Lincoln Electric SP-250 Figure B.5 Using the Toggle Function, Step Trigger Interlock Keys

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B-9

OPERATION

B-9

 

 

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12.TOGGLE KEY: When first pressed, this key turns ON the TOGGLE MODE and recalls the weld setup in memory 4. Pressing the key again switch- es to the weld setup in memory location 5. Each time the key is pressed, it alternates between the two memory locations. When the TOGGLE key is pressed, the LED screen displays the memory number the current setup was recalled from, indi- cates automatic (AUTO:) or manual (MAN:) mode, displays wire gauge (Auto Mode), wire feed speed, and arc voltage. The cursor underlines the mem- ory number currently selected.

If in AUTO mode, an up or down arrow shows whether the arc voltage has been adjusted above or below the recommended level. Spot or Stitch timer status is displayed in the lower left-hand cor- ner if either timer is active.

The gun thumb switch functions as a Toggle key in Toggle mode. Pushing the gun thumb switch for- ward (toward the tip) selects the setup in memory

5.Pulling gun thumb switch back selects the setup in memory 4. The gun thumb switch also functions with the trigger closed for "on the fly" changes dur- ing a weld. See Figure B.5.

To turn the toggle mode off, press the AUTO, MANU- AL, or any MEMORY Number key.

NOTE: Any changes made to settings in toggle mode are not automatically saved when power is removed, or if toggle mode is turned off. To save these changes

Press the SAVE key

Press the MEMORY number key that is currently dis- played on the screen (4 or 5)

Press the SAVE key

Press other MEMORY Number key that was displayed after the toggle (5 or 4).

When power is returned, the machine will not be in the toggle mode. However, the weld setting placed in memory when power was removed will return so you may continue to weld right where you left off. Press the TOGGLE key to return to toggle mode.

ARROW KEY OPERATION WHEN USED WITH THE TOGGLE KEY (See Table B.1.)

Left arrow keys: If metal thickness is displayed, Press the UP () arrow key to increase metal thickness. Press the DOWN () arrow key to decrease metal thickness. The Left arrow keys do not perform any function in any other mode.

Center arrow keys: Press the UP () arrow key to increase wire feed speed. Press DOWN () arrow key to decrease wire feed speed setting. If in Auto Mode, increasing or decreasing wire feed speed simultane- ously causes an increase or decrease in the arc volt- age and can change the metal thickness setting.

Right arrow keys: Press the UP () arrow key to increases arc voltage setting. Press the DOWN () arrow key to decrease the arc voltage setting. When in the Auto Mode, an up arrow indicator appears below the V in VOLTS if the arc voltage has been set higher than the recommended 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 recommended value.

FIGURE B.5 - Using the TOGGLE Function.

4-STEP TRIGGER INTERLOCK KEYS

Pressing

PROCESS

and

 

 

TOGGLE

WIRE/GAS

 

 

 

 

 

 

4

5

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Controls whether 4-step trigger interlock is activated or deactivated. (See “Using 4-Step Trigger Interlock Function” section)

Note: 4-step Trigger is automatically deactivated if either the spot or stitch timer mode is being used.

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 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