Lincoln Electric SP-250 manual

IDEALARC SP-250 SER VICE MANUAL Sales and Service through Subsidiaries and Distributors Worldwide 22801 St. Clair A ve. Cleveland, Ohio 441 17-1 199 U.S.A. T el. (216) 481-8100 World's Leader in W elding and Cutting Products Premier Manufacturer of Industrial Motors SVM 1 1 1-A January , 1996 Safety Depends on Y ou Lincoln arc welding and cutt[...]

i SAFETY i IDEALARC SP-250 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJUR Y OR DEA TH. KEEP CHILDREN A W A Y . P ACEMAKER WEARERS SHOULD CONSUL T WITH THEIR DOCTOR BEFORE OPERA TING. Read and understand the following safety highlights. For additional safety[...]

FOR ELECTRICALL Y powered equipment. 6.a. T urn off input power using the disconnect switch at the fuse box before working on the equipment. 6.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer ’ s recommendations. 6.c. Ground the equipment in accordance with the U.S. National Electrica[...]

iii SAFETY iii IDEALARC SP-250 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Mar . ‘93 ELECTRIC AND MAG- NETIC FIELDS may be dangerous 8.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). W elding current creates EMF fields around welding cables and welding [...]

iv SAFETY iv IDEALARC SP-250 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 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[...]

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i - v Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A T echnical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 Safety Precautions .[...]

INST ALLA TION IDEALARC SP-250 INST ALLA TION SECTION ........................................ Section A T echnical Specifications ...................................................A-1 Safety Precautions ...........................................................A-2 Select Proper Location .....................................................A-2 St[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Duty Cycle Amps V olts at Rated Amps 100% 145 amps 26 60% 200 amps 28 35% 250 amps 26 Current Range Maximum Open Circuit V oltage Wire Speed Range 30A - 250A 10V - 40V 50 - 600 I[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Read entire Installation Section before installing the IDEALARC SP-250 SAFETY PRECAUTIONS ELECTRIC SHOCK CAN KILL. • Only qualified personnel should install this machine. • T[...]

A-3 INST ALLA TION IDEALARC SP-250 A-3 FUSE AND WIRE SIZES Protect the input circuit with the super lag fuses or delay type circuit breakers listed on the Specifications page of this manual for the machine being used. The tripping action of delay type circuit breakers decreases as the magnitude of the current increases. They are also called inverse[...]

A-4 INST ALLA TION IDEALARC SP-250 A-4 For the 230/460/575V/ 60 HZ model which is not equipped with a plug, an input cord, or a receptacle, the input power supply leads are connected directly to the Reconnect Panel as shown Figure A.3. Refer to the specifications table at the beginning of this chapter for proper wiring sizes. 1. Connect the input p[...]

A-5 INST ALLA TION IDEALARC SP-250 A-5 1 1. Before opening the cylinder valve, turn the regula- tor adjusting knob counter clockwise until the pres- sure is released from the adjusting spring. 12. Open the cylinder valve slowly a fraction of a turn. a. When the cylinder pressure gage pointer stops moving, open the valve fully . NEVER ST AND DIRECTL[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC A-6 INST ALLA TION IDEALARC SP-250 A-6 FIGURE A.5 - Reconnect Diagram For Codes 9402, 9723, and 10001 208/230/1/60 Machines. FIGURE A.6 - Reconnect Diagram For Codes 9546 & 1[...]

A-7 INST ALLA TION IDEALARC SP-250 A-7 CONNECT OUTPUT COMPONENTS INST ALL THE WORK CLAMP Attach the work clamp to the cable which extends from the front of the machine using the following procedure: 1. Insert the lug on the end of the work cable through the strain relief hole in the work clamp handle. See Figure A.7. 2. Slide the work cable through[...]

A-8 INST ALLA TION IDEALARC SP-250 A-8 GUN & CABLE INST ALLA TION W ARNING: TURN THE WELDER POWER SWITCH OFF BEFORE INST ALLING GUN AND CABLE. ____________________________________ 1. Lay the cable out straight. 2. Make sure all pins on the gun cable connector are aligned with the proper mating sockets on the front panel gun connector and then j[...]

OPERA TION IDEALARC SP-250 OPERA TION SECTION ............................................ Section B Safety Instructions ............................................................B-1 General Description..........................................................B-1 Recommended Processes and Equipment ......................B-2 Operational Features a[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC B-1 OPERA TION B-1 Read and understand this entire section before operat- ing your Idealarc SP-250. SAFETY INSTRUCTIONS ELECTRIC SHOCK can kill. • Do not touch electrically liv[...]

B-2 OPERA TION B-2 The system includes the following features: • 2-step or 4-step selectable trigger function (above code 9500 only). • both timed spot and stitch welding selections. • drop-in 2" (51mm) O.D. wire reel spindle with a 22- 30 lb. (10 - 13.6 kg) Readi-Reel- adapter . • integral gas cylinder mounting undercarriage. • 12.5[...]

B-3 OPERA TION B-3 DESIGN FEA TURES AND ADV ANT AGES UNIT FEA TURES: Undercarriage for Hand Mobility - Heavy duty 10" (254mm) wheels and 4" (102mm) casters are factory installed along with the handle. Handle can be used for hanging the welding gun and work cable. Gas Cylinder Platform - Factory installed on under- carriage. It permits pla[...]

B-4 OPERA TION B-4 Gun and Cable (K524-1) - A 12.5 ft. (3.8) GMAW gun and cable assembly , rated 200 amps 60% duty , is pro- vided with the SP-250 and includes a liner , diffuser , and contact tips for .035 (0.9mm) and .045 (1.2mm) electrodes. The gun is equipped with a Fast-Mate con- nector with additional control lead connections for the thumb ac[...]

B-5 OPERA TION B-5 CONTROLS AND SETTINGS All operator controls are located on the Front Panel Keypad/Nameplate. See Figure B.1 for the location of each control. FIGURE B.1 - SP-250 Control Panel Keys 1. POWER SWITCH: T oggle switch to turn input power ON and OFF . When the switch is in the ON position the red LED backlighting of the LCD dis- play l[...]

B-6 OPERA TION B-6 ARROW KEY OPERA TION WHEN USED WITH PROCESS WIRE/GAS KEY : See T able B.1. Left Arrow Keys: Press to set Wire T ype. Pressing the UP and DOWN arrow keys changes the Wire T ype dis- played. Center Arrow Keys : Press to set Wire Diameter . Press the UP ( ) arrow key to increase the wire diam- eter displayed. Press the DOWN ( ) arro[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ARROW KEY OPERA TION WHEN USED WITH MANUAL KEY : See T able B.1. Left arrow keys: Do not function in Manual mode. Center arrow keys: Press the UP ( ) arrow key to increase wire f[...]

B-8 OPERA TION B-8 7. MEMOR Y KEYS: Press memory key location number in which you want to save a procedure or from which you want to recall a procedure from memory . See SA VE Key . FIGURE B.3 - Sample SA VE Sequence. 8. SPOT KEY : Press to turn ON the Spot Weld T imer and display the spot weld ON time. Pressing the SPOT KEY a second time returns t[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 12. TOGGLE KEY : When first pressed, this key turns ON the T OGGLE MODE and recalls the weld setup in memory 4. Pressing the key again switch- es to the weld setup in memory loca[...]

B-10 OPERA TION B-10 OPERA TING STEPS Before operating the machine, be sure you have all the materials needed to perform the work. Be sure you are familiar with and have taken all possible safety pre- cautions before starting the work. It is important that you follow these operating steps each time you use the machine. RUN-IN MODE The IDEALARC SP-2[...]

B-1 1 OPERA TION B-1 1 10. If SPOT timing mode required. a. Press SPOT key . b. Press CENTER UP or DOWN ARROW keys to select SPOT ON TIME required. c. Press SPOT key to return to previous display . d. Go to Step 12. 1 1. If STITCH timing mode required. a. Press STITCH key . b. Press CENTER UP and DOWN ARROW keys to select STITCH ON time required. c[...]

B-12 OPERA TION B-12 4. Press the CENTER UP & DOWN ARROW keys to set the required Spot On time. Suggested initial setting is 1.2 seconds. 5. Press the SPOT key . Display returns to Auto screen. Spot timer status is shown in bottom left corner of screen. 6. Install spot weld nozzle (if available) on gun. 7. Press spot weld nozzle against the top[...]

B-13 OPERA TION B-13 LOADING THE WIRE REEL T o mount a 22-30 lb. (10-14 kg) Readi-Reel- package using the Readi-Reel adapter provided: 1. Pull the Readi-Reel adapter and spindle up out of the SP-250 spindle mounting clips (V -brackets). 2. Rotate the spindle and adapter so the retaining spring is at the 12 o'clock position. 3. Position the Rea[...]

B-14 OPERA TION B-14 FEEDING ELECTRODE When inching, the electrode and drive mechanism are always “hot” to work and ground. The electrode remains “hot” several seconds after the gun trigger is released. ____________________________________ NOTE: Check that the proper drive rolls and gun parts are used for the wire size and wire type being u[...]

ACCESSORIES IDEALARC SP-250 ACCESSORIES SECTION ....................................... Section C Options/Accessories ........................................................C-1 Replacement Magnum 250-SP Gun and Cable Assemblies ........................................................C-1 Spool Gun Adapter Kit Installation Spool Gun Module Board Ins[...]

C-1 ACCESSORIES C-1 OPTIONS / ACCESSORIES Replacement Magnum 250-SP Gun and Cable Assemblies The following GMA W gun and cable assemblies are available for use with the SP-250. Each is rated at 200 amps at 60% duty cycle. Each is equipped with a Fast- Mate connector and additional control lead connec- tions for the thumb activated 2 momentary posit[...]

C-2 ACCESSORIES C-2 Figure C.2 - Spool Gun Module Board Installation. 1. Remove input power to the machine before start- ing. 2. Remove the six screws that hold the Case Side Panels. 3. Locate the four snap-mount fasteners mounted to the side panel of the control Board. 4. Position the spool gun module board over the snap-mount fasteners, making su[...]

C-3 ACCESSORIES C-3 SPOOL GUN CONNECTION BOX INST ALLA TION NOTE: Model codes below 9900 require the addition of three holes to the front of the machine's base as shown in Fig C.3. Figure C.3 - Spool Gun Connection Box Installation Mounting Holes 1. Remove the plug button, if present, from the cen- ter hole in the front of the machine's b[...]

C-4 ACCESSORIES C-4 SPOOL GUN CONNECTION CAUTION: The spool gun module is intended for use with Lincoln Electric Magnum Spool Guns only . Use with other units may cause damage to the equipment. For Spool Gun operation, refer to the instruction man- ual provided with the Magnum Spool Gun. 1. Connect the spool gun control cable 6-pin plug to mating r[...]

C-5 ACCESSORIES C-5 SPOOL GUN INST ALLA TION TO OLD K531 KIT . 1. Slide the spool gun cable assembly through the opening in the louvers provided for the work lead. See Figure C.6. 2. Remove the SP-250 gas line from the gas line con- nector . 3. Screw the spool gun 6-pin plug into the new con- nector just below the gas line connector . 4. Attach the[...]

MAINTENANCE IDEALARC SP-250 MAINTENANCE SECTION ...................................... Section D Safety Precautions ...........................................................D-1 Routine and Periodic Maintenance ..................................D-1 Component Locations ......................................................D-2 T ABLE OF CONTENTS - M[...]

D-1 MAINTENANCE D-1 SAFETY PRECAUTIONS •Have a qualified technician do the maintenance and troubleshooting work. •Disconnect input power at main input supply prior to working inside machine. ____________________________________ Read the Safety Precautions in the front of this manu- al before working on this machine. ROUTINE AND PERIODIC MAINTEN[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC D-2 MAINTENANCE D-2 Figure D.1 - Component Locations IDEALARC SP-250 2 1 3 4 5  5 4 3 1  2 Control Board Fan Assembly SCR Rectifier Choke Main Transformer[...]

THEOR Y OF OPERA TION IDEALARC SP-250 Figure E.1 -Block Logic Diagram NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion THEORY OF OPERA TION SECTION ...................... Section E Power Supply Operation ........................................E-1 - E-3 Input Line V oltage and Main T ransformer ...................E-1 Output[...]

E-1 THEOR Y OF OPERA TION E-1 IDEALARC SP-250 INPUT LINE VOL T AGE AND MAIN TRANS- FORMER The desired single phase input power is connected to the SP-250 through a line switch located on the front panel. A reconnect panel allows the user to configure the machine for the desired input voltage. This AC input voltage is applied to the primary of the m[...]

E-2 THEOR Y OF OPERA TION E-2 IDEALARC SP-250 OUTPUT RECTIFICA TION AND FEED- BACK CONTROL The AC output from the main transformer secondary weld winding is rectified and controlled through the SCR rectifier assembly . Output voltage and current are sensed at the shunt and output terminals and fed back to the control board. The control board compar[...]

E-3 THEOR Y OF OPERA TION E-3 IDEALARC SP-250 CONST ANT VOL T AGE OUTPUT The controlled DC output from the SCR rectifier assembly is filtered by the capacitor bank and the out- put choke, which is in series with the gun and welding load, resulting in a constant voltage output at the out- put terminals of the machine. Figure E.4 - Constant V oltage [...]

E-4 THEOR Y OF OPERA TION E-4 IDEALARC SP-250 WIRE DRIVE MOTOR AND FEEDBACK The wire drive motor is controlled by the control board. A motor speed feedback signal is generated at the motor tach and sent to the control board. The control board compares this feedback signal with the com- mands set forth by the keypad (or the gun thumb switch) and sen[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC E-5 THEOR Y OF OPERA TION E-5 IDEALARC SP-250 A thermostat protects the machine from excessive operating temperatures.. Excessive operating temper- atures may be caused by a lack[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC E-6 THEOR Y OF OPERA TION E-6 IDEALARC SP-250 A silicon controlled rectifier (SCR) is a three terminal device used to control rather large currents to a load. An SCR acts very mu[...]

TROUBLESHOOTING & REP AIR IDEALARC SP-250 TROUBLESHOOTING & REP AIR SECTION ........... Section F How to use T roubleshooting Guide ..................................F-1 PC Board T roubleshooting Procedures ............................F-2 T roubleshooting Guide ............................................F-3 - F10 Explanation of Prompting E[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-1 TROUBLESHOOTING & REP AIR F-1 IDEALARC SP-250 This T roubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-2 TROUBLESHOOTING & REP AIR F-2 IDEALARC SP-250 CAUTION: Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor el[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-3 TROUBLESHOOTING & REP AIR F-3 IDEALARC SP-250 TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understan[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-4 TROUBLESHOOTING & REP AIR F-4 IDEALARC SP-250 TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual OUTPUT PROBLEMS PROBLEMS (SYMPTOMS) PO[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-5 TROUBLESHOOTING & REP AIR F-5 IDEALARC SP-250 TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual OUTPUT PROBLEMS PROBLEMS (SYMPTOMS) PO[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-6 TROUBLESHOOTING & REP AIR F-6 IDEALARC SP-250 TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual FUNCTION PROBLEMS PROBLEMS (SYMPTOMS) [...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-7 TROUBLESHOOTING & REP AIR F-7 IDEALARC SP-250 TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual FUNCTION PROBLEMS PROBLEMS (SYMPTOMS) [...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-8 TROUBLESHOOTING & REP AIR F-8 IDEALARC SP-250 TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual WIRE FEEDING PROBLEMS PROBLEMS (SYMPTO[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-9 TROUBLESHOOTING & REP AIR F-9 IDEALARC SP-250 TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual WELDING PROBLEMS PROBLEMS (SYMPTOMS) P[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-10 TROUBLESHOOTING & REP AIR F-10 IDEALARC SP-250 TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual WELDING PROBLEMS PROBLEMS (SYMPTOMS)[...]

F-1 1 TROUBLESHOOTING & REP AIR F-1 1 IDEALARC SP-250 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC EXPLANA TION OF PROMPTING AND ERROR MESSAGES ON SCREEN ERROR MESSAGE PROCESS MUST MA TCH WIRE & GAS ONL Y SET UP FOR[...]

F-12 TROUBLESHOOTING & REP AIR F-12 IDEALARC SP-250 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC EXPLANA TION OF PROMPTING AND ERROR MESSAGES (CONT’D) ON SCREEN ERROR MESSAGE DA T A ***ERROR*** CHECK SETTINGS PRESS PR[...]

F-13 TROUBLESHOOTING & REP AIR F-13 IDEALARC SP-250 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC EXPLANA TION OF PROMPTING AND ERROR MESSAGES (CONT’D) ON SCREEN ERROR MESSAGE HIGH LINE: CHECK RECONNECT P ANEL PRESS AN[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-14 TROUBLESHOOTING & REP AIR F-14 IDEALARC SP-250 TEST DESCRIPTION This test will determine if the correct voltages are being a. applied to the primary windings of the Main[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-15 TROUBLESHOOTING & REP AIR F-15 IDEALARC SP-250 TEST PROCEDURE The ON/OFF POWER SWITCH will be "hot" during these tests. __________________________ NOTE: Second[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-16 TROUBLESHOOTING & REP AIR F-16 IDEALARC SP-250 G1992 (code 9402 only): 5. Connect main input power to the machine. 6. T urn the IDEALARC SP-250 ON/OFF POWER SWITCH to ON[...]

F-17 TROUBLESHOOTING & REP AIR F-17 IDEALARC SP-250 G1992 (Code 9402 only): 8. T urn OFF the machine 9. Locate the following leads on Plug J6 on the G2252 Control PC Board or Plug J3 on the G1992 Control PC Board. See Figures F .1A & F1.B. G2252: G1992 (Code 9402 only): 10. T urn ON the machine. 1 1. Make the following voltage tests at Plug[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-18 TROUBLESHOOTING & REP AIR F-18 IDEALARC SP-250 MAIN TRANSFORMER TEST b. If the correct nameplate voltage is being applied to the main transformer and one or more of the [...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-19 TROUBLESHOOTING & REP AIR F-19 IDEALARC SP-250 TEST DESCRIPTION The Static SCR T est is used to quickly determine if an SCR is shorted or "leaky ." See the W a[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FIGURE F .2B - Remove Plug J3 to Perform Static SCR Rectifier Assembly T est. TEST PROCEDURE 1. Disconnect main AC input power to the machine. 2. Disconnect Plugs J3 and J6 from [...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-21 TROUBLESHOOTING & REP AIR F-21 IDEALARC SP-250 NOTE: DO NOT DISASSEMBLE THE SCR RECTIFIER HEA T SINK ASSEM- BL Y . 6. T est for high or infinite resistance from the anod[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-22 TROUBLESHOOTING & REP AIR F-22 IDEALARC SP-250 TEST DESCRIPTION The Active SCR T est will determine if the device is able to be gated ON and conduct current from anode t[...]

F-23 TROUBLESHOOTING & REP AIR F-23 IDEALARC SP-250 TEST PROCEDURE 1. Disconnect main AC input power to the machine. 2. Disconnect Molex Plugs J3 and J6 from the G2252 Control Board or remove Plug J3 from G1992 Control Board (Code 9402 only) See Figures F .5A and F .5B. FIGURE F .5A - Control Board Molex Plug Locations for G2252 PC Control Boar[...]

F-24 TROUBLESHOOTING & REP AIR F-24 IDEALARC SP-250 7. Connect the T ester to the SCR 1 as shown in Figure F .7. a. Connect T ester lead (A) to the anode. b. Connect T ester lead (C) to the cathode. c. Connect T ester lead (G) to the gate. FIGURE F .7 - SCR T ester Circuit and SCR connections. 8. Close switch SW-1. NOTE: Switch SW-2 should be o[...]

F-25 TROUBLESHOOTING & REP AIR F-25 IDEALARC SP-250 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TEST DESCRIPTION This test will determine if any key is not functioning properly . MA TERIALS NEEDED 5/16" Nut Driver[...]

F-26 TROUBLESHOOTING & REP AIR F-26 IDEALARC SP-250 TEST PROCEDURE 1. Disconnect main input power to the machine. 2. Remove the Case T op and Side Panels using the 5/16" nut driver . 3. Locate and disconnect Plug J2 con- nected to the Control PC Board. See Figures F .8A and F8B. FIGURE F .8A - Plug J2 Location on G2252 PC Control Board. FI[...]

F-27 TROUBLESHOOTING & REP AIR F-27 IDEALARC SP-250 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TEST POINTS KEY PRESSED MAXIMUM ALLOW ABLE RESIST ANCE (TYPICAL RESIST ANCE) FROM PIN T O PIN 1J2 6J2 CENTER UP ARROW 100 [...]

F-28 TROUBLESHOOTING & REP AIR F-28 IDEALARC SP-250 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TEST DESCRIPTION This test will determine if the wire drive motor and voltage feedback circuit are functioning properly . [...]

F-29 TROUBLESHOOTING & REP AIR F-29 IDEALARC SP-250 TEST PROCEDURE NOTE: POLARITY MUST BE OBSERVED FOR THESE TESTS. T est for Correct Wire Drive Motor Armature V oltage 1. Disconnect main input power to the machine. 2. Remove the Case T op and Side Panels using a 5/16" nut driver . 3. Locate Plug J5 on the G2252 Control Board, or Plug J6 o[...]

F-30 TROUBLESHOOTING & REP AIR F-30 IDEALARC SP-250 FIGURE F .10B - Plug J6 Location on G1992 PC Control Board (Code 9402 only .) NOTE: Plugs J5 and J6 are on the inboard non-component side of the Control Board. 4. T est for 2-25 VDC between lead #539 (positive) and lead #541 (neg- ative) to determine if the correct armature voltage is being su[...]

F-31 TROUBLESHOOTING & REP AIR F-31 IDEALARC SP-250 T est for Supply V oltage to T achometer 1. T est for 15 VDC between lead #515B (positive) and lead #206B (negative). See Figure F . 10 for pin locations. a. Insert probes into Molex pin cavities. 2. Pull gun trigger . 3. Read meter for 15 VDC. a. If the 15 VDC is present, check the leads to t[...]

F-32 TROUBLESHOOTING & REP AIR F-32 IDEALARC SP-250 This is a typical DC output voltage wave- form generated from a properly operating machine. Note that each vertical division represents 20 volts and that each horizontal division represents 2 milliseconds in time. Note: Scope probes connected at machine output terminals: (+) probe to electrode[...]

F-33 TROUBLESHOOTING & REP AIR F-33 IDEALARC SP-250 This is a typical DC output voltage wave- form generated from a properly operating machine. Note that each vertical division represents 20 volts and that each horizontal division represents 5 milliseconds in time. The machine was loaded with a resistance grid bank. Note: Scope probes connected[...]

F-34 TROUBLESHOOTING & REP AIR F-34 IDEALARC SP-250 This is NOT a typical DC output voltage waveform. One output SCR is not function- ing. Note the increased ripple content. One SCR gate was disconnected to simulate an open or non-functioning output SCR. Each vertical division represents 20 volts and each horizontal division represents 5 mil- l[...]

F-35 TROUBLESHOOTING & REP AIR F-35 IDEALARC SP-250 This is NOT the typical DC output voltage waveform. The output capacitors are not functioning. Note the lack of “filtering” in the output waveform. The output capacitor bank was disconnected. Each vertical divi- sion represents 20 volts and each horizontal division represents 5 millisecond[...]

F-36 TROUBLESHOOTING & REP AIR F-36 IDEALARC SP-250 This is a typical SCR gate pulse voltage waveform. The machine was in an open cir- cuit condition (no load) and operating prop- erly . Note that each vertical division repre- sents 2 volts and each horizontal division represents 5 milliseconds in time. Note: Scope probes connected at Plug J3 o[...]

F-37 TROUBLESHOOTING & REP AIR F-37 IDEALARC SP-250 Printed Circuit Boards can be dam- aged by static electricity . Follow sta- tic handling guidelines detailed in “PC Board T roubleshooting Procedures” at the beginning of this chapter . _____________________________ REMOV AL AND REPLACEMENT PROCEDURE MA TERIALS NEEDED 5/16" Nut Driver[...]

F-38 TROUBLESHOOTING & REP AIR F-38 IDEALARC SP-250 4. Remove the eight Phillips Head mounting screws using a Phillips Head screwdriver . See Figure F .12. FIGURE F .12 - Control Board Mounting Screw Locations may vary with different Code Machines. 5. Lift the Control Board straight up and out from the machine. 6. Replace all mounting screws an[...]

F-39 TROUBLESHOOTING & REP AIR F-39 IDEALARC SP-250 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC MA TERIALS NEEDED 5/16" Nut Driver 1/4" Nut Driver KEYP AD REMOV AL AND REPLACEMENT Service and repair should be[...]

F-40 TROUBLESHOOTING & REP AIR F-40 IDEALARC SP-250 PROCEDURE NOTE: BEFORE REMOVING THE KEYP AD, PERFORM THE KEYP AD RESIST ANCE TEST TO BE SURE THE KEYP AD IS F AUL TY . 1. Disconnect main input power to the machine. 2. Remove the Case T op and Side Panels with 5/16" nut driver . 3. Disconnect Keypad Plug J2 from the Control Panel. 4. Rem[...]

F-41 TROUBLESHOOTING & REP AIR F-41 IDEALARC SP-250 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC MA TERIALS NEEDED Large slot head screwdriver 5/16" Nut Driver Small slot head screwdriver WIRE DRIVE ASSEMBL Y REMOV[...]

F-42 TROUBLESHOOTING & REP AIR F-42 IDEALARC SP-250 PROCEDURE 1. Disconnect main input power to the machine. 2. Remove the Case T op and Side Panels. 3. Remove the large mounting screw with a large slot head screwdriver located in front of the drive roll. See Figure F .13. a. Note the placement of the insu- lators and washers for replace- ment.[...]

F-43 TROUBLESHOOTING & REP AIR F-43 IDEALARC SP-250 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC MA TERIALS NEEDED 5/16" Nut Driver 1/2" Open End Wrench 1/2" Socket wrench, universal tool, and extension 3[...]

F-44 TROUBLESHOOTING & REP AIR F-44 IDEALARC SP-250 PROCEDURE 1. Disconnect lead #208 and T ransformer Lead X1 from the heat sink on the left side of the machine (facing the front) using a 1/2" socket wrench. See Figure F .14. a. Thin lead is always on the out- board side of the connection. FIGURE F .14 - Heat Sink lead discon- nection. 2.[...]

F-45 TROUBLESHOOTING & REP AIR F-45 IDEALARC SP-250 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC THE LIQUID ELECTROL YTE IN THE CAP ACITORS IS TOXIC. DO NOT TOUCH THE CAP ACITORS WITH ANY P ART OF YOUR BODY . MA TERIALS[...]

F-46 TROUBLESHOOTING & REP AIR F-46 IDEALARC SP-250 PROCEDURE See Figure F .17 for location of Capacitor Bank Removal and Replacement com- ponents. FIGURE F .17 - Location of Capacitor Bank Removal and Replacement Components 1. Disconnect main input power to the machine. 2. T est that the capacitors are dis- charged using a volt ohmmeter . Pola[...]

F-47 TROUBLESHOOTING & REP AIR F-47 IDEALARC SP-250 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC MA TERIALS NEEDED 5/16" Nut Driver 1/2" Open end wrench 3/8" Open end wrench 1/2" Socket wrench, exten[...]

F-48 TROUBLESHOOTING & REP AIR F-48 IDEALARC SP-250 PROCEDURE 1. Disconnect main input power to the machine. 2. Remove the Case T op and Side Panels. 3. Perform the Capacitor Bank Removal Procedure. 4. Remove lead X1 from the left side SCR heat sink assembly using a 1/2" socket wrench, extender and universal adapter . 5. Remove lead X4 fro[...]

F-49 TROUBLESHOOTING & REP AIR F-49 IDEALARC SP-250 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC MA TERIALS NEEDED 3/4" Open end wrench 1/2" Socket wrench with extension Phillips head screwdriver F AN MOTOR AN[...]

F-50 TROUBLESHOOTING & REP AIR F-50 IDEALARC SP-250 PROCEDURE See Figure F .18 for fan motor and fan removal components. FIGURE F .18 - Fan Motor and Fan Removal Components 1. Remove the Case Back screws. 2. Remove the gas solenoid using a 3/4" open end wrench. 3. Using a 5/16” wrench, remove the 5 screws holding the fan motor mount- ing[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-51 TROUBLESHOOTING & REP AIR F-51 IDEALARC SP-250 7. Remove the fan motor . a. Loosen and remove the two screws from the motor mounting bracket using a slot head screw driv[...]

F-52 TROUBLESHOOTING & REP AIR F-52 IDEALARC SP-250 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC INPUT IDLE AMPS AND W A TTS WIRE SPEED RANGE OPEN CIRCUIT VOL T AGE RETEST AFTER REP AIR Maximum Idle W atts Maximum Idle [...]

T ABLE OF CONTENTS - ELECTRICAL DIAGRAMS - Section G IDEALARC SP-250 ELECTRICAL DIAGRAMS SECTION ...................... Section G G1992 CONTROL PC BOARD LA YOUT .....................G - 1 G2252 CONTROL PC BOARD LA YOUT ......................G - 5 WIRING DIAGRAM (Code 9402) ..................................G - 9 WIRING DIAGRAM (Code 9546 & 1000[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC J5 J6 J3 J4 C16 C18 X14 R47 C19 DZ3 R40 R89 R90 R48 R50 C23 C22 D24 D25 D26 D27 D28 D29 D30 D31 X8 R56 R51 C21 D44 D42 X18 R45 R22 Q12 D41 R43 D39 D40 R44 D43 D63 D55 D56 R66 C30[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC G-2 ELECTRICAL DIAGRAMS G1992 CONTROL PC BOARD G-2 IDEALARC SP-250 NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshoot- ing.[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC R16 . . . . . . . . . . . . . . . . . . .RESISTOR-CC,1/2W ,10M,5% R32,R54,R1 19 . . . . . . . . . . . . . .RESISTOR-MF 22K 1/4W R60,R81,R82,R83,R91,R95 . . .RESISTOR-MF 2.2K 1/4W[...]

G-4 NOTES G-4 IDEALARC SP-250 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SP 250 CONTROL G2252- 2 1 9 1 16 G-5 ELECTRICAL DIAGRAMS G2252 CONTROL PC BOARD G-5 IDEALARC SP-250 NOTE: Lincoln Electric assumes no responsibility for liablilities resulting fr[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC G-6 ELECTRICAL DIAGRAMS G2252 CONTROL PC BOARD G-6 IDEALARC SP-250 Item Identification Item Identification C61,C64 . . . . . . . . . . . . . CAP ACITOR-PCF ,0.27,50V ,20% C73 . .[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Item Identification Item Identification G-7 ELECTRICAL DIAGRAMS G2252 CONTROL PC BOARD G-7 IDEALARC SP-250 Q1,Q2,Q3,Q4,Q5, TRANSISTOR-N,T226,0.5A,40V ,2N4401 Q10,Q12,Q14,Q22,Q23,[...]

G-8 NOTES G-8 IDEALARC SP-250 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC G-9 G-9 IDEALARC SP-250 IDEALARC SP-250 ELECTRICAL DIAGRAMS WIRING DIAGRAM FOR CODE 9402 NOTE: This diagram is for reference only. It may not be accurate for all machines covered[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC G-10 G-10 IDEALARC SP-250 IDEALARC SP-250 ELECTRICAL DIAGRAMS WIRING DIAGRAM FOR CODE 9546 & 10002 NOTE: This diagram is for reference only. It may not be accurate for all ma[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC G-11 G-11 IDEALARC SP-250 IDEALARC SP-250 ELECTRICAL DIAGRAMS WIRING DIAGRAM FOR CODE 9723 & 10001 NOTE: This diagram is for reference only. It may not be accurate for all ma[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC G-12 ELECTRICAL DIAGRAMS G-12 G1992 CONTROL PC BOARD SCHEMA TIC NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC B[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC G-13 ELECTRICAL DIAGRAMS G-13 G2252 CONTROL PC BOARD SCHEMA TIC NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC B[...]