Lincoln Electric SP-250 service manual Electrical Diagrams

Page 109

to Section TOC

to Master TOC

G-9

ELECTRICAL DIAGRAMS

 

 

WIRING DIAGRAM FOR CODE 9402

 

SP-250 (DUAL VOLTAGE) - WIRING DIAGRAM

G-9

 

 

 

 

 

A

541B

 

 

 

 

 

 

B

539B

1

 

 

 

 

 

C

322

2 LINE X 16 CHAR.

 

(J13)

 

2

 

 

D

321

 

 

3

ALPHA-NUMERIC

 

 

 

E

325B

 

 

 

4

 

 

 

 

 

F

324B

5

 

 

 

OPTIONAL SPOOL OR PULL

LCD

DISPLAY

 

6

 

 

 

GUN RECEPTACLE

7

 

 

 

 

 

 

 

 

 

 

 

 

 

 

8

 

 

 

 

 

 

 

9

 

 

 

 

 

 

 

10

AUTO

 

 

 

MANUAL

 

11

 

 

 

 

 

 

 

12

 

 

 

 

 

 

 

13

 

 

 

 

 

 

 

14

 

 

 

 

 

 

 

15

PROCESS

 

 

 

 

SAVE

 

16

WIRE/

 

 

 

 

 

 

5

GAS

 

 

 

 

 

 

 

 

 

 

 

 

3

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1

MEMORY

 

 

 

 

 

 

7

1

2

3

4

 

5

 

9

 

 

 

 

 

 

 

6

 

 

 

 

 

 

 

8

 

SPOT

SWITCH

IPM VOLTS

TOGGLE

 

2

 

 

4

TIMERS

SET

SET

 

4

5

 

 

 

 

OFF

DISPLAY

DISPLAY

 

 

 

 

 

KEYPAD MATRIX

N.F.

 

 

(J7)

 

 

 

 

 

 

 

*

 

 

 

 

 

1

2

3

4

 

 

 

 

R

 

 

 

 

 

 

(J1)

B

 

 

 

 

1

2

*

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

515

325

 

 

N.D.

 

 

 

 

 

 

 

 

(J5)

 

 

 

 

 

 

 

*

 

 

 

 

 

1

2

3

4

 

(J2)

 

 

 

 

 

 

 

*

 

 

326

325

327

324

 

 

 

 

 

B R

PIEZO

ALARM

CONTROL BOARD

 

*

(J4)

 

 

 

 

 

 

 

 

3

4

5

6

7

8

324

206

541A

495

542

543

 

 

(J6)

 

N.D.

 

 

 

*

 

 

 

 

 

 

1

2

3

4

5

6

515

555

539

206

 

541

 

 

1

(J8)

*

2

 

 

3

 

 

4

 

 

 

 

 

(J9)

*

 

 

 

 

 

 

 

 

 

 

 

1

2

3

4

5

6

7

8

9

10

2081

2092

2063

GND 4

204A 5

2026

203

7

325

*(J3)

8

204S

9

207

10

320

11

204

12

G1

13

G2

14

SP - 250

SPOOL GUN

 

 

MODULE

 

 

(J12)

 

 

 

 

 

*

 

 

 

 

 

(J11)

 

 

 

 

 

*

 

1

2

3

4

5

6

515

325

324

206

541A

495

GAS

SOLENOID

1541B

2321

3324B

6539B

7322

8325B

5

9

10

7 8

RF CHOKE

AS'BLY

542

543

GENERAL INFORMATION

ELECTRICAL SYMBOLS PER E1537

COLOR CODE:

B - BLACK

W - WHITE

R - RED

U - BLUE

*INDICATES CONNECTOR CAVITY NO.

Return to Section TOC

Return to Section TOC

Return to Master TOC

Return to Master TOC

TO

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

NOTES

 

WORK

N.A.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

N.A. WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE

 

N.C.

 

 

 

 

 

 

 

 

W

 

541

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

MOTOR/

 

 

 

 

 

 

 

 

 

 

 

CURRENT AND DUTY CYCLE OF IMMEDIATE AND

 

 

 

 

 

 

 

 

 

 

T

R

515

 

 

 

 

 

 

 

 

 

 

327

 

 

 

 

 

GEARBOX

 

 

 

 

 

 

 

 

 

 

FUTURE APPLICATIONS.

 

 

 

 

 

 

 

 

 

P.M.

 

A

U

555

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

C

GND

 

 

 

 

 

 

 

 

 

 

 

 

 

N.J.

324

 

 

 

 

 

 

 

 

H

B

206

 

 

 

 

 

 

 

N.B. THIS DIAGRAM SHOWS THE "ELECTRODE" POLARITY

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

325

 

 

206

207

N.B.

 

 

B

 

539

 

 

 

 

 

 

 

 

"POSITIVE". TO CHANGE POLARITY, TURN THE UNIT

 

 

326

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

OFF AND REVERSE LEAD CONNECTIONS AT CABLE

 

THUMB

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CONDUCTOR STRAP AND WORK STUD.

 

 

SWITCH

327

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

320

 

 

 

326

 

325

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

N.E.

 

 

 

R.F. TOROID AS'BLY.

 

 

N.C. CONNECTOR SHOWN GEARBOX SIDE VIEW.

 

INC.

DEC.

 

 

 

 

 

 

N.G.

 

 

 

 

TO SINGLE PHASE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

R.F. FILTER

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SUPPLY LINE

 

 

 

 

 

326

 

 

 

 

 

THERMOSTAT

 

 

 

THERMOSTAT

 

 

 

 

 

 

N.D. CONNECTORS MOUNTED ON NON-COMPONENT SIDE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

L1

OF BOARD.

 

 

 

324

 

 

 

 

 

S3

 

 

 

 

S4

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

TRIGGER

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

N.E. THERMOSTATS MOUNTED ON CHOKE COIL

.

 

325

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

L2

S2 MOUNTED CLOSEST TO FAN; S3 MOUNTED CLOSEST TO

 

 

 

 

 

X5

 

 

 

 

 

 

 

 

 

 

 

 

 

 

POWER TRANSFORMER.

 

 

 

 

 

 

 

 

 

202

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

N.F. KEYPAD MATRIX SHOWN FRONT VIEW.

 

 

 

 

 

 

 

X6

 

 

 

 

 

 

 

 

W

H4

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

204A

 

 

 

 

 

 

 

 

 

 

 

GND

N.G. THERMOSTAT S4 MOUNTED ON FAN SENSOR BRACKET

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

H2

 

H3

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

TO GROUND PER

 

 

 

 

 

 

X7

 

 

 

 

 

208

 

 

L1

 

 

 

 

 

 

 

 

 

 

 

 

 

T1

 

 

203

 

 

 

 

 

LOW V.

HIGH V.

NATIONAL ELECTRICAL

N.H. RESISTOR R2 MOUNTED ON FAN SENSOR BRACKET.

 

 

 

 

 

X1

 

 

 

 

 

G1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CODE

 

 

 

 

 

 

 

 

 

H1 H1

 

 

 

 

 

 

 

SCR 1

 

B

 

 

 

 

 

N.J. CONNECTOR SHOWN PIN SIDE VIEW.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

250V

 

 

L2

 

 

 

 

 

CAVITY NUMBERING SEQUENCE

 

 

 

 

 

 

 

 

 

204

 

 

 

 

470A

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

L1

L2

 

 

 

X2

 

 

 

 

 

 

SCR HEATSINK

 

 

 

 

 

 

 

(COMPONENT SIDE OF P.C. BOARD)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ASBLY

 

 

 

 

 

 

 

 

 

 

 

 

 

H2

 

 

 

 

 

 

 

 

 

GND.

RECONNECT PANEL

 

 

1

 

 

16

1

9

 

 

 

 

H2

X3

 

 

 

 

 

 

SCR 2

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

G

 

 

 

 

 

J1

 

 

 

J2

 

 

 

 

 

 

 

 

 

 

 

 

 

 

250V

 

 

 

 

 

 

 

 

 

 

 

 

 

 

P2

 

X4

 

 

 

 

 

 

470A

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

H3

 

 

 

 

 

 

G2

 

 

 

 

 

 

 

 

 

 

 

 

 

 

H1

H4

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1

7

1

5

1

4

 

 

H3

 

 

 

 

 

 

 

209

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

POWER TRANSFORMER

 

D1

 

 

 

 

 

 

 

 

 

 

 

J3

J9

 

 

J4

 

 

 

 

 

 

 

 

 

 

300V

 

 

 

 

 

 

 

 

 

 

 

 

 

J11

 

 

 

H1

 

 

 

 

 

 

85A

 

 

 

 

 

 

 

 

 

 

N.E.

P2

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

10

 

 

 

 

LINE

 

 

 

 

 

 

 

 

 

 

 

 

T1

 

 

 

T2

 

8

14

6

5

8

 

 

SWITCH

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

P1

P2

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1

2

1

3

 

 

 

S1

 

 

 

 

 

 

206

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

FAN

 

 

 

S2

J7

 

J12

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

MOTORS

 

 

 

J8

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

THERMOSTAT

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

15 OHMS

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

R1

 

 

 

 

 

 

3

4

4

6

 

 

 

 

C1

C2

 

C3

C4

 

 

 

 

 

 

100 W

 

 

 

 

 

 

 

 

 

C1 THRU C4

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(NON-COMPONENT SIDE OF BOARD)

 

 

 

30,000 MFD

+

 

+

+

 

+

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

50V

 

 

 

 

 

 

OUTPUT

 

 

 

 

 

 

 

 

1

2

1

3

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHOKE

 

 

 

R2

 

 

 

 

J5

 

J6

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

207

 

 

2.5K

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

204S

 

 

 

 

N.H.

10W

 

 

 

 

3

4

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

4

6

 

10-19-90N

L7976

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels.

IDEALARC SP-250

 

 

IDEALARC SP-250

 

 

 

Page 108 Page 110
Image 109
Page 108 Page 110
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 Height Depth Weight GUNStorage Operating 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 FeaturesLimitations Machine CapabilityDuty Amps Volts Cycle 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 StepsMaking a Spot Weld in Auto Mode Using the 4-STEP Interlock Function in Auto ModeTo make an arc spot plug weld 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 Adapter KIT Installation Options / AccessoriesSpool GUN Module Board 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 Input Line Voltage and Main Trans Power Supply OperationFormer 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 MessagesOn Screen Error Message Explanation of Prompting and Error Messages CONT’DXxxx Current Overload Reduce Output Press ANY KEY to Stop Message Test Description Main Transformer TestMaterials Needed 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 Board27F-27 Test Points KEY Pressed Maximum AllowableTable F.1 SP-250 Keypad Resistance Tests 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
Top Page Image Contents