYCOILS

TO PRIMARYCOILS

TO PRIMARYCOILS

231 233

(SWITCH SHOWN IN LOCAL POSITION)

220/380/440 OR230/400V MACHINES.

REMOTE CONTROL RECEPTACLE

2 3

16 17 18

11

8 66V

S

66V9

12

OPTIONAL POLARITY SWITCH(60 Hz ONLY)

11

10

126

4

5

7

8

9

TO GROUNDPER

NATIONALELECTRICAL

CODE

1

2

3

L1

L2

L3

ICR233232231

H3

H2

H1

X2

X1T2

TO SUPPLY LINES

RECONNECT PANEL SHOWN

TO PRIMARYCOILS

CONNECTED FOR 230V

230/400V

PRIMARY CONNECTIONS 1-7, 2-8 AND 3-9ARE MADE AT THE MAIN TRANSFORMER

PRIMARY CONNECTIONS 4-7, 5-8 AND 6-9ARE MADE AT THE MAIN TRANSFORMER

17

18

4-7, 5-8 AND 6-9

AUXILIARY COILS(ON BOTTOM PRI.COIL ASSEMBLIES)

L9376

A

IDEALARC R3R-400, 500-I, 500 & 600-I WIRING DIAGRAM

4

5

69

8

7

11

TO PRIMARY COILS

10

12

FLEXLEAD

JUMPER

RECONNECT PANELA

A A A

E-2WIRING DIAGRAMS

IDEALARC R3R, -300, -400, -500

E-2



LEGEND

D5D6D7


L1 DC OUTPUT FILTER

R1R2R3R4

TO GROUNDPER

NATIONALELECTRICAL

CODE

H3

H2

H1

X2

X1

T2

TO SUPPLY LINES




T1T2T3


TRANSFORMER

ICR INPUT STARTER

( DASHED ITEMS ON WIRING DIAGRAM ARE OPTIONAL )


CONNECTOR AND THESE THREE LEADSARE NOT USED WHEN OPTIONALPOCKET AMPTROL IS PROVIDED

A B C D E F


SW1SW2SW3SW4


L1

D4

D1 D2 D3

SCR1 SCR2 SCR3

R3

204

204

204

205206

SHUNT

218

R4

D5

D6

D7

219

219

CONTROLP.C.

BOARD

SW1

PILOT LIGHT

231

235

235

232

W

THESE LEADS AREPRESENT ONLY WITHOPTIONAL METER KIT.


77 76

75

75

217 206205

204

204

21475 210 211

R1

SW2

R2

204208

209

224

OPTIONAL METER KIT

VM AM+ +--

FRAME GROUND

- +

217

217

115 V

201 20220313 14 15

7 8 9

S S S

10 11 12

1 2 3

4 5 6

66VAUXILIARY COILS

BOTTOM PRIMARY

TOP PRIMARY


A

CHOKETHERMOSTAT

SECONDARYTHERMOSTAT

233231

204

ICR

L1

L2

L3


TO PRIMARY COILS

H4

234 235

FAN MOTOR

HIGH TEMP LIGHT

G2 G3

204

+

-

G1 G2 G3 204

220

204

211

210

213

77

212 76

SW3


COLORS

235232

66V 66V

7677

SW4

OPTIONAL POLARITY SWITCH (60 Hz ONLY)

161718

6

155

144

13

1

2

3

7

89 TAPE UP

SEPARATELYTO PROVIDE

AT LEAST600 VOLTSINSULATION

1816 17

CONNECTED FOR 230V

1

8

5

6

7

4

3

21

5

6

4

3

2

1

24

3

12

G1234123456

777675

GY

218219

J6

J7

204209208

217

CONTROLP.C.

BOARD

12345678

21475

213212

J2J4

J1


2 1 3 4 2 1

REMOTE CONTROLRECEPTACLE

1 2 3 4 5 6 7 8

J5SNUBBER BOARD

SNUBBER BOARD

226

224204

226

220225

221222 223

G1

RECTIFIERBRIDGE

201202203

204

201A

203AJ3

632154

115V

G

G

Y

T3

201A

203A

L8184

11-19-93B

IDEALARC R3R WIRING DIAGRAM (230/460/575 V) (FOR CANADA ONLY)

(SWITCH SHOWN INLOCAL POSITION)

235

WIRING DIAGRAMS



LEGEND

D5D6D7


L1 DC OUTPUT FILTER

R1R2R3R4

TO GROUNDPER

NATIONALELECTRICAL

CODE

H3

H2

H1

X2

X1

T2

TO SUPPLY LINES




T1T2T3


TRANSFORMER

ICR INPUT STARTER



CONNECTOR AND THESE THREE LEADSARE NOT USED WHEN OPTIONALPOCKET AMPTROL IS PROVIDED

A B C D E F


SW1SW2SW3SW4


L1

D4D1 D2 D3

SCR1 SCR2 SCR3

R3

204

204

204

205206

SHUNT

218

R4

D5

D6

D7

219

219

CONTROLP.C.

BOARD

SW1

PILOT LIGHT

231

235

235

232

W



77 76

75

75

217 206205

204

204

21475 210 211

R1

SW2

R2

204208

209

224

OPTIONAL METER KIT

VM AM+ +--

FRAME GROUND

- +

217

217

A

A115 V

201 202 20313 14 15

7 8 9

S S S

10 11 12

1 2 3

4 5 6

66VAUXILIARY COILS

BOTTOM PRIMARY

TOP PRIMARY


A

CHOKETHERMOSTAT

SECONDARYTHERMOSTAT

233231

204

ICR

L1

L2

L3


TO PRIMARY COILS

H4

234 235

FAN MOTOR

HIGH TEMP LIGHT

G2 G3

204

+ -

G1 G2 G3 204

220

204

211

210

213

77

212 76

SW3


COLORS

235232

66V 66V

7677

SW4


161718

6

155

144

13

1

2

3

7

89 TAPE UP



{

1816 17

CONNECTED FOR 230V

1

8

5

6

7

4

3

21

5

6

4

3

2

1

24

3

12

G1234123456

777675

GY

218219

{{J6

J7

204209208

217

CONTROLP.C.

BOARD

12345678

21475

213212{

{ {

J2J4

J1


2 1 3 4 2 1


1 2 3 4 5 6 7 8{

J5

SNUBBER BOARD

226

224204

226

220225

221222 223

G1

RECTIFIERBRIDGE

201202203

204

201A

203AJ3

632154{115V

G

G

Y

T3

201A

203A


235

32

15A

31

SILVER

OUTPUT PANELGROUND STUD

IDEALARC R3R WIRING DIAGRAM (230/460/575V) (FOR CANADA ONLY CODES 10857, 10858, 10881, 10882)

2-8-2002D

L11869

E-3E-3

WIRING DIAGRAMS



LEGEND

L1 DC OUTPUT FILTER

R1R2R3

TO GROUNDPER

NATIONALELECTRICAL

CODE

H3

H2

H1

X2

X1

T2

TO SUPPLY LINES




T1T2

MAIN TRANSFORMERCONTROL TRANSFORMER

ICR INPUT STARTER



A B C D E F


SW1SW2SW3SW4


L1

D4D1 D2 D3

SCR1 SCR2 SCR3

R3

204

204

204

205206

SHUNT

CONTROLP.C.

BOARD

SW1

PILOT LIGHT

231

235

235

232

W


77 76 75

217 206205

204

204

21475 210 211

R1

SW2

R2

204208

209

224

OPTIONAL METER KIT

VM AM+ +--

FRAME GROUND

- +

217

217

A

A115 V

201 202 20313 14 15

7 8 9

S

10 11 12

1 2 3

4 5 6

66VAUXILIARY COILS

BOTTOM PRIMARY

TOP PRIMARY


A

CHOKETHERMOSTAT

SECONDARYTHERMOSTAT

233231

ICR

L1

L2

L3


TO PRIMARY COILS

H4

234 235

FAN MOTOR

HIGH TEMP LIGHT

G2 G3

204

+ -

G1 G2 G3 204

220

204

211

210

213

77

212 76

SW3


COLORS

235232

66V

66V

SW4


161718

6

155

144

13

1

2

3

7

89 TAPE UP



{

1816 17

CONNECTED FOR 230V

1

8

5

6

7

4

3

21

5

6

4

3

2

1

24

3

12

204209208

217

CONTROLP.C.

BOARD

12345678

21475

213212{

{ {J2J4

J1

2 1 3 4 2 1


1 2 3 4 5 6 7 8{

J5

SNUBBER BOARD

226

224204

226

220225

221222 223

G1

RECTIFIERBRIDGE

201202203

204

201A

203AJ3

632154{


235

32A

15A

31

SILVER

OUTPUT PANELGROUND STUD

IDEALARC R3R WIRING DIAGRAM (230/460/575 V)

S

66V

S

66V

204

S

32

31A 32B

A

L11869-1

IDEALARC R3R WIRING DIAGRAM (230/460/575V) (FOR CODES 11043, 11044, 11045, 11046)

E-4E-4

E-5WIRING DIAGRAMS

IDEALARC R3R, -300, -400, -500

E-5

Part No. Type A B C D F G H

M12244-7 R3R 32.00 15.39 3092 1.44 30.02±.11 33.07±.06 .94

M12244-77-7-78

R3R’S

NOTES

WARNING

AVISO DEPRECAUCION

ATTENTION

WARNUNG

ATENÇÃO

Spanish

French

German

Portuguese

Japanese

Chinese

Korean

Arabic

READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TOBE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.

SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOSCONSUMIBLES 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 AETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.

LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

● Do not touch electrically live parts orelectrode with skin or wet clothing.

● Insulate yourself from work andground.

● No toque las partes o los electrodosbajo carga con la piel o ropa moja-da.

● Aislese del trabajo y de la tierra.

● Ne laissez ni la peau ni des vête-ments mouillés entrer en contactavec des pièces sous tension.

● Isolez-vous du travail et de la terre.

● Berühren Sie keine stromführendenTeile oder Elektroden mit IhremKörper oder feuchter Kleidung!

● Isolieren Sie sich von denElektroden und dem Erdboden!

● Não toque partes elétricas e elec-trodos com a pele ou roupa molha-da.

● Isole-se da peça e terra.

● Keep flammable materials away.

● Mantenga el material combustiblefuera del área de trabajo.

● Gardez à l’écart de tout matérielinflammable.

● Entfernen Sie brennbarres Material!

● Mantenha inflamáveis bem guarda-dos.

● Wear eye, ear and body protection.

● Protéjase los ojos, los oídos y elcuerpo.

● Protégez vos yeux, vos oreilles etvotre corps.

● Tragen Sie Augen-, Ohren- und Kör-perschutz!

● Use proteção para a vista, ouvido ecorpo.

WARNING

AVISO DEPRECAUCION

ATTENTION

WARNUNG

ATENÇÃO

Spanish

French

German

Portuguese

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA ASPRÁTICAS DE SEGURANÇA DO EMPREGADOR.

● Keep your head out of fumes.● Use ventilation or exhaust to

remove fumes from breathing zone.

● Los humos fuera de la zona de res-piración.

● Mantenga la cabeza fuera de loshumos. Utilice ventilación oaspiración para gases.

● Gardez la tête à l’écart des fumées.● Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zonesde travail.

● Vermeiden Sie das Einatmen vonSchweibrauch!

● Sorgen Sie für gute Be- undEntlüftung des Arbeitsplatzes!

● Mantenha seu rosto da fumaça.● Use ventilação e exhaustão para

remover fumo da zona respiratória.

● Turn power off before servicing.

● Desconectar el cable de ali-mentación de poder de la máquinaantes de iniciar cualquier servicio.

● Débranchez le courant avant l’entre-tien.

● Strom vor Wartungsarbeitenabschalten! (Netzstrom völlig öff-nen; Maschine anhalten!)

● Não opere com as tampas removidas.● Desligue a corrente antes de fazer

serviço.● Não toque as partes elétricas nuas.

● Do not operate with panel open orguards off.

● No operar con panel abierto oguardas quitadas.

● N’opérez pas avec les panneauxouverts ou avec les dispositifs deprotection enlevés.

● Anlage nie ohne Schutzgehäuseoder Innenschutzverkleidung inBetrieb setzen!

● Mantenha-se afastado das partesmoventes.

● Não opere com os paineis abertosou guardas removidas.

• 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

• World's Leader in Welding and Cutting Products •

idealarc r3r-500

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