Operator’s Manual IDEALARC R3R-400 · 3.i. When working above floor level, use a safety belt to protect yourself from a fall should you get a shock. 3.j. Also see It ems 6.c. and

IDEALARC ® R3R-400

Operator’s Manual

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Date Purchased

Code: (ex: 10859)

Serial: (ex: U1060512345)

IM10110 | Issue D ate 11-Aug

© Lincoln Global, Inc. All Rights Reserved.

For use with machines having Code Numbers:

11839

Register your machine: www.lincolnelectric.com/register

Authorized Service and Distributor Locator: www.lincolnelectric.com/locator

THANK YOU FOR SELECTING A QUALITY PRODUCT BY LINCOLN ELEC TRIC.

PLEASE EXAMINE CARTON AND EQUIPMENT FORDAMAGE IMMEDIATELY

When this equipment is shipped, title passes to the purchaserupon receipt by the carrier. Consequently, claims for materialdamaged in shipment must be made by the purchaser against thetransportation company at the time the shipment is received.

SAFETY DEPENDS ON YOU

Lincoln arc welding and cutting equipment is designed and builtwith safety in mind. However, your overall safety can be increasedby proper installation ... and thoughtful operation on your part. DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETYPRECAUTIONS CONTAINED THROUGHOUT. And, most importantly,think before you act and be careful.

This statement appears where the information must be followedexactly to avoid serious personal injury or loss of life.

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

KEEP YOUR HEAD OUT OF THE FUMES.

DON’T get too close to the arc.Use corrective lenses if necessaryto stay a reasonable distanceaway from the arc.

READ and obey the Safety DataSheet (SDS) and the warning labelthat appears on all containers ofwelding materials.

USE ENOUGH VENTILATION orexhaust at the arc, or both, tokeep the fumes and gases from your breathing zone and the general area.

IN A LARGE ROOM OR OUTDOORS, natural ventilation may beadequate if you keep your head out of the fumes (See below).

USE NATURAL DRAFTS or fans to keep the fumes away from your face.

If you de velop unusual symptoms, see your supervisor. Perhaps the welding atmosphere and ventilation system should be checked.

WEAR CORRECT EYE, EAR & BODY PROTECTION

PROTECT your eyes and face with welding helmetproperly fitted and with proper grade of filter plate(See ANSI Z49.1).

PROTECT your body from welding spatter and arcflash with protective clothing including woolenclothing, flame-proof apron and gloves, leatherleggings, and high boots.

PROTECT others from splatter, flash, and glarewith protective screens or barriers.

IN SOME AREAS, protection from noise may be appropriate.

BE SURE protective equipment is in good condition.

Also, wear safety glasses in work areaAT ALL TIMES.

SPECIAL SITUATIONS

DO NOT WELD OR CUT containers or materials which previouslyhad been in contact with hazardous substances unless they areproperly cleaned. This is extremely dangerous.

DO NOT WELD OR CUT painted or plated parts unless specialprecautions with ventilation have been taken. They can releasehighly toxic fumes or gases.

Additional precautionary measures

PROTECT compressed gas cylinders from excessive heat,mechanical shocks, and arcs; fasten cylinders so they cannot fall.

BE SURE cylinders are never grounded or part of an electrical circuit.

REMOVE all potential fire hazards from welding area.

ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FORIMMEDIATE USE AND KNOW HOW TO USE IT.

WARNING

CAUTION

Safety 01 of 04 - 5/16/2018

SECTION A:WARNINGS

CALIFORNIA PROPOSITION 65 WARNINGS

WARNING: Breathing diesel engine exhaustexposes you to chemicals known to the Stateof California to cause cancer and birth defects,

or other reproductive harm.• Always start and operate the engine in a

well-ventilated area.• If in an exposed area, vent the exhaust to the outside.• Do not modify or tamper with the exhaust system. • Do not idle the engine except as necessary.For more information go to www.P65 warnings.ca.gov/diesel

WARNING: This product, when used for welding or

cutting, produces fumes or gases which contain

chemicals known to the State of California to cause

birth defects and, in some cases, cancer. (California

Health & Safety Code § 25249.5 et seq.)

WARNING: Cancer and Reproductive Harm

www.P65warnings.ca.gov

ARC WELDING CAN BE HAZARDOUS. PROTECTYOURSELF AND OTHERS FROM POSSIBLE SERIOUSINJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITHTHEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. Foradditional 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 AREPERFORMED ONLY BY QUALIFIED INDIVIDUALS.

FOR ENGINE POWEREDEQUIPMENT.

1.a. Turn the engine off before troubleshootingand maintenance work unless themaintenance work requires it to be running.

1.b. Operate engines in open, well-ventilated areas or vent the engineexhaust fumes outdoors.

1.c. Do not add the fuel near an open flame weldingarc or when the engine is running. Stop theengine and allow it to cool before refueling toprevent spilled fuel from vaporizing on contact

with hot engine parts and igniting. Do not spill fuel when fillingtank. If fuel is spilled, wipe it up and do not start engine untilfumes have been eliminated.

1.d. Keep all equipment safety guards, covers and devices in position and in good repair.Keep hands, hair, clothing and tools away from V-belts, gears, fans and all other moving parts when starting, operating orrepairing equipment.

1.e. In some cases it may be necessary to remove safety guards toperform required maintenance. Remove guards only whennecessary and replace them when the maintenance requiringtheir removal is complete. Always use the greatest care whenworking near moving parts.

1.f. Do not put your hands near the engine fan. Do not attempt tooverride the governor or idler by pushing on the throttle controlrods while the engine is running.

1.g. To prevent accidentally starting gasoline engines while turningthe engine or welding generator during maintenance work,disconnect the spark plug wires, distributor cap or magneto wireas appropriate.

1.h. To avoid scalding, do not remove the radiatorpressure cap when the engine is hot.

ELECTRIC ANDMAGNETIC FIELDS MAYBE DANGEROUS

2.a. Electric current flowing through any conductorcauses localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines

2.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physicianbefore welding.

2.c. Exposure to EMF fields in welding may have other health effectswhich 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 and workcables. If the electrode cable is on your right side, thework cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close as pos-sible to the area being welded.

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

SAFETY

Safety 02 of 04 - 5/16/2018

ELECTRIC SHOCK CAN KILL.

3.a. The electrode and work (or ground) circuits areelectrically “hot” when the welder is on. Donot touch these “hot” parts with your bare skin or wet clothing.Wear dry, hole-free gloves to insulate hands.

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

In addition to the normal safety precautions, if

welding must be performed under electrically

hazardous conditions (in damp locations or while

wearing wet clothing; on metal structures such as

floors, gratings or scaffolds; when in cramped

positions such as sitting, kneeling or lying, if there

is a high risk of unavoidable or accidental contact

with the workpiece or ground) use the following

equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode,electrode reel, welding head, nozzle or semiautomatic weldinggun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electricalconnection with the metal being welded. The connection shouldbe 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 of electrodeholders connected to two welders because voltage between thetwo can be the total of the open circuit voltage of bothwelders.

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 It ems 6.c. and 8.

ARC RAYS CAN BURN.

4.a. Use a shield with the proper filter and cover plates to protect youreyes from sparks and the rays of the arc when welding orobserving open arc welding. Headshield and filter lens shouldconform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistant materialto protect your skin and that of your helpers from the 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.

FUMES AND GASESCAN BE DANGEROUS.

5.a. Welding may produce fumes and gaseshazardous to health. Avoid breathing thesefumes and gases. When welding, keep your head out of the fume.Use enough ventilation and/or exhaust at the arc to keep fumesand gases away from the breathing zone. When welding

hardfacing (see instructions on container or SDS)

or on lead or cadmium plated steel and other

metals or coatings which produce highly toxic

fumes, keep exposure as low as possible and

within applicable OSHA PEL and ACGIH TLV limits

using local exhaust or mechanical ventilation

unless exposure assessments indicate otherwise.

In confined spaces or in some circumstances,

outdoors, a respirator may also be required.

Additional precautions are also required when

welding

on galvanized steel.

5. b. The operation of welding fume control equipment is affected byvarious factors including proper use and positioning of theequipment, maintenance of the equipment and the specificwelding procedure and application involved. Worker exposurelevel should be checked upon installation and periodicallythereafter to be certain it is within applicable OSHA PEL andACGIH TLV limits.

5.c. Do not weld in locations near chlorinated hydrocarbon vaporscoming from degreasing, cleaning or spraying operations. Theheat and rays of the arc can react with solvent vapors to formphosgene, a highly toxic gas, and other irritating products.

5.d. Shielding gases used for arc welding can displace air and causeinjury or death. Always use enough ventilation, especially inconfined 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 theSafety Data Sheet (SDS) and follow your employer’s safetypractices. SDS forms are available from your weldingdistributor or from the manufacturer.

5.f. Also see item 1.b.

SAFETY

Safety 03 of 04 - 5/16/2018

WELDING AND CUTTINGSPARKS CAN CAUSEFIRE OR EXPLOSION.

6.a. Remove fire hazards from the welding area. Ifthis is not possible, cover them to prevent the welding sparksfrom starting a fire. Remember that welding sparks and hotmaterials from welding can easily go through small cracks andopenings to adjacent areas. Avoid welding near hydraulic lines.Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site, specialprecautions should be used to prevent hazardous situations.Refer to “Safety in Welding and Cutting” (ANSI Standard Z49.1)and the operating information for the equipment being used.

6.c. When not welding, make certain no part of the electrode circuit istouching the work or ground. Accidental contact can causeoverheating 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 procedures will not cause flammable or toxic vapors from substances inside.They can cause an explosion even though they have been“cleaned”. For information, purchase “Recommended SafePractices for the Preparation for Welding and Cutting ofContainers and Piping That Have Held Hazardous Substances”,AWS F4.1 from the American Welding Society (see address above).

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

6.f. Sparks and spatter are thrown from the welding arc. Wear oil freeprotective garments such as leather gloves, heavy shirt, cufflesstrousers, high shoes and a cap over your hair. Wear ear plugswhen welding out of position or in confined places. Always wearsafety glasses with side shields when in a welding area.

6.g. Connect the work cable to the work as close to the welding areaas practical. Work cables connected to the building framework orother locations away from the welding area increase thepossibility of the welding current passing through lifting chains,crane cables or other alternate circuits. This can create firehazards or overheat lifting chains or cables until they fail.

6.h. Also see item 1.c.

6.I. Read and follow NFPA 51B “Standard for Fire Prevention DuringWelding, Cutting and Other Hot Work”, available from NFPA, 1Batterymarch Park, PO box 9101, Quincy, MA 022690-9101.

6.j. Do not use a welding power source for pipe thawing.

CYLINDER MAY EXPLODE IFDAMAGED.

7.a. Use only compressed gas cylinders containingthe correct shielding gas for the process usedand properly operating regulators designed forthe gas and pressure used. All hoses, fittings,etc. should be suitable for the application andmaintained in good condition.

7.b. Always keep cylinders in an upright position securely chained toan undercarriage or fixed support.

7.c. Cylinders should be located:

• Away from areas where they may be struck or subjectedto physical damage.

• A safe distance from arc welding or cutting operationsand any 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 hand tightexcept when the cylinder is in use or connected for use.

7.g. Read and follow the instructions on compressed gas cylinders,associated equipment, and CGA publication P-l, “Precautions forSafe Handling of Compressed Gases in Cylinders,” available fromthe Compressed Gas Association, 14501 George Carter WayChantilly, VA 20151.

FOR ELECTRICALLYPOWERED EQUIPMENT.

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

8.b. Install equipment in accordance with the U.S. National ElectricalCode, all local codes and the manufacturer’s recommendations.

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

Refer to

http://www.lincolnelectric.com/safety

for additional safety information.

SAFETY

Safety 04 of 04 - 5/16/2018

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 LʼArc1. Protegez-vous contre la secousse électrique:

a. Les circuits à lʼélectrode 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 sʼisoler 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 lʼeau 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 sʼapplicuent 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 nʼimporte quelle partie ducorps.

3. Un coup dʼarc peut être plus sévère quʼun coup de soliel, donc:

a. Utiliser un bon masque avec un verre filtrant approprié ainsiquʼun verre blanc afin de se protéger les yeux du rayon-nement de lʼarc et des projections quand on soude ou quandon regarde lʼarc.

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

c. Protéger lʼautre personnel travaillant à proximité au soudageà lʼaide dʼécrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de lʼarc de soudage.Se protéger avec des vêtements de protection libres de lʼhuile,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 lʼon pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin deprévenir tout risque dʼincendie 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 dʼincendie.

8. Sʼassurer que la masse est connectée le plus prés possible dela zone de travail quʼil est pratique de le faire. Si on place lamasse sur la charpente de la construction ou dʼautres 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 dʼincendie ou dʼechauffement des chaines et descâbles jusquʼà ce quʼils 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 provenantdʼopérations de dégraissage, nettoyage ou pistolage. Lachaleur ou les rayons de lʼarc 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 delʼélectricité 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, Iʼinstallation et lʼentretien du poste seronteffectués par un électricien qualifié.

3. Avant de faires des travaux à lʼinterieur de poste, la debranch-er à lʼinterrupteur à la boite de fusibles.

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

viTABLE OF CONTENTSvi

Page

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

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

____________________________________________________________________________Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section B____________________________________________________________________________Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section D____________________________________________________________________________Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section E

Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1 thru E-10____________________________________________________________________________Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section F____________________________________________________________________________Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-689 SERIES____________________________________________________________________________

A-1INSTALLATION

IDEALARC® R3R-400

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

400 230 82.0 6 6 125460 41.0 10 10 60

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.

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. Donʼt 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-400

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)

400 2/0 (68 mm2) 2/0 (68 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 the R3R-400 two dials are used, The “A”range controls the current over about 1/2 of therange of the “B” range. A toggle switch on thecontrol panel allows selection of the desiredrange. The output control can be adjusted whilewelding.

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.

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)

RATINGS

Transformer insulation class 155(F)IP21 enclosure protection

IDEALARC® R3R-400

WARNING

D-1MAINTENANCED-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.

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-400

WARNING

E-1TROUBLESHOOTINGE-1

IDEALARC® R3R-400

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-400

Observe all Safety Guidelines detailed througout this manual


CAUTION

FUNCTION PROBLEMS

PROBLEMS(SYMPTOMS)

POSSIBLE CAUSE

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-400



CAUTION

FUNCTION PROBLEMS

PROBLEMS(SYMPTOMS)

POSSIBLE CAUSE


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-400



CAUTION

FUNCTION PROBLEMS

PROBLEMS(SYMPTOMS)

POSSIBLE CAUSE


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-400



CAUTION

FUNCTION PROBLEMS

PROBLEMS(SYMPTOMS)

POSSIBLE CAUSE


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-400



CAUTION

FUNCTION PROBLEMS

PROBLEMS(SYMPTOMS)

POSSIBLE CAUSE


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-400

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TROUBLESHOOTING PROCEDURES

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-400s have built-in protective ther-mostats. If the rectifier or transformer reaches the max-imum safe operating temperature because of frequentoverload or high room temperature plus overload, theline contactor drops out stopping the welder. The ther-mostats automatically reset and the line contactor pullsin when the temperature reaches a safe operatinglevel.

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-400


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 BRIDGEASSEMBLY

Precise evaluation of diodes or SCRs requirelaboratory 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-400

CAUTION

D-10TROUBLESHOOTINGE-10

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-400

DIAGRAM 1

DIAGRAM 2

F-1WIRING DIAGRAMSF-1

IDEALARC® R3R-400

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.

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.

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.

• 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 •

Documents

Operator’s Manual IDEALARC R3R-400 · 3.i. When working above floor level, use a safety belt to protect yourself from a fall should you get a shock. 3.j. Also see It ems 6.c. and