Lincoln Electric SP-250 service manual Figure C.2 Spool Gun Module Board Installation

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C-2

ACCESSORIES

C-2

 

 

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CAUTION

 

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CAUTION: Collect metal filings with a rag to protect

 

 

 

to

to

 

against possible metal contamination of the control

 

board or other internal electrical components.

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9.

Fasten the panel receptacle to the case with the

 

 

 

 

three #6-32 x 3/8" self tapping screws provided.

 

 

 

 

Insert screws from wire drive side, through the

 

 

 

 

sheet metal, and into the receptacle mounting

 

 

 

 

plate holes.

 

 

 

 

 

10.

Plug the 10-pin, 8-pin, and 6-pin connector plugs

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from the other end of the receptacle lead harness

 

 

into the 10-, 8-and 6-pin connectors (J12, J11 and

1.

Remove input power to the machine before start-

J13) at the top of the spool gun module board.

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the SP-250 control board (J4).

 

 

 

Figure C.2 - Spool Gun Module Board Installation.

Plug in the 8-pin connector at the opposite end of

 

 

 

 

this harness into the unused 8-pin connector on

to

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ing.

 

 

 

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11.

Disconnect the 4-pin gas solenoid plug from the

 

 

 

 

 

2. Remove the six screws that hold the Case Side

receptacle (J8) on the upper right corner of the

 

 

 

Panels.

Control Board.

See Figure C.2.

Reconnect this

 

 

 

 

plug into the 4-pin receptacle (J14) on the top of

 

 

3. Locate the four snap-mount fasteners mounted to

the Module Board.

 

 

 

 

the side panel of the control Board.

Plug the 4-pin connector plug, included with the

 

 

 

12.

 

 

4.

Position the spool gun module board over the

panel receptacle harness connected in step 10

 

 

 

snap-mount fasteners, making sure that the lead

above, into the Control Board receptacle (J8), dis-

 

 

 

plug connectors are placed at the top.

connected in step 11 above.

 

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5. Gently press the board onto the fasteners, making

13. Using the cable tie included in the kit, tie the two

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sure all of the fasteners snap into place.

harnesses together approximately 3.50 inches

 

(88.9mm) from the end of the lead plugs as shown

 

 

 

 

 

6. On the wire drive side of the machine, remove the

in Figure C.2.

to

to

hex-head screw from beneath the gas connector

14. Replace the Case.

releasing the metal cover. See Figure C-1.

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7. Slide the metal cover out from behind the motor

 

 

 

bracket. Flip the cover over so that the screw hole

 

 

 

is in the top right corner, then reinstall as a spacer

 

 

 

plate with the hex head screw. See Figure C-1.

 

 

 

8. Find the panel receptacle lead harness included in

 

 

 

the kit. See Figure C-2. Insert the panel recepta-

 

 

 

cle into the hole from the control board side of the

 

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panel, making sure that the panel receptacle

 

mounting plate is positioned so that the grounding

 

 

 

 

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screw is in the lower left corner of the plate.

 

NOTE: For model codes below 9900, small notches

 

 

 

 

to

to

may need to be filed at top and bottom of panel hole to

 

clear the plastic mounting ears of the receptacle.

 

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IDEALARC SP-250

 

 

Image 33
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 Depth Weight GUN HeightStorage 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 FeaturesMachine Capability LimitationsDuty 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 StepsUsing the 4-STEP Interlock Function in Auto Mode Making a Spot Weld 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 Options / Accessories Spool GUN Adapter KIT InstallationSpool 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 Power Supply Operation Input Line Voltage and Main TransFormer 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 MessagesExplanation of Prompting and Error Messages CONT’D On Screen Error MessageXxxx Current Overload Reduce Output Press ANY KEY to Stop Message Main Transformer Test Test DescriptionMaterials 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 BoardTest Points KEY Pressed Maximum Allowable 27F-27Table 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