Lincoln Electric SP-250 service manual Theory of Operation

Page 40

 

THEORY OF OPERATION

 

TOC

TABLE OF CONTENTS

 

- THEORY OF OPERATION SECTION -

to Master

THEORY OF OPERATION SECTION

Section E

Return

Input Line Voltage and Main Transformer

E-1

 

Power Supply Operation

E-1 - E-3

 

Output Rectification and Feedback Control

E-2

 

Constant Voltage Output

E-3

 

Wire Drive Motor and Feedback

E-4

 

Thermal Protection

E-5

 

SCR Operation

E-6

TOC

 

 

PIEZO

GAS

 

 

to Master

 

 

 

 

 

LCD

ALARM

SOLENOID

 

 

DISPLAY

 

 

 

WIRE

 

 

 

 

 

 

 

 

 

 

DRIVE

 

 

 

 

 

MOTOR

 

KEYPAD

 

 

 

 

Return

 

CONTROL BOARD

 

 

 

 

 

 

 

 

 

G

 

TACH

 

 

 

 

 

 

 

 

A

 

 

 

 

 

T

 

GUN TRIGGER AND THUMB SWITCH

 

LINE

MAIN

 

E

 

 

 

S

 

 

 

TRANSFORMER

 

 

 

 

SWITCH

 

I

 

FEEDBACK

 

 

 

 

G

 

 

 

 

 

N

 

 

 

 

 

 

A

 

 

 

 

 

 

L

 

 

 

 

RECONNECT

 

 

 

POSITIVE

 

 

 

 

 

 

 

 

 

 

 

 

TERMINAL

 

 

 

 

 

C

CHOKE

 

 

 

 

 

 

 

 

 

 

 

A

F

 

 

 

 

 

P

E

 

 

 

 

 

A

E

TOC

 

 

 

 

C

D

 

 

SCR

I

B

 

 

RECTIFIER

T

A

 

 

 

 

O

C

 

FAN

 

 

R

K

Return to Master

 

 

 

S

NEGATIVE

 

MOTORS

 

 

 

TERMINAL

 

 

 

 

 

 

 

 

 

 

SHUNT

 

 

 

 

 

 

Figure E.1 -Block Logic Diagram

Master TOC

 

to

NOTE: Unshaded areas of Block Logic

Diagram are the subject of discussion

Return

 

IDEALARC SP-250

 

Page 39 Page 41
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Page 39 Page 41
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 Height Depth Weight GUNStorage 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 FeaturesLimitations Machine CapabilityDuty 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 StepsMaking a Spot Weld in Auto Mode Using the 4-STEP Interlock Function 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 Spool GUN Adapter KIT Installation Options / AccessoriesSpool 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 Input Line Voltage and Main Trans Power Supply OperationFormer 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 ExplanationOn 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 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 Points27F-27 Test Points KEY Pressed Maximum AllowableTable 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. This information
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