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Lincoln Electric R3R 600-I manual

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Table of contents for the manual

  • Page 1

    IDEALARC ® R3R 600-I OPERA T OR’S MANUAL IM885-A November , 2006 Safety Depends on Y ou 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 INST ALL, OPERA TE OR REP AIR THIS EQUIPMENT WITHOUT R[...]

  • Page 2

    i SAFETY i FOR ENGINE powered equipment. 1.a. T urn 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. ____________________________________[...]

  • Page 3

    ii SAFETY ii ARC RA YS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable flame-resistant material to protect your skin[...]

  • Page 4

    iii SAFETY iii FOR ELECTRICALL Y powered equipment. 8.a. T urn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer ’s recommendations. 8.c. Ground the equipment in accordance with the U.S. Nati[...]

  • Page 5

    iv SAFETY iv Mar . ‘93 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L ’Arc 1. Protegez-vous contre la secousse électrique: a. L[...]

  • Page 6

    v v Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay[...]

  • Page 7

    vi T ABLE OF CONTENTS vi Page Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S ection A T echnical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 Input Power Connection . . . . . . . . . . . . . . . [...]

  • Page 8

    A-1 INST ALLA TION IDEALARC R3R 600-I A-1 TECHNICAL SPECIFICA TIONS – R3R 600-I K1381-[ ] V olts at Rated Amperes 35 40 44 Amps 375 500 600 Duty Cycle 100% 60% 35% INPUT - THREE PHASE ONL Y OUTPUT Insulation Class: 155°C (F) Standard V oltage Frequency 220-230V/50/60Hz 380-400V/50/60Hz 440-460V/50/60Hz 1 1.3@220V/50Hz .74 @ 500A Rated Input Curr[...]

  • Page 9

    A-2 INST ALLA TION IDEALARC R3R 600-I A-2 INST ALLA TION F ALLING EQUIPMENT can cause injury . • Do not lift this machine using lift bail if it is equipped with a heavy • accessory such as trailer or gas cylinder . • Lift only with equipment of adequate lifting capacity . • Be sure machine is stable when lifting. The machine should be locat[...]

  • Page 10

    B-1 OPERA TION B-1 OPERA TION ELECTRIC SHOCK can kill. • Do not touch electrically live parts or 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 brea[...]

  • Page 11

    B-2 OPERA TION B-2 B. ARC FORCE CONTROL DIAL Arc Force Increase/Decrease of Arc Force C. OUTPUT CURRENT CONTROL DIAL Output Current D. OUTPUT CURRENT CONTROL RANGE SWITCH (R3R 500-I and R3R 600-I only) Output Current Control Dial Range A Output Current Control Dial Range B E. OUTPUT CURRENT CONTROL “MACHINE- REMOTE” SWITCH Remote Output Current[...]

  • Page 12

    C-1 ACCESSORIES C-1 OPTIONAL EQUIPMENT K857 – REMOTE CURRENT CONTROL The K857 consists of a control box with 8.5 m (28 ft) of four conductor cable and a 6 pin Amphenol for easy connection to the front of the power source. The K857 will give the same control as the current con- trol on the machine depending on the position of the current dial sele[...]

  • Page 13

    D-1 MAINTENANCE D-1 ELECTRIC SHOCK can kill. • Have an electrician install and ser- vice this equipment. • T urn the input power off at the fuse box before working on equipment. • Do not touch electrically hot parts. ROUTINE MAINTENANCE 1. The fan motor has sealed bearings which require no service. 2. In extremely dusty locations, dirt may cl[...]

  • Page 14

    E-1 TROUBLESHOOTING E-1 IDEALARC R3R 600-I 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. CAUTION This T roubleshooting Guide is provided to help you locate and re[...]

  • Page 15

    E-2 TROUBLESHOOTING E-2 IDEALARC R3R 600-I Observe all Safety Guidelines detailed throughout this manual 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. CAUTION FUN[...]

  • Page 16

    E-3 TROUBLESHOOTING E-3 IDEALARC R3R 600-I Observe all Safety Guidelines detailed throughout this manual 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. CAUTION FUN[...]

  • Page 17

    E-4 TROUBLESHOOTING E-4 IDEALARC R3R 600-I Observe all Safety Guidelines detailed throughout this manual 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. CAUTION FUN[...]

  • Page 18

    E-5 TROUBLESHOOTING E-5 IDEALARC R3R 600-I Observe all Safety Guidelines detailed throughout this manual 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. CAUTION FUN[...]

  • Page 19

    E-6 TROUBLESHOOTING E-6 IDEALARC R3R 600-I Observe all Safety Guidelines detailed throughout this manual 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. CAUTION FUN[...]

  • Page 20

    E-7 TROUBLESHOOTING E-7 IDEALARC R3R 600-I Low output, low OCV , or erratic welding T urn control dial 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 wr[...]

  • Page 21

    E-8 TROUBLESHOOTING E-8 TROUBLESHOOTING PROCEDURES A. PROCEDURE FOR REPLACING PC BOARDS When a PC board is to be replaced, the following procedure must be followed: 1. Visually inspect PC board in question. Are any of the components damaged? Is a conductor on the back side of the board damaged? a. If there is no damage to the PC board, insert a new[...]

  • Page 22

    E-9 TROUBLESHOOTING E-9 3. If the needle stays to the right, the capacitor is shorted and the assembly is defective. 4. If the needle does not move, the capacitor is open and the assembly is defective. G. CHECKING CURRENT CONTROL RHEOST A T ON MACHINE 1. T urn machine off. 2. Remove the control panel screws and open the front cover . 3. T urn the c[...]

  • Page 23

    E-10 TROUBLESHOOTING E-10 2. POWER DIODE TEST a. Establish the polarity of the ohmmeter leads and set to X10 scale. b. Connect the ohmmeter positive lead to anode and negative lead to the cathode. c. Reverse the leads of the ohmmeter from Step b. d. A shorted diode will indicate zero or an equal- ly low resistance in both directions. An open diode [...]

  • Page 24

    F-1 WIRING DIAGRAMS F-1 IDEALARC R3R 600-I 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. ELECTRICAL SYMBOLS PER E1537 LEGEND D5 D6 D7 POCKET AMPTROL SENSING BRIDGE L1 DC OUTPUT FILTER R[...]

  • Page 25

    F-2 DIMENSION PRINT IDEALARC R3R 600-I F-2 R3R 600-I K817 or K817R (K841 not shown) Part No. T ype A B C D F G H M12244-7 R3R 32.00 15.39 3092 1.44 30.02±.1 1 33.07± .06 .94 M12244-7 7-7-78[...]

  • Page 26

    W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’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 F ABRICANTE P ARA E[...]

  • Page 27

    W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA ESTE EQUIPAMENTO E AS P ARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust to remove fumes f[...]

  • Page 28

    • Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 441 17-1 199 U.S.A. TEL: 216.481.8100 F AX: 216.486.1751 WEB SITE: www .lincolnelectric.com • World's Leader in W elding and Cutting Products •[...]