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Lincoln Electric SP-250 service manual Lead Plug Location, From Expected Lead Voltage

Models: SP-250

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F-16

TROUBLESHOOTING & REPAIR	F-16

MAIN TRANSFORMER TEST

SP-250 CONTROL

G1992

J2

J8

J7

J4

J6 J9

J5

#208

(1J3)

J3 #209 (2J3) #206 (3J3)

#204A (5J3) #202 (6J3)

#203

(7J3)

FIGURE F.1B - G1992 (Code 9402 Only) Control PC Board Main Transformer Test Points. Note: Plugs J5 and J6 are on inboard non-component side of Control Board.

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4.Locate the following leads on Plug J3:

LEAD	PLUG
	LOCATION

#202	1J3
#203	3J3
#204 A	2J3

G2252:

G1992 (code 9402 only):

5.Connect main input power to the machine.

6.Turn the IDEALARC SP-250 ON/OFF POWER SWITCH to ON.

7.Make the following voltage tests at Plug J3.

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LEAD	PLUG
	LOCATION

#202	6J3
#203	7J3
#204 A	5J3

FROM	TO	EXPECTED
LEAD	LEAD	VOLTAGE

#202	#203	30 VAC
(1J3)	(3J3)
#202	#204 A	15 VAC
(1J3)	(2J3)
#203	#204 A	15 VAC
(3J3)	(2J3)

IDEALARC SP-250

Image 63

Lincoln Electric SP-250 service manual Lead Plug Location, From Expected Lead Voltage

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 Depth Weight GUN HeightStorage Operating Stacking Safety PrecautionsSelect Proper Location Input Connections 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 Output Polarity Connection GUN Liner & Contact TIP InstallationInstall the Work Clamp Connect Output Components Figure A.9 European Style Connector GUN & Cable Installation Operation Electric Shock can kill Safety InstructionsAdditional Safety Precautions General Description Recommended Processes System includes the following featuresOperational Controls Power Source Features Design FeaturesUnit Features Wire Feeder Features Machine Capability LimitationsDuty Amps Volts Cycle 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 Right 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 function Step Trigger Interlock Keys Figure B.5 Using the Toggle Function Operating Steps RUN-IN ModeChanging RUN-IN Mode Codes 10001 and Above Making a Weld in Auto Mode Using the 4-STEP Interlock Function in Auto Mode Making a Spot Weld 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 Mode To mount 10 to 30 lb. spools 8 and 12 diameter Loading the Wire Reel Feeding Electrode Setting Idle Roll Pressure Accessories Options / Accessories Spool GUN Adapter KIT InstallationSpool GUN Module Board 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 Power Supply Operation Input Line Voltage and Main TransFormer 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 Portion of your body Liquid elecTrolyte in these capacitors is Toxic. Avoid contact with any Troubleshooting & Repair On Screen Error Message Message Explanation Explanation of Prompting and Error Messages Explanation 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 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 Test Points KEY Pressed Maximum Allowable 27F-27Table 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 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 230/60 375 Wire Speed RangeOpen Circuit Voltage Input Volts/Hertz 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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