Lincoln Electric SP-250 Current Overload Reduce Output Press ANY KEY to Stop Message

Page 60

Section TOC

Master TOC

F-13

TROUBLESHOOTING & REPAIR

F-13

 

 

EXPLANATION OF PROMPTING AND ERROR MESSAGES (CONT’D)

Return to

Return to

ON SCREEN ERROR MESSAGE

HIGH LINE: CHECK

RECONNECT PANEL

PRESS ANY KEY

TO STOP MESSAGE

MESSAGE EXPLANATION

Indicates to operator that the line voltage is too high, and the output voltage has been reduced to protect the capacitor bank voltage rating limits. The operator can continue to weld, but the voltage will be less than what is set on the machine. This message occurs when the line voltage is greater than 121% of nominal line. The operator should check if the reconnect panel is wired properly. Pressing any key or gun switch when the operator is not welding will stop the message from being displayed. Pressing any incre- ment or decrement arrow keys or gun switch while welding will temporarily stop the message from being displayed (approximately 1.3 sec. ) allowing the operator to view the increase or decrease in that setting.

Return to Master TOC

CURRENT OVERLOAD REDUCE OUTPUT

PRESS ANY KEY TO STOP MESSAGE

Indicates to operator that too much current is being drawn from the machine, and the output has been reduced to prevent the current from exceeding safe levels. This will typically occur in Manual mode using .045" (1.2mm) wire and WFS greater than 275 IPM (0.7m/min.). Lowering the WFS will reduce the output requirement and allow operation within the machine rating. Pressing any key or gun switch when the operator is not welding will stop the message from being displayed. Pressing any incre- ment or decrement arrow keys or gun switch while welding will temporarily stop the message from being displayed (approximately 1.3 seconds) allow- ing the operator to view the increase or decrease in that setting.

Return to Section TOC

Return to Section TOC

Return to Master TOC

Return to Master TOC

SXXXXX -X

Only displayed at power-up. Displays the

part number of the ROM

ROM ASSEMBLY

ASSEMBLY currently on the PC board.

 

 

 

 

C SXXXXX -X

Indicates a checksum error in the software.

Turn power off and back on

ROM ASSEMBLY

again. If this message persists, then replace the ROM assembly on the PC

 

board. Earlier units did not display the SXXXXX-X ROM ASSEMBLY num-

 

ber.

 

 

 

R

Indicates a fault in system RAM. Turn power off and back on again. If this

 

message persists, then replace the control PC board assembly.

 

 

SPOOL GUN HAS

Reminder that the Spool gun has been connected and the Manual key must

BEEN CONNECTED

be pressed to enter any Spool gun welding procedures.

PRESS MANUAL

 

 

TO ENTER SETTINGS

 

 

 

 

SPOOL GUN HAS

Reminder that the Spool gun has been removed and the Process key must

BEEN REMOVED

be pressed to enter SP-250 weld settings. This message may also be dis-

 

played if there is an open lead in the spool gun 6-pin plug assembly.

PRESS PROCESS TO

 

 

TO ENTER SETTINGS

 

 

 

IDEALARC SP-250

 

Page 59 Page 61
Image 60
Page 59 Page 61
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. This information
Top Page Image Contents