Manuals / Lincoln Electric / Power Tools / Welding System

Lincoln Electric SP-250 service manual Control PC Board Removal and Replacement

Models: SP-250

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F-37	TROUBLESHOOTING & REPAIR	F-37
	TROUBLESHOOTING & REPAIR

CONTROL PC BOARD REMOVAL AND REPLACEMENT

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CAUTION

Printed Circuit Boards can be dam- aged by static electricity. Follow sta- tic handling guidelines detailed in “PC Board Troubleshooting Procedures” at the beginning of this chapter.

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SP-250 CONTROL

G2252

J2

J8

J7

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REMOVAL AND REPLACEMENT PROCEDURE

MATERIALS NEEDED

5/16" Nut Driver

Phillips Head Screwdriver

Static Electricity Grounding Strap

J4

J5 J6

J3

J9

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1.Disconnect main input power the machine.

2.Remove the Case Top and Side Panels using 5/16" nut driver.

3.Disconnect all wiring harness plugs and Molex Plugs connect- ed to the Control Board. See Figure F.11.

SP-250 CONTROL

G1992

J2

J8

J7

J4

J6 J9

J5

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J3

FIGURE F.11 - Wiring Harness and Molex Plug Locations.

IDEALARC SP-250

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Lincoln Electric SP-250 Control PC Board Removal and Replacement, Removal and Replacement Procedure Materials Needed

Contents

Safety Depends on You Idealarc SP-250 ARC Welding can be hazardous Idealarc SP-250 Cylinder may explode if damaged Electric and MAG- Netic Fields Iii Précautions DE Sûreté Sûreté Pour Soudage a L’Arc Table of Contents Installation Depth Weight GUN HeightStorage Operating Safety Precautions Select Proper LocationInput Connections Stacking Fuse and Wire Sizes Input Power Connections Ground Connections Connect Shielding GAS Figure A.3 Ground Connection For 230/460/575 Volt Models Reconnect Procedure Side Return to Section TOC GUN Liner & Contact TIP Installation Install the Work ClampConnect Output Components Output Polarity Connection GUN & Cable Installation Figure A.9 European Style Connector Operation Safety Instructions Additional Safety PrecautionsGeneral Description Electric Shock can kill System includes the following features OperationalControls Recommended Processes Design Features Unit FeaturesWire Feeder Features Power Source Features Machine Capability LimitationsDuty Amps Volts Cycle Controls and Settings Figure B.1 SP-250 Control Panel Keys Arrow KEY Operation When Used with Process WIRE/GAS KEY Arrow KEY Operation When Used with Auto KEY Arrow KEY Operation When Used with Manual KEY Arrow KEY Operation When Used with Spot KEY Arrow KEY Operation When Used with Stitch KEYLeft arrow keys Do not function Right arrow keys Do not function Figure B.5 Using the Toggle Function Step Trigger Interlock Keys RUN-IN Mode Changing RUN-IN Mode Codes 10001 and AboveMaking a Weld in Auto Mode Operating Steps 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 Thumb Switch Magnum SP-250 only Using the Wire Drive RollMaking a Stitch Weld in Auto Mode Using the GUN Trigger Switch Loading the Wire Reel To mount 10 to 30 lb. spools 8 and 12 diameter Setting Idle Roll Pressure Feeding Electrode Accessories Options / Accessories Spool GUN Adapter KIT InstallationSpool GUN Module Board Installation Figure C.2 Spool Gun Module Board Installation Installation Spool GUN Connection BOX Spool GUN Connection Figure C.5 Spool Gun Connect Spool GUN Installation to OLD K531 KIT Figure C.6 Spool Gun Connection Maintenance Maintenance Routine and Periodic Control Board Choke Fan Assembly Main Transformer Theory of Operation Power Supply Operation Input Line Voltage and Main TransFormer Output Rectification and Feed Back Control Constant Voltage Output Figure E.4 Constant Voltage Output Wire Drive Motor and Feedback Figure E.5 Wire Drive Motor and Feedback Thermal Protection SCR Operation Figure E.6 SCR Operation Troubleshooting & Repair HOW to USE Troubleshooting Guide Recommended Course of Action PC Board Troubleshooting Procedures Board can be dam- aged by static electricity Output Problems Warn Troubleshooting & Repair Function Problems Troubleshooting & Repair Wire Feeding Problems Liquid elec Trolyte in these capacitors isToxic. Avoid contact with any Portion of your body Troubleshooting & Repair Explanation of Prompting and Error Messages On Screen Error Message Message Explanation 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 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-25 Figure F.8A Plug J2 Location on G2252 PC Control Board Figure F.9 Plug J2 Test Points Test Points KEY Pressed Maximum Allowable 27F-27Table F.1 SP-250 Keypad Resistance Tests 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 trigger Test for Supply Voltage to Tachometer Test for Feedback Voltage to the Control Board Scope Settings Normal Open Circuit Voltage Waveform Machine Loaded to 250 Amps AT 26 VDC Scope Settings Typical Output Voltage Waveform Machine Loaded Machine 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 Needed Troubleshooting & 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 Removal SCR Output Rectifier Removal 43F-43 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 FAN Motor and FAN Removal and Replacement Procedure Figure F.18 Fan Motor and Fan Removal Components Troubleshooting & Repair Wire Speed Range Open Circuit VoltageInput 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 Wiring Diagram for Code 9546 SP-250 230/460/575V Wiring Diagram Wiring Diagram for Code 9723 Thumb Switch Improper Lincoln Electric. 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