Lincoln Electric SP-250 service manual Test Points KEY Pressed Maximum Allowable, 27F-27

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F-27F-27

TROUBLESHOOTING & REPAIR

SP-250 KEYPAD RESISTANCE TEST

TABLE F.1 - SP-250 KEYPAD RESISTANCE TESTS

NOTE: THERE SHOULD NOT BE CONTINUITY BETWEEN PINS UNTIL A KEY IS PRESSED ON THE KEYPAD.

TEST POINTS		KEY PRESSED	MAXIMUM ALLOWABLE
			RESISTANCE
			(TYPICAL RESISTANCE)

FROM PIN	TO PIN

1J2	6J2	CENTER UP ARROW	100 OHMS (30 TYPICAL)

1J2	8J2	CENTER DOWN ARROW	100 OHMS (30 TYPICAL)

1J2	2J2	MEMORY 3	100 OHMS (30 TYPICAL)

1J2	4J2	SWITCH SET DISPLAY	100 OHMS (30 TYPICAL)

2J2	9J2	MEMORY 5	100 OHMS (30 TYPICAL)

2J2	7J2	MEMORY 4	100 OHMS (30 TYPICAL)

2J2	3J2	MEMORY 2	100 OHMS (30 TYPICAL)

2J2	5J2	MEMORY 1	100 OHMS (30 TYPICAL)

3J2	6J2	LEFT UP ARROW	100 OHMS (30 TYPICAL)

3J2	8J2	LEFT DOWN ARROW	100 OHMS (30 TYPICAL)

3J2	4J2	SPOT	100 OHMS (30 TYPICAL)

4J2	9J2	TOGGLE	100 OHMS (30 TYPICAL)

4J2	7J2	IMP VOLTS	100 OHMS (30 TYPICAL)

4J2	5J2	TIMERS OFF	100 OHMS (30 TYPICAL)

5J2	6J2	AUTO	100 OHMS (30 TYPICAL)

5J2	8J2	PROCESS WIRE/GAS	100 OHMS (30 TYPICAL)

6J2	9J2	MANUAL	100 OHMS (30 TYPICAL)

6J2	7J2	RIGHT UP ARROW	100 OHMS (30 TYPICAL)

7J2	8J2	RIGHT DOWN ARROW	100 OHMS (30 TYPICAL)

8J2	9J2	SAVE	100 OHMS (30 TYPICAL)

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 Input Connections Safety PrecautionsSelect Proper Location 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 Connect Output Components GUN Liner & Contact TIP InstallationInstall the Work Clamp Output Polarity ConnectionGUN & Cable Installation Figure A.9 European Style ConnectorOperation General Description Safety InstructionsAdditional Safety Precautions Electric Shock can killControls System includes the following featuresOperational Recommended ProcessesWire Feeder Features Design FeaturesUnit 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 KEYLeft arrow keys Do not function Arrow KEY Operation When Used with Spot KEYArrow KEY Operation When Used with Stitch KEY Right arrow keys Do not functionFigure B.5 Using the Toggle Function Step Trigger Interlock KeysMaking a Weld in Auto Mode RUN-IN ModeChanging RUN-IN Mode Codes 10001 and Above Operating StepsTo make an arc spot plug weld Using the 4-STEP Interlock Function in Auto ModeMaking a Spot Weld in Auto Mode Making a Stitch Weld in Auto Mode Using the GUN Thumb Switch Magnum SP-250 onlyUsing the Wire Drive Roll 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 Toxic. Avoid contact with any Liquid elecTrolyte in these capacitors is 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 Input Volts/Hertz Wire Speed RangeOpen Circuit Voltage 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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