Lincoln Electric SP-250 service manual Identification

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G-2

ELECTRICAL DIAGRAMS

G-2

G1992 CONTROL PC BOARD

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Item

Identification

C45 . . . . . . . . . . . . . . .CAPACITOR-PEMF,.047,100V,10% C21 . . . . . . . . . . . . . . . . .CAPACITOR-TAEL,39,20V,10% C16 . . . . . . . . . . . .CAPACITOR-ALEL,2200,63V,+30/-10% C30,C47,C95 . . . . . . . . . .CAPACITOR-TAEL,4.7,35V,10% C15 . . . . . . . . . . . . . . . . .CAPACITOR-TAEL,39,10V,10% C14,C20 . . . . . . . . . . . . . .CAPACITOR-TAEL,18,15V,10% C39,C40 . . . . . . . . . . . . .CAPACITOR-TAEL,1.0,35V,10% C25 . . . . . . . . . . . . .CAPACITOR-ALEL,6,150V,+50/-10% C55 . . . . . . . . . . . . .CAPACITOR-ALEL,20,50V,+75/-10% C13 . . . . . . . . . . . . . . . .CAPACITOR-PEF,.001,400V,10% C18 . . . . . . . . . . . . .CAPACITOR-ALEL,50,25V,+75/-10% C24,C26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27/50 C19 . . . . . . . . . . . .CAPACITOR-ALEL,3300,50V,+30/-10% OCI2,OCI3 OPTOCOUPLER-PHOTO-SCR,400V,MCS2401 OCI1 . . . . . . . . . . .OPTOCOUPLER-PHOTO-Q,30V,4N35 X10 . . . . . . . . .IC-CMOS,INVERTER,SCHMITT,HEX,4584 X14,X17,X18 . . . . . . .IC-VOLTREF,ADJ,PRECISION,431I X16 . . . . . . . . . . . . . . . .IC-VOLTREG,FIXED,3-T,(-),1A,5V R3 . . . . . . . . . . . . .TRIMMER-MT,1/2W,10K,10%,LINEAR R100 . . . . . . . . .RESISTOR-NETWORK,100,8-RESISTOR C6,C8 . . . . . . . . . . . . . .CAPACITOR-CEMO,22P,100V,5%

C11,C32,C33,C34, . . . . .CAPACITOR-CEMO,0.1,50V,10% C35,C36,C37,C38,C51,C52,C77,C78

C81,C82,C83,C846, . .CAPACITOR-CEMO,100P,100V,5% C85,C8,C87,C88,C90,C91

C17 . . . . . . . . . . . . . . .CAPACITOR-CEMO,2700P,50V,5%

C1,C2,C3,C4,C5,C7, . .CAPACITOR-CEMO,.022,50V,20% C9,C10,C27,C28,C31,C43,C44,C48,C49,C50,C56

J2 . . . . . . . . . . . . .CONNECTOR,PCB,WW,MALE,DIL,1X9 Q12 . . . . . . . . . . . . . . . . . . . . . . . . . . .HEATSINK ASBLY DD1 . . . . . . . . . .MULTIPLE DIODE & HEAT SINK ASBLY J9 . . . . . . . . . . . .CONNECTOR,MOLEX,MINI,PCB,10-PIN J3 . . . . . . . . . . . .CONNECTOR,MOLEX,MINI,PCB,14-PIN J5,J7,J8 . . . . . . . .CONNECTOR,MOLEX,MINI,PCB,4-PIN J6 . . . . . . . . . . . . .CONNECTOR,MOLEX,MINI,PCB,6-PIN

J4 . . . . . . . . . . . . .CONNECTOR,MOLEX,MINI,PCB,8-PIN R103 . . . . . . . .THERMISTOR-PTC,.02-0.47 OHMS,0.90A X15 . . . . . . . . .POS VOLTAGE REG & HEAT SINK ASBLY Q11 . . . . . . . . . . . . . .TRANSISTOR & HEAT SINK ASBLY J1 . . . . . . . . . .CONNECTOR,PCB,WW,VERTICAL,16-PIN R138 . . . . . . . . . . . . .TRIMMER-ST,1/2W,1K,10%,LINEAR C29 . . . . . . . . . . . . . . . .CAPACITOR-PEF,0.22,100V,10% C22,C23 . . . . . .CAPACITOR-PPEF,0.68,400V,10%,RIGID

Item

Identification

C79,C80,C92, . . .CAPACITOR-CD,.0047/.005,1400V,20% C93,C94

D1,D2,D24,D25,D26,D27, . . . . . .DIODE-AXLDS,1A,400V D28,D29,D30,D31,D32,D34,D35,D37,D38,D39,D40,D41, D42,D43,D44,D45,D46,D47,D48,D49,D50,D51,D52,D53, D54,D55,D56,D57,D63,D65,D66,D67,D68,D69,D70,D71, D72,D73,D75,D76

D58,D59,D60,D61,D62,D64 . . . .DIODE-AXLDS,1A,1000V L3,L4,L5,L6,L7 . . . .CHOKE-330UH,10%,110MA,MOLDED L1,L2 . . . . . . . .CHOKE-390UH,5%,225MA,CONFORMAL R40 . . . . . . . . . . . . . . . . . . .RESISTOR-WW,7W,0.25,1% DZ5 . . . . . . . . . . . . .ZENER DIODE-1W,16V,5%,1N4745A DZ4 . . . . . . . . . . . . .ZENER DIODE-1W,15V,5%,1N4744A DZ3 . . . . . . . . . . . . .ZENER DIODE-5W,10V,5%,1N5347B DZ7 . . . . . . . . . . . .ZENER DIODE-1W,6.2V,5%,1N4735A DZ1,DZ2,DZ6 . . . . .ZENER DIODE-1W,18V,5%,1N4746A Q9,Q16 . . . . . . . .TRANSISTOR-P,T226,0.2A,30V,2N4125 Q17 . . . . . . . .TRANSISTOR-NMF,T220,15A,60V,15N06E D20 . . . . . . . . . . . . . .DIODE-AXLDS,1A,30V,SCHOTTKY R66 . . . . . . . . . . . . . . . . . . . .RESISTOR-MF,1/2W,1K,2% R35 . . . . . . . . . . . . . . . . . . .RESISTOR-MF,1/2W,2.7K,2% R87,R94 . . . . . . . . . . . . . . . .RESISTOR-MF,1/2W,330,2% R123 . . . . . . . . . . . . . . . . . .RESISTOR-MF,1/2W,6.8K,2% R22,R70 . . . . . . . . . . . . . . .RESISTOR-MF,1/2W,3.9K,2% R47 . . . . . . . . . . . . . . . . . . . .RESISTOR-MF,1/2W,3K,2% R121 . . . . . . . . . . . . . . . . . .RESISTOR-MF,1/2W,27K,2%

R5,R6,R7,R30,R75,R99, . . . .RESISTOR-MF,1/2W,100,2% R113,R114,R115,R120

R37,R122 . . . . . . . . . . . . . . .RESISTOR-MF,1/2W,750,2% R52,R57 . . . . . . . . . . . . . . .RESISTOR-MF,1/2W,1.8K,2% R118 . . . . . . . . . . . . . . . . . . . .RESISTOR-MF,1/2W,68,2% R89,R90 . . . . . . . . . . . . . . . .RESISTOR-MF,1/2W,270,2% R31 . . . . . . . . . . . . . . . . . . .RESISTOR-MF,1/2W,1.5K,2% R62 . . . . . . . . . . . . . . . . . . .RESISTOR-MF,1/2W,10K,2% R1 . . . . . . . . . . . . . . . . . . . .RESISTOR-MF,1/2W,18K,2% R86,R92 . . . . . . . . . . . . . . . . .RESISTOR-MF,1/2W,15,2% R51,R56 . . . . . . . . . . . . . . . .RESISTOR-MF,1/2W,56K,2% R71 . . . . . . . . . . . . . . . . . . .RESISTOR-MF,1/2W,470,2% R48,R50 . . . . . . . . . . . . . . . . .RESISTOR-CC,2W,10,10% R43 . . . . . . . . . . . . . . . . . . .RESISTOR-WW,5W,3.3K,5% TP3,TP5 . . . . . . . . . . . . . . . . . .MOV-50VRMS,15J,14MM TP1,TP2 . . . . . . . . . . . . . . . . . .MOV-75VRMS,22J,14MM R106 . . . . . . . . . . . . . . . . . . . .RESISTOR-MF 102K 1/4W R49,R55,R67,R69,R139 . . . . . .RESISTOR-MF 10K 1/4W

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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

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Contents Safety Depends on You Idealarc SP-250ARC Welding can be hazardous Idealarc SP-250Cylinder may explode if damaged Electric and MAG- Netic Fields IiiPrécautions DE Sûreté Sûreté Pour Soudage a L’ArcTable of Contents Installation Depth Weight GUN HeightStorage Operating Input Connections Safety PrecautionsSelect Proper Location StackingFuse and Wire Sizes Input Power Connections Ground ConnectionsConnect Shielding GAS Figure A.3 Ground Connection For 230/460/575 Volt ModelsReconnect Procedure SideReturn to Section TOC Connect Output Components GUN Liner & Contact TIP InstallationInstall the Work Clamp Output Polarity ConnectionGUN & Cable Installation Figure A.9 European Style ConnectorOperation General Description Safety InstructionsAdditional Safety Precautions Electric Shock can killControls System includes the following featuresOperational Recommended ProcessesWire Feeder Features Design FeaturesUnit Features Power Source FeaturesMachine Capability LimitationsDuty Amps Volts Cycle Controls and Settings Figure B.1 SP-250 Control Panel KeysArrow KEY Operation When Used with Process WIRE/GAS KEYArrow KEY Operation When Used with Auto KEY Arrow KEY Operation When Used with Manual KEYLeft arrow keys Do not function Arrow KEY Operation When Used with Spot KEYArrow KEY Operation When Used with Stitch KEY Right arrow keys Do not functionFigure B.5 Using the Toggle Function Step Trigger Interlock KeysMaking a Weld in Auto Mode RUN-IN ModeChanging RUN-IN Mode Codes 10001 and Above Operating StepsUsing the 4-STEP Interlock Function in Auto Mode Making a Spot Weld in Auto ModeTo make an arc spot plug weld Making a Stitch Weld in Auto Mode Using the GUN Thumb Switch Magnum SP-250 onlyUsing the Wire Drive Roll Using the GUN Trigger SwitchLoading the Wire Reel To mount 10 to 30 lb. spools 8 and 12 diameterSetting Idle Roll Pressure Feeding ElectrodeAccessories Options / Accessories Spool GUN Adapter KIT InstallationSpool GUN Module Board Installation Figure C.2 Spool Gun Module Board Installation Installation Spool GUN Connection BOXSpool GUN Connection Figure C.5 Spool Gun ConnectSpool GUN Installation to OLD K531 KIT Figure C.6 Spool Gun ConnectionMaintenance Maintenance Routine and PeriodicControl Board Choke Fan Assembly Main Transformer Theory of Operation Power Supply Operation Input Line Voltage and Main TransFormer Output Rectification and Feed Back ControlConstant Voltage Output Figure E.4 Constant Voltage OutputWire Drive Motor and Feedback Figure E.5 Wire Drive Motor and FeedbackThermal Protection SCR Operation Figure E.6 SCR OperationTroubleshooting & Repair HOW to USE Troubleshooting Guide Recommended Course of ActionPC Board Troubleshooting Procedures Board can be dam- aged by static electricityOutput Problems Warn Troubleshooting & Repair Function Problems Troubleshooting & Repair Wire Feeding Problems Toxic. Avoid contact with any Liquid elecTrolyte in these capacitors is Portion of your bodyTroubleshooting & Repair Explanation of Prompting and Error Messages On Screen Error Message Message ExplanationExplanation of Prompting and Error Messages CONT’D On Screen Error MessageXxxx Current Overload Reduce Output Press ANY KEY to Stop Message Main Transformer Test Test DescriptionMaterials Needed Main Transformer Test Test Procedure Lead Plug Location From Expected Lead Voltage#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 SP-250 Keypad Resistance Test 25F-25Figure F.8A Plug J2 Location on G2252 PC Control Board Figure F.9 Plug J2 Test PointsTest Points KEY Pressed Maximum Allowable 27F-27Table F.1 SP-250 Keypad Resistance Tests Wire Drive Motor and Tachometer Feedback Test Wire Drive Motor and Tachometer Feedback Test Test Procedure Figure F.10A Plug J5 Location on G2252 PC Control Board#206B 4J6 #515B 1J6 #555 2J6 #541 6J6 #539 3J6 Pull the gun triggerTest for Supply Voltage to Tachometer Test for Feedback Voltage to the Control BoardScope Settings Normal Open Circuit Voltage WaveformMachine Loaded to 250 Amps AT 26 VDC Scope Settings Typical Output Voltage Waveform Machine LoadedMachine Loaded to 220 Amps AT 22 VDC Scope Settings Troubleshooting & Repair Typical SCR Gate Voltage Waveform Control PC Board Removal and Replacement Removal and Replacement Procedure Materials NeededTroubleshooting & Repair Keypad Removal and Replacement Keypad Removal and Replacement Procedure Wire Drive Assembly Removal and Replacement Wire Drive Assembly Removal and Replacement Procedure Figure F.13 Wire Drive Assembly RemovalSCR Output Rectifier Removal 43F-43Figure 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 FAN Motor and FAN Removal and Replacement Procedure Figure F.18 Fan Motor and Fan Removal ComponentsTroubleshooting & Repair Input Volts/Hertz Wire Speed RangeOpen Circuit Voltage 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 Wiring Diagram for Code 9546 SP-250 230/460/575V Wiring DiagramWiring Diagram for Code 9723 Thumb SwitchImproper Lincoln Electric. This information
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