Lincoln Electric SP-250 service manual Electrical Diagrams G1992 Control PC Board

Page 101

TOC

TOC

G-1

ELECTRICAL DIAGRAMS

G-1

G1992 CONTROL PC BOARD

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C11

C88

R132

C87

R131

C86

R130

C85

R129

X21

R100

C84

R128

C83

R127

C82

R126

C81

R125

C77

R98

C35

C34

R97

J1

X5

Y1

R16

SP-250 CONTROL

		G1992-2
		X17
		R138
	C95
B	R69
B	R67	R139			J8
	R68	R106
	R108				D57
	C27	D2		R53	D57
	R107	D2
	R107		R52
	C28	D54	R52
		D54

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D37

R135

R133

D20

R1

C91

R134

C90

R5

R6

R7

L7

R2

R104

Q20

X7

X20

R8

R11

D34

D32

R19

R10

C78

Q3

Q1

Q4

C37

R9

J2

Q2

D31

D27

D30

D29

D26

D28

D25

D24

D72

R12

R109

R13

X8

R76

R14

R77

R15

R79

R20

J7

C44

C29

D73

C38

C31

R31

R80

D51

D52

R62

C1

R81

R82

R78

X13

R83

C50

C2

X11

C14

R37

C9

R36

C43

C13

R35

D64

C48

D58

X19

R34

R38

X12

R39

R32

R112

R25

C15

C3

D61

D60

R115

R114

D59

D62

C49

R113

R56

R51

Q9

J4

R28

Q8

L5

L4

L6

L3

L2

J5

R84

J3

R136

L1

R90

R89

	X4			C6
				C8
				X6
				R18
				C10
				R33
C17	X2	C32	X3	C33
	X2		X3
				C36

X9

			R121		Q7	Q6
						Q6

					R122
		X16			R44
	C20		D43			D39	D40
					C18	D39	D40
			R119
			D75		DZ3
			D75		R118
			D76		R118
	C55		C56
	C55
			X10
			R120			DD1
				DZ1		DD1
				DZ1
					Q21
			Q11
			DZ2	C		R40
		R116	DZ2
D35	R30		C45
D35	R30		C45
			C51
			J9
	J6
		TP1	TP2 C94 C93		C92	C23
						C23
	R137		C79
		C80	C79
			R48	R50

R65

D53

R54

R61

R111

R3

C4

C47

R4

D38

D69

X1

D50

C5

R58

D49

D

R63

R59

R60

R70

Q14

R105

R57

R95

Q18

R91

Q19

R123

R117

D47

D45

D70

R55

Q10

D48

D46

R49

D71

C26

C24

C7

R101

C52

C25

D1

R140

X15

D44

C21

DZ7

DZ6

A

D42

R45

R47

R22

R43

C19

R46

R23

X14

X18

Q13

R99

D41

Q12

C16

R94

R87

R71

OCI3

OCI2

OCI1

R93

R88

TP5

TP3

D68

R92

D67

C40

D65

D66

R86

C39

C30

DZ4

R74 R72 R73

C22

Q16

Q15

Q17

R124

R96

R85

R66

D63

R75

DZ5

D55

D56

R103

R102

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NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshoot- ing. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.

IDEALARC SP-250

Image 101

Contents Idealarc SP-250 Safety Depends on YouIdealarc SP-250 ARC Welding can be hazardousCylinder may explode if damaged Iii Electric and MAG- Netic FieldsSûreté Pour Soudage a L’Arc Précautions DE SûretéTable of Contents Installation Storage Operating Depth Weight GUNHeight Select Proper Location Safety PrecautionsInput Connections StackingInput Power Connections Ground Connections Fuse and Wire SizesFigure A.3 Ground Connection For 230/460/575 Volt Models Connect Shielding GASSide Reconnect ProcedureReturn to Section TOC Install the Work Clamp GUN Liner & Contact TIP InstallationConnect Output Components Output Polarity ConnectionFigure A.9 European Style Connector GUN & Cable InstallationOperation Additional Safety Precautions Safety InstructionsGeneral Description Electric Shock can killOperational System includes the following featuresControls Recommended ProcessesUnit Features Design FeaturesWire Feeder Features Power Source FeaturesDuty Amps Volts Cycle Machine CapabilityLimitations Figure B.1 SP-250 Control Panel Keys Controls and SettingsProcess WIRE/GAS KEY Arrow KEY Operation When Used withArrow KEY Operation When Used with Manual KEY Arrow KEY Operation When Used with Auto KEYArrow KEY Operation When Used with Stitch KEY Arrow KEY Operation When Used with Spot KEYLeft arrow keys Do not function Right arrow keys Do not functionStep Trigger Interlock Keys Figure B.5 Using the Toggle FunctionChanging RUN-IN Mode Codes 10001 and Above RUN-IN ModeMaking a Weld in Auto Mode Operating StepsTo make an arc spot plug weld Using the 4-STEP Interlock Function in Auto ModeMaking a Spot Weld in Auto Mode Using the Wire Drive Roll Using the GUN Thumb Switch Magnum SP-250 onlyMaking a Stitch Weld in Auto Mode Using the GUN Trigger SwitchTo mount 10 to 30 lb. spools 8 and 12 diameter Loading the Wire ReelFeeding Electrode Setting Idle Roll PressureAccessories Spool GUN Module Board Installation Options / AccessoriesSpool GUN Adapter KIT Installation Figure C.2 Spool Gun Module Board Installation Spool GUN Connection BOX InstallationFigure C.5 Spool Gun Connect Spool GUN ConnectionFigure C.6 Spool Gun Connection Spool GUN Installation to OLD K531 KITMaintenance Routine and Periodic MaintenanceControl Board Choke Fan Assembly Main Transformer Theory of Operation Former Power Supply OperationInput Line Voltage and Main Trans Back Control Output Rectification and FeedFigure E.4 Constant Voltage Output Constant Voltage OutputFigure E.5 Wire Drive Motor and Feedback Wire Drive Motor and FeedbackThermal Protection Figure E.6 SCR Operation SCR OperationTroubleshooting & Repair Recommended Course of Action HOW to USE Troubleshooting GuideBoard can be dam- aged by static electricity PC Board Troubleshooting ProceduresOutput Problems Warn Troubleshooting & Repair Function Problems Troubleshooting & Repair Wire Feeding Problems Trolyte in these capacitors is Liquid elecToxic. Avoid contact with any Portion of your bodyTroubleshooting & Repair On Screen Error Message Message Explanation Explanation of Prompting and Error MessagesXxxx Explanation of Prompting and Error Messages CONT’DOn Screen Error Message Current Overload Reduce Output Press ANY KEY to Stop Message Materials Needed Main Transformer TestTest Description Main Transformer Test Test Procedure From Expected Lead Voltage Lead Plug Location#206 4J6 #208 16J6 #209 7J6 G1992 Code 9402 only Troubleshooting & Repair Static SCR Rectifier Assembly Test Leads Figure F.4 SCR 1 Test Points Active SCR Rectifier Assembly Test Leads Figure F.7 SCR Tester Circuit and SCR connections 25F-25 SP-250 Keypad Resistance TestFigure F.9 Plug J2 Test Points Figure F.8A Plug J2 Location on G2252 PC Control BoardTable F.1 SP-250 Keypad Resistance Tests Test Points KEY Pressed Maximum Allowable27F-27 Wire Drive Motor and Tachometer Feedback Test Figure F.10A Plug J5 Location on G2252 PC Control Board Wire Drive Motor and Tachometer Feedback Test Test ProcedurePull the gun trigger #206B 4J6 #515B 1J6 #555 2J6 #541 6J6 #539 3J6Test for Feedback Voltage to the Control Board Test for Supply Voltage to TachometerNormal Open Circuit Voltage Waveform Scope SettingsTypical Output Voltage Waveform Machine Loaded Machine Loaded to 250 Amps AT 26 VDC Scope SettingsMachine Loaded to 220 Amps AT 22 VDC Scope Settings Troubleshooting & Repair Typical SCR Gate Voltage Waveform Removal and Replacement Procedure Materials Needed Control PC Board Removal and ReplacementTroubleshooting & Repair Keypad Removal and Replacement Keypad Removal and Replacement Procedure Wire Drive Assembly Removal and Replacement Figure F.13 Wire Drive Assembly Removal Wire Drive Assembly Removal and Replacement Procedure43F-43 SCR Output Rectifier RemovalFigure F.14 Heat Sink lead discon- nection Capacitor Bank Removal and Replacement Capacitor Bank Removal and Replacement Procedure Main Transformer Removal and Replacement Power Switch FAN Motor and FAN Removal and Replacement Figure F.18 Fan Motor and Fan Removal Components FAN Motor and FAN Removal and Replacement ProcedureTroubleshooting & Repair Open Circuit Voltage Wire Speed RangeInput Volts/Hertz 230/60 375Table of Contents Electrical Diagrams G1992 Control PC Board Identification X9 . . . . . .IC-CMOS,UNDERVOLT-SENSING,RESET,MCU Idealarc SP-250 Electrical Diagrams G2252 Control PC Board TOC OCI2,OCI3 Optocoupler Triac Driver Idealarc SP-250 Electrical Diagrams SP-250 230/460/575V Wiring Diagram Wiring Diagram for Code 9546Thumb Switch Wiring Diagram for Code 9723Improper Lincoln Electric. This information