Lincoln Electric SP-250 service manual Arrow KEY Operation When Used with Auto KEY

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B-7

OPERATION

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4.AUTO KEY: Press for automatic welding set up of recommended Wire Speed and Arc Voltage based on Metal Thickness selected.

ARROW KEY OPERATION WHEN USED WITH AUTO KEY:

See Table B.1.

Left Arrow Keys: Press to change the metal thickness displayed. Press the UP ( )arrow key to increase metal thickness. Press the DOWN () arrow key to decrease the metal thickness. Increasing or decreas- ing metal thickness automatically increases or decreases both wire feed speed (IPM) and arc voltage (VOLTS) simultaneously. See gauge chart on the instruction label on the inside of SP-250 door for avail- able sizes.

Center Arrow Keys: Press to change wire feed speed setting. Press the UP () arrow key to increase the wire feed speed setting displayed. Press the DOWN () arrow key to decrease the wire feed speed setting displayed. Increasing or decreasing the wire feed speed simultaneously causes an increase or decrease in the arc voltage and can change the metal thickness setting.

ARROW KEY OPERATION WHEN USED WITH MANUAL KEY:

See Table B.1.

Left arrow keys: Do not function in Manual mode.

Center arrow keys: Press the UP () arrow key to increase wire feed speed. Press the DOWN () arrow key to decrease wire feed speed.

Right arrow key: Press the UP ( ) arrow key to increase arc voltage. Press the DOWN () arrow key to decrease arc voltage.

NOTE: If the spot or stitch timers are ON, it will be indi- cated in the bottom left corner of the display. See Figure B.2.

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Right Arrow Keys: Press to change arc voltage set- ting. Press the UP () arrow key to increase the arc voltage setting displayed. Press the DOWN () arrow key to decrease arc voltage setting displayed. An up arrow indicator appears below the V in VOLTS if the arc voltage has been set higher than the recommend- ed value. A down arrow indicator appears below the V in VOLTS if the arc voltage is below the recommended value. No arrow indicates that you are set to the rec- ommended value.

Pressing the AUTO key again resets the wire feed speed and arc voltage settings to the recommended values for the metal thickness displayed. (NOTE: If the spot or stitch timers are on, metal thickness is not displayed and, therefore, the reset function does not work.)

5.MANUAL KEY: Press to set wire feed speed and arc voltage for manual procedure setup. The manual screen displays wire feed speed, arc volt- age, and a cursor that indicates when the wire feed speed or arc voltage is being controlled by the thumb switch on the SP-250 gun.

FIGURE B.2 - Display when Stitch or Spot Weld Timers are ON.

6.SAVE KEY: Press to save the current set up. The process, procedure, and timer functions (if used) are saved to one of five memory locations by pressing one of the five memory keys. When the Save key is pressed, a prompting message instructing the operator to "PRESS MEMORY 1-5 TO SAVE SETUP" is displayed. See Figure B. 3

for sample SAVE sequence. This message remains displayed until a memory number key is selected or one of the other keys, such as Auto, Manual, or Process, is pressed. If a memory num- ber key is selected, a message will be displayed for 2.5 seconds that confirms that the setup was saved to that memory number.

The six arrow keys perform no function when saving a setup.

NOTE: When a setup is saved to a memory location, the previous contents of that memory is lost because it is replaced by the present setup. Removing input power does not effect the setup in memory.

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 Storage Operating Depth Weight GUNHeight 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 FeaturesDuty Amps Volts Cycle Machine CapabilityLimitations 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 ModeTo make an arc spot plug weld Using the 4-STEP Interlock Function in Auto ModeMaking a Spot Weld in Auto Mode 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 Module Board Installation Options / AccessoriesSpool GUN Adapter KIT 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 Former Power Supply OperationInput Line Voltage and Main Trans 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 MessagesXxxx Explanation of Prompting and Error Messages CONT’DOn Screen Error Message Current Overload Reduce Output Press ANY KEY to Stop Message Materials Needed Main Transformer TestTest Description 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 BoardTable F.1 SP-250 Keypad Resistance Tests Test Points KEY Pressed Maximum Allowable27F-27 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. 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