Lincoln Electric SP-250 Design Features, Advantages, Unit Features, Wire Feeder Features

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B-3

 

OPERATION

B-3

 

 

 

 

DESIGN FEATURES AND

 

Automatic Burnback - Provides proper burnback of

ADVANTAGES

 

 

the electrode to prevent it from sticking in the weld pud-

 

 

dle at the end of a weld.

 

 

 

 

 

 

 

 

 

 

Output Terminals - Easily accessible in wire drive

UNIT FEATURES:

 

 

section for quick cable connection and polarity rever-

 

 

sal.

 

 

Undercarriage for Hand Mobility - Heavy duty 10"

Work Cable - 10 ft. (3.0m) long with work clamp.

 

 

(254mm) wheels and 4" (102mm) casters are factory

 

 

 

installed along with the handle. Handle can be used for

 

 

 

hanging the welding gun and work cable.

 

WIRE FEEDER FEATURES:

 

 

Gas Cylinder Platform - Factory installed on under-

Drop-in Wire Loading - Wire spindle snaps into

carriage. It permits platform mounting and support of a

Readi-Reel-Adapter, included with SP-250, or most

single gas cylinder.

No full lifting of gas

cylinder

any 2" (51mm) I.D. wire spool. The wire spindle drops

required during loading.

 

into the top loading SP-250 case design.

Adjustable Flow Regulator - Accommodates CO2 or

Accommodating standard 12” (305mm) and 8”

(203mm) diameter coils, the unique spindle and sup-

argon blend gas. Includes a cylinder pressure gauge

port design automatically provides appropriate de-reel-

and a dual seal flow gauge.

 

ing drag to prevent wire reel overrun and loop-offs

 

 

 

without manual brake adjustments.

 

 

Easy Accessability - Wire feeder enclosure protects

Tachometer Controlled Wire Drive - Precision con-

wire and wire drive from dirt, dust, and damage. Allows

easy top-access for "drop-in" wire reel loading and to

trol of permanent magnet motor provides proper wire

load or service the wire drive.

 

feed acceleration and speed accuracy, independent of

 

 

 

fluctuations in line voltage and wire loading. This

 

 

 

means reliable arc starting and weld consistency.

 

 

POWER SOURCE FEATURES:

 

Low Speed Start - When the trigger is pulled, the wire

 

 

 

10 Ft. (3.0m) Input Power Cable - Includes plug and

feeder feeds wire at low speed regardless of the set

mating receptacle for 208/230V unit. Convenient rear

wire feed speed until welding current is drawn or 2 sec-

panel reconnect allows easy access for 208V re-con-

onds has expired. This feature enhances starting and

nection.

 

 

makes setting stick out a snap. The 2 second limit per-

 

 

 

mits high speed loading of the gun and cable. In later

Power Switch - Front panel toggle switch turns input

versions of the SP-250, a user selectable feature

power on and off.

 

 

allows the wire feeder to feed wire directly at the set

 

 

 

speed, thus bypassing the 2 second slow start.

 

 

Thermostatically Controlled Fans - Provides cooling

Solid State Wire Feed Overload Protection - No cir-

of transformer and other components only when

required. When used intermittently or at low current

cuit breaker to reset. Simply pull the trigger to resume

procedures, the fan motors stay off, reducing the

welding once the overload condition has been cleared.

amount of dust and dirt drawn into the machine. Also

Unique Drive Roll and Guide Tube Design - Long

reduces power consumption.

 

 

 

 

life, precisely aligned guide tubes and drive rolls.

Electronic Overload Protection - Protects machine

Quickly reloads by simply starting wire into ingoing

from short circuit or high current overloading.

 

guide tube. Adjustable tension setting minimizes

 

 

 

'birdnesting', eliminates milling through the wire, and

Power Source Line Voltage Regulation - Precise

gives positive feeding. The double groove, reversible

SCR phase control circuit holds the voltage setting

drive roll included with the SP-250 allows use of .030

constant to maintain weld quality even when the input

(0.8mm) through .045 (1.2mm) diameter wire. Drive

voltage fluctuates +/-10%.

 

Roll kits for other sizes and types of wire are also avail-

 

 

 

able.

 

 

Solid State Contactor - Output is turned on and off by

Fast-Mate Gun Connector - European style gun con-

SCR's instead of a

mechanical contactor

providing

 

 

 

extra long life in highly repetitive welding applications.

nector provides electrode, shielding gas and gun con-

 

IDEALARC SP-250

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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 Stacking Safety PrecautionsSelect Proper Location Input ConnectionsInput 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 Output Polarity Connection GUN Liner & Contact TIP InstallationInstall the Work Clamp Connect Output ComponentsFigure A.9 European Style Connector GUN & Cable InstallationOperation Electric Shock can kill Safety InstructionsAdditional Safety Precautions General DescriptionRecommended Processes System includes the following featuresOperational ControlsPower Source Features Design FeaturesUnit Features Wire Feeder 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 KEYRight arrow keys Do not function Arrow KEY Operation When Used with Spot KEYArrow KEY Operation When Used with Stitch KEY Left arrow keys Do not functionStep Trigger Interlock Keys Figure B.5 Using the Toggle FunctionOperating Steps RUN-IN ModeChanging RUN-IN Mode Codes 10001 and Above Making a Weld in Auto ModeMaking a Spot Weld in Auto Mode Using the 4-STEP Interlock Function in Auto ModeTo make an arc spot plug weld Using the GUN Trigger Switch Using the GUN Thumb Switch Magnum SP-250 onlyUsing the Wire Drive Roll Making a Stitch Weld in Auto ModeTo 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 Portion of your body Liquid elecTrolyte in these capacitors is Toxic. Avoid contact with anyTroubleshooting & 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 230/60 375 Wire Speed RangeOpen Circuit Voltage Input Volts/HertzTable 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