RETURN TO MAIN INDEX
IM409-E
IDEALARC ® R3R-300, -400 AND -500
November, 2006
9500 thru 10500,
For use with machine Code Numbers:
10857, 10858, 10881, 10882,
11043, 11044, 11045, 11046
11342, 11347
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 READ-
ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON-
TAINED THROUGHOUT. And,
most importantly, think before you
act and be careful.
OPERATOR’S MANUAL
Copyright © 2006 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
i i
SAFETY
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
The engine exhaust from this product contains
Diesel engine exhaust and some of its constituents
chemicals known to the State of California to cause
are known to the State of California to cause can-
cancer, birth defects, or other reproductive harm.
cer, birth defects, and other reproductive harm.
The Above For Gasoline Engines
The Above For Diesel 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 1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
powered equipment. 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.
ELECTRIC AND
MAGNETIC FIELDS
____________________________________________________
may be dangerous
1.c. Do not add the fuel near an open flame weld-
ing arc or when the engine is running. Stop
the engine and allow it to cool before refuel- 2.a. Electric current flowing through any conductor causes
ing to prevent spilled fuel from vaporizing on localized Electric and Magnetic Fields (EMF). Welding
contact with hot engine parts and igniting. Do current creates EMF fields around welding cables and
not spill fuel when filling tank. If fuel is spilled, welding machines
wipe it up and do not start engine until fumes
have been eliminated. 2.b. EMF fields may interfere with some pacemakers, and
____________________________________________________ welders having a pacemaker should consult their physician
1.d. Keep all equipment safety guards, covers before welding.
and devices in position and in good
repair.Keep hands, hair, clothing and tools 2.c. Exposure to EMF fields in welding may have other health
away from V-belts, gears, fans and all other effects which are now not known.
moving parts when starting, operating or
repairing equipment. 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
1.e. In some cases it may be necessary to remove safety
them with tape when possible.
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
2.d.2. Never coil the electrode lead around your body.
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
2.d.3. Do not place your body between the electrode and
parts.
work cables. If the electrode cable is on your right
___________________________________________________
side, the work cable should also be on your right side.
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. 2.d.4. Connect the work cable to the workpiece as close as
___________________________________________________ possible to the area being welded.
1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance 2.d.5. Do not work next to welding power source.
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
Mar �95
ii ii
SAFETY
ARC RAYS can burn.
ELECTRIC SHOCK can kill.
3.a. The electrode and work (or ground) circuits 4.a. Use a shield with the proper filter and cover
are electrically “hot� when the welder is on. plates to protect your eyes from sparks and
Do not touch these “hot� parts with your bare the rays of the arc when welding or observing
skin or wet clothing. Wear dry, hole-free open arc welding. Headshield and filter lens
gloves to insulate hands. should conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant
3.b. Insulate yourself from work and ground using dry insulation.
material to protect your skin and that of your helpers from
Make certain the insulation is large enough to cover your full
the arc rays.
area of physical contact with work and ground.
4.c. Protect other nearby personnel with suitable, non-flammable
In addition to the normal safety precautions, if welding
screening and/or warn them not to watch the arc nor expose
must be performed under electrically hazardous
themselves to the arc rays or to hot spatter or metal.
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
FUMES AND GASES
accidental contact with the workpiece or ground) use
can be dangerous.
the following equipment:
� Semiautomatic DC Constant Voltage (Wire) Welder.
5.a. Welding may produce fumes and gases
� DC Manual (Stick) Welder. hazardous to health. Avoid breathing these
� AC Welder with Reduced Voltage Control. fumes and gases. When welding, keep
your head out of the fume. Use enough
3.c. In semiautomatic or automatic wire welding, the electrode, ventilation and/or exhaust at the arc to keep
electrode reel, welding head, nozzle or semiautomatic fumes and gases away from the breathing zone. When
welding gun are also electrically “hot�. welding with electrodes which require special
ventilation such as stainless or hard facing (see
3.d. Always be sure the work cable makes a good electrical instructions on container or MSDS) or on lead or
connection with the metal being welded. The connection cadmium plated steel and other metals or coatings
should be as close as possible to the area being welded. which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
3.e. Ground the work or metal to be welded to a good electrical using local exhaust or mechanical ventilation. In
(earth) ground. confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
3.f. Maintain the electrode holder, work clamp, welding cable and also required when welding on galvanized steel.
welding machine in good, safe operating condition. Replace
damaged insulation. 5. b. The operation of welding fume control equipment is affected
by various factors including proper use and positioning of the
3.g. Never dip the electrode in water for cooling. equipment, maintenance of the equipment and the specific
welding procedure and application involved. Worker expo-
3.h. Never simultaneously touch electrically “hot� parts of sure level should be checked upon installation and periodi-
electrode holders connected to two welders because voltage cally thereafter to be certain it is within applicable OSHA PEL
between the two can be the total of the open circuit voltage and ACGIH TLV limits.
of both welders.
5.c. Do not weld in locations near chlorinated hydrocarbon vapors
3.i. When working above floor level, use a safety belt to protect coming from degreasing, cleaning or spraying operations.
yourself from a fall should you get a shock. The heat and rays of the arc can react with solvent vapors to
form phosgene, a highly toxic gas, and other irritating prod-
3.j. Also see Items 6.c. and 8. ucts.
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.
AUG 06
iii iii
SAFETY
WELDING SPARKS can CYLINDER may explode
cause fire or explosion. if damaged.
6.a. Remove fire hazards from the welding area.
7.a. Use only compressed gas cylinders
If this is not possible, cover them to prevent
containing the correct shielding gas for the
the welding sparks from starting a fire.
process used and properly operating
Remember that welding sparks and hot
regulators designed for the gas and
materials from welding can easily go through small cracks
pressure used. All hoses, fittings, etc. should be suitable for
and openings to adjacent areas. Avoid welding near
the application and maintained in good condition.
hydraulic lines. Have a fire extinguisher readily available.
7.b. Always keep cylinders in an upright position securely
6.b. Where compressed gases are to be used at the job site,
chained to an undercarriage or fixed support.
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting� (ANSI
7.c. Cylinders should be located:
Standard Z49.1) and the operating information for the
� Away from areas where they may be struck or subjected to
equipment being used.
physical damage.
6.c. When not welding, make certain no part of the electrode
� A safe distance from arc welding or cutting operations and
circuit is touching the work or ground. Accidental contact can
any other source of heat, sparks, or flame.
cause overheating and create a fire hazard.
7.d. Never allow the electrode, electrode holder or any other
6.d. Do not heat, cut or weld tanks, drums or containers until the
electrically “hot� parts to touch a cylinder.
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
7.e. Keep your head and face away from the cylinder valve outlet
inside. They can cause an explosion even though they have
when opening the cylinder valve.
been “cleaned�. For information, purchase “Recommended
Safe Practices for the Preparation for Welding and Cutting of
7.f. Valve protection caps should always be in place and hand
Containers and Piping That Have Held Hazardous
tight except when the cylinder is in use or connected for
Substances�, AWS F4.1 from the American Welding Society
use.
(see address above).
7.g. Read and follow the instructions on compressed gas
6.e. Vent hollow castings or containers before heating, cutting or
cylinders, associated equipment, and CGA publication P-l,
welding. They may explode.
“Precautions for Safe Handling of Compressed Gases in
Cylinders,� available from the Compressed Gas Association
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
1235 Jefferson Davis Highway, Arlington, VA 22202.
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.
FOR ELECTRICALLY
Always wear safety glasses with side shields when in a
powered equipment.
welding area.
6.g. Connect the work cable to the work as close to the welding
8.a. Turn off input power using the disconnect
area as practical. Work cables connected to the building
switch at the fuse box before working on
framework or other locations away from the welding area
the equipment.
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate circuits.
8.b. Install equipment in accordance with the U.S. National
This can create fire hazards or overheat lifting chains or
Electrical Code, all local codes and the manufacturer’s
cables until they fail.
recommendations.
6.h. Also see item 1.c.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Mar �95
iv iv
SAFETY
6. Eloigner les matériaux inflammables ou les recouvrir afin de
PRÉCAUTIONS DE SÛRETÉ prévenir tout risque d’incendie dû aux étincelles.
Pour votre propre protection lire et observer toutes les instructions et
7. Quand on ne soude pas, poser la pince à une endroit isolé de
les précautions de sûreté specifiques qui parraissent dans ce
la masse. Un court-circuit accidental peut provoquer un
manuel aussi bien que les précautions de sûreté générales suiv-
échauffement et un risque d’incendie.
antes:
8. S’assurer que la masse est connectée le plus prés possible de
Sûreté Pour Soudage A L’Arc
la zone de travail qu’il est pratique de le faire. Si on place la
1. Protegez-vous contre la secousse électrique:
masse sur la charpente de la construction ou d’autres endroits
éloignés de la zone de travail, on augmente le risque de voir
a. Les circuits à l’électrode et à la piéce sont sous tension
passer le courant de soudage par les chaines de levage,
quand la machine à souder est en marche. Eviter toujours
câbles de grue, ou autres circuits. Cela peut provoquer des
tout contact entre les parties sous tension et la peau nue ou
risques d’incendie ou d’echauffement des chaines et des
les vétements mouillés. Porter des gants secs et sans trous
câbles jusqu’� ce qu’ils se rompent.
pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand on
9. Assurer une ventilation suffisante dans la zone de soudage.
soude dans des endroits humides, ou sur un plancher met-
Ceci est particuliérement important pour le soudage de tôles
allique ou des grilles metalliques, principalement dans
galvanisées plombées, ou cadmiées ou tout autre métal qui
les positions assis ou couché pour lesquelles une grande
produit des fumeés toxiques.
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble de
10. Ne pas souder en présence de vapeurs de chlore provenant
soudage et la machine à souder en bon et sûr état defonc-
d’opérations de dégraissage, nettoyage ou pistolage. La
tionnement.
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
d.Ne jamais plonger le porte-électrode dans l’eau pour le
du solvant pour produire du phosgéne (gas fortement toxique)
refroidir.
ou autres produits irritants.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder
11. Pour obtenir de plus amples renseignements sur la sûreté, voir
parce que la tension entre les deux pinces peut être le total
le code “Code for safety in welding and cutting� CSA Standard
de la tension à vide des deux machines.
W 117.2-1974.
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.
PRÉCAUTIONS DE SÛRETÉ POUR
2. Dans le cas de travail au dessus du niveau du sol, se protéger
LES MACHINES À SOUDER À
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie du
TRANSFORMATEUR ET À
corps.
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 1. Relier à la terre le chassis du poste conformement au code de
qu’un verre blanc afin de se protéger les yeux du rayon- l’électricité et aux recommendations du fabricant. Le dispositif
nement de l’arc et des projections quand on soude ou quand de montage ou la piece à souder doit être branché à une
on regarde l’arc. bonne mise à la terre.
b. Porter des vêtements convenables afin de protéger la peau
de soudeur et des aides contre le rayonnement de l‘arc. 2. Autant que possible, I’installation et l’entretien du poste seront
c. Protéger l’autre personnel travaillant à proximité au soudage effectués par un électricien qualifié.
à l’aide d’écrans appropriés et non-inflammables.
3. Avant de faires des travaux à l’interieur de poste, la debranch-
4. Des gouttes de laitier en fusion sont émises de l’arc de soudage. er à l’interrupteur à la boite de fusibles.
Se protéger avec des vêtements de protection libres de l’huile,
tels que les gants en cuir, chemise épaisse, pantalons sans 4. Garder tous les couvercles et dispositifs de sûreté à leur
revers, et chaussures montantes. place.
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.
Mar. �93
v v
for selecting a QUALITY product by Lincoln Electric. We want you
Thank You to take pride in operating this Lincoln Electric Company product •â?¢â??
as much pride as we have in bringing this product to you!
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.
IDEALARC R3R, -300, -400, -500
vi vi
TABLE OF CONTENTS
Page
____________________________________________________________________________
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A
Location and Stacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Input Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Output 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
____________________________________________________________________________
IDEALARC R3R, -300, -400, -500
A-1 A-1
INSTALLATION
Dual or triple voltage (eg: 230/460, 220/380/440, etc.)
LOCATION AND STACKING
models are shipped connected for highest voltage. To
change the connection, see the wiring or connection
WARNING
diagram pasted to the inside of the access panel in the
case back.
FALLING EQUIPMENT can cause
injury.
Be sure the voltage, phase and frequency of the input
� Do not lift this machine using lift power is as specified on the welder nameplate.
bail if it is equipped with a heavy
� accessory such as trailer or gas cylinder. Have a qualified electrician remove the access panel in
the case back and connect the three phase AC power
� Lift only with equipment of adequate lifting
to terminals L1, L2, L3 of the input contactor in accor-
capacity.
dance with the U. S. National Electrical Code, all local
� Be sure machine is stable when lifting. codes, and the wiring diagram located inside the
machine.
Install the welder in a dry location where there is a free The welder frame must be grounded. A stud marked
circulation of air in through the front louvers and out the with the symbol located on the floor of the input
back of the case. A location which minimizes the box is provided for this purpose. See the U.S. National
amount of smoke and dirt drawn into the front louvers Electrical Code for details on proper grounding
reduces the chance of dirt accumulation that can block methods.
air passages, causing overheating and nuisance shut-
down of the machine. Recommended Input Wire,
Ground Wire and Fuse Sizes
The Idealarc® R3R welders can be stacked three high Based on U.S. National Electrical Code.
when the following precautions are observed: For 60 hertz, 3 phase Welders at 60% Duty Cycle.
1. Be sure the bottom machine is on a firm, level sur- Copper Wire Size
face suitable for the total weight {up to 1350 pounds Type 75°C in Conduit
(608 Kg)} of the stacked machines. Input Amps 3 Input 1 Ground Super Lag Fuse
Welder Volts Input Wires Wire Size in Amps
2. Stack the machines with the fronts flush. Be certain 300 230 56.0 8 8 80
the pins on the top front corners of the lower 460 28.0 10 10 40
machines fit through the holes in the base rails of
400 230 82.0 6 6 125
the upper machines. 460 41.0 10 10 60
500 230 100.0 4 6 150
3. No unit heavier than the bottom unit should be
460 50.0 8 8 70
stacked on top of it. For example, an R3R-500 shall
not be stacked on top of an R3R-400, but an R3R-
400 may be stacked on top of an R3R-500. This welder is rated for 60% duty cycle. Duty cycle is
based on a ten minute period. Therefore, the welder
INPUT WIRING can be operated at nameplate rated output for 6 min-
utes of every 10 minute period without overheating.
WARNING An amber high temperature warning light provides a
visual indication of an over temperature condition.
ELECTRIC SHOCK can kill.
� Have an electrician install and ser-
vice this equipment. CAUTION
� Turn the input power off at the fuse
Failure to follow these instructions can cause
box before working on equipment.
immediate failure of components within the
� Do not touch electrically hot parts. 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!
IDEALARC R3R, -300, -400, -500
A-2 A-2
INSTALLATION
TIG WELDING
OUTPUT CONNECTIONS
The R3R is shipped with proper R.F. By-pass circuitry
OUTPUT STUDS
installed to protect the control circuit when TIG welding
with a Hi-Freqâ„? unit. To provide protection, the
With the machine off, run electrode and work cables of
welder frame grounding stud must be connected to
the appropriate sizes (see the following table) up
ground.
through the rectangular holes in the machine base
located below the output studs. Connect the cable lugs
to the output terminals marked (+) and (-) or, if the
welder comes equipped with the polarity switch option
“electrode� and “to work�. Tighten the holding nuts with
a wrench.
Cable Sizes for Combined Length of Electrode
and Work Cable (Copper) at 60% Duty Cycle
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)
1/0 (54 mm2) 1/0 (54 mm2) 2/0 (68 mm2) 3/0 (86 mm2)
300
2/0 (68 mm2) 2/0 (68 mm2) 3/0 (86 mm2) 4/0 (108 mm2)
400
2/0 (68 mm2) 3/0 (86 mm2) 3/0 (86 mm2) 4/0 (108 mm2)
500
CONNECTION OF OPTIONAL REMOTE CONTROL
� K857
Turn the machine off. The K857 consists of a control
box with 28 feet (8.5m) of four conductor cable and a 6
pin connector for easy connection to the power source.
This control will give the same control as the current
control on the machine depending on the position of
the current dial selector switch. (There is no current
dial selector switch on the R3R-300.)
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.
(8.5m) cord before connecting to the R3R terminal
strip. 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 water-
proof. Don’t let the lugs touch against the case.
OPTIONAL K963 HAND AMPTROL AND K870
FOOT AMPTROL
These amptrols connect directly to the 6 pin connector
on the front of the power source.
IDEALARC R3R, -300, -400, -500
B-1 B-1
OPERATION
b. Provisions for remote control are standard on
WARNING each power source. A current control switch on
the machine control panel labeled “Current
ELECTRIC SHOCK can kill. Control at R3R� or “Current Control Remote� is
provided for selecting the desired mode of oper-
� Do not touch electrically live parts
ation, either at the machine or remote, Be certain
or electrode with skin or wet cloth-
the machine remote switch is in the machine
ing.
position, unless a remote control is connected,
� Insulate yourself from work and ground. or the R3R is equipped with optional pocket
amptrol.
� Always wear dry insulating gloves.
c. The “Arc Force Control�, located on the right side
FUMES AND GASES can be danger-
of the front control panel, is calibrated from one
ous.
to ten. Lower settings will provide less short cir-
� Keep your head out of fumes.
cuit current and a softer arc. A setting that is too
� Use ventilation or exhaust to low may cause the electrode to stick in the pud-
� remove fumes from breathing zone. dle. Higher settings will provide a higher short
circuit current, a more forceful arc, and possibly
WELDING SPARKS can cause fire or more spatter. For most welding, the dial should
explosion. be set at approximately mid range (5 � 6).
Adjustment up or down can then be made
� Keep flammable material away.
depending on the electrode, procedures, and
� Do not weld on containers that
operator preference. For most TIG welding appli-
have held combustibles.
cations adjust this control to minimum for best
operating characteristics.
ARC RAYS can burn.
� Wear eye, ear and body protection. 3. Pocket Amptrol (Optional)
The pocket amptrol option provides a remote cur-
rent control for the R3R welders. This “wireless�
NOTE: The P.C. Board is protected by a moisture control requires no control cable connection to the
resistant coating. When the welder is operated, this welder.
coating will “bake off� of certain power resistors that
normally operate at high temperatures, emitting some a. On the R3R-400 and -500 the welder “Current
smoke and odor for a short time. These resistors and Control� switch must be in the “Remote� position
the P.C. Board beneath them may become blackened. and the “Current Dial Selector� switch in the “B�
This is a normal occurrence and does not damage the range. The R3R-300 has only one dial and no
component or affect the machine performance. selection switch. The R3R-300 does not have a
“Current Dial Selector� switch. With the “Current
1. To Start the Welder, move the “Power� switch to Control� switch in the “Remote� position, the cur-
“On�. This starts the welder and lights the white pilot rent control potentiometer on the welder is
light on the machine control panel. This light indi- removed from the circuit and its setting has no
cates that the line contactor is energized). effect on the output. With the “Current Dial
Selector� switch in the “B� range position, the
2. Setting Welding Current pocket amptrol provides total control from NEMA
minimum to NEMA maximum output of the
a. The “Current Control� dial on the front of the welder.
machine indicates the output current at the
NEMA arc voltage. b. Turn the welder power switch on.
On R3R-300, one dial covers the complete c. Insert one end of the probe into the electrode
range. On the R3R-400 and -500, two dials are holder and hold the other end on the work for
used, The “A� range controls the current over approximately five seconds.
about 1/2 of the range of the “B� range. A toggle
switch on the control panel allows selection of d. To change current, change the probe dial setting
the desired range. The output control can be and repeat the five second procedure of placing
adjusted while welding. the probe between electrode and work.
IDEALARC R3R, -300, -400, -500
B-2 B-2
OPERATION
The solid state circuitry within the welder senses this
change in probe setting and automatically resets the
welding current to the new level. Each time the welder
is turned off, the output goes to minimum and must be
reset when the welder is turned on again.
115VAC DUPLEX RECEPTACLE AND CIRCUIT
BREAKER (60 Hertz Models for Code Numbers
10857, 10858, 10881, 10882, 11043, 11044, 11045,
11046 only )
� This receptacle provides up to 15 Amps of 115VAC
auxiliary power.
� 15 Amp circuit breaker protects the 115VAC recepta-
cle.
� The receptacle and the circuit breaker are located in
the output panel between the output studs.
OPTIONAL EQUIPMENT
1. Remote Current Control � See “Operation�.
2. Amptrol � See “Operation�.
3. Polarity Switch (Factory Installed Only). Permits
changing polarity at the machine output terminals.
(See also “Output Connections�.)
4. Meters � Ammeter and Voltmeter (Factory Installed
Only)
5. Pocket Amptrol � (Factory Installed Only) See
“Operation�.
6. Undercarriage � (K817, K817R) includes a spring
loaded handle for hand towing and a choice of
wheels.
RATINGS
Transformer insulation class 155(F)
IP21 enclosure protection
IDEALARC R3R, -300, -400, -500
C-1 C-1
MAINTENANCE
WARNING
ELECTRIC SHOCK can kill.
� Have an electrician install and ser-
vice this equipment.
� Turn the input power off at the fuse
box before working on equipment.
� Do not touch electrically hot parts.
GENERAL 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 welder at regular intervals. The side panels can
be removed even when the machines are stacked.
POCKET AMPTROL MAINTENANCE
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 fail-
ure 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, -300, -400, -500
D-1 D-1
TROUBLESHOOTING
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 This column provides a course of action for the
locate and repair possible machine malfunctions. Possible Cause, generally it states to contact your
Simply follow the three-step procedure listed below. local Lincoln Authorized Field Service Facility.
Step 1. LOCATE PROBLEM (SYMPTOM). If you do not understand or are unable to perform the
Look under the column labeled “PROBLEM (SYMP- Recommended Course of Action safely, contact your
TOMS)�. This column describes possible symptoms local Lincoln Authorized Field Service Facility.
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
WARNING
ELECTRIC 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.
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, -300, -400, -500
D-2 D-2
TROUBLESHOOTING
Observe all Safety Guidelines detailed througout this manual
POSSIBLE
PROBLEMS RECOMMENDED
CAUSE
(SYMPTOMS) COURSE OF ACTION
FUNCTION PROBLEMS
Input contactor chatters. 1.Faulty input contactor.
2.Low line voltage.
Machine input contactor does not 1.Supply line fuse blown.
operate.
2.Power circuit dead.
3.Broken or loose power lead.
4.Wrong voltage.
5.Thermostats tripped. (High
Temperature Warning Light
should be lit.) (Welder
overheated.)
If all recommended possible areas
of misadjustment have been
checked and the problem persists,
Contact your local Lincoln
6.Input contactor coil open. Authorized Field Service Facility.
7.Open winding on 115V pilot
transformer.
8.Power ON-OFF switch not
closing.
9.Lead broken or loose connec-
tion in 115V starter circuit.
10.Thermostats defective. (High
Temperature Warning Light
should be lit.)
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, -300, -400, -500
D-3 D-3
TROUBLESHOOTING
Observe all Safety Guidelines detailed througout this manual
POSSIBLE
PROBLEMS RECOMMENDED
CAUSE
(SYMPTOMS) COURSE OF ACTION
FUNCTION PROBLEMS
Machine input contactor closes but 1. Electrode or work lead loose or
has no or low output. Open circuit broken.
voltage should be 67 to 71 volts.
2. Open transformer primary or
secondary circuit.
3. Supply line fuse blown.
4. Input line grounded causing
single phase input.
5. Input leads not connected to
contactor.
6. Latching resistor, R3, open.
If all recommended possible areas
of misadjustment have been
7. Control circuit problems. checked and the problem persists,
Contact your local Lincoln
Authorized Field Service Facility.
Machine has maximum output but
no control. 1. Possible defective power SCR.
2. Possible defective control board.
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, -300, -400, -500
D-4 D-4
TROUBLESHOOTING
Observe all Safety Guidelines detailed througout this manual
POSSIBLE
PROBLEMS RECOMMENDED
CAUSE
(SYMPTOMS) COURSE OF ACTION
FUNCTION PROBLEMS
Machine does not have maximum 1. Input fuse blown. Machine is
output (67 to 71 volts). single phased.
2. One phase of main transformer
windings open.
3. Defective power bridge.
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.
If all recommended possible areas
3. Fan inoperative. of misadjustment have been
checked and the problem persists,
Contact your local Lincoln
Authorized Field Service Facility.
4. Shorted diode or SCR in power
rectifier bridge.
Machine comes on but reduces to 1. Excessive load causing the over-
low output under load and remains load protection on control board
there until the load is broken and to operate.
arc re-started. See Fault Protection
Operation Section. 2. Machine output shorted causing
overload protection on control
board to operate.
3. Control circuit 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, -300, -400, -500
D-5 D-5
TROUBLESHOOTING
Observe all Safety Guidelines detailed througout this manual
POSSIBLE
PROBLEMS RECOMMENDED
CAUSE
(SYMPTOMS) COURSE OF ACTION
FUNCTION PROBLEMS
Machine trips off when under no 1. Power bridge rectifier may have
load or makes excessive noise like a shorted diode or SCR.
it is loaded.
2. Short in the transformer.
3. Fan hitting vertical baffle.
Variable or sluggish welding arc. 1. Poor work or electrode cable
connection.
2. Current too low.
3. Welding leads too small.
If all recommended possible areas
of misadjustment have been
4. Open SCR or diode in power checked and the problem persists,
rectifier bridge. Contact your local Lincoln
Authorized Field Service Facility.
5. Control circuit problems.
Welder will not shut off. 1. Input contactor contacts frozen.
115VAC Receptacle not working. 1. Circuit Breaker Tripped.
2. Defective Cicuit Breaker.
3. Broken connectionin wiring.
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, -300, -400, -500
D-6 D-6
TROUBLESHOOTING
Observe all Safety Guidelines detailed througout this manual
POSSIBLE
PROBLEMS RECOMMENDED
CAUSE
(SYMPTOMS) COURSE OF ACTION
FUNCTION PROBLEMS
Current control on machine not 1. Current control switch in wrong
functioning. position.
2. Current control switch defective.
3. Current control potentiometer
defective.
4. Lead or connection in control
circuit open.
5. Defective control or circuit
boards.
If all recommended possible areas
Optional remote current control not 1. Current control switch in the of misadjustment have been
functioning. See Troubleshooting wrong position. checked and the problem persists,
Procedures before connecting. Contact your local Lincoln
2. Leads 75, 76 and 77 not con- Authorized Field Service Facility.
nected to correct numbers on
models with terminal strip.
3. Remove control leads broken.
4. Remote control potentiometer
open.
5. Lead or connection in current
control circuit open.
6. Control PC board plug discon-
nected or loose.
7. Control circuit problems.
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, -300, -400, -500
Low output, low OCV, or erratic welding
D-7
Turn control pot. to minimum
Check OCV
OCV is 35-55V OCV is 40-45V OCV is 0 Rated OCV but OCV less than rated
erratic welding but more than 55V
OCV 45-55V OCV 35-45V Possible machine Check leads 76, 77, Possible Loose lead Possible intermittent Possible Possible wrong connection Possible defective
is being 212, 213, 210, 211 defective connections or loose connections defective of gate leads if recent PC board
single phased & SW2 for open PC board on shunt in control circuit. PC board PC board or rectifier
Check aux. voltages Check PC board con- stack change.
on PC board nector, switches,
potentiometers, etc.
201-202 = 120V ± 10% Replace Retighten Replace See wiring diagram Replace
201-202 = 120V ± 10% leads and correct
202-203 = 120V ± 10% Remove and replace Gate leads
G-1, G-2, G-3 from PC board
one at a time.
If aux. voltages
are incorrect, If aux. voltages If removing each gate lead If removing and replacing
check & repair. are OK one at a time changes OCV each gate lead one at a
time does NOT change OCV
Codes below 9500
with power off, remove leads from Identify gate lead that, when
Codes above 9500 75, 76, 77 terminal strip and removed, OCV did not change.
with power off, disconnect welding leads from output terminals Remove gate lead. Voltage
remote control amphenol between gate lead and 204 must be 13-17V.
and welding leads from
IDEALARC R3R, -300, -400, -500
output terminals.
TROUBLESHOOTING
Check resistance of each If voltage OK If voltage is
terminal on this terminal not correct
strip to ground. Resistance
Check the following pins must be as follows: Defective power SCR
for resistance to ground. 75-GND 2K minimum Possible defective
Resistance must be as 76-GND 2K minimum PC board
follows: 77-GND 12K minimum Replace
75-GND 2K min.
76-GND 2K min. Replace.
77-GND 12K min.
If not, clear terminal strip If resistance is OK,
and leads, and also check possible defective
If not, examine amphenol SW2 and R1 for dirt. PC board.
assembly for faults.
If fault found, repair or If amphenol OK, possible
replace amphenol assembly. defective PC board.
D-7
D-8 D-8
TROUBLESHOOTING
For example, if an arc gouging carbon or the electrode
TROUBLESHOOTING
is allowed to touch � or almost touch � the work for a
PROCEDURES
couple of seconds or more, the overload protection
P.C. Board automatically reduces the output to mini-
PROCEDURE FOR REPLACING P.C.
mum and keeps it there until the overload is removed
BOARD
or the machine is turned off.
(The P.C. Board is located behind the front control
CHECKING SNUBBER CIRCUIT
panel. Remove the nameplate screws to loosen the
control panel.)
In case of an SCR malfunction or failure, the snubber
assembly should be checked. Turn the machine off
When the P.C. Board is to be replaced, follow this pro-
and disconnect one lead of the snubber assembly.
cedure:
(Either 221, 222, or 223 depending on the SCR in
question. See wiring diagram.) The sides of the
Visually inspect P.C. Board in question. Are any of
machine have to be removed to do this. (See parts list
the components damaged? Is a conductor on the
for the exact location.)
back side of the board damaged?
1. Visually inspect the snubber assembly for overheat-
1. If there is no damage to the P.C. Board, insert a
ed components.
new one and see if this remedies the problem. If
the problem is remedied, re-insert the old P.C.
2. Using a V.O.M meter on the X10 scale connect the
Board and see if the problem still exists with the
positive lead to the lead removed. Touch the nega-
old P.C. Board.
tive lead to the shunt. The indicating needle on the
meter will move quickly to the right (low resistance
a. If the problem does not exist with the old
value) and then slowly return to the left (high resis-
board, check the harness plug and P.C.
tance value). This indicates that the capacitor in the
Board plug for corrosion, contamination, or
snubber circuit is taking a charge.
oversize.
3. If the needle stays to the right, the capacitor is
b. Check leads in the harness for loose connec-
shorted and the assembly is defective.
tions.
4. If the needle does not move, the capacitor or resis-
2. If there is damage to the P.C. Board, refer to the
tor on the snubber assembly is open and the
Troubleshooting Guide.
assembly is defective.
OUTPUT VOLTAGE
CHECKING CURRENT CONTROL
RHEOSTAT ON MACHINE
The open circuit voltage of the machine should be 67
to 71 volts and should not vary when the rheostat is
Turn the machine off.
varied. If any other condition exists, refer to the
Troubleshooting Guide.
Remove the control panel screws and open the front
cover.
OVERLOAD PROTECTION
Turn the current control switch to remote.
All IDEALARC R3R, -300, -400, -500s have built-in
Disconnect the harness plug from the control board.
protective thermostats. If the rectifier or transformer
reaches the maximum safe operating temperature
Put current range switch to “B� range.
because of frequent overload or high room tempera-
ture plus overload, the line contactor drops out stop-
With an ohmmeter on X1K, connect it to lead 210 and
ping the welder. The thermostats automatically reset
211 on SW #2.
and the line contactor pulls in when the temperature
reaches a safe operating level.
Rotate the current control rheostat. The resistance
reading should be from around zero to 10K ohms.
The power rectifier bridge is also protected against
Check the resistance reading between 75 on the ter-
short term, high current overloads generally caused by
minal strip and 211 on SW #2. The reading must be
poor operating techniques.
10K ohms.
IDEALARC R3R, -300, -400, -500
D-9 D-9
TROUBLESHOOTING
No reading will indicate an open rheostat and a low
reading will indicate a shorted or partially shorted rheo- 1. Wiring harness gate leads (G1, G2, G3) from
stat; in either case, replace. gate lead connector J4 on control P.C. Board
TOGGLE SWITCH CHECK 2. AC leads X1, X2, and X3 from the anodes of the
SCRs and cathodes of the diodes.
1. Turn off the machine power input. SW #1 has 115
volts across it when the input power is connected. 3. The 200, 221, 222, and 223 leads from the
Snubber P.C. Board.
2. Isolate the switch to be tested by removing all con-
necting leads. 4. Lead 220 that connects to the latching resistor
(R3).
3. Check to make sure the switch is making connec-
tions with a V.O.M. meter. The meter should read 5. The cathode of each diode (4 total).
zero resistance.
4. Put the ohmmeter on X1K scale and measure the POWER DIODE TEST
resistance between the terminal and the case of the
machine (touch a self tapping screw). Reading 1. Establish the polarity of the ohmmeter leads and
should be infinite. set to the X10 scale.
5. If either step (3) or step (4) fails, replace the switch. 2. Connect the ohmmeter positive led to anode and
negative lead to the cathode.
REMOTE CONTROL CHECK
3. Reverse the leads of the ohmmeter from Step 2.
Disconnect the remote field control and connect an
ohmmeter across 75 and 76 and rotate the rheostat in 4. A shorted diode will indicate zero or an equally
the remote control. The resistance reading should go low resistance in both directions. An open diode
from zero to 10K ohms. Repeat with ohmmeter across will have an infinite or high resistance in both
77 and 76 with same results. Connect ohmmeter directions; and a good diode will have a low
across 75 and 77. The reading should be 10K ohms. A resistance in Step 2 and a much higher resis-
lower reading will indicate a shorted or partially short- tance in Step 3.
ed rheostat. A very high reading will indicate an open
rheostat. In either of the last two cases, replace the
POWER SILICON CONTROLLED
rheostat. Check for any physical damage.
RECTIFIER TEST
CHECKING POWER RECTIFIER BRIDGE The SCR must be mounted in the heat sink when mak-
ASSEMBLY ing this test.
Precise evaluation of diodes or SCRs require
1. Connect the ohmmeter (set to the X10 scale) leads
CAUTION to the anode and cathode.
laboratory equipment. If a bridge problem still 2. Reverse the leads of the ohmmeter from Step 1.
exists after test, please call a Lincoln Field
Service Shop. 3. A shorted SCR will indicate zero or an equally low
resistance in one or both directions.
Equipment Needed:
4. Establish the polarity of the ohmmeter. Connect the
1. V.O.M. or ohmmeter for diodes positive lead to the gate and the negative lead to
the cathode.
2. Circuit Diagram 1 for SCRs
5. An open gate circuit will have an infinite or high
DEVICE ISOLATION (See the instruction manual resistance. A good gate circuit will read a low resis-
parts list for the exact location.) tance, but not zero ohms.
Disconnect the following leads from the bridge,
shown in Diagram 2:
IDEALARC R3R, -300, -400, -500
D-10 D-10
TROUBLESHOOTING
DIAGRAM 1
DIAGRAM 2
BATTERY TEST
4. With switch SW #1 closed, close switch SW #2 for
Check the batteries by shorting leads (A) and (C), then
two seconds and release. The voltmeter should
close switch SW-1. Replace batteries if voltage is less
read 2 to 2.5 volts before and after switch SW #2 is
than 3 volts.
released. If the voltmeter does not read, or reads
only while SW #2 is depressed, the SCR is open or
batteries are defective (repeat Battery Test
SCR TEST
Procedure).
1. Isolate SCR to be tested by disconnecting gate
5. Open switch SW #1, disconnect the gate lead (G)
leads from the terminals on the P. C. Board. (Do not
and reverse the (A) and (C) leads on the SCR.
remove SCR from the heat sink.)
Close switch SW #1. The voltmeter should read
zero. If the voltage is higher than zero, the SCR is
2. Connect SCR into the test circuit as shown (A) lead
shorted.
to anode (C) lead to cathode and (G) lead to the
gate.
3. Close switch SW #1 (switch SW#2 should be open);
voltmeter should read zero. If the voltmeter reads
higher than zero, the SCR is shorted.
IDEALARC R3R, -300, -400, -500
E-1 E-1
WIRING DIAGRAMS
IDEALARC R3R-400, 500-I, 500 & 600-I WIRING DIAGRAM
PRIMARY CONNECTIONS 4-7, 5-8 AND 6-9 PRIMARY CONNECTIONS RECONNECT PANEL SHOWN
TO SUPPLY LINES
TO SUPPLY LINES TO SUPPLY LINES
ARE MADE AT THE MAIN TRANSFORMER 4-7, 5-8 AND 6-9 CONNECTED FOR 220V
TO GROUND TO GROUND
TO GROUND ARE MADE AT THE
TO SUPPLY LINES PER RECONNECT PANEL
PER
PER
A
NATIONAL NATIONAL
MAIN TRANSFORMER
RECONNECT PANEL SHOWN NATIONAL 6
11 9
TO GROUND ELECTRICAL ELECTRICAL
CONNECTED FOR LOW VOLTAGE ELECTRICAL
PER CODE CODE
RECONNECT PANEL SHOWN
CODE
NATIONAL FLEX
CONNECTED FOR LOW VOLTAGE 5
8
H3
H3 H4 10
L3
ELECTRICAL 3 9 6 LEAD
X2 X2 X2
CODE 3 3
L3 H3 L3
H3 L2 2 8 5 7 4
12
T2 T2 T2
X2 18
A
3
A
X1 X1
A
H2 L2
H2 2 2
L2
L3 1
L1 H2
7 4
T2 17
2 X1
X1 1
H2 1
L1
H1
H1
L2 L1 JUMPER
H1
16
1 TO PRIMARY COILS
H1 L1
TO PRIMARY 231
ICR
ICR ICR 233
233
231 232 COILS
TO PRIMARY
231 232 233
ICR COILS
TO PRIMARY
231 232 233 TO PRIMARY
SINGLE, 346V AND ABOVE
COILS 220/380/440
SINGLE, BELOW 346V OR COILS
(EXCEPT 380V.)
380/500 OR 460/575 DUAL VOLTAGE
PRIMARY CONNECTIONS 1-7, 2-8 AND 3-9
ARE MADE AT THE MAIN TRANSFORMER
TO SUPPLY LINES
TO GROUND
PER RECONNECT PANEL SHOWN
NATIONAL CONNECTED FOR 230V HIGH TEMP LIGHT
ELECTRICAL 232
CODE A 235
H3 9 11
5
X2
233 SECONDARY
CHOKE
3
L3 8 FAN MOTOR
4 10
T2 THERMOSTAT
THERMOSTAT 231
X1 H2 2
L2 12
7 6
234 235
H1 L1 1
A
A
115 V
ICR 202
201
TO PRIMARY
231 232 233 203
COILS
230/400V AUXILIARY COILS
66V 66V
66V
(ON BOTTOM PRI. 9
8
7
COIL ASSEMBLIES)
ELECTRICAL SYMBOLS PER E1537 S S
S
204
TOP PRIMARY
THERE IS NO 10-11-12
12
10 11
LEGEND CONNECTION ON 380,
16, 17, & 18 ARE PRESENT
ON 380/500 OR 460/575 220/380/440 OR
16 17 18
MACHINES ONLY. 230/400V MACHINES.
D5
D6 POCKET AMPTROL SENSING BRIDGE
D7 1 2 3
L1 DC OUTPUT FILTER BOTTOM PRIMARY
10K OHM POT., OUTPUT CONTROL
R1 219
4 5 6
10K OHM POT., ARC FORCE CONTROL
R2 T1
40 OHM X3
X1
R3 218
X2 204
.4 OHM POCKET AMPTROL SENSING RESISTOR SEC SEC SEC
R4 L1
R4
220
SW1 POWER SWITCH
219
D2
SW2 MACHINE/REMOTE SWITCH D3
D1 204 D5
R3
SW3 D4
DIAL SELECTOR SWITCH
RECTIFIER
SW4 OPTIONAL POLARITY SWITCH SHUNT
SCR2 D6
SCR3
SCR1
BRIDGE
(60 Hz ONLY) -
+ D7
SCR1-D1
SCR AND DIODE
SCR2-D2
205
204
222
RECTIFIER BRIDGE
SCR3-D3 223 204 THESE LEADS ARE
221
D4 PRESENT ONLY WITH
G1 G2 G3
226 206
204
OPTIONAL METER
204
220
KIT.
T1 MAIN TRANSFORMER 224
225
T2 CONTROL TRANSFORMER G G1 G2 G3 204
203A
T3 POCKET AMPTROL OPTION
Y 115V
TRANSFORMER 6 201A
3 201
201A
OPTIONAL POCKET 2 3
1 4 2 1
G 2 202
1 2 3 4 5 6 78
AMPTROL P.C.
ICR INPUT STARTER J2
J4 1 203
BOARD
J3
1 203A
5
G T3 J5 204
4
2
COLORS Y SNUBBER BOARD 232
J7 3
A = AMBER G 1 204
226
4
G = GREEN 235 W
2 209
1 218
W = WHITE 3 208
CONTROL
2 PILOT LIGHT
219
Y = YELLOW 4 214
OPTIONAL METER KIT P.C.
3 75 235
J6 5 75
BOARD
AM
VM
4 76 J1
-+
-+
( DASHED ITEMS ON WIRING 6 212
5 77
DIAGRAM ARE OPTIONAL ) 7 213 231
6
8 217
205
235
217 217 206
2 1
SW1
1
5
4 1
217
2
6
212 76
5 2
214 204
210
3 75
7
208
211
210
75
6 209
3
1
3 204
76
8 4
204
77 224
2
4
211 77 R2
R1
213
CAVITY NUMBERING SEQUENCE 77 76 75
SW3
SW2
(COMPONENT SIDE OF BOARD) (SWITCH SHOWN IN LOCAL POSITION)
CONNECTOR AND THESE THREE FRAME GROUND
A B C D E F
LEADS ARE NOT USED WHEN
OPTIONAL POCKET AMPTROL REMOTE CONTROL RECEPTACLE
IS PROVIDED.
- +
SW4
A
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, -300, -400, -500
E-2 E-2
WIRING DIAGRAMS
IDEALARC R3R WIRING DIAGRAM (230/460/575 V) (FOR CANADA ONLY)
TO SUPPLY LINES
RECONNECT PANEL SHOWN
CONNECTED FOR 230V
TO GROUND
PER
NATIONAL
ELECTRICAL
CODE
13
3
H4
TAPE UP
X2 14
9
SEPARATELY
L3 4 15
H3 8
TO PROVIDE
T2 5
2 16
L2 6 AT LEAST
H2
600 VOLTS
17
7
X1
INSULATION
18
1
L1
H1
ICR
TO PRIMARY COILS
HIGH TEMP LIGHT
232
A 235
233 SECONDARY
CHOKE
FAN MOTOR
THERMOSTAT
THERMOSTAT
ELECTRICAL SYMBOLS PER E1537 231
234 235
LEGEND 115 V
D5 202
201
203
13 14 15
D6 POCKET AMPTROL SENSING BRIDGE
D7
AUXILIARY COILS
L1 DC OUTPUT FILTER 66V 66V
66V
9
8
7
S S
10K OHM POT., OUTPUT CONTROL
R1 S
204
10K OHM POT., ARC FORCE CONTROL
R2 TOP PRIMARY
40 OHM 10 11 12
R3
.4 OHM POCKET AMPTROL SENSING RESISTOR
R4
18
17
16
SW1 POWER SWITCH
SW2 MACHINE/REMOTE SWITCH
SW3 DIAL SELECTOR SWITCH 3
2
1
BOTTOM PRIMARY
SW4 OPTIONAL POLARITY SWITCH (60 Hz ONLY)
4 5 6 219
SCR1-D1
T1
X3
SCR AND DIODE
SCR2-D2 X1 218
X2 204
SEC SEC SEC
RECTIFIER BRIDGE
SCR3-D3
L1
D4 R4
220
219
D2 D3
D1
204 D5
R3
T1 MAIN TRANSFORMER D4
T2 CONTROL TRANSFORMER RECTIFIER
SHUNT
SCR2 SCR3 D6
SCR1
T3 POCKET AMPTROL OPTION BRIDGE
-
+
TRANSFORMER
D7
206
ICR INPUT STARTER
205
204
222 223 204 THESE LEADS ARE
221
PRESENT ONLY WITH
COLORS G1 G2 G3
226 204
OPTIONAL METER
A = AMBER 204
220
KIT.
G = GREEN 224
225
W = WHITE G G1 G2 G3 204
203A
Y = YELLOW
Y 115V 6 201A
OPTIONAL POCKET 3 201
2 1 3 4 2 1
201A
( DASHED ITEMS ON WIRING
G 2 202
AMPTROL P.C. 1 2 3 4 5 6 7 8 J2
DIAGRAM ARE OPTIONAL ) J4 1 203
BOARD
J3 203A
5
T3 J5
1 G 204
4
SNUBBER BOARD 232
2
2 1
Y
J7
1
5
SNUBBER BOARD
3
4
226
1
G
2
6
235 W
4
2
5
1 204
3
7
1 218 PILOT LIGHT
6 3
1
3
2 209
2 219
8 4
235
3 208
2
4
3 CONTROL
75
J6 4 214
4 P.C.
76 OPTIONAL METER KIT
5 75
CAVITY NUMBERING SEQUENCE 5 BOARD 235
77
J1
AM
VM 6 212
(COMPONENT SIDE OF BOARD) 6 -+
-+ 231
7 213
75
8 217 SW1
205
217 217 206
217
212 76
214 204
210 208
211
210
75 209
204
76
204
77
224
211 77 R2
CONNECTOR AND THESE THREE LEADS R1
213
ARE NOT USED WHEN OPTIONAL
SW3
SW2
76
77 75
POCKET AMPTROL IS PROVIDED
(SWITCH SHOWN IN
LOCAL POSITION)
FRAME GROUND
A B C D E F
REMOTE CONTROL
RECEPTACLE
- +
SW4
11-19-93B
L8184
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, -300, -400, -500
E-3 E-3
WIRING DIAGRAMS
IDEALARC R3R WIRING DIAGRAM (230/460/575V) (FOR CANADA ONLY CODES 10857, 10858, 10881, 10882)
TO SUPPLY LINES
RECONNECT PANEL SHOWN
( DASHED ITEMS ON WIRING CONNECTED FOR 230V
TO GROUND
DIAGRAM ARE OPTIONAL )
PER
{
NATIONAL
ELECTRICAL
2 1
CODE
1
5
13
4 1
3
H4 L3
2
6
TAPE UP
X2 14
9
2
5
SEPARATELY
3
7
H3 4 15
8 TO PROVIDE
T2
6 3
5
1
3
2 16
L2
8 4
6 AT LEAST
H2
2
4
600 VOLTS
17
7
X1
INSULATION
L1 18
1
H1
CAVITY NUMBERING SEQUENCE
(COMPONENT SIDE OF BOARD)
ICR
OUTPUT PANEL TO PRIMARY COILS
GROUND STUD
15A
HIGH TEMP LIGHT
32
SILVER 232
A
ELECTRICAL SYMBOLS PER E1537 235
233 SECONDARY
CHOKE
FAN MOTOR
THERMOSTAT THERMOSTAT 231
LEGEND
234 235
31
D5
115 V
A
D6 A
POCKET AMPTROL SENSING BRIDGE
D7
202
201
L1 DC OUTPUT FILTER 203
13 14 15
R1 10K OHM POT., OUTPUT CONTROL AUXILIARY COILS
66V 66V
66V
R2 10K OHM POT., ARC FORCE CONTROL 9
8
7
R3 40 OHM S S
S
R4 204
.4 OHM POCKET AMPTROL SENSING RESISTOR
TOP PRIMARY
10 11 12
SW1 POWER SWITCH
SW2 MACHINE/REMOTE SWITCH
DIAL SELECTOR SWITCH
SW3 18
17
16
OPTIONAL POLARITY SWITCH (60 Hz ONLY)
SW4
3
2
1
BOTTOM PRIMARY
SCR1-D1
SCR2-D2 SCR AND DIODE
219
4 5 6
SCR3-D3 RECTIFIER BRIDGE
D4 T1
218
X3
X1 X2 204
SEC SEC SEC
L1
T1 MAIN TRANSFORMER R4
220
T2 CONTROL TRANSFORMER
219
D2 D3
D1
T3 POCKET AMPTROL OPTION 204 D5
R3
D4
TRANSFORMER
RECTIFIER
SHUNT
SCR2 SCR3
SCR1 D6
BRIDGE
ICR INPUT STARTER -
+
D7
206
COLORS
205
204
222
A = AMBER 223 204 THESE LEADS ARE
221
G = GREEN PRESENT ONLY WITH
G1 G2 G3
226
W = WHITE 204
OPTIONAL METER
220 204
Y = YELLOW KIT.
225 224
G G1 G2 G3 204
203A
{
Y 115V 6 201A
{
{
OPTIONAL POCKET 3 201
{
21 3 4 2 1
201A
G 202
2
AMPTROL P.C. 1 23 45 67 8
J2 1 203
BOARD J4 J3 203A
5
T3
{
1 G 204
4
J5 232
2 Y
J7 SNUBBER BOARD
3 226
G
235 W
4
{
{
204
1
1 218 PILOT LIGHT
209
2
2 219
235
208
3
3 CONTROL
75
J6 4 214
P.C.
4 76 OPTIONAL METER KIT
5 75
BOARD J1 235
5 77
AM
VM 6 212
6 -+
-+ 231
7 213
217
8 SW1
205
75
217 217 206
217
212 76
214 204
210 208
211
210
75 209
204
76
204
CONNECTOR AND THESE THREE LEADS 77 224
211 77 R2
ARE NOT USED WHEN OPTIONAL R1
POCKET AMPTROL IS PROVIDED 213
SW3
SW2
76 75
77
(SWITCH SHOWN IN
LOCAL POSITION)
FRAME GROUND
A B C D E F
REMOTE CONTROL
RECEPTACLE
- +
SW4
2-8-2002D
L11869
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.
E-4 E-4
WIRING DIAGRAMS
IDEALARC R3R WIRING DIAGRAM (230/460/575V) (FOR CODES 11043, 11044, 11045, 11046)
IDEALARC R3R WIRING DIAGRAM (230/460/575 V)
TO SUPPLY LINES
RECONNECT PANEL SHOWN
( DASHED ITEMS ON WIRING
CONNECTED FOR 230V
DIAGRAM ARE OPTIONAL ) TO GROUND
{
PER
NATIONAL
ELECTRICAL
2 1
CODE
1
5
13
4 1
3
H4
2
6 L3 TAPE UP
X2 14
9
5 2
SEPARATELY
3
7
H3 4 15
8 TO PROVIDE
T2
6 3
5
1
3
2 16
8 4
L2 6 AT LEAST
H2
2
4
600 VOLTS
17
7
X1
INSULATION
18
L1 1
H1
CAVITY NUMBERING SEQUENCE
(COMPONENT SIDE OF BOARD)
ICR
OUTPUT PANEL TO PRIMARY COILS
GROUND STUD
15A
HIGH TEMP LIGHT
32A
SILVER 232
32 A 235
233 SECONDARY
CHOKE
FAN MOTOR
THERMOSTAT
THERMOSTAT 231
234 235
ELECTRICAL SYMBOLS PER E1537 31 32B
31A
A
115 V A
LEGEND
202
201
L1 DC OUTPUT FILTER 203
13 14 15
10K OHM POT., OUTPUT CONTROL
R1 AUXILIARY COILS 66V 66V
10K OHM POT., ARC FORCE CONTROL
R2 8 9
7
40 OHM
R3 S
TOP PRIMARY
10 11 12
SW1 POWER SWITCH
SW2 MACHINE/REMOTE SWITCH 18
17
16
SW3 DIAL SELECTOR SWITCH 66V 66V
66V
SW4 OPTIONAL POLARITY SWITCH (60 Hz ONLY)
S
S S 204
3
2
1
BOTTOM PRIMARY
SCR1-D1
SCR AND DIODE
SCR2-D2
4 5 6
RECTIFIER BRIDGE
SCR3-D3
D4 T1
X3
X1 X2 204
SEC SEC SEC
L1
T1 MAIN TRANSFORMER
220
T2 CONTROL TRANSFORMER
D2 D3
D1 204
R3
D4
RECTIFIER
SHUNT
SCR2 SCR3
SCR1
BRIDGE
ICR INPUT STARTER -
+
206
COLORS
205
204
A = AMBER 222 223 204 THESE LEADS ARE
221
G = GREEN PRESENT ONLY WITH
G1 G2 G3
226
W = WHITE 204
OPTIONAL METER
204
220
Y = YELLOW KIT.
224
225
G1 G2 G3 204
6 201A
{
{
{
{
3 201
2 1 3 4 2 1
2 202
1 23 4 5 67 8
J2 1 203
J4 J3 203A
5
204
4
J5 232
SNUBBER BOARD
226
235 W
1 204
{
PILOT LIGHT
209
2
235
3 208
CONTROL
4 214
P.C.
OPTIONAL METER KIT
5 75
BOARD 235
J1
AM
VM 6 212
-+
-+ 231
213
7
8 217 SW1
205
217 217 206
217
212 76
214 204
210 208
210 211
75 209
204
204
224
211 77 R2
R1
213
SW3
SW2
76
77 75
(SWITCH SHOWN IN
LOCAL POSITION)
FRAME GROUND
A B C D E F
REMOTE CONTROL
RECEPTACLE
- +
SW4
A
L11869-1
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.
E-5 E-5
WIRING DIAGRAMS
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
M12244-7
7-7-78
IDEALARC R3R, -300, -400, -500
NOTES
R3R’S
NOTES
R3R’S
G Do not touch electrically live parts or G Keep flammable materials away. G Wear eye, ear and body protection.
WARNING electrode with skin or wet clothing.
G Insulate yourself from work and
ground.
Spanish
G No toque las partes o los electrodos G Mantenga el material combustible G Protéjase los ojos, los oÃdos y el
AVISO DE bajo carga con la piel o ropa moja- fuera del área de trabajo. cuerpo.
da.
PRECAUCION G Aislese del trabajo y de la tierra.
French G Ne laissez ni la peau ni des vête- G Gardez à l’écart de tout matériel G Protégez vos yeux, vos oreilles et
ments mouillés entrer en contact inflammable. votre corps.
ATTENTION avec des pièces sous tension.
G Isolez-vous du travail et de la terre.
G Berühren Sie keine stromführenden
German G Entfernen Sie brennbarres Material! G Tragen Sie Augen-, Ohren- und Kör-
Teile oder Elektroden mit Ihrem perschutz!
WARNUNG Körper oder feuchter Kleidung!
G Isolieren Sie sich von den
Elektroden und dem Erdboden!
Portuguese
G Não toque partes elétricas e elec- G Mantenha inflamáveis bem guarda- G Use proteção para a vista, ouvido e
trodos com a pele ou roupa molha- dos. corpo.
ATENÇÃO da.
G Isole-se da peça e terra.
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 HER-
STELLERS. DIE UNFALLVERHÃœTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
G Keep your head out of fumes. G Turn power off before servicing. G Do not operate with panel open or
G Use ventilation or exhaust to
WARNING
guards off.
remove fumes from breathing zone.
Spanish
G Los humos fuera de la zona de res- G Desconectar el cable de ali- G No operar con panel abierto o
AVISO DE
piración. mentación de poder de la máquina guardas quitadas.
G Mantenga la cabeza fuera de los antes de iniciar cualquier servicio.
PRECAUCION
humos. Utilice ventilación o
aspiración para gases.
French
G N’opérez pas avec les panneaux
G Gardez la tête à l’écart des fumées. G Débranchez le courant avant l’entre-
G Utilisez un ventilateur ou un aspira- ouverts ou avec les dispositifs de
tien.
ATTENTION
protection enlevés.
teur pour ôter les fumées des zones
de travail.
German
G Anlage nie ohne Schutzgehäuse
G Vermeiden Sie das Einatmen von G Strom vor Wartungsarbeiten
oder Innenschutzverkleidung in
Schweibrauch! abschalten! (Netzstrom völlig öff-
WARNUNG
G Sorgen Sie für gute Be- und Betrieb setzen!
nen; Maschine anhalten!)
Entlüftung des Arbeitsplatzes!
Portuguese
G Não opere com as tampas removidas. G Mantenha-se afastado das partes
G Mantenha seu rosto da fumaça.
G Desligue a corrente antes de fazer
G Use ventilação e exhaustão para moventes.
ATENÇÃO
serviço. G Não opere com os paineis abertos
remover fumo da zona respiratória.
G Não toque as partes elétricas nuas. ou guardas removidas.
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÃTICAS DE SEGURANÇA DO EMPREGADOR.
� 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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