Lincoln Electric SP-250 Loading the Wire Reel, To mount 10 to 30 lb. spools 8 and 12 diameter

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B-13

OPERATION

B-13

 

 

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LOADING THE WIRE REEL

To mount a 22-30 lb. (10-14 kg) Readi-Reel- package using the Readi-Reel adapter provided:

1.Pull the Readi-Reel adapter and spindle up out of the SP-250 spindle mounting clips (V-brackets).

2.Rotate the spindle and adapter so the retaining spring is at the 12 o'clock position.

3.Position the Readi-Reel so that it will rotate in a clockwise direction when wire is dereeled from the top of the coil. See Figure B. 6.

7.Check that the mating surfaces of the spindle hubs and spindle mounting clips (V-brackets) are clear of dirt and debris and that the adapter is fully engaged onto the spindle.

8.Lower the loaded spindle into the spindle mounting clips (V brackets) so wire dereels from top of coil toward wire drive.

NOTE: The retaining spring side of the adapter should be facing the center (inner) panel of the SP-250.

9.To remove the Readi-Reel from Adapter, depress retaining spring tab with thumb while pulling the Readi-Reel cage from the molded adapter with both hands. Do not remove adapter from spindle.

To mount 10 to 30 lb. spools: (8" and 12" diameter):

1.Remove the Readi-Reel adapter shipped on the 2 inch diameter spindle.

2.Be sure that the mating surfaces of the spindle hubs and spindle mounting clips (V-brackets) are clear of dirt and debris.

3.Place the spool on the spindle. Make certain the brake driving pin enters one of the holes in the back side of the spool.

4.Lower the loaded spindle into the spindle mounting clips (V brackets) so the wire dereels from the top of the reel toward the wire drive.

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FIGURE B. 6 - Wire Reel Loading

4.Set one of the Readi-Reel inside cage wires on the slot in the retaining spring tab.

5.Lower the Readi-Reel to depress the retaining spring and align the other inside cage wires with the grooves in the molded adapter.

6.Slide the cage all the way onto the adapter until the retaining spring "pops up" fully.

NOTE: The SP-250 Spindle was designed to mount 12"- (300mm) and 8"- (200mm) diameter spools meet- ing international spool size specifications. If the spool being used is too narrow to keep the brake driving pin* engaged with the spool pin hole, a 2" (51mm) I D shim washer could be used between the spool and the spin- dle retaining clip to take up the space.

*A later spindle design uses a longer "D"-shaped pin to assure engagement.

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WARNING

WARNING: Check to be sure the the retaining spring has fully returned to the locking position and has securely locked the readi-reel cage in place. Retaining spring must rest on the cage, not the welding elec- trode.

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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 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 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 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 StepsTo make an arc spot plug weld Using the 4-STEP Interlock Function in Auto ModeMaking a Spot Weld in Auto Mode 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 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 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 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 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