Lincoln Electric SP-250 service manual Leads

Page 67

TOC

TOC

F-20

TROUBLESHOOTING & REPAIR	F-20

STATIC SCR RECTIFIER ASSEMBLY TEST

Return to Section

Return to Section TOC

Return to Section TOC

Return to Master

Return to Master TOC

Return to Master TOC

TEST PROCEDURE

1.Disconnect main AC input power to the machine.

2.Disconnect Plugs J3 and J6 from the G2252 Control Board or remove Plug J3 from the G1992 Control Board (Code 9402 only.) This elec- trically isolates the SCR bridge assembly. See Figures F.2A and F.2B.

SP-250 CONTROL

G2252

J2

J8

J7

J4

J9 J3

J5 J6

FIGURE F.2A - Remove Plugs J3 and J6 to Perform Static SCR Rectifier Assembly Test.

SP-250 CONTROL

G1992

J2

J8

J7

J4

J9

J5

3.Test with an Analog Volt-Ohm meter that capacitors have completely dis- charged.

4.Disconnect leads X2 and X3 from the negative capacitor bank using a ﬁ" open end wrench. See Figure F.3.

LEADS

X2 AND X3

NEGATIVE

CAPACITOR

BANK

BUSS BAR

FIGURE F.3 - Location of Leads X2 and X3.

5.Separate leads X2 and X3 from the negative capacitor bank buss bar. Be sure there is no electrical con- tact. See Figure F.3.

Return to Section TOC

Return to Master TOC

J3J6

FIGURE F.2B - Remove Plug J3 to Perform Static SCR Rectifier Assembly Test.

IDEALARC SP-250

Image 67

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 Height Depth Weight GUNStorage Operating Stacking Safety PrecautionsSelect Proper Location Input ConnectionsInput 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 Output Polarity Connection GUN Liner & Contact TIP InstallationInstall the Work Clamp Connect Output ComponentsFigure A.9 European Style Connector GUN & Cable InstallationOperation Electric Shock can kill Safety InstructionsAdditional Safety Precautions General DescriptionRecommended Processes System includes the following featuresOperational ControlsPower Source Features Design FeaturesUnit Features Wire Feeder FeaturesLimitations Machine CapabilityDuty 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 KEYRight arrow keys Do not function Arrow KEY Operation When Used with Spot KEYArrow KEY Operation When Used with Stitch KEY Left arrow keys Do not functionStep Trigger Interlock Keys Figure B.5 Using the Toggle FunctionOperating Steps RUN-IN ModeChanging RUN-IN Mode Codes 10001 and Above Making a Weld in Auto ModeMaking a Spot Weld in Auto Mode Using the 4-STEP Interlock Function in Auto ModeTo make an arc spot plug weld Using the GUN Trigger Switch Using the GUN Thumb Switch Magnum SP-250 onlyUsing the Wire Drive Roll Making a Stitch Weld in Auto ModeTo mount 10 to 30 lb. spools 8 and 12 diameter Loading the Wire ReelFeeding Electrode Setting Idle Roll PressureAccessories Spool GUN Adapter KIT Installation Options / AccessoriesSpool 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 Input Line Voltage and Main Trans Power Supply OperationFormer 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 Portion of your body Liquid elecTrolyte in these capacitors is Toxic. Avoid contact with anyTroubleshooting & Repair On Screen Error Message Message Explanation Explanation of Prompting and Error MessagesOn 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 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 Board27F-27 Test Points KEY Pressed Maximum AllowableTable 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 230/60 375 Wire Speed RangeOpen Circuit Voltage Input Volts/HertzTable 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