Lincoln Electric IDEALARC SP-250 User Manual

IDEALARC SP-250SERVICE MANUALSales and Service through Subsidiaries and Distributors Worldwide22801 St. Clair Ave. Cleveland, Ohio 44117-1199 U.S.A.

A-3INSTALLATION IDEALARC SP-250A-3FUSE AND WIRE SIZESProtect the input circuit with the super lag fuses ordelay type circuit breakers listed on the

TABLE OF CONTENTS- ELECTRICAL DIAGRAMS -Section GIDEALARC SP-250ELECTRICAL DIAGRAMS SECTION ... Section GG1992 CONTROL PC BOARD LA

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

G-4NOTESG-4IDEALARC SP-250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

G-8NOTESG-8IDEALARC SP-250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

A-4INSTALLATION IDEALARC SP-250A-4For the 230/460/575V/ 60 HZ model which is notequipped with a plug, an input cord, or a receptacle,the input power

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

A-5INSTALLATION IDEALARC SP-250A-511. Before opening the cylinder valve, turn the regula-tor adjusting knob counter clockwise until the pres-sure is

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

A-7INSTALLATION IDEALARC SP-250A-7CONNECT OUTPUT COMPONENTSINSTALL THE WORK CLAMPAttach the work clamp to the cable which extends fromthe front of t

A-8INSTALLATION IDEALARC SP-250A-8GUN & CABLE INSTALLATIONWARNING: TURN THE WELDER POWER SWITCHOFF BEFORE INSTALLING GUN AND CABLE.____________

OPERATIONIDEALARC SP-250OPERATION SECTION ... Section BSafety Instructions...

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

B-2OPERATIONB-2The system includes the following features:• 2-step or 4-step selectable trigger function (abovecode 9500 only).• both timed spot and s

B-3OPERATIONB-3DESIGN FEATURES AND ADVANTAGESUNIT FEATURES:Undercarriage for Hand Mobility - Heavy duty 10"(254mm) wheels and 4" (102mm) cas

iSAFETYiIDEALARC SP-250Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCPROTECT YOURSELF AND OTHERS FROM POSSIBLE SE

B-4OPERATIONB-4Gun and Cable (K524-1) - A 12.5 ft. (3.8) GMAW gunand cable assembly, rated 200 amps 60% duty, is pro-vided with the SP-250 and include

B-5OPERATIONB-5CONTROLS AND SETTINGSAll operator controls are located on the Front PanelKeypad/Nameplate. See Figure B.1 for the location ofeach cont

B-6OPERATIONB-6ARROW KEY OPERATION WHEN USED WITHPROCESS WIRE/GAS KEY:See Table B.1.Left Arrow Keys: Press to set Wire Type. Pressing theUP and DOWN a

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

B-8OPERATIONB-87. MEMORY KEYS: Press memory key locationnumber in which you want to save a procedure orfrom which you want to recall a procedure fromm

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

B-10OPERATIONB-10OPERATING STEPSBefore operating the machine, be sure you have all thematerials needed to perform the work. Be sure you arefamiliar w

B-11OPERATIONB-1110. If SPOT timing mode required.a. Press SPOT key.b. Press CENTER UP or DOWN ARROW keys toselect SPOT ON TIME required.c. Press SPOT

B-12OPERATIONB-124. Press the CENTER UP & DOWN ARROW keys toset the required Spot On time. Suggested initialsetting is 1.2 seconds.5. Press the S

B-13OPERATIONB-13LOADING THE WIRE REELTo mount a 22-30 lb. (10-14 kg) Readi-Reel- packageusing the Readi-Reel adapter provided:1. Pull the Readi-Reel

FOR ELECTRICALLYpowered equipment.6.a. Turn off input power using the disconnectswitch at the fuse box before working onthe equipment.6.b. Install equ

B-14OPERATIONB-14FEEDING ELECTRODEWhen inching, the electrode and drive mechanism arealways “hot” to work and ground. The electroderemains “hot” seve

ACCESSORIESIDEALARC SP-250ACCESSORIES SECTION ... Section COptions/Accessories ...

C-1ACCESSORIESC-1OPTIONS / ACCESSORIESReplacement Magnum 250-SP Gun and CableAssembliesThe following GMAW gun and cable assemblies areavailable for us

C-2ACCESSORIESC-2Figure C.2 - Spool Gun Module Board Installation.1. Remove input power to the machine before start-ing.2. Remove the six screws that

C-3ACCESSORIESC-3SPOOL GUN CONNECTION BOXINSTALLATIONNOTE: Model codes below 9900 require the additionof three holes to the front of the machine&apos

C-4ACCESSORIESC-4SPOOL GUN CONNECTIONCAUTION: The spool gun module is intended for usewith Lincoln Electric Magnum Spool Guns only. Usewith other un

C-5ACCESSORIESC-5SPOOL GUN INSTALLATION TO OLD K531 KIT.1. Slide the spool gun cable assembly through theopening in the louvers provided for the work

MAINTENANCEIDEALARC SP-250MAINTENANCE SECTION ... Section DSafety Precautions...

D-1MAINTENANCED-1SAFETY PRECAUTIONS•Have a qualified technician do the maintenanceand troubleshooting work. •Disconnect input power at main input sup

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

iiiSAFETYiiiIDEALARC SP-250Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCMar. ‘93ELECTRIC AND MAG-NETIC FIELDSmay

THEORY OF OPERATIONIDEALARC SP-250Figure E.1 -Block Logic DiagramNOTE: Unshaded areas of Block LogicDiagram are the subject of discussionTHEORY OF OPE

E-1THEORY OF OPERATIONE-1IDEALARC SP-250INPUT LINE VOLTAGE AND MAIN TRANS-FORMERThe desired single phase input power is connected tothe SP-250 through

E-2THEORY OF OPERATIONE-2IDEALARC SP-250OUTPUT RECTIFICATION AND FEED-BACK CONTROLThe AC output from the main transformer secondaryweld winding is rec

E-3THEORY OF OPERATIONE-3IDEALARC SP-250CONSTANT VOLTAGE OUTPUTThe controlled DC output from the SCR rectifierassembly is filtered by the capacitor ba

E-4THEORY OF OPERATIONE-4IDEALARC SP-250WIRE DRIVE MOTOR AND FEEDBACKThe wire drive motor is controlled by the control board.A motor speed feedback si

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

TROUBLESHOOTING & REPAIRIDEALARC SP-250TROUBLESHOOTING & REPAIR SECTION ... Section FHow to use Troubleshooting Guide ...

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

ivSAFETYivIDEALARC SP-250Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCPRÉCAUTIONS DE SÛRETÉPourvotre propre prot

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

F-11TROUBLESHOOTING & REPAIRF-11IDEALARC SP-250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Ma

F-12TROUBLESHOOTING & REPAIRF-12IDEALARC SP-250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Ma

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i - vInstallation . . . . .

F-13TROUBLESHOOTING & REPAIRF-13IDEALARC SP-250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Ma

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

F-17TROUBLESHOOTING & REPAIRF-17IDEALARC SP-250G1992 (Code 9402 only):8. Turn OFF the machine9. Locate the following leads on PlugJ6 on the G2252

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

INSTALLATIONIDEALARC SP-250INSTALLATION SECTION ... Section ATechnical Specifications ...

F-23TROUBLESHOOTING & REPAIRF-23IDEALARC SP-250TEST PROCEDURE1. Disconnect main AC input power tothe machine.2. Disconnect Molex Plugs J3 and J6fr

F-24TROUBLESHOOTING & REPAIRF-24IDEALARC SP-2507. Connect the Tester to the SCR 1 asshown in Figure F.7.a. Connect Tester lead (A) to theanode.b.

F-25TROUBLESHOOTING & REPAIRF-25IDEALARC SP-250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Ma

F-26TROUBLESHOOTING & REPAIRF-26IDEALARC SP-250TEST PROCEDURE1. Disconnect main input power to themachine.2. Remove the Case Top and SidePanels us

F-27TROUBLESHOOTING & REPAIRF-27IDEALARC SP-250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Ma

F-28TROUBLESHOOTING & REPAIRF-28IDEALARC SP-250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Ma

F-29TROUBLESHOOTING & REPAIRF-29IDEALARC SP-250TEST PROCEDURENOTE: POLARITY MUST BEOBSERVED FOR THESE TESTS.Test for Correct Wire Drive MotorArmat

F-30TROUBLESHOOTING & REPAIRF-30IDEALARC SP-250FIGURE F.10B - Plug J6 Location on G1992 PC Control Board (Code 9402 only.)NOTE: Plugs J5 and J6 ar

F-31TROUBLESHOOTING & REPAIRF-31IDEALARC SP-250Test for Supply Voltage toTachometer1. Test for 15 VDC between lead#515B (positive) and lead #206B(

F-32TROUBLESHOOTING & REPAIRF-32IDEALARC SP-250This is a typical DC output voltage wave-form generated from a properly operatingmachine. Note tha

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

F-33TROUBLESHOOTING & REPAIRF-33IDEALARC SP-250This is a typical DC output voltage wave-form generated from a properly operatingmachine. Note tha

F-34TROUBLESHOOTING & REPAIRF-34IDEALARC SP-250This is NOT a typical DC output voltagewaveform. One output SCR is not function-ing. Note the incr

F-35TROUBLESHOOTING & REPAIRF-35IDEALARC SP-250This is NOT the typical DC output voltagewaveform. The output capacitors are notfunctioning. Note

F-36TROUBLESHOOTING & REPAIRF-36IDEALARC SP-250This is a typical SCR gate pulse voltagewaveform. The machine was in an open cir-cuit condition (n

F-37TROUBLESHOOTING & REPAIRF-37IDEALARC SP-250Printed Circuit Boards can be dam-aged by static electricity. Follow sta-tic handling guidelines de

F-38TROUBLESHOOTING & REPAIRF-38IDEALARC SP-2504. Remove the eight Phillips Headmounting screws using a PhillipsHead screwdriver. See Figure F.12

F-39TROUBLESHOOTING & REPAIRF-39IDEALARC SP-250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Ma

F-40TROUBLESHOOTING & REPAIRF-40IDEALARC SP-250PROCEDURENOTE: BEFORE REMOVING THEKEYPAD, PERFORM THE KEYPADRESISTANCE TEST TO BE SURE THEKEYPAD IS

F-41TROUBLESHOOTING & REPAIRF-41IDEALARC SP-250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Ma

F-42TROUBLESHOOTING & REPAIRF-42IDEALARC SP-250PROCEDURE1. Disconnect main input power to themachine.2. Remove the Case Top and SidePanels.3. Remo

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

F-43TROUBLESHOOTING & REPAIRF-43IDEALARC SP-250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Ma

F-44TROUBLESHOOTING & REPAIRF-44IDEALARC SP-250PROCEDURE1. Disconnect lead #208 andTransformer Lead X1 from the heatsink on the left side of the m

F-45TROUBLESHOOTING & REPAIRF-45IDEALARC SP-250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Ma

F-46TROUBLESHOOTING & REPAIRF-46IDEALARC SP-250PROCEDURESee Figure F.17 for location of CapacitorBank Removal and Replacement com-ponents.FIGURE F

F-47TROUBLESHOOTING & REPAIRF-47IDEALARC SP-250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Ma

F-48TROUBLESHOOTING & REPAIRF-48IDEALARC SP-250PROCEDURE1. Disconnect main input power to themachine.2. Remove the Case Top and SidePanels.3. Perf

F-49TROUBLESHOOTING & REPAIRF-49IDEALARC SP-250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Ma

F-50TROUBLESHOOTING & REPAIRF-50IDEALARC SP-250PROCEDURESee Figure F.18 for fan motor and fanremoval components.FIGURE F.18 - Fan Motor and FanRem

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

F-52TROUBLESHOOTING & REPAIRF-52IDEALARC SP-250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Ma