Lincoln Electric
service manual
Idealarc SP-250
Troubleshooting
Install
Error codes
Electrical Diagrams
Fuse and Wire Sizes
Maintenance
Output Problems
Keypad Removal and Replacement
Accessories
Reconnect Procedure
Page 104
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G-4
NOTES
G-4
IDEALARC
SP-250
Page 103
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Contents
Safety Depends on You
Idealarc SP-250
ARC Welding can be hazardous
Idealarc SP-250
Cylinder may explode if damaged
Electric and MAG- Netic Fields
Iii
Précautions DE Sûreté
Sûreté Pour Soudage a L’Arc
Table of Contents
Installation
Storage Operating
Depth Weight GUN
Height
Safety Precautions
Select Proper Location
Input Connections
Stacking
Fuse and Wire Sizes
Input Power Connections Ground Connections
Connect Shielding GAS
Figure A.3 Ground Connection For 230/460/575 Volt Models
Reconnect Procedure
Side
Return to Section TOC
GUN Liner & Contact TIP Installation
Install the Work Clamp
Connect Output Components
Output Polarity Connection
GUN & Cable Installation
Figure A.9 European Style Connector
Operation
Safety Instructions
Additional Safety Precautions
General Description
Electric Shock can kill
System includes the following features
Operational
Controls
Recommended Processes
Design Features
Unit Features
Wire Feeder Features
Power Source Features
Duty Amps Volts Cycle
Machine Capability
Limitations
Controls and Settings
Figure B.1 SP-250 Control Panel Keys
Arrow KEY Operation When Used with
Process WIRE/GAS KEY
Arrow KEY Operation When Used with Auto KEY
Arrow KEY Operation When Used with Manual KEY
Arrow KEY Operation When Used with Spot KEY
Arrow KEY Operation When Used with Stitch KEY
Left arrow keys Do not function
Right arrow keys Do not function
Figure B.5 Using the Toggle Function
Step Trigger Interlock Keys
RUN-IN Mode
Changing RUN-IN Mode Codes 10001 and Above
Making a Weld in Auto Mode
Operating Steps
To make an arc spot plug weld
Using the 4-STEP Interlock Function in Auto Mode
Making a Spot Weld in Auto Mode
Using the GUN Thumb Switch Magnum SP-250 only
Using the Wire Drive Roll
Making a Stitch Weld in Auto Mode
Using the GUN Trigger Switch
Loading the Wire Reel
To mount 10 to 30 lb. spools 8 and 12 diameter
Setting Idle Roll Pressure
Feeding Electrode
Accessories
Spool GUN Module Board Installation
Options / Accessories
Spool GUN Adapter KIT Installation
Figure C.2 Spool Gun Module Board Installation
Installation
Spool GUN Connection BOX
Spool GUN Connection
Figure C.5 Spool Gun Connect
Spool GUN Installation to OLD K531 KIT
Figure C.6 Spool Gun Connection
Maintenance
Maintenance
Routine and Periodic
Control Board Choke Fan Assembly Main Transformer
Theory of Operation
Former
Power Supply Operation
Input Line Voltage and Main Trans
Output Rectification and Feed
Back Control
Constant Voltage Output
Figure E.4 Constant Voltage Output
Wire Drive Motor and Feedback
Figure E.5 Wire Drive Motor and Feedback
Thermal Protection
SCR Operation
Figure E.6 SCR Operation
Troubleshooting & Repair
HOW to USE Troubleshooting Guide
Recommended Course of Action
PC Board Troubleshooting Procedures
Board can be dam- aged by static electricity
Output Problems
Warn
Troubleshooting & Repair
Function Problems
Troubleshooting & Repair
Wire Feeding Problems
Liquid elec
Trolyte in these capacitors is
Toxic. Avoid contact with any
Portion of your body
Troubleshooting & Repair
Explanation of Prompting and Error Messages
On Screen Error Message Message Explanation
Xxxx
Explanation of Prompting and Error Messages CONT’D
On Screen Error Message
Current Overload Reduce Output Press ANY KEY to Stop Message
Materials Needed
Main Transformer Test
Test Description
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-25
Figure F.8A Plug J2 Location on G2252 PC Control Board
Figure F.9 Plug J2 Test Points
Table F.1 SP-250 Keypad Resistance Tests
Test Points KEY Pressed Maximum Allowable
27F-27
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 trigger
Test for Supply Voltage to Tachometer
Test for Feedback Voltage to the Control Board
Scope Settings
Normal Open Circuit Voltage Waveform
Machine Loaded to 250 Amps AT 26 VDC Scope Settings
Typical Output Voltage Waveform Machine Loaded
Machine 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 Needed
Troubleshooting & 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 Removal
SCR Output Rectifier Removal
43F-43
Figure 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 Components
Troubleshooting & Repair
Wire Speed Range
Open Circuit Voltage
Input Volts/Hertz
230/60 375
Table 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 Diagram
Wiring Diagram for Code 9723
Thumb Switch
Improper
Lincoln Electric. This information
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