Lincoln Electric SP-250 Liquid elec, Trolyte in these capacitors is, Portion of your body

Page 56

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F-9

TROUBLESHOOTING & REPAIR

 

 

 

 

F-9

 

 

 

 

 

 

 

TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual

 

 

 

 

 

 

 

 

PROBLEMS

 

POSSIBLE AREAS OF

 

RECOMMENDED

 

 

(SYMPTOMS)

 

MISADJUSTMENTS(S)

 

COURSE OF ACTION

 

 

 

 

 

 

 

 

 

 

 

 

 

 

WELDING PROBLEMS

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

The arc is unstable and or "hunting".

1.

Check for worn or melted con-

1.

Check for loose connections at

 

 

 

tact tip.

 

the output terminals, the choke,

 

 

 

 

 

the capacitor bank and all heavy

 

 

2.

Check for loose or faulty con-

 

current carrying leads.

 

 

 

 

nections on the work and elec-

 

 

 

 

 

 

 

 

 

 

trode cables.

2.

Make sure that the transformer

 

 

 

 

 

secondary

 

leads

are

securely

 

 

3.

Make sure electrode polarity is

 

connected to the SCR Rectifier

 

 

 

correct or welding process being

 

Assembly.

 

 

 

 

 

 

 

used.

 

 

 

 

 

 

 

 

 

 

 

3.

The output capacitor bank may

 

 

4.

Check for rusty or dirty wire.

 

be faulty.

Check for loose con-

 

 

 

 

 

nections at the capacitors. Also

 

 

5.

Make sure machine settings and

 

check

for

leaky

capacitors.

 

 

 

gas are correct for process

 

Replace if necessary.

 

 

 

 

being used.

 

WARNING:

The

liquid elec-

 

 

 

 

 

trolyte in these capacitors is

 

 

 

 

 

toxic. Avoid contact with any

 

 

 

 

 

portion of your body.

 

 

 

 

 

4.

The control board may be faulty.

 

 

 

 

 

Replace.

 

 

 

 

 

 

 

 

 

Weld bead is narrow or ropey. May

1.

Make sure the weld procedure

1.

The output capacitor bank may

have porosity with electrode stub-

 

and electrode polarity is correct

 

be faulty.

Check for loose con-

bing into plate.

 

for the process being used.

 

nections at the capacitors. Also

 

 

 

 

 

check

for

leaky

capacitors.

 

 

2.

Make sure shielding gas is cor-

 

Replace if necessary.

 

 

 

 

rect and flow is proper.

 

WARNING:

The

liquid elec-

 

 

 

 

 

trolyte in these capacitors is

 

 

3.

Make sure the weld joint is not

 

toxic. Avoid contact with any

 

 

 

"contaminated".

 

portion of your body.

 

 

 

 

 

2.

Perform

 

the SCR

Rectifier

 

 

 

 

 

Assembly Test.

 

 

 

 

 

 

3.

The control board may be faulty.

 

 

 

 

 

Replace.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con- tact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed call 216- 383-2531 or 1-800-833-9353

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 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