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Lincoln Electric SP-250 service manual Electrical Diagrams G1992 Control PC Board

Models: SP-250

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G-1

ELECTRICAL DIAGRAMS

G-1

G1992 CONTROL PC BOARD

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C11

C88

R132

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X21

R100

C84

R128

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R125

C77

R98

C35

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J1

X5

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R16

SP-250 CONTROL

		G1992-2
		X17
		R138
	C95
B	R69
B	R67	R139			J8
	R68	R106
	R108				D57
	C27	D2		R53	D57
	R107	D2
	R107		R52
	C28	D54	R52
		D54

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D37

R135

R133

D20

R1

C91

R134

C90

R5

R6

R7

L7

R2

R104

Q20

X7

X20

R8

R11

D34

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R19

R10

C78

Q3

Q1

Q4

C37

R9

J2

Q2

D31

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R109

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X8

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J7

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C1

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X13

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C14

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C9

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C13

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X12

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R112

R25

C15

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L1

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R89

	X4			C6
				C8
				X6
				R18
				C10
				R33
C17	X2	C32	X3	C33
	X2		X3
				C36

X9

			R121		Q7	Q6
						Q6

					R122
		X16			R44
	C20		D43			D39	D40
					C18	D39	D40
			R119
			D75		DZ3
			D75		R118
			D76		R118
	C55		C56
	C55
			X10
			R120			DD1
				DZ1		DD1
				DZ1
					Q21
			Q11
			DZ2	C		R40
		R116	DZ2
D35	R30		C45
D35	R30		C45
			C51
			J9
	J6
		TP1	TP2 C94 C93		C92	C23
						C23
	R137		C79
		C80	C79
			R48	R50

R65

D53

R54

R61

R111

R3

C4

C47

R4

D38

D69

X1

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C5

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D

R63

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Q14

R105

R57

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R117

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Q10

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C26

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R101

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D1

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A

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C19

R46

R23

X14

X18

Q13

R99

D41

Q12

C16

R94

R87

R71

OCI3

OCI2

OCI1

R93

R88

TP5

TP3

D68

R92

D67

C40

D65

D66

R86

C39

C30

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R74 R72 R73

C22

Q16

Q15

Q17

R124

R96

R85

R66

D63

R75

DZ5

D55

D56

R103

R102

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NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshoot- ing. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.

IDEALARC SP-250

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Lincoln Electric SP-250 service manual Electrical Diagrams G1992 Control PC Board

Contents

Idealarc SP-250 Safety Depends on You Idealarc SP-250 ARC Welding can be hazardous Cylinder may explode if damaged Iii Electric and MAG- Netic Fields Sûreté Pour Soudage a L’Arc Précautions DE Sûreté Table of Contents Installation Storage Operating Depth Weight GUNHeight Select Proper Location Safety PrecautionsInput Connections Stacking Input Power Connections Ground Connections Fuse and Wire Sizes Figure A.3 Ground Connection For 230/460/575 Volt Models Connect Shielding GAS Side Reconnect Procedure Return to Section TOC Install the Work Clamp GUN Liner & Contact TIP InstallationConnect Output Components Output Polarity Connection Figure A.9 European Style Connector GUN & Cable Installation Operation Additional Safety Precautions Safety InstructionsGeneral Description Electric Shock can kill Operational System includes the following featuresControls Recommended Processes Unit Features Design FeaturesWire Feeder Features Power Source Features Duty Amps Volts Cycle Machine CapabilityLimitations Figure B.1 SP-250 Control Panel Keys Controls and Settings Process WIRE/GAS KEY Arrow KEY Operation When Used with Arrow KEY Operation When Used with Manual KEY Arrow KEY Operation When Used with Auto KEY Arrow KEY Operation When Used with Stitch KEY Arrow KEY Operation When Used with Spot KEYLeft arrow keys Do not function Right arrow keys Do not function Step Trigger Interlock Keys Figure B.5 Using the Toggle Function Changing RUN-IN Mode Codes 10001 and Above RUN-IN ModeMaking a Weld in Auto Mode Operating Steps To make an arc spot plug weld Using the 4-STEP Interlock Function in Auto ModeMaking a Spot Weld in Auto Mode Using the Wire Drive Roll Using the GUN Thumb Switch Magnum SP-250 onlyMaking a Stitch Weld in Auto Mode Using the GUN Trigger Switch To mount 10 to 30 lb. spools 8 and 12 diameter Loading the Wire Reel Feeding Electrode Setting Idle Roll Pressure Accessories Spool GUN Module Board Installation Options / AccessoriesSpool GUN Adapter KIT Installation Figure C.2 Spool Gun Module Board Installation Spool GUN Connection BOX Installation Figure C.5 Spool Gun Connect Spool GUN Connection Figure C.6 Spool Gun Connection Spool GUN Installation to OLD K531 KIT Maintenance Routine and Periodic Maintenance Control Board Choke Fan Assembly Main Transformer Theory of Operation Former Power Supply OperationInput Line Voltage and Main Trans Back Control Output Rectification and Feed Figure E.4 Constant Voltage Output Constant Voltage Output Figure E.5 Wire Drive Motor and Feedback Wire Drive Motor and Feedback Thermal Protection Figure E.6 SCR Operation SCR Operation Troubleshooting & Repair Recommended Course of Action HOW to USE Troubleshooting Guide Board can be dam- aged by static electricity PC Board Troubleshooting Procedures Output Problems Warn Troubleshooting & Repair Function Problems Troubleshooting & Repair Wire Feeding Problems Trolyte in these capacitors is Liquid elecToxic. Avoid contact with any Portion of your body Troubleshooting & Repair On Screen Error Message Message Explanation Explanation of Prompting and Error Messages Xxxx 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 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 Test Figure F.9 Plug J2 Test Points Figure F.8A Plug J2 Location on G2252 PC Control Board Table F.1 SP-250 Keypad Resistance Tests Test Points KEY Pressed Maximum Allowable27F-27 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 Procedure Pull the gun trigger #206B 4J6 #515B 1J6 #555 2J6 #541 6J6 #539 3J6 Test for Feedback Voltage to the Control Board Test for Supply Voltage to Tachometer Normal Open Circuit Voltage Waveform Scope Settings Typical Output Voltage Waveform Machine Loaded Machine Loaded to 250 Amps AT 26 VDC Scope Settings Machine 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 Replacement Troubleshooting & 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 Procedure 43F-43 SCR Output Rectifier Removal Figure 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 Procedure Troubleshooting & Repair Open Circuit Voltage Wire Speed RangeInput Volts/Hertz 230/60 375 Table 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 9546 Thumb Switch Wiring Diagram for Code 9723 Improper Lincoln Electric. 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