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Lincoln Electric SP-250 service manual Troubleshooting & Repair

Models: SP-250

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F-18	TROUBLESHOOTING & REPAIR	F-18
	TROUBLESHOOTING & REPAIR

MAIN TRANSFORMER TEST

b.If the correct nameplate voltage is being applied to the main transformer and one or more of the secondary voltages are missing or are incorrect, the main transformer may faulty. Replace.

IDEALARC SP-250

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Lincoln Electric SP-250 service manual Troubleshooting & Repair

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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