Lincoln Electric SP-250 service manual Operational, Controls, Recommended Processes, Equipment

Page 18

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B-2

OPERATION

 

B-2

 

 

 

The system includes the following features:

OPERATIONAL

FEATURES

AND

• 2-step or 4-step selectable trigger function (above

CONTROLS

 

 

 

 

 

code 9500 only).

 

Keypad - Consists of 20 membrane keys that have

 

 

• both timed spot and stitch welding selections.

large touch areas. The keys are spaced far enough

 

 

apart to provide easy selection, even if wearing weld-

• drop-in 2" (51mm) O.D. wire reel spindle with a 22-

ing gloves. An audible

feedback beep is

provided

30 lb. (10 - 13.6 kg) Readi-Reel- adapter.

 

whenever a key is pressed to ensure proper entry.

• integral gas cylinder mounting undercarriage.

Display - Wide temperature range liquid crystal display

 

 

combines large 0.32" (8.1mm) high characters in a 2-

• 12.5 ft. (3.8m) Magnum 250SP GMAW gun and

line by 16-character alphanumeric format. It has long

cable.

 

life LED backlighting and a non-glare cover for easy

 

 

viewing under bright or dark conditions. Multi lan-

• dual groove drive roll and a gun liner for .035

guage display capability permits the SP-250 to com-

(0.9mm) and .045 (1.2mm) electrodes.

 

municate in English, German, French, Spanish, or

 

 

Japanese (Katakana).

 

 

• one contact tip for each wire size.

 

Auto Mode - Simply set the thickness of the material

 

 

• adjustable CO2 or argon blend flow regulator with

being welded and the SP-250 automatically sets the

cylinder pressure gauge.

 

proper wire feed speed and arc voltage for the process

 

being used. This eliminates the need for look-up

 

 

• 10 ft. (3.0m) plug cable with receptacle.

 

tables, procedure slide rules, or notebooks to find the

 

proper settings. Auto Mode also provides one key con-

 

 

• 12 ft. (3.6m) work cable with clamp.

 

trol of the output by automatically adjusting both the

 

wire feed speed and arc voltage for an increase or

 

 

RECOMMENDED PROCESSES AND

decrease in material thickness or wire feed speed.

This allows the operator to easily increase or decrease

EQUIPMENT

 

his output without having to know how much to change

 

 

each parameter.

 

 

The SP-250 is recommended for GMA welding

Thumb Switch on Gun - Allows the operator to set or

processes using 10 to 30 lb. (4.5 to 13.6 kg) 2" (51mm)

change the output of the machine, the wire feed speed,

I.D. spools or Readi-Reel coils of

 

 

or the arc voltage from the gun, even during welding.

 

 

• .025" through .045" (0.61.2mm) solid steel using

This permits "on the fly" adjustment. In toggle opera-

tion mode, the thumb switch allows the operator to

CO2, ArCO2, or ArO2 shielding gas

 

 

toggle between two procedures stored in memory.

 

 

• .035" (0.9mm) stainless steel using ArO2 or

Memory - There are five separate memory locations

HeArCO2 shielding gas

 

that the operator can use to save or recall a setup pro-

 

 

cedure. This eliminates dial marking and makes recall-

• 3/64" (1.2mm) aluminum using Ar shielding gas

ing a setup as simple as pushing one of the five mem-

 

 

ory keys for instant recall. Also, when power is

• .045" (1.2mm) Outershield- electrodes using CO2

removed, these five memories as well as any current

or ArCO2 shielding gas

 

setup in use is automatically saved. This feature does

 

not require batteries. When power is restored, the pro-

 

 

• .035" (0.9mm) and .045 (1.2mm) Innershield self-

cedure in use will automatically return the unit to what-

ever was set up was being used when power was

shielded electrodes.

 

 

removed.

 

 

 

 

 

 

The SP-250 is factory equipped to feed .035 (0.9mm)

Trigger Interlock (Above code 9500 only) - Selectable

and .045 (1.2mm) electrodes and includes a 200A,

four-step trigger interlock

allows operator to release

60% duty cycle rated, 12.5 ft. (3.8m) GMA gun and

gun trigger after weld current is established and con-

cable assembly equipped for these wire sizes. The

tinue welding. Breaking the arc or re-closing and then

SP-250 is factory equipped with an adjustable CO2 or

releasing the gun trigger, stops the welding process.

argon blend flow regulator. A supply of shielding gas is required for GMAW processes.

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. 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