Lincoln Electric SP-250 service manual Options / Accessories, Spool GUN Adapter KIT Installation

Page 32

C-1

ACCESSORIES

C-1

 

 

Return to Section TOC

Return to Section TOC

Return to Master TOC

Return to Master TOC

OPTIONS / ACCESSORIES

Replacement Magnum 250-SP Gun and Cable Assemblies

The following GMAW gun and cable assemblies are available for use with the SP-250. Each is rated at 200 amps at 60% duty cycle. Each is equipped with a Fast- Mate connector and additional control lead connec- tions for the thumb activated 2 momentary position slide switch control designed into the gun handle to use with the SP-250 remote control features:

K524-1 Gun and Cable -A 12.5 ft. (3.8m) GMAW gun and cable assembly; includes a liner, diffuser, and con- tact tips for .035 (0.9mm) and .045 (1.2mm) elec- trodes.

K524-2 Gun and Cable -A 12.5 ft. (3.8m) GMAW gun and cable assembly; includes a liner, diffuser, and con- tact tips for .025 (0.6mm) and .030 (0.8mm) elec- trodes.

K524-3 Gun and Cable -A 15 ft. (4.6m) GMAW gun and cable assembly; includes a liner, diffuser and con- tact tips for .035 (0.9mm) and .045 (1.2mm) elec- trodes.

K524-4 Gun and Cable -A 15 ft. (4.6m) GMAW gun and cable assembly; includes a liner, diffuser, and con- tact tips for .025 (0.6mm) and .030 (0.8mm) elec- trodes.

The connection box mounts to the front of the machine's base and provides for inlet connection of the spool gun gas supply hose. It provides up-front easy connection of the spool gun gas line, control plug, and electrode lead (using the Twist-Mate plug provided with the kit). Installation and Operation Accessory Manual (AM-105) is included with the kit.

SPOOL GUN MODULE BOARD

INSTALLATION

NOTE: The K607-1 Spool Gun Adapter Kit is designed for use with SP-250, SP 250-I and Wire-matic 250 model codes above code 9900. Model Codes below 9900 may be used with the addition of holes to the case as described in the installation instructions below.

SP-250 model code 9402 must have S19636-2 read on display just after power switch is turned on.

WARNING

WARNING: HIGH VOLTAGE CAN KILL!

Do not operate with covers removed.

Disconnect input power before servicing

Only qualified persons should install, use or service this equipment.

Return to Section TOC

Return to Section TOC

Return to Master TOC

Return to Master TOC

K607-1 Spool Gun adapter Kit

The K607-1 Spool Gun Adapter Kit provides "up front" direct connection with the SP-250. It is used with the K487 Spool Gun (with remote speed control) or the K469 Spool Gun (requiring K518 Connection Adapter). It also provides single switch transfer between the machine's feeder gun or the spool gun for same polar- ity welding with different wire and gas processes. The kit includes a spool gun module board, a connection box assembly with connecting plug and lead harness- es, mounting hardware, and installation and operation instructions.

SPOOL GUN ADAPTER KIT

INSTALLATION

(Option K607-1)

The spool gun module mounts inside the control sec- tion of the machine and provides control and inter-con- nection between the machine's control board and the spool gun kit connection box.

____________________________________

See Figures C-1 and C-2.

Figure C.1 - Spool Gun Installation.

IDEALARC SP-250

Image 32
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 Storage Operating Depth Weight GUNHeight Safety Precautions Select Proper LocationInput Connections 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 GUN Liner & Contact TIP Installation Install the Work ClampConnect Output Components Output Polarity ConnectionGUN & Cable Installation Figure A.9 European Style ConnectorOperation Safety Instructions Additional Safety PrecautionsGeneral Description Electric Shock can killSystem includes the following features OperationalControls Recommended ProcessesDesign Features Unit FeaturesWire Feeder Features Power Source FeaturesDuty Amps Volts Cycle Machine CapabilityLimitations 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 KEYArrow KEY Operation When Used with Spot KEY Arrow KEY Operation When Used with Stitch KEYLeft arrow keys Do not function Right arrow keys Do not functionFigure B.5 Using the Toggle Function Step Trigger Interlock KeysRUN-IN Mode Changing RUN-IN Mode Codes 10001 and AboveMaking 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 GUN Thumb Switch Magnum SP-250 only Using the Wire Drive RollMaking a Stitch Weld in Auto Mode Using the GUN Trigger SwitchLoading the Wire Reel To mount 10 to 30 lb. spools 8 and 12 diameterSetting Idle Roll Pressure Feeding ElectrodeAccessories Spool GUN Module Board Installation Options / AccessoriesSpool GUN Adapter KIT 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 Former Power Supply OperationInput Line Voltage and Main Trans 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 Liquid elec Trolyte in these capacitors isToxic. Avoid contact with any Portion of your bodyTroubleshooting & Repair Explanation of Prompting and Error Messages On Screen Error Message Message ExplanationXxxx 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 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 PointsTable F.1 SP-250 Keypad Resistance Tests Test Points KEY Pressed Maximum Allowable27F-27 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 Wire Speed Range Open Circuit VoltageInput 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 Wiring Diagram for Code 9546 SP-250 230/460/575V Wiring DiagramWiring Diagram for Code 9723 Thumb SwitchImproper Lincoln Electric. This information