Lincoln Electric SP-250 Spool GUN Installation to OLD K531 KIT, Figure C.6 Spool Gun Connection

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C-5

ACCESSORIES

C-5

 

 

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SPOOL GUN INSTALLATION TO OLD K531 KIT.

1.Slide the spool gun cable assembly through the opening in the louvers provided for the work lead. See Figure C.6.

2.Remove the SP-250 gas line from the gas line con- nector.

3.Screw the spool gun 6-pin plug into the new con- nector just below the gas line connector.

4.Attach the spool gun gas hose to the gas connec- tor.

5.Tighten the gas hose tightly, being careful not to strip the brass threads.

NOTE: If using a K469 Spool Gun with a 4-pin plug, use the K518 adapter.

6.Thread the removed SP-250 gas line between the new gas hose and spool gun cable. See Figure C.6.

7.Pull the SP-250 gas hose up and through until it wedges between the cable connector and gas con- nector.

a.Make sure the SP-250 gas hose connector does not touch the wire drive unit.

8.With the SP-250 connected electrode positive (+), remove the positive electrode lead from the termi- nal on the wire drive.

9.Position the spool gun electrode lead on the termi- nal.

10.Place the SP-250 electrode lead on the terminal. The spool gun electrode lead should be on the inboard side.

11.Tighten the hex nut, being careful not to strip the threads.

12.Confirm the spool gun has been connected prop- erly.

a.Toggle the POWER SWITCH to the “ON” posi- tion.

b.If the spool gun cable has been installed prop- erly, the following display appears

SPOOL GUN HAS BEEN CONNECTED PRESS MANUAL TO ENTER SETTINGS.

c.Press the MANUAL key for spool gun welding mode.

Refer to the Instruction Manual for the K487 or K469 spool gun for information on spool gun set up and operation.

FIGURE C.6 - Spool Gun Connection.

IDEALARC SP-250

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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 Depth Weight GUN HeightStorage Operating 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 FeaturesMachine Capability LimitationsDuty Amps Volts Cycle 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 StepsUsing the 4-STEP Interlock Function in Auto Mode Making a Spot Weld in Auto ModeTo make an arc spot plug weld 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 Options / Accessories Spool GUN Adapter KIT InstallationSpool GUN Module Board 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 Power Supply Operation Input Line Voltage and Main TransFormer 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 ExplanationExplanation 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 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 PointsTest Points KEY Pressed Maximum Allowable 27F-27Table F.1 SP-250 Keypad Resistance Tests 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. 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