Home

Lincoln Electric IDEALARC SP-250 User's Manual

1. o SP 250 CONTROL a FTT R100 sias G1992 2 4 xi E R138 951 R 69 e o O TERM a 8 035 i RS a 1 n FOB 8106 4 4 e le R108 dxs Y1 bs a a C27 02 R53 5 5 4 gt e 107 4 816 4 028 54 R52 4 4 b X4 66 le R65 53 R54 4 b e le 5 1 X p pum pL V 1 38 4 M C5 4 b un 4 50 58 4 LI 5 C10 4 ld 49 R59 1 RP R33 tD R63 tm Riot 6 L N 4 b R95 429 X7 20 X2 8 xa 5 1 b RO 5 1 jms fg Li 11 AiO iE RHT E 036 Q8 S 5 90 44 PTI
2. 5 3 ple pic a Z CRYSTAL UPPLY VOLTAGE NET GROUND CONNECTION 6000000000000000 5 GENERAL INFORMATION B BLACK LEAD SP 250 CONTROL SCHEMATIC 10 9 920 TACH CIRCUITRY G 2251 NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting 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 IDEALARC SP 250 Return to Section TOC Return to Master TOC
3. Q O H 5 e wn 5 4 ac Return to Master TOC e ME a uj a5 gt Li e 5 28 58 EB N g 3 3 2 8 3 v v E M
4. 5 Process Wire Gas Key B 5 8 A to K y B 7 Manual B 7 9 Save 7 E Memory OVE B 8 8 8 a Stitch Key P B 8 Eu ciego B 8 Gun Switch Control IPM Volts B 8 OSG B 9 Operating 10 14 Q 4 gt 4 c 5 Return to Master IDEALARC SP 250 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC FE E lu 2 nile 818 EJE Bi 0 iac Return to Section TOC Return to Master TOC Return to Master TOC Read and understand this entire section before operat ing your Idealarc SP 250 SAFETY INSTRUCTIONS A WARNING ELECTRIC SHOCK can kill Do not touch electrically live parts such as output terminals or internal wiring Insulate yourself from the work and ground Always wear dry insulating gloves Only qualified personnel should operate this equip ment ADDITIONAL SAFETY PRECAUTIONS Always operate the welder with the hinged door closed and the side panels in place as these provide maxi mum protection from moving parts and insure proper cooling air flow GENERAL DESCRIPTION Product Description The
5. FE lau 2 nile 818 EJE o iac FIGURE F 8B Plug J2 Location on G1992 PC Control Board Code 9402 only Return to Section TOC Return to Master TOC IDEALARC SP 250 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC lu 5 nile 818 EJE Bi ic Return to Section TOC Return to Master TOC dad TROUBLESHOOTING amp REPAIR SP 250 KEYPAD RESISTANCE TEST TABLE F 1 SP 250 KEYPAD RESISTANCE TESTS NOTE THERE SHOULD NOT BE CONTINUITY BETWEEN PINS UNTIL A KEY IS PRESSED ON THE KEYPAD TEST POINTS KEY PRESSED MAXIMUM ALLOWABLE RESISTANCE ________ IDEALARC SP 250 LINCOLN ree TROUBLESHOOTING amp REPAIR PR WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST A WARNING Service and repair should be performed only by Lincoln Electric factory trained per sonnel Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and pre cautions detailed throughout this manual Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the tests rep
6. ZENER DIODE 1W 15V 5 1N4744A DZ3 adage ds ZENER DIODE 5W 10V 5 1N5347B DZT Lois eid Un ZENER DIODE 1W 6 2V 5 1N4735A 071 072 076 ZENER DIODE 1W 18V 5 1N4746A Q9 Q16 TRANSISTOR P T226 0 2A 30V 2N4125 ies TRANSISTOR NMF T220 15A 60V 15NO6E D20 nasse t DIODE AXLDS 1A 30V SCHOTTKY ROG anotada kane RESISTOR MF 1 2W 1K 2 RID aes RESISTOR MF 1 2W 2 7K 2 87 94 RESP RESISTOR MF 1 2W 330 2 uera REA EE RESISTOR MF 1 2W 6 8K 2 R22 H70 o RESISTOR MF 1 2W 3 9K 2 PA RESISTOR MF 1 2W 3K 2 wii RESISTOR MF 1 2W 27K 2 R5 R6 R7 R30 R75 R99 RESISTOR MF 1 2W 100 2 R113 R114 R115 R120 R37 H122 oo ta alice RESISTOR MF 1 2W 750 2 H52 H57 5 eeu RESISTOR MF 1 2W 1 8K 296 i bo ee dss mend RESISTOR MF 1 2W 68 2 889 90 ea RESISTOR MF 1 2W 270 2 R31 EE RESISTOR MF 1 2W 1 5K 296 R62 ic ce tates RESISTOR MF 1 2W 10K 2 une eese tee RESISTOR MF 1 2W 18K 296 H86 H92 och on Dl ees RESISTOR MF 1 2W 15 2 51 56 RESISTOR MF 1 2W 56K 2 RESISTOR MF 1 2W 470 2 48 50 RESISTOR CC 2W 10 10 ee e RESISTOR WW 5W 3 3K 5 IPSNWPS tele te MOV 50VRMS 15J 14MM 1 2 xe Rees MOV 75VRMS 22J 14MM 8106 etal ee RESIST
7. D 1 Component Locations D 2 Theory of Operation Section E Power Supply Operation 1 4 Thermal Protection 5 SCGR OperatioN si T E 6 Troubleshooting and Repair Section F How to use Troubleshooting Guide F 1 PC Board Troubleshooting Procedures F 2 Troubleshooting Guide F 3 F 53 Error messages F 11 F 13 Retest after Repair F 52 Electrical Diagrams Section G Parts Manual 2 4 1 P 201 IDEALARC SP 250 LINCOLN Return to Master TOC Return to Master TOC Q 4 gt 4 c 5 Return to Master INSTALLATION TABLE OF CONTENTS INSTALLATION SECTION INSTALLATION SECTION Section Technical 1 Safety Precautions ere ater bbs UE A 2 Select Proper 2 succi casos A 2 Input Electrical A 2 Fuse a
8. Return to Section TOC Return to Master TOC Ae 206 3J3 ES enia 5J3 202 6J3 203 7 3 Return to Section TOC Return to Master TOC 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 4 Locate the following leads on Plug J3 G1992 code 9402 only 5 Connect main input power to the LOCATION 6 the IDEALARC SP 250 103 ON OFF POWER SWITCH to 3 3 2 3 7 Make the following voltage tests at Plug J3 FROM TO EXPECTED LEAD LEAD VOLTAGE 2 nile 818 EJE o iac G2252 LEAD PLUG LOCATION 6J3 7J3 5J3 Return to Section TOC Return to Master TOC IDEALARC SP 250 LINCOLN oN TROUBLESHOOTING amp REPAIR pu MAIN TRANSFORMER TEST G1992 Code 9402 only G2252 FROM TO EXPECTED FROM TO EXPECTED LEAD LEAD VOLTAGE LEAD LEAD VOLTAGE Return to Section TOC Return to Master TOC 8 Turn OFF the machine G1992 Code 9402 only 9 Locate the following leads on Plug FROM TO EXPECTED J6 on the G2252 Control PC Board LEAD LEAD VOLTAGE or Plug J3 on the G1992 Control PC Board See Figures F 1A amp G2252 LEAD PLUG LOCATION 206 4J6 208 16J6 209 7J6 p o dei E
9. Q e ui 5 rs a e O e e 2 E 5 5 olg lu o o 2 4 5 5 zs pic a 21 to amp 8 2 gt a 5 225 T 858 t g c a K 8 E 5 m 5 8 E E 92558 8 x E gt 82 2 zou gt 5 2 5 2 E 5 24k SEG a y 8 lt a a8 SP 250 E 85 2 SCHEMATIC pm 10 19 90N oR 81922 NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components 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 Return to Section TOC Return to Master TOC Operator or Technician Improper PC board repairs could result in damage to the machine IDEALARC SP 250 IDEALARC SP 250 G 13 ELECTRICAL DIAGRAMS G 13 G2252 CONTROL PC BOARD SCHEMATIC SOLENOID DRIVER CIRCUITRY y 59 MOTOR CONTROL CIRCUITRY Return to Section TOC Return to Master TOC gt gt VA
10. Return to Master c If any of the voltages tested are G1992 Code 9402 only incorrect check for loose or bro ken leads between the test points and the main transformer elt LEAD PLUG 9 ocanon d If ALL the voltages tested are 9 5 incorrect or missing go to Step 212 206 3J3 42 208 1J3 5 B 209 2J3 12 Test for correct nameplate input volt 9 E 10 age between the H1 lead at the Turn ON the machine ON OFF POWER SWITCH to H2 or H3 at the reconnect panel Voltage 11 Make the following voltage tests at tested will vary depending on Input Plug J6 on the G2252 Control PC Voltage Connection See wiring dia Board or at Plug J3 on the G1992 gram for test point locations Control PC Board Code 9402 only a If the voltage test is incorrect a Turn the machine OFF between 5 5 each test check for loose or broken leads between the reconnect 5 5 b Carefully insert the meter panel and the ON OFF POWER 19 probes into the back of each SWITCH 5 Molex Plug pin cavity to perform 918 the test test the ON OFF POWER E SWITCH for proper operation IDEALARC SP 250 LINCOLN rae TROUBLESHOOTING amp REPAIR ind 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 Return to Section TOC Return t
11. Return to Section TOC Return to Master TOC 1 Disconnect main input power the machine SP 250 CONTROL G1992 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 2 nile 818 EJE o iac FIGURE F 11 Wiring Harness and Molex Plug Locations Return to Section TOC Return to Master TOC IDEALARC SP 250 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC FE au 2 nile 818 EJE 5 o iac Return to Section TOC Return to Master TOC TROUBLESHOOTING amp REPAIR CONTROL BOARD REMOVAL AND REPLACEMENT 4 Remove the eight Phillips Head mounting screws using a Phillips Head screwdriver See Figure F 12 FIGURE F 12 Control Board Mounting Screw Locations may With different Code Machines 5 Lift the Control Board straight up and out from the machine 6 Replace all mounting screws and wiring connections when installing the C
12. Return to Section TOC Return to Master TOC Q O H f 5 F 46 TROUBLESHOOTING amp REPAIR CAPACITOR BANK REMOVAL AND REPLACEMENT PROCEDURE See Figure F 17 for location of Capacitor Bank Removal and Replacement com ponents LEADS X2 AND X3 LEAD 206 CHOKE LEAD SCR LEAD CAPACITOR BANK ASSEMBLY MOUNTING SCREWS 2 FIGURE F 17 Location of Capacitor Bank Removal and Replacement Components 1 Disconnect main input power to the machine Test that the capacitors are dis charged using a volt ohmmeter Polarity must be observed Remove the two transformer sec ondary leads X2 and for the negative capacitor bank buss bar using two fi open end wrenches Remove the output choke lead and the heavy lead extending from the SCR Rectifier Assembly to the posi tive capacitor bank buss bar using a fi open end wrench Remove lead 206 and the D1 diode lead from the negative capac itor bank buss bar using a slot head screwdriver and 3 8 open end wrench IDEALARC SP 250 LINCOLN 6 Remove the 204 lead from the pos itive buss bar Remove the shunt from the negative capacitor bank buss bar using a 1 2 socket wrench with a universal tool adapter a Two people may be required to remove the shunt One person may have to reach through from the left side of the machine to keep the bolt in position while the ot
13. Dum LINE SENSING Return to Master TOC Return to Section TOC GATE DRIVE CIRCUITRY ZERO CROSSING DETECTOR
14. FE au 2 nile 818 EJE o iac Return to Section TOC Return to Master TOC dinis TROUBLESHOOTING amp REPAIR En FAN MOTOR AND FAN REMOVAL AND REPLACEMENT PROCEDURE See Figure F 18 for fan motor and fan removal components SCREWS HOLDING RECONNECT er PANEL Y 8 FITTING FAN MOTOR MOUNTING BRACKET SCREWS MOUNTING CASE BACK TO FLOOR FIGURE F 18 Fan Motor and Fan Removal Components 1 Remove the Case Back screws 5 Loosen the two screws holding the reconnect panel in place and a slide 2 Remove the gas solenoid using a the reconnect panel from the frame 3 4 open end wrench 6 Remove the fan blade Note fan 3 Using a 5 16 wrench remove the 5 blade position on motor shaft for ref screws holding the fan motor mount erence for replacing fan ing bracket to the case back a Pry the fan blade off the motor 4 Tilt the Case Back away from the machine and remove the screws b Slide the fan blade off the motor holding the Case Back to the floor of shaft the machine using a 1 2 socket wrench with extension IDEALARC SP 250 LINCOLN TROUBLESHOOTING amp REPAIR didi FAN MOTOR AND FAN REMOVAL AND REPLACEMENT 7 Remove the fan motor a Loosen and remove the two screws from the motor mounting bracket using a slot head screw driver Return to Section TOC Return to Master TOC b When the motor is free from the
15. 111 Q January 1996 IDEALARC SP 250 i For use with machines having Code Numbers 9402 5 9546 8 9723 2 10001 E 10002 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind However your overall safety can be increased by proper installation and thoughtful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READ ING THIS MANUAL AND THE SAFETY PRECAUTIONS CON TAINED THROUGHOUT And most importantly think before you act and be careful Return to Master TOC View Safety Info View Safety Info dud c SERVICE MANUAL LINCOLN ELECTRIC Sales and Service through Subsidiaries and Distributors Worldwide 22801 St Clair Ave Cleveland Ohio 44117 1199 U S A Tel 216 481 8100 View Safety Info Return to Master TOC World s Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors SAFETY WARNING PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase copy of Safety in Welding amp Cutting ANSI Standard 249 1 from the American Welding S
16. 5 Route the control cable of the connection box up through the opening in the front louver provided for the work lead then up behind the wire drive and connect the plug to the kit receptacle installed in the previous section A See Figure C 4 6 Route the electrode lead of the connection box up through the same opening in the front louver With Return to Section TOC Return to Master TOC IDEALARC SP 250 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC FE lu 2 nile 818 EJE o iac Return to Section TOC Return to Master TOC Return to Master TOC ACCESSORIES SPOOL GUN CONNECTION A CAUTION CAUTION The spool gun module is intended for use with Lincoln Electric Magnum Spool Guns only Use with other units may cause damage to the equipment For Spool Gun operation refer to the instruction man ual provided with the Magnum Spool Gun 1 Connect the spool gun control cable 6 pin plug to mating receptacle on the front of the spool gun adapter connection box NOTE If using a K469 spool gun with 4 pin plug use the K518 adapter 2 Insert the Twist Mate plug into the mating recepta cle on the front of the connection box and twist to lock the connection 3 Attach the spool gun gas line to the gas outlet fit ting on the front of the connection box 4 Refer to the Instruction Manual included with the K487 or K469 Spool Gun for
17. FIGURE F 2B Remove Plug J3 to Perform Static SCR Rectifier Assembly Test IDEALARC SP 250 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC E Eur 5 4 ac Return to Section TOC Return to Master TOC Q O H f 5 a F 21 TROUBLESHOOTING amp REPAIR STATIC SCR RECTIFIER ASSEMBLY TEST NOTE DO NOT DISASSEMBLE THE SCR RECTIFIER HEAT SINK ASSEM BLY 6 Test for high or infinite resistance from the anode to the cathode of SCR 1 See Figure F 4 Use an analog ohmmeter Multimeter FIGURE F 4 SCR 1 Test Points 7 10 11 Test for high or infinite resistance from the cathode to the anode of SCR 1 by reversing the meter leads See Figure F 4 a high or infinite resistance is indicated for both tests 6 and 7 the SCR 1 is not shorted b If alow resistance is indicated in either tests 6 or 7 the SCR is faulty Replace SCR Assembly Repeat Steps 7 to test SCR 2 Reconnect leads X2 and X3 Reconnect Plugs J3 and J6 If this test did not identify the prob lem or to further test the SCR go to the Active SCR Test IDEALARC SP 250 LINCOLN F 21 dex TROUBLESHOOTING amp REPAIR ACTIVE SCR RECTIFIER ASSEMBLY TEST Return to Section TOC Return to Master TOC A WARNING Service and repair should be performed only by Lin
18. STACKING The IDEALARC SP 250 cannot be stacked INPUT CONNECTIONS WARNING input power must be electrically disconnected before proceeding 1 Before starting the installation check with the local power company to determine if there is any ques tion about whether your power supply is adequate for the voltage amperes phase and frequency specified on the welder nameplate Also be sure the planned installation will meet the U S National Electrical Code and local code requirements This welder may be operated from a single phase line or from one phase of a three phase line 2 Models that have multiple input voltages specified on the nameplate e g 208 230 are shipped con nected for the highest voltage If the welder is to be operated at a lower voltage it must be recon nected according to the instructions on the inside of the removable panel Reconnect Access Door near the top left side of the Case Back Assembly Also see the Reconnect Section of this manual for details on reconnecting the machine to operate at different voltages 3 Be sure the voltage phase and frequency of the input power is as specified on the machine rating plate See Figure A 1 for the location of the machine s input cord entry Reconnect Access Door Reconnect Panel and Rear Nameplate RECONNECT PANEL E ACCESS DOOR REAR NAMEPLATE RECONNECT PANEL ASSEMBLY FIGURE A 1
19. remove the positive electrode lead from the termi nal on the wire drive 9 Position the spool gun electrode lead on the termi nal 10 Place the SP 250 electrode lead on the terminal The spool gun electrode lead should be on the inboard side FE au 2 nile 818 EJE 5 o iac 11 Tighten the hex nut being careful not to strip the threads 12 Confirm the spool gun has been connected prop erly a Toggle the POWER SWITCH to the ON posi tion b If the spool gun cable has been installed prop erly the following display appears SPOOL GUN HAS BEEN CONNECTED PRESS MANUAL TO ENTER SETTINGS Return to Section TOC Return to Master TOC IDEALARC SP 250 LINCOLN Return to Master TOC Return to Master TOC Q 4 gt 4 c 5 Return to Master MAINTENANCE TABLE OF CONTENTS MAINTENANCE SECTION MAINTENANCE SECTION Section D Safety 4 4 4 00 00 04 22 D 1 Routine and Periodic Maintenance D 1 Component Locations usi oro eee D 2 IDEALARC SP 250 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC lux 5 nile 818 EJE aic Return to Section TOC Return to Master TOC Return to Master TOC SAFETY PRECAUTIONS
20. CHANGING RUN IN MODE CODES 10001 AND ABOVE NOTE Arc starting characteristics may be affected when using the fast run in mode because normal start ing processes are overridden 1 Turn the ON OFF POWER SWITCH to ON 2 Press and hold both the TIMERS OFF key and the PROCESS key NOTE The order in which the TIMERS OFF key and the PROCESS key are pressed does not matter 3 Read the SP 250 LED display One of two mes sages appear FAST INCH ENABLED Fast run in mode FAST INCH DISABLED Slow run in mode NOTE The run in message appears on the display for 2 seconds Pressing the PROCESS key causes the message to disappear immediately 4 Select run in mode required a lf run in mode displayed is the required mode continue with weld process OPERATION B 10 b If run in mode displayed is not the required mode repeat Step 1 By repeating Step 1 the run in mode changes Pressing the TIMERS OFF key and the PROCESS key allows you to switch back and forth between the two run in modes You need only perform the above procedure when you want to change the run in mode It is not necessary to repeat the above procedure each time the unit is pow ered up The unit will remember the run in mode from the previous power down and return you to that same state on your next power up When saving to Memory locations 1 5 the run in mode is saved at the same time All operators should be aware that when recalling a procedure
21. RESISTOR MF 10K 1 4W R76 R77 R78 R79 R88 R93 R97 R98 R104 R111 R140 880 osea hte RESISTOR MF 33K 1 4W ALS ive eR ns RESISTOR MF 100K 1 4W RI hey aetna RESISTOR MF 2 7K 1 4W is cotes RESISTOR MF 47K 1 4W RIG RAG ores os RESISTOR MF 15K 1 4W R12 R13 R14 R15 R72 R101 RESISTOR MF 1K 1 4W R44 RBA oie oe eae RESISTOR WW 5W 1K 5 SQ R45 R85 R96 RESISTOR WW 5W 50 5 SQ R102 R124 RESISTOR WW 5W 20 5 SQ R136 R137 RESISTOR WW 7W 0 25 596 AD IC CMOS MCU NO ROM DIP 68HC114A1P IC CMOS UNDERVOLT SENSING RESET MCU X12 IC CMOS SWITCH ANALOG QUAD 4066 Xl ed IC OP AMP QUAD GEN PURPOSE 224N Yl eher CRYSTAL QUARTZ 4 000MHZ ka IC CMOS GATE NAND 2 INPUT QUAD HC00 AD ans IC CMOS LATCH 3 STATE OCTAL HC373A X2 X20 IC CMOS INVERTER SCHMITT HEX HC14A er ee IC CMOS REGISTER SHFT SI PO 8 BIT X11 X13 X19 IC COMPARATOR QUAD 2901N X8 nosse 2 IC CMOS REGISTER SHFT S PI SO 8 BIT X21 ELS IC CMOS TRNSCVR BUS 3 STATE OCTAL Q1 Q2 Q3 Q4 Q6 TRANSISTOR N T226 0 2A 30V 2N4123 Q8 Q10 Q14 Q15 Q18 Q19 Q20 07 013 TRANSISTOR N T226 0 5A 300V MPS A42 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 i
22. form generated from a properly operating Volts Div machine Note that each vertical division represents 20 volts and that each horizontal Horizontal Sweep division represents 5 milliseconds in time The machine was loaded with a resistance Coupling 2 nile 818 EJE o iac grid bank Trigger Note Scope probes connected at machine output terminals probe to electrode probe to work Return to Section TOC Return to Master TOC IDEALARC SP 250 LINCOLN dai TROUBLESHOOTING amp REPAIR ES ABNORMAL OUTPUT VOLTAGE WAVEFORM MACHINE LOADED ONE OUTPUT SCR NOT FUNCTIONING Return to Section TOC Return to Master TOC CH1 0 volts Return to Section TOC Return to Master TOC 20 volts 5ms MACHINE LOADED TO 220 AMPS AT 22 VDC SCOPE SETTINGS This is NOT a typical DC output voltage waveform One output SCR is not function volts Div ing Note the increased ripple content One SCR gate was disconnected to simulate an Horizontal Sweep open or non functioning output SCR Each vertical division represents 20 volts Coupling each horizontal division represents 5 mil 2 nile 818 EJE o iac liseconds in time The machine was loaded Trigger with a resistance grid bank Note Scope probes connected at machine output term
23. iac Return to Section TOC Return to Master TOC IDEALARC SP 250 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC lu 2 nile 818 EJE o Return to Section Return to Master TOC F 20 TROUBLESHOOTING amp REPAIR STATIC SCR RECTIFIER ASSEMBLY TEST TEST PROCEDURE 1 Disconnect main AC input power to the machine Disconnect Plugs J3 and J6 from the G2252 Control Board or remove Plug J3 from the G1992 Control Board Code 9402 only This elec 3 Test with an Analog Volt Ohm meter that capacitors have completely dis charged Disconnect leads X2 and X3 from the negative capacitor bank using a fi open end wrench See Figure F 3 trically isolates the SCR bridge assembly See Figures F 2A and F 2B SP 250 CONTROL G2252 NEGATIVE CAPACITOR BUSS BAR FIGURE Location of Leads X2 FIGURE 2 Remove Plugs J3 and and X3 J6 to Perform Static SCR Rectifier Assembly Test 5 Separate leads X2 and X3 from the negative capacitor bank buss bar Be sure there is no electrical con tact See Figure F 3 SP 250 CONTROL G1992 J8
24. o o 43 5 gt LOW V JUMPER Q O 5 wn 4 c x 2 J3 1 6 1 5 000000 09900 J4 200000 lo 0000 J11 7 12 52 THERMOSTAT 15 OHMS ca C1 THRU 1005 30 000 MFD 7 50V OUTPUT 7 7 8 05 J6 14 9 16 2 28 92B 8423 Return to Section TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels IDEALARC SP 250 IDEALARC SP 250 ELECTRICAL DIAGRAMS G 12 G 12 gg G1992 CONTROL PC BOARD SCHEMATIC H 9 8 8 4 788 5 3 9 POWER SUPPLIES
25. Disconnect main AC input power to the machine 2 Disconnect Molex Plugs J3 and J6 from the G2252 Control Board or remove Plug J3 from G1992 Control Board Code 9402 only See Figures F 5A and F 5B SP 250 CONTROL G2252 000000 9 0000000 FIGURE 5 Control Board Molex Plug Locations for G2252 PC Control Board SP 250 CONTROL G1992 J8 FIGURE F 5B Control Board Molex Plug Locations for G1992 PC Control Board Code 9402 only 3 Test with an Analog Volt Ohm meter that capacitors have completely dis charged Disconnect leads X2 and X3 from the negative capacitor bank using a fi open end wrench See Figure F 6 NEGATIVE CAPACITOR BANK BUSS BAR FIGURE F 6 Location of Leads X2 and X3 5 Separate leads X2 and X3 from the negative capacitor bank buss bar Be sure there is no electrical con tact See Figure F6 NOTE DO NOT DISASSEMBLE THE SCR RECTIFIER HEAT SINK ASSEM BLY 6 Construct the circuit shown in Figure F 8 One 6 volt lantern battery can be used H1 and R2 resistor values are 10 Set voltmeter scale low at approximately 0 5 volts or 5 10 volts a Testthe voltage level of the bat tery Short leads A and C Close sw
26. IPM VOLTS TOGGLE gt 4 2 45 TIMERS VOLTS TOGGLE OFF STITCH KEY KEY KEY KEY POWER SWITCH gt EEA FIGURE B 1 SP 250 Control Panel Keys FE 2 nile gis EJE iac 1 POWER SWITCH Toggle switch to turn input 3 PROCESS WIRE GAS KEY Press key to Return to Section TOC Return to Master TOC power ON and OFF When the switch is in the ON position the red LED backlighting of the LCD dis play lights and alphanumeric characters appear The welding setup in operation when the power was shut off or disconnected is displayed when power is restored SET UP ARROW KEYS Press keys to change the display selection directly above the keys See Figure B 1 Function of arrow keys change depending on PROCESS KEY being used For function of arrow keys refer to each process or procedure Table B 1 for summary of arrow key operation display the Wire Type Wire Diameter and Welding Gas Each combination of wire and gas dictates a unique relationship between the wire feed speed and the arc voltage The SP 250 uses this unique relationship along with the metal thickness to set the proper values for wire feed speed and arc volt age Therefore it is very important that the wire type wire diameter and welding gas displayed match the actual wire type wire diameter and welding gas being used
27. REQ S STAINLESS An attempt was made to recall from memory an Auto setup whose process WIRE 035 Ar Oo does not match the process in the machine This message indicates the process required and alternates with the second message until the Process key is pressed PRESS PROCESS WHEN INSTALLED Return to Section TOC Return to Master TOC IDEALARC SP 250 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 5 9 E Ja 5 42 ac Return to Section TOC Return to Master TOC Q O ks 4 c 5 a Pag TROUBLESHOOTING amp REPAIR oe EXPLANATION OF PROMPTING AND ERROR MESSAGES CONT D ON SCREEN ERROR MESSAGE DATA ERROR CHECK SETTINGS PRESS PROCESS TO CHECK SETTINGS MOTOR OVERLOADED CHECK GUN DRIVE XXXX ERROR CHECK SETTINGS PRESS PROCESS TO CHECK SETTINGS GUN SWITCH BEING USED FOR TOGGLE CONNECT FOR NEG POLARITY LOW LINE CHECK RECONNECT PANEL PRESS ANY KEY TO STOP MESSAGE MESSAGE EXPLANATION An attempt was made to recall a setup from memory that has improper set tings due to excessive electrical interference The SP 250 will recall the setup and reset the improper data to within machine limits However all settings should be checked properly set if needed and then resaved to that memory This message alternates with the second message until the Proces
28. specifiques qui parraissent dans manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher met allique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonc tionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines soud er parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines pr venir tout risque d incendie aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s p
29. 035 0 9mm diameter in stainless steel wire 035 STAINLESS Other wire diameters can be accommodated by using the Manual mode ONLY ARGON USED Unit is programmed to use only argon gas with aluminum electrodes Other WITH ALUMINUM gases can be accommodated by using the manual mode 5 Q 2 ONLY SET UP FOR Unit is only programmed for 045 1 1mm diameter in Outershield elec 5 5 045 OUTERSHIELD trode wire Other wire diameters within the SP 250 rating can be 519 modated by using the Manual mode gt 918 EJE NO GAS REQUIRED Innershield electrode wire does not require a shielding gas In the Auto 8 WITH INNERSHIELD mode the SP 250 automatically leaves the solenoid de energized even cic when the trigger is closed memory 4 to find out what process is required The memory number indi cates which memory 4 or 5 does not match MEMORY 1 NOW Verifies that the setup was saved to memory number 1 The actual memo CONTAINS SETUP ry number is determined by the memory number key that was pressed fol lowing Save Vly MEMORY 2 An attempt was made to recall a setup from a memory that does not con 15 tain one The actual memory number is determined by the memory num c ber key that was just pressed 918 MEMORY 4 DOESN T An attempt was made to enter Toggle mode and the process of the Auto t MATCH WIRE amp GAS setup in memory 4 does not match the process in the machine Press 8 2 2
30. 60 14 2 5mm 12 4mm 575 60 14 2 5mm 12 4mm PHYSICAL DIMENSIONS HEIGHT Width DEPTH WEIGHT W GUN 3 6 4 2 40 1 222 Ibs 1019mm 101 Kg OPERATING TEMPERATURE STORAGE OPERATING 40 C 20 C to 40 C IDEALARC SP 250 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC FE 2 nile 818 EJE y DIH o iac Return to Section TOC Return to Master TOC Return to Master TOC A INSTALLATION ia Read entire Installation Section before installing the IDEALARC SP 250 SAFETY PRECAUTIONS ELECTRIC SHOCK CAN KILL WARNING Only qualified personnel should install E this machine Turn the input power OFF at the dis connect switch or fuse box before working on the equipment Do not touch electrically hot parts e Always connect the IDEALARC SP 250 grounding terminal located on the side of the Case Back Assembly to a good electrical earth ground e Set the IDEALARC SP 250 Power switch to the OFF position when connecting power cord to input power SELECT PROPER LOCATION Place the IDEALARC SP 250 where clean air can freely circulate in through the front intake and out through the rear louvers Dirt dust or any foreign material that can be drawn into the machine should be kept at a minimum Not following these precautions can result in the nuisance shutdown of the machine because of excessive operating temperatures
31. CH1 0 volts 2 volts This is a typical SCR gate pulse voltage waveform The machine was in an open cir cuit condition no load and operating prop erly Note that each vertical division repre sents 2 volts and each horizontal division represents 5 milliseconds in time Note Scope probes connected at Plug J3 on the control board The probe to lead G2 and the probe to lead 204 5ms SCOPE SETTINGS Volts Div Horizontal Sweep Coupling Trigger IDEALARC SP 250 LINCOLN TROUBLESHOOTING 4 REPAIR dnd CONTROL PC BOARD REMOVAL AND REPLACEMENT CAUTION SP 250 CONTROL G2252 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 Return to Section TOC Return to Master TOC REMOVAL AND REPLACEMENT PROCEDURE MATERIALS NEEDED 5 16 Nut Driver Phillips Head Screwdriver Static Electricity Grounding Strap
32. Return to Section TOC Return to Master TOC IDEALARC SP 250 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC G 6 ELECTRICAL DIAGRAMS G2252 CONTROL PC BOARD Item Identification 1 20 AWG UNINSULATED JUMPER iso CAPACITOR ALEL 50 25V 75 10 X10 22225552 IC CMOS INVERTER SCHMITT HEX 4584 ap VOLTAGE REGULATOR R48 TRIMMER MT 1 2W 10K 10 LINEAR C30 C81 CAPACITOR CEMO 22P 100V 5 C10 C11 C12 CAPACITOR CEMO 100P 100V 5 C13 C14 C15 C16 C17 C18 C19 C36 ce CAPACITOR CEMO 2700P 50V 5 C2 C3 C4 C5 C33 CAPACITOR CEMO 022 50V 20 C40 C41 C52 C53 C57 C60 C62 C63 C100 C101 C102 C103 C104 C105 C106 C107 C117 CONNECTOR PCB WW MALE DIL 1X9 cadet ae ED HEAT SINK ASBLY DD dels DIODE amp HEAT SINK ASBLY J7 8 CONNECTOR MOLEX MINI PCB 4 PIN CONNECTOR MOLEX MINI PCB 6 PIN CONNECTOR MOLEX MINI PCB 8 PIN R61 THERMISTOR PTC 02 0 47 OHMS 0 90A re POS VOLTAGE REG amp HEAT SINK ASBLY Q24 os ere TRANSISTOR amp HEAT SINK ASBLY diss PERS TRANSISTOR amp HEATSINK ASBLY D1 D2 D3 D4 D5 D6 D7 D8 DIODE AXLDS 1A 400V D21 D22 D23 D24 D33 D34 D40 D41 D50 D51 D52 D53 D54 D60 D61 D62 D70 D
33. b induced on the weld winding and auxiliary windings MATERIALS NEEDED 5 16 Nut Driver Volt Ohm Meter lu 2 nile 818 EJE o iac Return to Section TOC Return to Master TOC IDEALARC SP 250 LINCOLN TROUBLESHOOTING amp REPAIR ii MAIN TRANSFORMER TEST TEST PROCEDURE A WARNING The ON OFF POWER SWITCH will be hot during these tests Return to Section TOC Return to Master TOC NOTE Secondary voltages will vary pro portionably with the primary input volt age 1 Disconnect the main input power supply to the machine 2 Remove the Case Top and Side Panels with a 5 16 nut driver 3 Locate Plug J3 and Plug J6 on the G2252 Control PC Board or Plug J3 on the G1992 Code 9402 only Control PC Board See Figures and Return to Section TOC Return to Master TOC NOTE The location of Plugs may vary depending on the machine code SP 250 CONTROL G2252 d lu 2 nile 818 EJE o LA 203 204 202 343 203 143 FIGURE G2252 Control PC Board Main Transformer Test Points Return to Section TOC Return to Master TOC IDEALARC SP 250 LINCOLN inda TROUBLESHOOTING amp REPAIR a MAIN TRANSFORMER TEST SP 250 CONTROL G1992
34. e 7 gt 855 8126 1525 087 E x aN e Ro X22 e 5 T xis E RS p n 9 oc Return to Master TOC Ts SEE 275 T e2 Se R113 eg els mej RIIS E ue x M Rigs 4 zb GB 5 SX 8 B E T Ri48 m 4 C55 HI ES BE N t id B ef LLL L LI e y L
35. for the weld IDEALARC SP 250 LINCOLN ES OPERATION TABLE B 1 Arrow Key Functions PRESS TO SELECT LEFT DISPLAY CENTER RIGHT Welding Gas Return to Section TOC Return to Master TOC Wire Type PROCESS SOLID STEEL GAS WIRE 035 ArCO Wire Diameter AUTO IPM VOLTS 14GA 229 17 8 Arc Voltage Metal Thickness Wire Feed Speed Manual Mode IPM VOLTS CR us Voltage Wire Feed Speed Wire Type Wire Diameter Welding Gas WIRE GAS Automatic Mode Metal Thickness Wire Arc Feed Voltage Speed No Wire Arc Function Feed Voltage Speed No No No Function Function Function E S p n 9 oc Return to Master TOC Spot Welder Timer On POT ON 2 505 Selected On Time No Spot No Function Weld Function On Time Stitch Weld Timer On STITCH ON OFF 1 90s 1 25s STITCH No SET Function DISPLAY Stitch Weld On Time Stitch Weld Off Time Wire Arc Selected On Time Selected Off Time Metal Memory Currently Active IDEALARC SP 250 LINCOLN P Thickness Feed Voltage geas Speed Ce 918 9 gt ARROW KEY OPERATION WHEN USED WITH Wire Type Wire Diameter Welding Gas 0 9 PROCESS WIRE GAS KEY ele Solid Steel 025 0 6mm 512 See Table B 1 Solid Steel 025 0 6mm ArCO2 ele Solid Steel 030 0 8mm Left Arrow Keys Press t
36. from a memory location the run in mode in memory overrides any present run in mode setting The run in mode remains in effect until either the run in mode is changed using the double keystroke or until a memorized procedure containing the opposite run in mode is recalled MAKING A WELD IN AUTO MODE 1 Check that the polarity is correct for the process being used 2 Turn the ON OFF POWER SWITCH to ON 3 Press PROCESS key 4 Press LEFT UP or DOWN ARROW Keys to select wire type being used 5 Press CENTER UP or DOWN ARROW Keys to select wire diameter being used 6 Press RIGHT UP or DOWN ARROW Keys to select welding gas type being used 7 Press AUTO key When the AUTO key is pressed an alarm will beep three times The following mes sage is displayed for 2 5 seconds PROCESS MUST MATCH WIRE amp GAS 8 Press UP or DOWN ARROW Keys to select metal thickness 9 If SPOT or STITCH timing modes NOT required go to Step 12 IDEALARC SP 250 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 5 9 E Eid 5 ac Return to Section TOC Return to Master TOC Q O 4 c 5 a B 11 10 If SPOT timing mode required a Press SPOT key b Press CENTER UP or DOWN ARROW keys to select SPOT ON TIME required c Press SPOT key to return to previous display d Go to Step 12 11 I
37. motor armature current is normal the control board may be faulty Replace If the motor armature current is high over 3 amps and there are NO restrictions in the wire feed ing path then the motor or gear box may be defective Replace CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely con tact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed call 216 383 2531 or 1 800 833 9353 IDEALARC SP 250 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC T o dei I Return to Section TOC Return to Master TOC Q O 4 c dis TROUBLESHOOTING amp REPAIR EA TROUBLESHOOTING GUIDE Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENTS S COURSE OF ACTION No control of wire feed speed Other machine functions are normal There is no wire feed when gun 119 11 ger is pulled Normal open circuit voltage is present WIRE FEEDING PROBLEMS The thumb switch circuit in the 1 gun may be faulty Check or replace If the drive rolls are turning then check for a mechanical restric tion in the wire feed path The gun liner may be clogged Check or replace If the drive roll
38. mounting bracket place it care fuly on the bottom of the machine c Cut any necessary wire wraps bundling the motor leads d Remove the leads from the fan motor 8 Install the replacement motor in the reverse order of removal 9 Install the fan blade When installing the fan blade the blade is flush with the end of the motor shaft Return to Section TOC Return to Master TOC a Spin the fan to be sure it is free to rotate 10 Reassemble the remaining compo nents in reverse order of removal FE au 2 nile 818 EJE 5 o iac Return to Section TOC Return to Master TOC IDEALARC SP 250 LINCOLN TROUBLESHOOTING amp REPAIR RETEST AFTER REPAIR INPUT IDLE AMPS AND WATTS Input Volts Hertz Maximum Idle Amps Maximum Idle Watts Return to Section TOC Return to Master TOC OPEN CIRCUIT VOLTAGE 10 to 40 VDC 35 40 VDC Strike Voltage Return to Section TOC Return to Master TOC WIRE SPEED RANGE 50 600 IPM 1 27 15 2 m minute au 2 nile 818 EJE o iac Return to Section TOC Return to Master TOC IDEALARC SP 250 LINCOLN TABLE OF CONTENTS Section G ELECTRICAL DIAGRAMS Q 5 ELECTRICAL DIAGRAMS SECTION Section G 81992 CONTROL PC BOARD LAYOUT G 1 G2252 CONTROL PC BOARD LAYOUT G 5 E WIRING DIAGRAM
39. on the out put choke energizes the cooling fan motors when required The other choke thermostat opens the trig ger circuit preventing machine weld output and wire feed if excessive operating temperatures are detect ed The third thermostat insures that the fan motors are operating when required Return to Section TOC Return to Master TOC The thermostats are self resetting once the machine cools sufficiently It the thermostat shutdown is caused by excessive output or duty cycle and the fans are operating normally the power switch may be left on and the reset should occur within a 15 minute period If the fans are not turning or the air intake louvers are obstructed then the input power must be removed and the fan problem or air obstruction be corrected Return to Section TOC Return to Master TOC lu 2 nile 818 EJE 5 o Return to Section Return to Master TOC IDEALARC SP 250 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC FE a 2 nile 818 EJE iac Return to Section TOC Return to Master TOC Return to Master TOC EP THEORY OF OPERATION ES SCR OPERATION INPUT OUTPUT 1 a NOTE AS THE GATE PULSE IS APPLIED LATER IN THE CYCLE THE SCR OUTPUT IS DECREASED Figure E 6 SCR Operation A silicon controlled rectifier SCR is a three terminal device used to
40. running 7 6 Operate engines in open well ventilated areas or vent the engine exhaust fumes 2 11 40 outdoors Do not add the fuel near an open flame welding arc or when the engine is run ning Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting Do not spill fuel when filling tank If fuel is spilled wipe it up and do not start engine until fumes have been eliminated 7 4 Keep all equipment safety guards covers and devices in position and in good repair Keep hands hair clothing and tools away AS from V belts gears fans and all other moving parts when starting operating or repairing equipment In some cases it may be necessary to remove safety guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts Do not put your hands near the engine fan Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate 7 h To avoid scalding do not remove the radiator pressure cap when the engine is hot SAFETY ELE
41. strain relief grommet through which the positive output lead passes through the horizontal baffle of the machine Pull down on the positive output lead until it slides out the hole in the baffle Carefully remove the main trans former a Be sure all leads are clear F 48 18 TROUBLESHOOTING amp REPAIR dinis FAN MOTOR AND FAN REMOVAL AND REPLACEMENT A WARNING Service and repair should be performed only by Lincoln Electric factory trained per sonnel Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and pre cautions detailed throughout this manual Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 216 383 2531 or 800 833 9353 WELD Return to Section TOC Return to Master TOC MATERIALS NEEDED 3 4 Open end wrench 1 2 Socket wrench with extension Phillips head screwdriver FE au 2 nile 818 EJE o iac Return to Section TOC Return to Master TOC IDEALARC SP 250 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC
42. the work cable through the hole up to the bolt and nut 3 Fasten work cable using the bolt and nut provided STRAIN RELIEF HOLE FIGURE A 7 Installing The Work Clamp OUTPUT POLARITY CONNECTION A WARNING WARNING TURN THE WELDER POWER SWITCH OFF BEFORE CHANGING OUTPUT CONNECTION The welder is shipped from the factory connected for electrode positive polarity This is the normal polar ity for GMA welding If negative polarity is required interchange the con nection of the two cables located in the wire drive com partment near the front panel The negative lead is the lead closest to the front panel where the leads come out of the floor of the compartment and should be reconnected to the brass conductor tube of the gun connector The positive lead is stamped on its ter minal and should be reconnected to the work lead ter minal oid INSTALLATION GUN LINER amp CONTACT TIP INSTALLATION The Magnum 250 SP gun and cable provided with the SP 250 is factory installed with a liner for a 035 or 045 0 9 or 1 2mm diameter electrode and an 035 0 9mm contact tip 1 Ifa 045 diameter wire size is to be used install the 045 contact tip also provided 2 For other wire sizes use the following procedure for contact tip and gas nozzle installation See Figure A 8 a Choose the correct size contact tip for the electrode being used wire size is stenciled on the side of the co
43. they may be struck or subjected to physical damage safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 6 a Turn off input power using the disconnect switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Feb 95 IDEALARC SP 250 LINCOLN Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FOR ENGINE powered equipment 7 a Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be
44. this manual If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 216 383 2531 or 800 833 9353 WELD TEST DESCRIPTION This test will determine if any key is not functioning properly MATERIALS NEEDED 5 16 Nut Driver Analog volt ohmmeter IDEALARC SP 250 LINCOLN ree TROUBLESHOOTING amp REPAIR rae SP 250 KEYPAD RESISTANCE TEST TEST PROCEDURE 1 Disconnect main input power to the 4 Measure the resistance of each key machine at Plug J2 using an analog volt ohm meter as described in Table F 1 2 Remove the Case Top and Side Panels using the 5 16 nut driver Return to Section TOC Return to Master TOC a The resistance measurements are taken from the pin locations 3 Locate and disconnect Plug J2 con on Plug J2 See Figure for nected to the Control PC Board each pin location See Figures F 8A and F8B b If any of the resistance tests not correct the keypad may be SP 250 CONTI faulty G2252 Return to Section TOC Return to Master TOC FIGURE F 8A Plug J2 Location on G2252 PC Control Board L 1 1 1 1 L 1 1 1 1 SP 250 CONTROL G1992 J8 FIGURE F 9 Plug J2 Test Points
45. used Check for rusty or dirty wire Make sure machine settings and gas are correct for process being used Make sure the weld procedure and electrode polarity is correct for the process being used Make sure shielding gas is cor rect and flow is proper Make sure the weld joint is not contaminated 2 Check for loose connections at the output terminals the choke the capacitor bank and all heavy current carrying leads Make sure that the transformer secondary leads are securely connected to the SCR Rectifier Assembly The output capacitor bank may be faulty Check for loose con nections at the capacitors Also check for leaky capacitors Replace if necessary WARNING The liquid elec trolyte in these capacitors is toxic Avoid contact with any portion of your body The control board may be faulty Replace The output capacitor bank may be faulty Check for loose con nections at the capacitors Also check for leaky capacitors Replace if necessary WARNING The liquid elec trolyte in these capacitors is toxic Avoid contact with any portion of your body Perform the SCR Rectifier Assembly Test The control board may be faulty Replace A CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely con tact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed call 216 383 2531 o
46. 0 SP is to be used it must conform to standard European style connector Magnum Fast Mate speci fications See Figure A 9 NOTE The thumb switch functions available on the Magnum 250 SP gun will only be operable from the front panel keypad The gun trigger switch must be capable of switching 5 milliamps at 15 volts DC resis tive FIGURE A 9 European Style Connector A CAUTION The gun trigger switch connected to the gun trig ger control cable must be a normally open momen tary switch The terminals of the switch must be insulated from the welding circuit Improper opera tion of or damage to the SP 250 might result if this switch is common to an electrical circuit other than the SP 250 trigger circuit IDEALARC SP 250 LINCOLN OPERATION 9 TABLE CONTENTS 5 OPERATION SECTION gt OPERATION SECTION 8 Safety 1 ac General 1 Recommended Processes Equipment 2 Operational Features and Controls B 2 Design Features and Advantages B 3 B 4 Machine 4 Limitations ee 4 9 Controls and 5 B 5 B 9 Power B 5 5 5
47. 0 ft input cord and plug connected to the welder mount the matching receptacle supplied with the machine 1 Mount the receptacle in a suitable location using the screws provided 2 Locate the receptacle within reach of the 10 ft input cord attached to the welder 3 Mount the receptacle with the grounding terminal at the top This allows the power cable to hang down without bending See Figure A 2 a The center terminal in the receptacle is for the grounding connection b Fuse the two hot lines of the receptacle with super lag type fuses as shown in Figure A 2 A green wire in the input cord connects this ter minal to the frame of the welder This ensures proper grounding of the welder frame when the welder plug is inserted into the receptacle 4 Use proper wire sizes See the Specification table for proper wire sizes For cable lengths over 100 feet larger copper wires should be used CONNECT TO A SYSTEM GROUNDING WIRE SEE THE UNITED STATES NATIONAL ELECTRICAL CODE AND OR LOCAL CODES FOR OTHER DETAILS AND MEANS FOR PROPER GROUNDING GREEN WIRE d CONNECT TO HOT WIRES OF A THREE WIRE SINGLE PHASE SYSTEM OR TO ONE PHASE OF A THREE PHASE SYSTEM FIGURE 2 Ground Connections IDEALARC SP 250 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC T o
48. 1 Hoc ae 6 209 MEMORY Bey 1 4 9 9 Hoc 10 205 411 IPM VOLTS TOGGLE gt c TIMERS b 4p 45 912 2068 13 GER Ec q 313 325A lt 14 lt 9 14 327 320 15 lt 208 16 117111711 7 KEYPAD MATRIX Return to Section TOC Return to Master TOC CHOKE AS BLY 3 sis rep sie 326 4 326 555 292 555 325 2 41 325 5 5 327 b 3 q 327 2068 4 2068 324 4 324 ul NOTES cma WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND MOTOR FUTURE APPLICATIONS GEARBOX THIS DIAGRAM SHOWS THE ELECTRODE POLARITY POSITIVE TO CHANGE POLARITY TURN THE UNIT OFF AND REVERSE LEAD CONNECTIONS AT CABLE CONDUCTOR STRAP AND WORK STUD CONNECTOR SHOWN GEARBOX SIDE VIEW DU THERMOSTATS MOUNTED ON CHOKE COIL 325A S2 MOUNTED CLOSEST TO FAN 58 MOUNTED CLOSEST TO 327 f POWER TRANSFORMER FILTER THERMOSTAT THERMOSTAT SUPPLY LINE KEYPAD MATRIX SHOWN FRONT VIEW 1 53 THERMOSTAT 54 MOUNTED ON FAN SENSOR BRACKET RESISTOR R2 MOUNTED ON FAN SENSOR BRACKET CONNECTOR SHOWN PIN SIDE VIEW GND CAVITY NUMBERING SEQUENCE COMPONENT SIDE OF P C BOARD 250 470A 1 16 1 9 sce pK J2 GND RECONNECT PANEL O 42 721
49. 2mm aluminum using Ar shielding gas e 045 1 2mm Outershield electrodes using COo or ArCO shielding gas 035 0 9mm and 045 1 2mm Innershield self shielded electrodes The SP 250 is factory equipped to feed 035 0 9mm and 045 1 2mm electrodes and includes a 200A 6096 duty cycle rated 12 5 ft 3 8m GMA gun and cable assembly equipped for these wire sizes The SP 250 is factory equipped with an adjustable or argon blend flow regulator A supply of shielding gas is required for GMAW processes E OPERATION He OPERATIONAL FEATURES AND CONTROLS Keypad Consists of 20 membrane keys that have large touch areas The keys are spaced far enough apart to provide easy selection even if wearing weld ing gloves An audible feedback beep is provided whenever a key is pressed to ensure proper entry Display Wide temperature range liquid crystal display combines large 0 32 8 1mm high characters in a 2 line by 16 character alphanumeric format It has long life LED backlighting and a non glare cover for easy viewing under bright or dark conditions Multi lan guage display capability permits the SP 250 to com municate in English German French Spanish or Japanese Katakana Auto Mode Simply set the thickness of the material being welded and the SP 250 automatically sets the proper wire feed speed and arc voltage for the process being used This eliminates the need for look up tables procedure slid
50. 3 gt 4 5 6 gt 27 8 9 10 oi 12 13 325A 14 lt 14 gt 327 320 lt 15 208 lt 16 111111111 sss s 555 555 539 2068 4 pon GEARBOX THERMOSTAT 53 250 470A HEATSINK CONTROL BOARD ET 4 f 1 1234 J SP 250 SPOOL GUN MODULE I LI 1 gt GAS SOLENOID GENERAL INFORMATION ELECTRICAL SYMBOLS PER E1537 321 COLOR CODE 3248 76 445398 B BLACK W WHITE 4 3 7 222 R RED 8 gt 3258 U BLUE TO SINGLE PHASE SUPPLY LINE 11 GND TO GROUND PER NATIONAL ELECTRICAL CODE 1 INDICATES CONNECTOR CAVITY NO R F CHOKE AS BLY NOTES WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS THIS DIAGRAM SHOWS THE ELECTRODE POLARITY POSITIVE TO CHANGE POLARITY TURN THE UNIT OFF AND REVERSE LEAD CONNECTIONS AT CABLE CONDUCTOR STRAP AND WORK STUD CONNECTOR SHOWN GEARBOX SIDE VIEW THERMOSTATS MOUNTED ON CHOKE COIL S2 MOUNTED CLOSEST TO FAN S3 MOUNTED CLOSEST TO POWER TRANSFORMER KEYPAD MATRIX SHOWN FRONT VIEW THERMOSTAT 4 MOUNTED ON FAN SENSOR BRACKET RESISTOR R2 MOUNTED ON FAN SENSOR BRACKET CONNECTOR SHOWN PIN SIDE VIEW CAVITY NUMBERING SEQUENCE COMPONENT SIDE OF P C BOARD 16 1
51. 5 ft 3 8 GMAW gun and cable assembly rated 200 amps 60 duty is pro vided with the SP 250 and includes a liner diffuser and contact tips for 035 0 9mm and 045 1 2mm electrodes The gun is equipped with a Fast Mate con nector with additional control lead connections for the thumb activated 2 momentary position slide switch control designed into the gun handle for use with SP 250 remote control features Return to Section TOC Return to Master TOC MACHINE CAPABILITY The IDEALARC SP 250 is rated at the following duty cycles based upon 10 minute time period i e for 6096 duty cycle it is 6 minutes on and 4 minutes off ewe ptm mm CYCLE 145 200 250 26 28 26 LIMITATIONS The SP 250 may not operate satisfactorily if powered with a portable or in plant generating system Return to Section TOC Return to Master TOC lu 2 nile 818 EJE 5 o Return to Section Return to Master TOC IDEALARC SP 250 LINCOLN 29 OPERATION CONTROLS AND SETTINGS All operator controls are located on the Front Panel Keypad Nameplate See Figure B 1 for the location of each control Return to Section TOC Return to Master TOC A SAVE kd So SET UP KEYS PROCESS WIRE GAS PROCESS WIRE GAS KEYS Return to Section TOC Return to Master TOC SPOT STITCH SET DISPLAY m
52. 6 nut driver 3 Disconnect Keypad Plug J2 from the Control Panel 4 Remove the two screws holding the POWER SWITCH and bezel using a 1 4 nut driver 5 Grasp the upper right hand corner of the Keyboard and peel it off the front panel Return to Section TOC Return to Master TOC a The back of the Keypad is an adhesive material that bonds the Keypad to the Front Panel 6 Install a new Keypad a Remove the paper backing from the new Keypad to uncover the adhesive backing b Install the new Keypad by care fully pressing the Keypad to the Front Panel Be sure to smooth out any air bubbles that become trapped under the Keypad FE au 2 nile 818 EJE 5 iac Return to Section TOC Return to Master TOC IDEALARC SP 250 LINCOLN TROUBLESHOOTING amp REPAIR ind WIRE DRIVE ASSEMBLY REMOVAL AND REPLACEMENT A WARNING Service and repair should be performed only by Lincoln Electric factory trained per sonnel Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and pre cautions detailed throughout this manual Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln E
53. 71 D72 D73 D74 D75 D76 D77 D78 D79 D80 D82 D83 D85 D86 D87 D90 D91 D92 D93 D9 D10 D11 D12 D13 D14 DIODE AXLDS 1A 1000V L1 L4 L5 L6 L7 L8 CHOKE 330UH 10 110MA MOLDED L10 L11 L12 L13 L14 rures CHOKE 390UH 5 225MA CONFORMAL H149 cele ciel la RESISTOR WW 5W 3 3K 5 2 MOV 75VRMS 22J 14MM HZ cid isle RESISTOR CC 1 2W 10M 5 R140 R141 RESISTOR WW 7W 0 25 5 SQ C21 034 CAPACITOR TAEL 4 7 35V 10 656 CAPACITOR TAEL 39 10V 10 655 679 eae CAPACITOR TAEL 18 15V 10 91 692 CAPACITOR TAEL 1 0 35V 10 C51 kis ai CAPACITOR ALEL 20 50V 75 10 001 400 10 G 6 Item Identification C61 C64 CAPACITOR PCF 0 27 50V 20 a acs CAPACITOR ALEL 3300 50V 30 10 X14 X17 X18 IC VOLT REF ADJ PRECISION 4311 X22 IC OP AMP SINGLE PRECISION OP 27GZ C20 C35 C108 CAPACITOR CEMO 0 1 50V 10 C109 C110 C111 0112 0113 C114 C115 C116 CONNECTOR MOLEX MINI PCB 12 PIN db rat ate CONNECTOR MOLEX MINI PCB 14 PIN id Sirdar CONNECTOR MOLEX MINI PCB 16 PIN JT sis ee eke CONNECTOR PCB WW VERTICAL 16 PIN 79 TRIMMER ST 1 2W 1K 10 LINEAR GAP ER CAPACITOR PEF 0 22 100V 10 C70 C75 CAPACITOR PPEF 0 68 400V 10 RIGID C71 C72 C80 CAPACITOR CD 0047 005 1400V 20 C90
54. A WARNING Have a qualified technician do the maintenance and troubleshooting work Disconnect input power at main input supply prior to working inside machine Read the Safety Precautions in the front of this manu al before working on this machine ROUTINE AND PERIODIC MAINTENANCE Disconnect input AC power supply lines to the machine before performing periodic maintenance tightening cleaning or replacing parts See Figure D 1 Perform the following daily 1 Check that no combustible materials are in the welding or cutting area or around the machine 2 Remove any debris dust dirt or materials that could block the air flow to the machine for cooling 3 Inspect the electrode cables for any slits punc tures in the cable jacket or any condition that would affect the proper operation of the machine Perform Periodically Clean the inside of the machine with low pressure air stream Clean the following parts Refer td Figure Main transformer and choke Electrode and work cable connections SCR rectifier bridge and heat sink fins Control board Fan Assembly NOTE The fan motor has sealed bearings which require no maintenance pili MAINTENANCE uidi Drive Rolls and Guide Tubes After every coil of wire inspect the wire drive mecha nism Clean it as necessary by blowing with low pres sure compressed air Do not use solvents for cleaning the idle roll because it may wash the lubricant out of the b
55. ARY SUP PORT 1 Set the gas cylinder on the rear platform of the SP 250 2 Hook the chain in place to secure cylinder to rear of welder 3 Remove the cylinder cap 4 Inspect the cylinder valves for damaged threads dirt dust oil or grease a Remove dust and dirt with a clean cloth NOTE DO NOT ATTACH THE REGULATOR IF OIL GREASE OR DAMAGE IS PRESENT Inform your gas supplier of this condition Oil or grease in the pres ence of high pressure oxygen is explosive 5 Stand to one side away from the outlet and open the cylinder valve for an instant to blow away any dust or dirt which may have accumulated in the valve outlet BE SURE TO KEEP YOUR FACE AWAY FROM THE VALVE OUTLET WHEN OPENING THE VALVE 6 Inspect the regulator for damaged threads dirt dust oil or grease a Remove dust and dirt with a clean cloth NOTE DO NOT USE THE REGULATOR IF OIL GREASE OR DAMAGE IS PRESENT Have an authorized repair station clean the regulator or repair any damage 7 Attach the flow regulator to the cylinder valve and tighten the union nut s securely with a wrench a NOTE f connecting the flow regulator to 100 CO2 cylinder insert regulator adapter provided between regulator and cylinder valve If adapter is equipped with a plastic washer be sure it is seated properly to connect to the CO2 cylinder 8 Connect one end of the inlet gas hose to the outlet fitting of the flow regulator 9 Connect th
56. C93 RIO 5 oe Ge hee at eee ee RESISTOR WW 7W 0 25 196 022 eth ZENER DIODE 1W 16V 596 1N4745A DZ li ZENER DIODE 1W 15V 596 1N4744A imu ZENER DIODE 5W 10V 596 1N5347B DZ6 RYE es ZENER DIODE 1W 6 2V 596 1N4735A DZ3 DZ4 DZ5 ZENER DIODE 1W 18V 596 1N4746A TRANSISTOR NMF T220 15A 60V 15NO6E D20 LEPIDE DIODE AXLDS 1A 30V SCHOTTKY 144 152 RESISTOR CC 2W 10 10 Blaise MOV 130VRMS 38u 14MM MOV 50VRMS 15J 14MM E EMT MOV 150VRMS 80J 20MM 74 153 RESISTOR WW 5W 1K 5 SQ R145 R162 R175 RESISTOR WW 5W 50 5 SQ RBZ R58 wens RESISTOR WW 5W 20 5 SQ 50 even CAPACITOR PEMF 047 100V 10 es oS beds EOS CAPACITOR TAEL 39 20V 10 Sar CAPACITOR ALEL 2200 63V 30 10 R14 R17 R20 R30 R31 R32 RESISTOR MF 1 4W 100 1 R41 R42 R43 R44 R45 R54 R55 R56 R65 R94 R103 R108 R121 R129 R148 R192 R193 R6 R7 R8 R9 R60 R62 RESISTOR MF 1 4W 1 00K 1 R63 R64 R72 R163 R176 R1 R2 R3 R4 R5 R13 RESISTOR MF 1 4W 10 0K 1 R16 R19 R24 R25 R78 R80 R93 R96 R124 R134 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 tr
57. CTRIC AND MAG 2 NETIC FIELDS may be dangerous 8 a Electric current flowing through any conductor causes localized Electric and Magnetic Fields EMF Welding current creates EMF fields around welding cables and welding machines EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding Exposure to EMF fields in welding may have other health effects which are now not known All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit 8 d 1 Route the electrode and work cables together Secure them with tape when possible 8 d 2 Never coil the electrode lead around your body 8 d 3 Do not place your body between the electrode and work cables If the electrode cable is on your right side the work cable should also be on your right side 8 d 4 Connect the work cable to the workpiece as close as possible to the area being welded 8 d 5 Do not work next to welding power source IDEALARC SP 250 LINCOLN 8 Return to Master TOC Return to Master TOC gJ 0 o hz c nd Return to Master TOC SAFETY PRECAUTIONS DE SURETE zones pique le laitier Pour votre propre protection lire et observer toutes les instructions 6 Eloigner les materiaux inflammables ou les recouvrir afin de et les pr cautions de s ret
58. Case Back Assembly Input Power Cable Entry Connections IDEALARC SP 250 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC FE a 2 nile 818 EJE iac Return to Section TOC Return to Master TOC Return to Master TOC INSTALLATION Aa FUSE AND WIRE SIZES Protect the input circuit with the super_lag es 0 delay type circuit breakers listed on th ree this manual for the machine being used The tripping action of delay type circuit breakers decreases as the magnitude of the current increases They are also called inverse time or thermal magnetic circuit breakers DO NOT use fuses or circuit breakers with a lower amp rating than recommended This can result in nui sance tripping caused by inrush current even when machine is not being used for welding at high output currents Use input and grounding wire sizes that meet local electrical codes or see the Specifications in this manual INPUT POWER CONNECTIONS AND GROUND CONNECTIONS Have a qualified electrician connect the receptacle or cable to the input power lines and the system ground according to the U S National Electrical Code and any applicable local codes 1 Follow the Input Supply Connection Diagram on the inside of the Reconnect Panel Access Door 2 Use a single phase line or one phase of a three phase line For the 208V 230V 60 HZ model SP 250 shipped with a 1
59. Code 9402 G 9 8 WIRING DIAGRAM Code 9546 amp 10002 10 WIRING DIAGRAM Code 9723 amp 10001 G 11 G1992 CONTROL PC BOARD SCHEMATIC 12 G2252 CONTROL PC BOARD SCHEMATIC G 13 Return to Master TOC Q 4 gt 4 c 5 Return to Master IDEALARC SP 250 LINCOLN 8 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC FE lax AE 2 nile 818 EJE 5 iac Return to Section TOC Return to Master TOC 6 1 ELECTRICAL DIAGRAMS 6 1 G1992 CONTROL PC BOARD
60. ER INTERLOCK KEYS PROCESS TOGGLE WIRE GAS 4b q5 Controls whether 4 step trigger interlock is activated or deactivated See l Using 4 Step Trigger Interlock Function section Note 4 step Trigger is automatically deactivated if either the spot or stitch timer mode is being used 1 96 IDEALARC SP 250 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 5 9 E k gt 42 ac Return to Section TOC Return to Master TOC Q O gt 4 c 5 a B 10 OPERATING STEPS Before operating the machine be sure you have all the materials needed to perform the work Be sure you are familiar with and have taken all possible safety pre cautions before starting the work It is important that you follow these operating steps each time you use the machine RUN IN MODE The IDEALARC SP 250 can operate in either a slow or fast run in mode It is factory set to operate in the slow run in mode In the slow run in mode the SP 250 ini tially feeds wire at the rate of 50 IPM until output cur rent is reached or for 2 seconds whichever condition is reached first When either of these conditions are reached the SP 250 accelerates to the preset wire feed speed When the SP 250 is in the fast run in mode the wire feed speed immediately accelerates to the preset wire feed speed available on later codes only
61. I RI46 2 o SSS 985 e ola gt m EL OS 5 e c g sA TITTTT B z Fo ann In x SUUSS SS IE a N e me s mee BEN 3 ES Bu S ERI c p Q aa g eue aes wet ea OCI2 OCI3 o 9 TE 9 J3 pan gu e o o o o e m o m ES 5 ef e cob eo to co Ko s gt to e ec Nellie Tj lt 1 ES pir 5 A EIE E E 5 5 E g al ac a 8I _ R74 8 2 in o cog d 865 Lt 3 d x 5 8 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
62. IBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENTS S COURSE OF ACTION Major Physical or Electrical 1 is Evident Machine is dead No Open Circuit 1 Voltage output and No Wire Feed when gun trigger is pulled No Display No Open Circuit Voltage output but 1 wire feeds normally when gun trigger is pulled Display lights properly OUTPUT PROBLEMS Contact your local Lincoln Electric Authorized Field Service Facility Make certain that the input power switch is in the ON posi tion Check the input voltage at the machine Input voltage must match the rating plate and the reconnect panel Blown or missing fuses in the input line Check the input voltage at the machine Input voltage must match the rating plate and the reconnect panel High or Low Line message may be displayed The gun may be faulty Check or replace Contact The Lincoln Electric Service Dept 216 383 2531 or 1 800 833 9353 WELD Check input power switch S1 It may be faulty Check for loose or broken wires at the reconnect panel Perform Main Transformer Test Check for loose or broken con nections at the output terminals the choke the capacitor bank and all heavy current carrying leads Make sure that the transformer secondary leads are securely connected to the SCR Rectifier Assembly Perform the SCR Rectifier assembly Test The Control board may be faulty Replace CAUTION If fo
63. IDEALARC SP 250 is a complete semiautomatic constant voltage DC arc welding machine built to meet NEMA specifications This unit combines a constant voltage power source a constant speed wire feeder and a microcomputer based controller to form an intel ligent welding system A front panel touch key entry system with audible feed back along with a two line 32 character ic display provide user friendly control of the system The system provides full range control from the keypad or from the thumb switch built into the SP 250 welding gun which permits on the fly control while welding Multi language display capability allows the SP 250 to communicate with the user in any of the following five languages English German French Spanish or Japanese Katakana OPERATION EH Proper welding setup is simple You only need to select the gauge size of the material to be welded and enter the welding process to used With that data the system e automatically computes the proper wire feed speed and arc voltage relationship for the process selects the right procedure for optimum starting welding and burnback The system allows you to store up to five separate welding setup procedures You can recall them at any time at the touch of a single key All active setup selec tions as well as those stored in the memory locations are automatically saved when power is turned off or disconnected Whatever procedu
64. Ji e ES GND RECONNECT PANEL pi 15 OHMS C1 THRU C4 30 000 MFD 4 50V LINCOLN SHOWN CONNECTED FOR 230 VOLT J3 1 6 000000 7 52 THERMOSTAT p 4 6 7 js 8 14 It may not be accurate for all machines covered by this manual The specific diagram for a particular code is pasted inside the machine one of the enclosure panels 2 28 92B L7977 G 10 IDEALARC SP 250 ELECTRICAL DIAGRAMS WIRING DIAGRAM FOR CODE 9723 amp 10001 SP 250 DUAL VOLTAGE WIRING DIAGRAM G 11 G 11 n CONTROL BOARD x 4 gt 322 2 LINE 16 CHAR 13 3 321 ALPHA NUMERIC E 3 3258 F 8248 LCD DISPLAY OPTIONAL SPOOL OR PULL m mum m m mum m m mum m m mum m m GUN RECEPTACLE TEE EEE TEE TEE Return to Section TOC Return to Master TOC GAS SP 250 z SOLENOID GENERAL INFORMATION tui ELECTRICAL SYMBOLS PER E1537 SI COLOR CODE 012 TTTTTTTTT UH 5 6 9 5308 B BLACK W WHITE gt H 322 R RED i 2258 U BLUE 5 INDICATES CONNECTOR CAVITY NO 29 10 gt 2 3 206 lt 4 PROCESS WIRE GAS 4 207 lt 5 5 GND 6 Saks 202 lt 1 204 2 203 lt 3 lt Hac G1 K 5 lt 204 6 lt G2 47 lt 1
65. KE INDICATES CONNECTOR CAVITY NO SET SET P 4 b G2 DISPLAY DISPLAY n n n Return to Section TOC Return to Master TOC NE KEYPAD MATRIX NOTES work J NA WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE MOTOR CURRENT AND DUTY CYCLE OF IMMEDIATE AND GEARBOX FUTURE APPLICATIONS N J THIS DIAGRAM SHOWS THE ELECTRODE POLARITY rh POSITIVE TO CHANGE POLARITY TURN THE UNIT THUMB u OFF AND REVERSE LEAD CONNECTIONS AT CABLE SWITCH by CONDUCTOR STRAP AND WORK STUD 325 C rini TOROID AS BLY TO SINGLE PHASE C CONNECTOR SHOWN GEARBOX SIDE VIEW R F FILTER SUPPLY LINE THERMOSTAT THERMOSTAT D CONNECTORS MOUNTED ON NON COMPO 54 OF BOARD THERMOSTATS MOUNTED ON CHOKE COIL TRIGGER 52 MOUNTED CLOSEST FAN 53 MOUNTED CLOSEST 325 POWER TRANSFORMER I KEYPAD MATRIX SHOWN FRONT VIEW GND NOCROUNDPER N G THERMOSTAT S4 MOUNTED ON FAN SENSOR BRACKET cane Tm NATIONAL ELECTRICAL N H RESISTOR R2 MOUNTED ON FAN SENSOR BRACKET m N J CONNECTOR SHOWN PIN SIDE VIEW CAVITY NUMBERING SEQUENCE SOR HEATSINK PPM COMPONENT SIDE OF P C BOARD GND RECONNECT PANEL 1 16 E J1 0000000000000000 470A ER E 1 T 3 POWER TRANSFORMER 03 9 0000000 8 14 ERE E bod oo 15 OHMS 100 W 4 6 C1 THR
66. L 5 PROCEDURE 4 Cut the SCR gate leads G1 and G2 ols see wire markers and wiring dia 8 8 1 Disconnect lead 208 2 b Cut any necessary cable ties a Thin lead is always on the board side of the connection 5 Remove the four screws holding the SCR Assembly to the floor of the machine using a 5 16 nut driver 6 Pivot the SCR Assembly counter clockwise to provide access to the right side heat sink See Figure F 16 Return to Section TOC Return to Master TOC DISCONNECT LEADS 208 AND X1 FIGURE F 14 Heat Sink lead discon nection 2 Disconnect lead 204 and heavy lead from the middle heat sink with a 1 2 socket wrench and 1 2 open end wrench See Figure F 15 FIGURE F 16 Heat Sink Lead 3 Remove the diode lead from the Disconnection negative capacitor band buss bar on the right side of the machine using a slot head screwdriver and 3 8 open end wrench 7 Remove lead 209 and Transformer Lead X4 from the right side heat sink using a 1 2 socket wrench and 1 2 open end wrench FE au 2 nile 818 EJE o iac 8 Clear the leads and carefully remove the SCR Rectifier Assembly NOTE When installing the SCR Rectifier Assembly apply a thin coating of Dow Corning 340 Compound to the 9 electrical connections BP c 918 E LEAD HEAVY LEAD 01 9 cle FIGURE F 15 Heat Sink lead discon 5 5 necti
67. LARC SP 250 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC lu 2 nile 818 EJE o iac Return to Section TOC Return to Master TOC F 43 TROUBLESHOOTING amp REPAIR F 43 SCR OUTPUT RECTIFIER REMOVAL A WARNING Service and repair should be performed only by Lincoln Electric factory trained per sonnel Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and pre cautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 216 383 2531 or 800 833 9353 WELD MATERIALS NEEDED 5 16 Nut Driver 1 2 Open End Wrench 1 2 Socket wrench universal tool and extension 3 8 Open End Wrench Slot head screwdriver Wire cutters IDEALARC SP 250 LINCOLN TROUBLESHOOTING amp REPAIR Transformer Lead X1 from the heat sink on the left side of the machine facing the front using a 1 2 socket wrench See Figure F 14 a The easiest access to these leads is from the right side of the machine 8 8 SCR OUTPUT RECTIFIER REMOVA
68. OL 2 5 UINJOY DOL 5 03 UIN Y DOL 5 03 UNY DOL UORISS 0 unge d Return to Master TOC Return to Master TOC Q 4 c 5 Return to Master THEORY OF OPERATION TABLE OF CONTENTS THEORY OF OPERATION SECTION THEORY OF OPERATION SECTION Section E Power Supply Operation 1 E 3 Input Line Voltage and Main Transformer E 1 Output Rectification and Feedback Control E 2 Constant Voltage E 3 Wire Drive Motor and Feedback E 4 Thermal Protection E 5 ee E 6 GUN TRIGGER AND THUMB SWITCH LINE SWITCH FEEDBACK POSITIVE TERMINAL SCR RECTIFIER ODOA OFVUSO NEGATIVE TERMINAL Figure E 1 Block Logic Diagram NOTE Unshaded areas of Block Logic Diagram are the subject of discussion IDEALARC SP 250 LINCOLN THEORY OF OPERATION E POWER SUPPLY OPERATION Return to Section TOC Return to Master TOC LINE SWITCH FEEDBACK POSITIVE TERMINAL SCR RECTIFIER AOoP uummrem NEGATIVE TERMINAL Return to Section TOC Return to Master TOC Figure E 2 Input Line Voltage and Main Transformer INPUT LINE VOLTAGE AND MAIN TRANS FORMER The desired single phase input powe
69. OR CEMO 100P 100V 5 C85 C8 C87 C88 C90 C91 Rute CAPACITOR CEMO 2700P 50V 5 C1 C2 C3 C4 C5 C7 CAPACITOR CEMO 022 50V 20 C9 C10 C27 C28 C31 043 044 048 C49 C50 C56 estote c CONNECTOR PCB WW MALE DIL 1X9 iue Repente RACE Sehr ceed HEATSINK ASBLY DDI n MULTIPLE DIODE amp HEAT SINK ASBLY 497 2 CONNECTOR MOLEX MINI PCB 10 PIN CONNECTOR MOLEX MINI PCB 14 PIN J5 77 8 CONNECTOR MOLEX MINI PCB 4 PIN VG iri Gate aa ene CONNECTOR MOLEX MINI PCB 6 PIN CONNECTOR MOLEX MINI PCB 8 PIN ees THERMISTOR PTC 02 0 47 OHMS 0 90A XV Ses ees Soe POS VOLTAGE REG amp HEAT SINK ASBLY QI ics oer TRANSISTOR amp HEAT SINK ASBLY Ji eaae he CONNECTOR PCB WW VERTICAL 16 PIN eer TRIMMER ST 1 2W 1K 10 LINEAR Oe ee CAPACITOR PEF 0 22 100V 10 C22 C23 CAPACITOR PPEF 0 68 400V 10 RIGID Item Identification C79 C80 C92 CAPACITOR CD 0047 005 1400V 20 C93 C94 D1 D2 D24 D25 D26 D27 DIODE AXLDS 1A 400V D28 D29 D30 D31 D32 D34 D35 D37 D38 D39 D40 D41 D42 D43 D44 D45 D46 D47 D48 D49 D50 D51 D52 D53 D54 D55 D56 D57 D63 D65 D66 D67 D68 D69 D70 D71 D72 D73 D75 D76 D58 D59 D60 D61 D62 D64 DIODE AXLDS 1A 1000V L3 L4 L5 L6 L7 CHOKE 330UH 1096 110MA MOLDED CHOKE 390UH 5 225MA CONFORMAL RAO Vues gree ie ae ated RESISTOR WW 7W 0 25 1 ZENER DIODE 1W 16V 5 1N4745A
70. OR MF 102K 1 4W R49 R55 R67 R69 R139 RESISTOR MF 10K 1 4W 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 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC G 3 ELECTRICAL DIAGRAMS Gs G1992 CONTROL PC BOARD 2 95 Item Identification RESISTOR CO 1 2W 10M 596 R32 R54 R119 RESISTOR MF 22K 1 4W R60 R81 R82 R83 R91 R95 RESISTOR MF 2 2K 1 4W RZ RIIG 2mm RESISTOR MF 330 1 4W R61 R107 R108 RESISTOR MF 100 1 4W RESISTOR MF 270 1 4W R34 R117 R125 R126 R127 RESISTOR MF 3 3K 1 4W R128 R129 R130 R131 R132 R133 R134 R135 R18 R19 R20 R33 R109 RESISTOR MF 4 7K 1 4W R25 R28 R74 RESISTOR MF 5 6K 1 4W R23 R38 R53 R58 R59 R68 RESISTOR MF 6 8K 1 4W R105 R8 R9 R10 R11 R63 R65
71. RIES SECTION ACCESSORIES SECTION Section C Options Accessories 1 Replacement Magnum 250 SP Gun and Cable Assembll8s 1 Spool Gun Adapter Kit Installation Spool Gun Module Board Installation C 1 Spool Gun Connection Box Installation C 3 Spool Gun Connection C 4 Spool Gun Installation to Old K531 C 5 IDEALARC SP 250 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC c T o dei Return to Section TOC Return to Master TOC Q O ks 4 c 5 a OPTIONS ACCESSORIES Replacement Magnum 250 SP Gun and Cable Assemblies The following GMAW gun and cable assemblies are available for use with the SP 250 Each is rated at 200 amps at 60 duty cycle Each is equipped with a Fast Mate connector and additional control lead connec tions for the thumb activated 2 momentary position slide switch control designed into the gun handle to use with the SP 250 remote control features K524 1 Gun and Cable A 12 5 ft 3 8m GMAW gun and cable assembly includes a liner diffuser and con tact tips for 035 0 9mm and 045 1 2mm elec trodes K524 2 Gun and Cable A 12 5 ft 3 8m GMAW gun and cable assembly includes a liner diffuser and con tact ti
72. Return to Master TOC Return to Section TOC Return to Master TOC E Uu Eid k Return to Section Return to Master TOC Q O H f 5 ree TROUBLESHOOTING amp REPAIR WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST FIGURE F 10B Plug J6 Location on G1992 PC Control Board Code 9402 only NOTE Plugs J5 and J6 are on the inboard non component side of the Control Board 4 Test for 2 25 VDC between lead b Ifthe wires are okay and voltage 539 positive and lead 541 neg to the drive motor armature is ative to determine if the correct zero the Control Board may be armature voltage is being supplied faulty Replace F 10A F 10B c If the correct DC armature volt Insert probes in to the Molex pin age is present at the wire drive cavities motor the motor or motor brush es may be faulty Test and or 5 Pull the gun trigger replace 6 Read meter Normal DC volts is d If the motor is running at high from 2 25 VDC VDC varies speed and the armature voltage depending on wire feed speed is high and uncontrollable pro ceed with the tachometer test a If voltage to the wire drive motor armature is zero check the wires between Plug J5 J6 on Code 9402 and the wire drive motor IDEALARC SP 250 LINCOLN F 30 Return to Section TOC Return to Master TOC Return to Sec
73. SISTOR MF 1 4W 3 32K 1 R38 R39 R40 R50 R51 R52 R53 R92 R112 R100 R101 R164 R169 RESISTOR MF 1 4W 33 2 1 R66 R146 RESISTOR MF 1 4W 3 92K 1 889 iuto eese RESISTOR MF 1 4W 475 1 R71 R81 R90 R91 RESISTOR MF 1 4W 4 75K 1 R136 R190 RILO nhi doe RESISTOR MF 1 4W 47 5K 1 81258127 RESISTOR MF 1 4W 511 1 8126 8131 RESISTOR MF 1 4W 51 1K 1 R167 R168 R173 R174 RESISTOR MF 1 4W 562 1 R10 R68 R104 R106 RESISTOR MF 1 4W 5 62K 1 R77 R109 R113 R122 RESISTOR MF 1 4W 6 81K 1 R133 R149 R107ZR117 RESISTOR MF 1 4W 750 196 IC CMOS MCU NO ROM DIP 68HC11A1P X9 IC CMOS UNDERVOLT SENSING RESET MCU Al ak IC CMOS SWITCH ANALOG QUAD 4066 Xl IC OP AMP QUAD GEN PURPOSE 224N esses IC CMOS GATE NAND 2 INPUT QUAD HC00 XB IC CMOS LATCH 3 STATE OCTAL HC373A X2 X20 1C CMOS INVERTER SCHMITT HEX HC14A eaten IC CMOS REGISTER SHFT SI PO 8 BIT i oe ees OPTOCOUPLER PHOTO Q 70V CNY17 3 11 13 19 IC COMPARATOR QUAD 2901N X8 cis IC CMOS REGISTER SHFT S PI SO 8 BIT X2 REG IC CMOS TRNSCVR BUS 3 STATE OCTAL Q21 Q31 TRANSISTOR N T226 0 5A 300V MPS A42 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 fr
74. TION FIGURE A 5 Reconnect Diagram For Codes 9402 9723 and 10001 208 230 1 60 Machines ALL MACHINES ARE SHIPPED FROM THE FACTORY CONNECTED FOR THE HIGHEST NAME PLATED SINGLE PHASE INPUT VOLTAGE TO CHANGE CONNECTIONS FOR A DIFFERENT INPUT VOLTAGE RECONNECT BOTH COPPER JUMPERS PER DIAGRAM BELOW ALWAYS CONNECT JUMPERS BETWEEN OUTER STEEL NUT AND INNER BRASS NUT ON TERMINAL STUDS CONNECT THE INPUT POWER TO THE INPUT TERMINAL BLOCK L1 AND L2 AT THE UPPER COR NER OF THE PANEL FOR INPUT LEADS 10AWG AND SMALLER USE FERRULES PROVIDED TORQUE TO 16 IN LBS CONNECT A GROUNDING LEAD TO THE GROUND STUD ON THE MACHINE NEAR THE TER MINAL BLOCK JUMPER CONNECTION DIAGRAMS JUMPERS GROUND PER NATIONAL ELECTRICAL CODE SINGLE PHASE INPUT POWER SUPPLY LINES FIGURE A 6 Reconnect Diagram For Codes 9546 amp 10002 230 460 575 1 60 Machine IDEALARC SP 250 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC c 9 o dei I Return to Section TOC Return to Master TOC Q O 4 c 5 a CONNECT OUTPUT COMPONENTS INSTALL THE WORK CLAMP Attach the work clamp to the cable which extends from the front of the machine using the following procedure 1 Insert the lug on the end of the work cable through the strain relief hole in the work clamp handle See Figure A 7 2 Slide
75. TTITI RS C26 Ds C24 27 poo g i p z 25 28 o5 f 72 Di R140 R12 R109 R13 R76 Rid X8 R77 R15 R79 R20 eae J7 C29 73 688 222 pii 51 8 21 076 52 mese 42 R45 O C1 ON X13 R43 Xii a 014 yO R37 C55 gt C9 R86 xia C13 D y J L m5 H 4 AAF alg 4 Ra R99 N 5 12 R388 R32 4 R112 ms b 012 4 b C15 LI dt3 e ox lela se ji DA EE RU 69 o o La OEE ood 0012 is R93 R88 m E 111 d d a n 105 dsl elk 3 Bo 51 2 8 48 x _ Jla ri 2E 017 R84 oca 8124 R96 85 2 890 2 8 H 72 2014 NOTE Lincoln Electric assumes 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 Improp
76. U C4 30 000 MFD 4 SIDE BOARD 50V 1 3 4 6 e 8 3 ple pic a 10 19 90N L7976 Return to Section TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels IDEALARC SP 250 IDEALARC SP 250 Return to Section TOC Return to Section TOC Return to Master TOC 5 3 ple pic a Return to Section TOC Return to Master TOC Return to Master TOC G 10 NOTE This diagram is for reference only IDEALARC SP 250 gt 541 gt 5398 322 2 LINE 16 CHAR 13 D 3 321 ALPHA NUMERIC E 3 3258 F 29 3248 LCD DISPLAY OPTIONAL SPOOL OR PULL m mem m m mum m m mum m m mum mom GUN RECEPTACLE 217 TE PROCESS WIRE GAS MEMORY SPOT stitcH 0175 TIMERS SET SET b 4 OFF DISPLAY NDISPLAY 7 KEYPAD MATRIX us 74 325 9 2 g 325 327 lt 327 324 4 61 324 L R F FILTER SHUNT LINE SWITCH 51 111111111 1 ELECTRICAL DIAGRAMS WIRING DIAGRAM FOR CODE 9546 amp 10002 SP 250 230 460 575V WIRING DIAGRAM gt 2
77. ace IDEALARC SP 250 LINCOLN RETURN TO MAIN INDEX TABLE OF CONTENTS Page i v Irist llallo iaa usos ke RE RAE GR dO E ERROR A eR as e Section A Technical Specifications A 1 Safety PISDATDHS 2243 15 X ELE dS a ER ERO A 2 Select Proper Location A 2 Input Connections A 2 Reconnect Procedure A 5 Connect Output Components A 7 9 Section Safety Precautions 1 General Description B 1 Recommended Processes and Equipment B 2 Operational Features and Controls B 2 Design Features and Advantages B 3 B 4 Machine Capability B 4 Nur PITT B 4 B 9 Controls and Settings B 5 B 9 Operating Steps B 10 B 14 Accessories RM M MP Section C Options AccessoOrl8S C 1 Maintenance Section D Safety Precautions D 1 Routine and Periodic Maintenance
78. ach circuit Check the leads from the tach circuit to the Control Board for loose or bro ken connections If the leads are okay the Control Board may be faulty Replace IDEALARC SP 250 LINCOLN F 31 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 9 E 9 4 ac Return to Section TOC Return to Master TOC Q O H f 5 F 32 TROUBLESHOOTING amp REPAIR F 32 NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM CH1 20 volts This is a typical DC output voltage wave form generated from a properly operating machine Note that each vertical division represents 20 volts and that each horizontal division represents 2 milliseconds in time Note Scope probes connected at machine output terminals probe to electrode probe to work 2ms Volts Div 0 volts SCOPE SETTINGS Horizontal Sweep Coupling Trigger IDEALARC SP 250 LINCOLN Ps TROUBLESHOOTING amp REPAIR s TYPICAL OUTPUT VOLTAGE WAVEFORM MACHINE LOADED Return to Section TOC Return to Master TOC CH1 HEE EHH 5 Return to Section TOC Return to Master TOC 20 volts 5ms MACHINE LOADED TO 250 AMPS AT 26 VDC SCOPE SETTINGS This is a typical DC output voltage wave
79. airs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 216 383 2531 or 800 833 9353 WELD Return to Section TOC Return to Master TOC TEST DESCRIPTION This test will determine if the wire drive motor and voltage feedback circuit are functioning properly MATERIALS NEEDED 5 16 Nut Driver Volt Ohmmeter FE au 2 nile 818 EJE o iac Return to Section TOC Return to Master TOC IDEALARC SP 250 LINCOLN Ines TROUBLESHOOTING amp REPAIR diii WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST TEST PROCEDURE NOTE POLARITY MUST BE OBSERVED FOR THESE TESTS Return to Section TOC Return to Master TOC Test for Correct Wire Drive Motor Armature Voltage 1 Disconnect main input power to the machine 2 Remove the Case Top and Side Panels using a 5 16 nut driver Return to Section TOC 5 3 Locate Plug J5 on the G2252 Control Board or Plug J6 on the 8 G1992 Control Board Code 9402 E only See Figures F 10A and 2 108 SP 250 CONTROL 255 7 lux nile 818 EJE o E i 555 539 541 105 845 9J5 J6 FIGURE F 10A Plug J5 Location on G2252 PC Control Board Return to Section TOC Return to Master TOC IDEALARC SP 250 LINCOLN Return to Section TOC
80. and output terminals and fed back to the control board The control board compares the commands of the keypad or gun thumb switch with the feedback signals The appropriate gate firing pulses are generated by the control board and applied to the SCR rectifier assembly The control board con trols the firing of the SCRs thus controlling the output of the machine See SCR Operation The control board also powers and commands the keypad the LCD Display the piezo alarm the gas solenoid and the wire drive motor NOTE Unshaded areas of Block Logic Diagram are the subject of discussion IDEALARC SP 250 LINCOLN 2 nile 818 EJE iac Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC E 2 nile 818 EJE o iac Return to Section TOC Return to Master TOC Return to Master TOC En THEORY OF OPERATION EM POWER SUPPLY OPERATION CONTINUED LINE SWITCH FEEDBACK POSITIVE TERMINAL SCR RECTIFIER vDo AOoP uumrm NEGATIVE TERMINAL Figure E 4 Constant Voltage Output CONSTANT VOLTAGE OUTPUT The controlled DC output from the SCR rectifier assembly is filtered by the capacitor bank and the out put choke which is in series with the gun and welding load resulting in a constant voltage output at the out put terminals of the machine NOTE Unshad
81. ant bag and perform the following pro cedures P C Board can be dam aged by static electricity Remove your body s stat ic charge before opening the static shielding bag ATTENTION Wear an anti static wrist Static Sensitive strap For safety use a 1 Devices Meg ohm resistive cord Handle only at connected to a grounded Static Safe part of the equipment Workstations frame Reusable Container Do Not Destroy If you don t have a wrist strap touch an unpainted grounded part of the equip ment frame Keep touching the frame to pre vent static build up Be sure not to touch any electrically live parts at the same time Tools which come in contact with the Board must be either conductive anti static or static dissipative IDEALARC SP 250 LINCOLN Remove the P C Board from the static shielding bag and place it directly into the equipment Don t set the P C Board or near paper plastic or cloth which could have a sta tic charge If the P C Board can t be installed immediately put it back in the static shielding bag the P C Board uses protective shorting jumpers don t remove them until installation is complete f you return a P C Board to The Lincoln Electric Company for credit it must be in the static shielding bag This will prevent further damage and allow proper failure analysis 4 Test the machine to determine if the failure symptom has been corrected by t
82. aster TOC 5 9 E Ja k 5 42 ac Return to Section TOC Return to Master TOC Q O 4 c 5 a B 13 LOADING THE WIRE REEL To mount a 22 30 Ib 10 14 kg Readi Reel package using the Readi Reel adapter provided 1 Pull the Readi Reel adapter and spindle up out of the SP 250 spindle mounting clips V brackets 2 Rotate the spindle and adapter so the retaining spring is at the 12 o clock position 3 Position the Readi Reel so that it will rotate in a clockwise direction when wire is dereeled from the top of the coil See Figure B 6 RETAINING REDI REEL ADAPTER 2 O D SPINDLE WIRE SEN DEREELING MS DIRECTION 2 INSIDE CAGE WIRES READI REEL FIGURE B 6 Wire Reel Loading 4 Set one of the Readi Reel inside cage wires on the slot in the retaining spring tab 5 Lower the Readi Reel to depress the retaining spring and align the other inside cage wires with the grooves in the molded adapter 6 Slide the cage all the way onto the adapter until the retaining spring pops up fully A WARNING WARNING Check to be sure the the retaining spring has fully returned to the locking position and has securely locked the readi reel cage in place Retaining spring must rest on the cage not the welding elec trode OPERATION B 13 7 Check that the mating surfaces of the spindle hubs and spindle mounting clips V bracket
83. ber Indicates a fault in system RAM Turn power off and back on again If this message persists then replace the control PC board assembly Reminder that the Spool gun has been connected and the Manual key must be pressed to enter any Spool gun welding procedures Reminder that the Spool gun has been removed and the Process key must be pressed to enter SP 250 weld settings This message may also be dis played if there is an open lead in the spool gun 6 pin plug assembly IDEALARC SP 250 LINCOLN dads TROUBLESHOOTING amp REPAIR ins MAIN TRANSFORMER TEST A WARNING Service and repair should be performed only by Lincoln Electric factory trained per sonnel Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and pre cautions detailed throughout this manual Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 216 383 2531 or 800 833 9353 WELD Return to Section TOC Return to Master TOC TEST DESCRIPTION This test will determine if the correct voltages are being a applied to the primary windings of the Main Transformer
84. citor Bank Remove Replace F 45 F 46 Main Transformer Remove Replace F 47 F 48 Fan Motor Remove Replace F 49 F 51 Retest After 52 Q 42 2 5 4 a Return to Master TOC IDEALARC SP 250 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC c T o dei I Return to Section TOC Return to Master TOC Q O H f 5 TROUBLESHOOTING amp REPAIR F 1 HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty For your safety and to avoid Electrical Shock please observe all safety notes and precautions detailed throughout this manual This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMPTOMS This column describes pos sible symptoms that the machine may exhib it Find the listi
85. coln Electric factory trained per sonnel Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and pre cautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 216 383 2531 or 800 833 9353 WELD Return to Section TOC Return to Master TOC TEST DESCRIPTION The Active SCR Test will determine if the device is able to be gated ON and conduct current from anode to cathode MATERIALS NEEDED An SCR Tester as specified in this procedure IDEALARC SP 250 wiring diagrams See Electrical Diagrams Section of this Manual SCR Heat Sink Assembly Drawings FE au 2 nile 818 EJE o iac Return to Section TOC Return to Master TOC IDEALARC SP 250 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC c T o dei Return to Section TOC Return to Master TOC Q O H f 5 mes TROUBLESHOOTING amp REPAIR ACTIVE SCR RECTIFIER ASSEMBLY TEST TEST PROCEDURE 1
86. control rather large currents to a load An SCR acts very much like a switch When a gate sig nal is applied to the SCR it is turned ON and there is current flow from anode to cathode In the ON state the SCR acts like a closed switch When the SCR is turned OFF there is no current flow from anode to cathode thus the device acts like an open switch As the name suggests the SCR is a rectifier so it passes current only during positive half cycles of the AC supply The positive half cycle is the portion of the sine wave in which the anode of the SCR is more positive than the cathode When an AC supply voltage is applied to the SCR the device spends a certain portion of the AC cycle time in the off state and the remainder of the time in the on state The amount of time spent in the ON state is con trolled by the gate An SCR is fired by a short burst of current into the gate This gate pulse must be more positive than the cath ode voltage Since there is a standard PN junction between gate and cathode the voltage between these terminals must be slightly greater than 0 6V Once the SCR has fired it is not necessary to continue the flow of gate current As long as current continues to flow from anode to cathode the SCR will remain on When the anode to cathode current drops below a minimum value called holding current the SCR will shut off This normally occurs as the AC supply voltage passes through zero into the negative portion of the si
87. ction when using SPOT or STITCH timed welding modes MAKING A SPOT WELD IN AUTO MODE Arc spot plug welds are used when continuous welds are not needed or to hold thin sheet metal together prior to stitch welding or continuous welding Arc spot plug welds are made by using a punch to make a 3 16 inch diameter hole in the top sheet and arc welding through the hole into the back sheet To make an arc spot plug weld 1 Punch 3 16 hole in top sheet 2 Set the procedure for the metal thickness to be welded IDEALARC SP 250 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 9 E 9 4 ac Return to Section TOC Return to Master TOC Q O ks 5 a B 12 4 Press the CENTER UP amp DOWN ARROW keys to set the required Spot On time Suggested initial setting is 1 2 seconds 5 Press the SPOT key Display returns to Auto screen Spot timer status is shown in bottom left corner of screen 6 Install spot weld nozzle if available on gun 7 Press spot weld nozzle against the top sheet so the top and bottom sheets are tight together If a spot weld nozzle is not used smoother welds will result by moving the welding wire in a small circle while making the weld 8 Close the trigger and hold it closed until the arc goes out MAKING A STITCH WELD IN AUTO MODE A stitch weld is u
88. d acceleration and speed accuracy independent of fluctuations in line voltage and wire loading This means reliable arc starting and weld consistency Low Speed Start When the trigger is pulled the wire feeder feeds wire at low speed regardless of the set wire feed speed until welding current is drawn or 2 sec onds has expired This feature enhances starting and makes setting stick out a snap The 2 second limit per mits high speed loading of the gun and cable In later versions of the SP 250 a user selectable feature allows the wire feeder to feed wire directly at the set speed thus bypassing the 2 second slow start Solid State Wire Feed Overload Protection No cir cuit breaker to reset Simply pull the trigger to resume welding once the overload condition has been cleared Unique Drive Roll and Guide Tube Design Long life precisely aligned guide tubes and drive rolls Quickly reloads by simply starting wire into ingoing guide tube Adjustable tension setting minimizes birdnesting eliminates milling through the wire and gives positive feeding The double groove reversible drive roll included with the SP 250 allows use of 030 0 8mm through 045 1 2mm diameter wire Drive Roll kits for other sizes and types of wire are also avail able Fast Mate Gun Connector European style gun con nector provides electrode shielding gas and gun con IDEALARC SP 250 LINCOLN Ed OPERATION Gun and Cable K524 1 A 12
89. dei I Return to Section TOC Return to Master TOC Q O H gt 5 a INSTALLATION oie For the 230 460 575V 60 HZ model which is not equipped with a plug an input cord or a receptacle the input power supply leads are connected directly to the Reconnect Panel as shown Figure A 3 Refer to the specifications tablg at the beginning of this chapter for proper wiring sizes 1 Connect the input power leads to terminals L1 and L2 on the Reconnect Panel Assembly a For input power supply leads of 10 AWG or smaller connect leads to Reconnect Panel using the ferrules S19117 1 provided b Strip fi 18mm of insulation from the input power supply leads c Place ferrule over wire e Torque the terminal screws to 16 in lbs 1 8nm INPUT LINES INPUT LINE WITH 50 INCH 13mm OF INSULATION REMOVED USE FERRULE WITH 10 AWG AND SMALLER WIRE TORQUE TERMINAL SCREWS TO 16 IN LBS 1 8 Nm FIGURE A 3 Ground Connection For 230 460 575 Volt Models CONNECT SHIELDING GAS Customer must provide cylinder of appropriate type of shielding gas for gas metal arc welding for the process being used Sed Figure Ad for the location of the com ponents used to connect the air supply cylinder WARNING GAS UNDER PRESSURE IS EXPLO SIVE ALWAYS KEEP GAS CYLIN ALWAYS KEEP CHAINED TO UNDER CARRIAGE OR STATION
90. e du corps LES MACHINES SOUDER Un coup d arc peut tre plus s v re qu un coup de soliel TRANSFORMATEUR ET donc REDRESSEUR a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du ray 1 onnement de l arc et des projections quand on soude ou quand on regarde l arc Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur pl
91. e other end of the inlet gas hose to the SP 250 rear fitting 10 Tighten both the union nuts securely with a wrench IDEALARC SP 250 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC T o dei Return to Section TOC Return to Master TOC Q O gt 4 c 5 ac 11 Before opening the cylinder valve turn the regula tor adjusting knob counter clockwise until the pres sure is released from the adjusting spring 12 Open the cylinder valve slowly a fraction of a turn a When the cylinder pressure gage pointer stops moving open the valve fully NEVER STAND DIRECTLY IN FRONT OF OR BEHIND THE FLOW REGULATOR WHEN OPENING THE CYLINDER VALVE ALWAYS STAND TO ONE SIDE 13 Adjust the flow regulator for the flow rate recom mended for the procedure and process being used before making the weld INLET CONNECTOR CYLINDER PLATFORM ASSEMBLY FIGURE A 4 Shielding Gas Supply Connections st INSTALLATION ne RECONNECT PROCEDURE Multiple voltage machines are shipped connected to the highest input voltage listed on the machine s rating plate Before installing the machine check that the Reconnect Panel in the Input Box Assembly is con nected for the proper voltage CAUTION Failure to follow these instructions can cause imm
92. e rules or notebooks to find the proper settings Auto Mode also provides one key con trol of the output by automatically adjusting both the wire feed speed and arc voltage for an increase or decrease in material thickness or wire feed speed This allows the operator to easily increase or decrease his output without having to know how much to change each parameter Thumb Switch on Gun Allows the operator to set or change the output of the machine the wire feed speed or the arc voltage from the gun even during welding This permits on the fly adjustment In toggle opera tion mode the thumb switch allows the operator to toggle between two procedures stored in memory Memory There are five separate memory locations that the operator can use to save or recall a setup pro cedure This eliminates dial marking and makes recall ing a setup as simple as pushing one of the five mem ory keys for instant recall Also when power is removed these five memories as well as any current setup in use is automatically saved This feature does not require batteries When power is restored the pro cedure in use will automatically return the unit to what ever was set up was being used when power was removed Trigger Interlock Above code 9500 only Selectable four step trigger interlock allows operator to release gun trigger after weld current is established and con tinue welding Breaking the arc or re closing and then releasing the gun tr
93. earing All drive rolls are stamped with the wire sizes they will feed If a wire size other than that stamped on the roll is used the drive roll must be changed Drop In Reel Spindle and Clips Before loading a coil of wire into the SP 250 drop in spindle inspect the mating surfaces of the spindle hubs and the spindle mounting clips V brackets and if necessary wipe or blow out any dirt and debris which may have deposited on these surfaces Cable Cleaning Clean cable liner after using approximately 300 pounds 136 kg of electrode Remove the cable from the wire feeder and lay it out straight on the floor Remove the contact tip from the gun Using an air hose and only partial pressure gently blow out the cable liner from the gas diffuser end CAUTION Excessive pressure at the start may cause dirt to form a plug Flex the cable over its entire length and again blow out the cable Repeat this procedure until no further dirt comes out Gun Tubes and Nozzles a Replace worn contact tips as required b Remove spatter from inside of gas nozzle and from tip after each 10 minutes of arc time or as required IDEALARC SP 250 LINCOLN D 2 5 Main Transformer IDEALARC SP 250 LINCOLN jo MAINTENANCE Figure D 1 Component Locations 2 Fan Assembly 3 SCR Rectifier 3 Control Board DOL ISe W uinjeu DOL W DOL 5 W UINJ Y DOL 5 W UINJ Y D
94. ed areas of Block Logic Diagram are the subject of discussion IDEALARC SP 250 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC 2 nile 818 EJE E iac Return to Section TOC Return to Master TOC Return to Master TOC ES THEORY OF OPERATION ES POWER SUPPLY OPERATION CONTINUED LINE SWITCH FEEDBACK POSITIVE TERMINAL SCR RECTIFIER AOoP uummrem NEGATIVE TERMINAL Figure E 5 Wire Drive Motor and Feedback WIRE DRIVE MOTOR AND FEEDBACK The wire drive motor is controlled by the control board A motor speed feedback signal is generated at the motor tach and sent to the control board The control board compares this feedback signal with the com mands set forth by the keypad or the gun thumb switch and sends the appropriate armature voltage to the wire drive motor The drive motor speed is thus controlled which in turn regulates the electrode wire feed speed through the gun NOTE Unshaded areas of Block Logic Diagram are the subject of discussion IDEALARC SP 250 LINCOLN E 5 THEORY OF OPERATION THERMAL PROTECTION A thermostat protects the machine from excessive operating temperatures Excessive operating temper atures may be caused by a lack of cooling air or oper ating the machine beyond the duty cycle and output rating There are three thermostats within the SP 250 machine One of the thermostats located
95. edi ate failure of components within the machine To reconnect a dual or triple voltage machine to a dif ferent voltage change the position of the leads or links on the Reconnect Panel based on the type of machine Follow The Input Supply Connection Diagram located on the inside of the Case Back Reconnect Panel Access Door For codes 9402 9723 and 10001 208 230 1 60 machines Figure A 5 For codes 9546 and machines Figure A 6 10002 230 460 575 1 60 IDEALARC SP 250 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC c T o dei I Return to Section TOC Return to Master TOC Q O H f 4 c 5 S INSTALLATION idi ALL MACHINES ARE SHIPPED FROM THE FACTORY CONNECTED FOR THE HIGHER OF THE TWO INPUT VOLTAGES LISTED ON THE NAMEPLATE TO CHANGE VOLTAGE CONNECTION PROCEED AS FOLLOWS 1 REMOVE THE OUTER STEEL HEX NUT FROM THE TERMINAL WHERE THE TRANSFORMER INPUT LEAD IS CONNECTED 2 SHIFT THE TRANSFORMER INPUT LEAD TO THE TERMINAL THAT THE UNIT IS TO OPERATE ON AND FASTEN SECURELY WITH THE HEX NUT REMOVED IN STEP1 MAKE CERTAIN THAT BRASS NUTS ARE TIGHT OUTER STEEL HEX NUT OUTER STEEL HEX NUT INPUT POWER CABLE INPUT POWER CABLE RECONNECT RECONNECT TRANSFORMER TRANSFORMER INPUT LEAD INPUT LEAD LOWER VOLTAGE CONNECTION HIGHER VOLTAGE CONNEC
96. eft off Press the TOGGLE key to return to toggle mode ARROW KEY OPERATION WHEN USED WITH THE TOGGLE KEY See Table 1 Left arrow keys If metal thickness is displayed Press the UP arrow key to increase metal thickness Press the DOWN v arrow key to decrease metal thickness The Left arrow keys do not perform any function in any other mode 29 OPERATION ET Center arrow keys Press the UP 4 arrow key to increase wire feed speed Press DOWN arrow key to decrease wire feed speed setting If in Auto Mode increasing or decreasing wire feed speed simultane ously causes an increase or decrease in the arc volt age and can change the metal thickness setting Right arrow keys Press the UP 4 arrow key to increases arc voltage setting Press the DOWN v arrow key to decrease the arc voltage setting When in the Auto Mode an up arrow indicator appears below the V in VOLTS if the arc voltage has been set higher than the recommended value A down arrow indicator appears below the V in VOLTS if the arc voltage is below the recommended value No arrow indicates that you are set to the recommended value Press AUTO IPM VOLTS TOGGLE 14GA 229 17 8 4b 45 m o IPM VOLTS TOGGLE STCH 150 20 1 A 5AUTO IPM VOLTS 10GA 1 19 ap 45 310 9 3 Or Push Gun Switch Press TOGGLE 4 gt 45 Or Pull Gun Switch 2 FIGURE B 5 Using the TOGGLE Function 4 STEP TRIGG
97. el is wired properly Lowering the set VOLTS and or IPM can eliminate the message Pressing any key or gun switch when the operator is not welding will stop the message from being displayed Pressing any increment or decrement arrow keys or gun switch while welding will temporarily stop the message from being displayed approximately 1 3 sec allowing the operator to view the increase or decrease in that setting IDEALARC SP 250 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 5 9 E Ja 5 42 ac Return to Section TOC Return to Master TOC Q O 4 c 5 a diis TROUBLESHOOTING amp REPAIR ipn EXPLANATION OF PROMPTING AND ERROR MESSAGES CONT D ON SCREEN ERROR MESSAGE HIGH LINE CHECK RECONNECT PANEL PRESS ANY KEY TO STOP MESSAGE CURRENT OVERLOAD REDUCE OUTPUT PRESS ANY KEY TO STOP MESSAGE SXXXXX X ROM ASSEMBLY C SXXXXX X ROM ASSEMBLY SPOOL GUN HAS BEEN CONNECTED PRESS MANUAL TO ENTER SETTINGS SPOOL GUN HAS BEEN REMOVED PRESS PROCESS TO TO ENTER SETTINGS MESSAGE EXPLANATION Indicates to operator that the line voltage is too high and the output voltage has been reduced to protect the capacitor bank voltage rating limits The operator can continue to weld but the voltage will be less than what is set on the machine This message occurs when the line v
98. emselves to the arc rays or to hot spatter or metal 5 5 5 can be dangerous 3 a Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and below Threshold Limit Values TLV using local exhaust or mechanical ventilation In confined spaces or in some circumstances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating products Shielding gases used for arc welding can displace air and cause injury or death Always use enough ventilation especially in confined areas to insure breathing air is safe Read and understand the manufacturer s instructions for this equipment and the consumables to be used including the material safety data sheet MSDS and follow y
99. er PC board repairs could result in damage to the machine IDEALARC SP 250 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC 6 2 ELECTRICAL DIAGRAMS G 2 G1992 CONTROL PC BOARD Item Identification 45 CAPACITOR PEMF 047 100V 10 21 edie CAPACITOR TAEL 39 20V 10 CAPACITOR ALEL 2200 63V 30 10 C30 C47 C95 CAPACITOR TAEL 4 7 35V 10 615 boue CAPACITOR TAEL 39 10V 10 C14 020 oe rb I CAPACITOR TAEL 18 15V 10 C39 040 CAPACITOR TAEL 1 0 35V 10 CAPACITOR ALEL 6 150V 4 50 1096 655 CAPACITOR ALEL 20 50V 75 10 001 400 10 18 CAPACITOR ALEL 50 25V 75 10 024 626 mes s debe 27 50 G19 9 sees CAPACITOR ALEL 3300 50V 30 10 2 OPTOCOUPLER PHOTO SCR 400V MCS2401 OCM OPTOCOUPLER PHOTO Q 30V 4N35 meu IC CMOS INVERTER SCHMITT HEX 4584 X14 X17 X18 IC VOLTREF ADJ PRECISION 4311 6 test IC VOLTREG FIXED 3 T 1A 5V TRIMMER MT 1 2W 10K 1096 LINEAR 100 RESISTOR NETWORK 100 8 RESISTOR 66 08 svo deem exu CAPACITOR CEMO 22P 100V 5 C11 C32 C33 C34 CAPACITOR CEMO 0 1 50V 1096 C35 C36 C37 C38 C51 C52 C77 C78 C81 C82 C83 C846 CAPACIT
100. er to the machine before start ing 11 2 Remove the six screws that hold the Case Side Panels 3 Locate the four snap mount fasteners mounted to the side panel of the control Board ia 4 Position the spool gun module board over the snap mount fasteners making sure that the lead plug connectors are placed at the top 5 Gently press the board onto the fasteners making 13 sure all of the fasteners snap into place 6 On the wire drive side of the machine remove the hex head screw from beneath the gas connector releasing the metal cover See 14 7 Slide the metal cover out from behind the motor bracket Flip the cover over so that the screw hole is in the top right corner then reinstall as a spacer plate with the hex head screw See Figure C 1 8 Find the panel receptacle lead harness included in the kit See Figure C 2 Insert the panel recepta cle into the hole from the control board side of the panel making sure that the panel receptacle mounting plate is positioned so that the grounding screw is in the lower left corner of the plate NOTE For model codes below 9900 small notches may need to be filed at top and bottom of panel hole to clear the plastic mounting ears of the receptacle ACCESSORIES is A CAUTION CAUTION Collect metal filings with a rag to protect CONTROL BOARD STEP 11 against possible metal contamination of the control STEP 12 board or other internal electrical components Fasten t
101. f STITCH timing mode required a Press STITCH key b Press CENTER UP and DOWN ARROW keys to select STITCH ON time required c Press RIGHT UP or DOWN ARROW keys to select STITCH OFF time required d Press STITCH key to return to previous dis play e Go to Step 12 12 Inch the electrode through the gun and cable 13 Cut the electrode within approximately 3 8 of the end of the contact tip 3 4 for Outershield NOTE When the trigger is pulled the wire feeder feeds wire at low speed regardless of the set wire feed speed until the welding arc starts or 2 seconds has elapsed This feature enhances starting and makes it easier to set the stick out The two second limit per mits high speed loading of the gun_and cable To 8 Run In Mode see changing Run In Mode sec 14 If welding gas is to be used turn on the gas supply and set the required flow rate typically 25 35 CFH 12 16 NOTE When using an Innershield electrode the gas nozzle may be removed from the insulation on the end of the gun This will give improved visibility and elimi nate the possibility of the gas nozzle overheating 15 Connect work clamp to metal to be welded Work clamp must make good electrical contact to the A WARNING work The work must be grounded WARNING WHEN USING AN ARC PROCESS IT IS NECESSARY TO USE CORRECT EYE HEAD AND BODY PROTECTION 16 Position electrode over joint End of electrode may be lig
102. f an error is 22 Make sure that the proper wire and procedures are being used Check gun and work cable for loose or faulty connections 3 Check thermostats and associ ated leads for loose or broken connections See Wiring Diagram The Main Transformer Test The control board may be faulty Replace Check for loose or faulty con nections of the heavy current carrying leads The output capacitor bank may be faulty Check for loose con nections at the capacitors Also check for leaky capacitors Replace if necessary WARN ING The liquid electrolyte in these capacitors is toxic Avoid contact with any portion of your body SCR Rectifier Perform the Main Transformer Perform the Assembly Test The control board may be faulty Replace CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely con tact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed call 216 383 2531 or 1 800 833 9353 IDEALARC SP 250 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC T o dei I Return to Section TOC Return to Master TOC Q O H 4 c 5 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE Observe Sa
103. fety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENTS S COURSE OF ACTION The output voltage and wire feed is 1 present continuously or pulsing when gun trigger is NOT activated Output settings voltage and or wire feed speed are being changed even though gun thumb switch or keypad keys are not being activated No wire feed or open circuit voltage when gun trigger is pulled The dis play lights up but the audio alarm and the display do not function prop erly OUTPUT PROBLEMS Remove the gun the problem is resolved the gun trigger circuit is faulty Repair or replace If the problem is not resolved then contact your Local Lincoln Electric Authorized Field Service Facility Remove the gun If the problem is resolved the gun thumb switch circuit may be faulty Repair or replace If the problem persists after gun removal then the keypad may be faulty Check for burned or dam aged areas on the keypad Check the input voltage at the machine Input voltage must match the rating plate and the reconnect panel High or Low Line message may be displayed Remove the gun If the problem is resolved the gun is faulty Replace Check the machine s internal trigger leads for grounds or shorts See Wiring Diagram The control board may be faulty Replace Check leads 326 and 327 for grounds or shorts See Wiring Diagram The Keypad may be fau
104. for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode Sparks and spatter are thrown from the welding arc Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap over your hair Wear ear plugs when welding out of position or in confined places Always wear safety glasses with side shields when in a welding area Connect the work cable to the work as close to the welding area as practical Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains crane cables or other alternate circuits This can create fire hazards or overheat lifting chains or cables until they fail 4 h Also see item 7c CYLINDER may explode si if damaged 5 a Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Oylinders should be located Away from areas where
105. for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical trou bleshooting assistance before you proceed call 216 383 2531 or 1 800 833 9353 IDEALARC SP 250 LINCOLN P Return to Section TOC Return to Master TOC Return to Section TOC lu 2 nile 818 EJE o Return to Section Return to Master TOC Return to Master TOC TROUBLESHOOTING amp REPAIR F 2 PC BOARD TROUBLESHOOTING PROCEDURES A WARNING ELECTRIC SHOCK can Y e kill Have an electrician install and service this equipment Turn the input power OFF at the fuse box before working on equipment Do not touch electrically hot parts CAUTION Sometimes machine failures appear to be due to PC board failures These problems can sometimes be traced to poor electrical connections To avoid problems when troubleshooting and replacing PC boards please use the following procedure 1 Determine to the best of your technical abil ity that the PC board is the most likely com ponent causing the failure symptom 2 Check for loose connections at the PC board to assure that the PC board is proper ly connected 3 If the problem persists replace the suspect PC board using standard practices to avoid static electrical damage and electrical shock Read the warning inside the static resist
106. for the wire type diameter and gas per instructions on name plate SETTING IDLE ROLL PRESSURE The idle roll pressure wing screw is set at the factory backed out 2fi turns from full pressure This is an approximate setting The optimum idle roll pressure varies with type of wire wire diameter surface condi tion lubrication and hardness As a general rule hard wires may require greater pressure and soft or alu minum wire may require less pressure than the facto ry setting The optimum idle roll setting can be deter mined as follows 1 Press end of gun against a solid object that is elec trically isolated from the welder output and press the gun trigger for several seconds OPERATION 2 B 14 If the wire birdnests jams or breaks at the drive roll the idle roll pressure is too great Back the wing screw out fi turn and run new wire through the gun Repeat above step If the drive roll slips loosen the gun cable Fast Mate connection nut from the front of the SP 250 Pull the gun cable forward about 6 There should be a slight waviness in the exposed wire If there is no waviness the pressure is too low Tighten the wing screw 1 4 turn and lock the gun cable in place Repeat the above procedure IDEALARC SP 250 LINCOLN Return to Master TOC Return to Master TOC Q 4 gt 4 c 5 Return to Master ACCESSORIES TABLE OF CONTENTS ACCESSO
107. he replacement PC board NOTE It is desirable to have a spare known good PC board available for PC board trou bleshooting NOTE Allow the machine to heat up so that all electrical components can reach their oper ating temperature 5 Remove the replacement PC board and substitute it with the original PC board to recreate the original problem a If the original problem does not reappear by substituting the original board then the PC board was not the problem Continue to look for bad connections in the control wiring harness junction blocks and terminal strips b If the original problem is recreated by the substitution of the original board then the PC board was the problem Reinstall the replacement PC board and test the machine 6 Always indicate that this procedure was fol lowed when warranty reports are to be sub mitted NOTE Following this procedure and writing on the warranty report INSTALLED AND SWITCHED PC BOARDS TO VERIFY PROB LEM will help avoid denial of legitimate PC board warranty claims Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC T o dei I Return to Section TOC Return to Master TOC Q O H 4 c dis TROUBLESHOOTING amp REPAIR ES TROUBLESHOOTING GUIDE Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSS
108. he bolt under the positive elec trode lead so the connection box electrode lead is sandwiched between the positive electrode lead terminal and the wire drive contact surface Tighten snugly being careful not to strip the threads of three holes to the front of the machine s base as shown in Fig C 3 Return to Section TOC Return to Master TOC 4 4 62 4 62 117 3MM 117 3MM 6 75 171 5MM Return to Master TOC Return to Section TOC Figure C 3 Spool Gun Connection Box Installation POSITIVE ELECTRODE LEAD Mounting Holes 1 Remove the plug button if present from the cen ter hole in the front of the machine s base and par tially thread the two 10 thread forming screws provided with kit into the two small holes on both sides of the center hole Figure C 4 Spool Gun Connection Box Installation 2 Route a user provided gas supply hose from the flow regulator of the spool gun gas cylinder over the rear axle of the machine and out to the front through the center hole in the front of the base FE au 2 nile 818 EJE iac 3 Connect the gas hose to the 5 8 18 female inert gas fitting on the back of the connection box 4 Slip the connection box mounting keyholes over the screw heads installed in Step 1 above and pivot the box clockwise to engage and level the box then tighten the screws
109. he panel receptacle to the case with the three 6 32 x 3 8 self tapping screws provided Insert screws from wire drive side through the sheet metal and into the receptacle mounting plate holes Plug the 10 pin 8 pin and 6 pin connector plugs from the other end of the receptacle lead harness into the 10 8 and 6 pin connectors J12 J11 and J13 at the top of the spool gun module board Plug in the 8 pin connector at the opposite end of this harness into the unused 8 pin connector on the SP 250 control board J4 Disconnect the 4 pin gas solenoid plug from the receptacle J8 on the upper right corner of the Control Board See Figure C 2 Reconnect this plug into the 4 pin receptacle J14 on the top of the Module Board Plug the 4 pin connector plug included with the panel receptacle harness connected in step 10 above into the Control Board receptacle J8 dis connected in step 11 above Using the cable tie included in the kit tie the two harnesses together approximately 3 50 inches 88 9mm from the end of the lead plugs as shown in Figure C 2 Replace the Case IDEALARC SP 250 LINCOLN ns ACCESSORIES ve SPOOL GUN CONNECTION BOX the machine connected for electrode positive INSTALLATION refer to instruction manual remove the positive electrode lead from its connection on the wire NOTE Model codes below 9900 require the addition drive Then reconnect with the connection box electrode lead on t
110. her person loosens the nut b There is no shunt on machine code 9402 Remove the two screws holding the capacitor bank to the floor of the machine using a 5 16 nut driver Clear the leads and carefully remove the capacitor bank assem bly from the machine F 46 ee TROUBLESHOOTING amp REPAIR dni MAIN TRANSFORMER REMOVAL AND REPLACEMENT A WARNING Service and repair should be performed only by Lincoln Electric factory trained per sonnel Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and pre cautions detailed throughout this manual Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 216 383 2531 or 800 833 9353 WELD Return to Section TOC Return to Master TOC MATERIALS NEEDED 5 16 Nut Driver 1 2 Open end wrench 3 8 Open end wrench 1 2 Socket wrench extender universal adapter Wire cutters FE au 2 nile 818 EJE o iac Return to Section TOC Return to Master TOC IDEALARC SP 250 LINCOLN Return to Section TOC Return to Master TOC Return to Secti
111. htly touching the work 17 Lower welding helmet close gun trigger and begin welding Hold the gun so the contact tip to work OPERATION B 11 distance is about 3 8 inch 3 4 for Outershield 18 To stop welding release the gun trigger and then pull the gun away from the work after the arc goes out 19 When no more welding is to be done close valve on gas cylinder if used Momentarily operate gun trigger to release gas pressure 20 Turn the ON OFF POWER SWITCH to OFF USING THE 4 STEP INTERLOCK FUNCTION IN AUTO MODE When the 4 Step Interlock function is not activated the trigger functions in the normal mode so that welding happens only when the trigger is closed When the 4 Step Interlock function is activated it functions as follows When the arc is struck the gun trigger may be released The welding continues until welding is stopped by either of these two methods 1 The arc is extinguished by manually jerking the gun away from the work 2 The gun trigger is closed and then released at the end of the weld This action returns the trigger function to the normal mode so the weld stops when the trigger is released Releasing the trigger reinstates the trigger interlock function for the next weld This is the preferred Interlock mode because it provides better control at the end of the weld and allows automatic burnback to prevent excessive wire feed speed overrun The 4 step trigger feature does not fun
112. igger stops the welding process IDEALARC SP 250 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC lu 2 nile 818 EJE Return to Section Return to Master TOC Return to Master TOC DESIGN FEATURES AND ADVANTAGES UNIT FEATURES Undercarriage for Hand Mobility Heavy duty 10 254mm wheels and 4 102mm casters are factory installed along with the handle Handle can be used for hanging the welding gun and work cable Gas Cylinder Platform Factory installed on under carriage It permits platform mounting and support of a single gas cylinder No full lifting of gas cylinder required during loading Adjustable Flow Regulator Accommodates CO argon blend gas Includes a cylinder pressure gauge and a dual seal flow gauge Easy Accessability Wire feeder enclosure protects wire and wire drive from dirt dust and damage Allows easy top access for drop in wire reel loading and to load or service the wire drive POWER SOURCE FEATURES 10 Ft 3 0m Input Power Cable Includes plug and mating receptacle for 208 230V unit Convenient rear panel reconnect allows easy access for 208V re con nection Power Switch Front panel toggle switch turns input power on and off Thermostatically Controlled Fans Provides cooling of transformer and other components only when required When used intermittently or at lo
113. inals probe to electrode probe to work Return to Section TOC Return to Master TOC IDEALARC SP 250 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 9 E 9 4 ac Return to Section TOC Return to Master TOC Q O H f 5 TROUBLESHOOTING amp REPAIR ave ABNORMAL OPEN CIRCUIT VOLTAGE OUTPUT CAPACITOR BANK NOT FUNCTIONING CH1 volts 20 volts This is NOT the typical DC output voltage waveform The output capacitors are not functioning Note the lack of filtering in the output waveform The output capacitor bank was disconnected Each vertical divi sion represents 20 volts and each horizontal division represents 5 milliseconds in time Note Scope probes connected at machine output terminals probe to electrode probe to work 5ms SCOPE SETTINGS Volts Div Horizontal Sweep Coupling Trigger IDEALARC SP 250 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 9 E 9 4 ac Return to Section TOC Return to Master TOC Q O H f 5 F 36 TROUBLESHOOTING amp REPAIR F 36 TYPICAL SCR GATE VOLTAGE WAVEFORM
114. is selected a message will be displayed for 2 5 seconds that confirms that the setup was saved to that memory number The six arrow keys perform no function when saving a setup NOTE When a setup is saved to a memory location the previous contents of that memory is lost because it is replaced by the present setup Removing input power does not effect the setup in memory IDEALARC SP 250 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 5 9 E Uu Ei S 5 per ac Return to Section TOC Return to Master TOC Q O 4 c 5 7 MEMORY KEYS Press memory key location number in which you want to save a procedure or from which you want to recall a procedure from memory See SAVE Key EXISTING SCREEN AUTO IPM VOLTS 14GA 229 17 8 PRESS MEMORY 1 5 TO SAVE SETUP 2 5 seconds MEMORY 1 NOW CONTAINS SETUP SAVE SEQUENCE FIGURE B 3 Sample SAVE Sequence 8 SPOT KEY Press to turn ON the Spot Weld Timer and display the spot weld ON time Pressing the SPOT KEY a second time returns the screen to the previous display without turning off the spot timer Anytime the Spot weld timer is on and the display is in the Auto or Manual mode the word SPOT will appear in the bottom left corner of the display See Figure B 2 ARROW KEY OPERATION WHEN USED WITH SPOT KEY See Table B 1 Left a
115. itch SW 1 Battery voltage should be 4 5 volts or higher If lower replace the bat tery IDEALARC SP 250 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC FE a 2 nile 818 EJE 5 iac Return to Section TOC Return to Master TOC Return to Master TOC F 24 TROUBLESHOOTING amp REPAIR ACTIVE SCR RECTIFIER ASSEMBLY TEST 7 Connect the Tester to the SCR 1 as shown in Figure F 7 a Connect Tester lead A to the anode b Connect Tester lead C to the cathode c Connect Tester lead G to the gate R1 4 ohms 10watts R2 3 ohms 10watts To test SCR s construct the circuit outlined above Resistor values are plus or minus ten percent The voltmeter scale should be low approximately 0 5 or 0 10 volts DC FIGURE F7 SCR Tester Circuit and SCR connections 8 Close switch SW 1 NOTE Switch SW 2 should be open 9 Read meter for zero voltage a the voltage reading is higher than zero the SCR is shorted 10 Close or keep closed switch SW 1 11 Close switch SW 2 for 2 seconds and release and read meter If the voltage is 3 6 volts while the switch is closed and after the switch is open the SCR is functioning b If the voltages is 3 6 volts only when the switch is closed or there is no voltage when the switch is closed the SCR is defective NOTE Be sure battery is functioning properly A lo
116. key is pressed the LED screen displays the memory number the current setup was recalled from indi cates automatic AUTO or manual MAN mode displays wire gauge Auto Mode wire feed speed and arc voltage The cursor underlines the mem ory number currently selected If in AUTO mode an up or down arrow shows whether the arc voltage has been adjusted above or below the recommended level Spot or Stitch timer status is displayed in the lower left hand cor ner if either timer is active The gun thumb switch functions as a Toggle key in Toggle mode Pushing the gun thumb switch for ward toward the tip selects the setup in memory 5 Pulling gun thumb switch back selects the setup in memory 4 The gun thumb switch also functions with the trigger closed for on the fly changes dur ing a weld See Figure B 5 To turn the toggle mode off press the AUTO MANU AL or any MEMORY Number key NOTE Any changes made to settings in toggle mode are not automatically saved when power is removed or if toggle mode is turned off To save these changes Press the SAVE key Press the MEMORY number key that is currently dis played on the screen 4 or 5 Press the SAVE key Press other MEMORY Number key that was displayed after the toggle 5 or 4 When power is returned the machine will not be in the toggle mode However the weld setting placed in memory when power was removed will return so you may continue to weld right where you l
117. lectric service department for technical troubleshooting assistance before you proceed Call 216 383 2531 or 800 833 9353 WELD Return to Section TOC Return to Master TOC MATERIALS NEEDED Large slot head screwdriver 5 16 Nut Driver Small slot head screwdriver FE au 2 nile 818 EJE o iac Return to Section TOC Return to Master TOC IDEALARC SP 250 LINCOLN Paz TROUBLESHOOTING amp REPAIR WIRE DRIVE ASSEMBLY REMOVAL AND REPLACEMENT PROCEDURE 1 Disconnect main input power to the machine Return to Section TOC Return to Master TOC 2 Remove the Case Top and Side Panels 3 Remove the large mounting screw with a large slot head screwdriver located in front of the drive roll See Figure F 13 a Note the placement of the insu lators and washers for replace ment MOUNTING SCREW Return to Section TOC Return to Master TOC FE au 2 nile 818 EJE o iac FIGURE F 13 Wire Drive Assembly Removal 4 Using a small slot head screw driver a The six pin plug contains the loosen the set screw holding the out wire feed drive motor wires going guide tube into the drive roll assembly Carefully slide out the 6 Remove carefully the drive motor wire drive assembly and drive roll assembly 5 Disconnect the six pin plug from the vertical baffle connector Return to Section TOC Return to Master TOC IDEA
118. lty Perform the Keypad Test The control board may be faulty Replace Perform the Keypad Test Perform the The control board may be faulty Replace The LCD display may be faulty Replace CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely con tact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed call 216 383 2531 or 1 800 833 9353 IDEALARC SP 250 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC T o dei I Return to Section Return to Master TOC Q O H 4 c 5 a TROUBLESHOOTING amp REPAIR ES TROUBLESHOOTING GUIDE Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENTS S COURSE OF ACTION The audio alarm does NOT sound 1 when a key is pressed but display changes The audio alarm does not sound when a key is pressed and the dis play does NOT change There is no gas flow when gun trig ger is pulled Wire feeds and weld voltage is present The display func tions properly No readable message on the dis play Backlight is lit indicating there is power to the machine 1 FUNCTION PROBLEMS The background noise may be 1 too l
119. more detail in Spool Gun set up and operation TWIST MATE FERRULE CUT AND SKIN BOOT PLUG ah Figure C 5 Spool Gun Connect IDEALARC SP 250 LINCOLN P 4 i ACCESSORIES as 2 Remove the SP 250 gas line from the gas line con nector SPOOL GUN INSTALLATION TO OLD 531 c Press the MANUAL key for spool gun welding 25 mode 55 1 Slide the spool gun cable assembly through the opening in the louvers provided for the work lead Refer to the Instruction Manual for the K487 or K469 gt See Figure C 6 spool gun for information on spool gun set up and BIS operation EJE 2 2 gle 3 Screw the spool gun 6 pin plug into the new con nector just below the gas line connector 4 Attach the spool gun gas hose to the gas connec tor 5 Tighten the gas hose tightly being careful not to strip the brass threads Qio Ojo NOTE If using a K469 Spool Gun with a 4 pin plug 918 use the K518 adapter 9 2 E 6 Thread the removed SP 250 gas line between the ie ps new gas hose and spool gun cable See Figure 515 6 7 Pull the SP 250 gas hose up and through until it wedges between the cable connector and gas con OSTNE ELECTRODE TEND nector a Make sure the SP 250 gas hose connector does not touch the wire drive unit FIGURE C 6 Spool Gun Connection 8 With the SP 250 connected electrode positive
120. nd Wire Sizes A 3 Input Power Connections and Ground Connections A 3 Connect Shielding A 4 Reconnect 2 222 A 5 Connect Output 5 A 7 9 Install the Work Clamp A 7 Output Polarity Connection A 7 Gun Liner amp Contact Tip Installation A 7 Gun Cable A 8 IDEALARC SP 250 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 2 nile 818 EJE E Bi iac Return to Section TOC Return to Master TOC a INSTALLATION TECHNICAL SPECIFICATIONS Idealarc SP 250 INPUT SINGLE PHASE 60 HERTZ ONLY Standard Voltage Input Current at Rated Output 208 230 1 60 53 49 Amps 230 460 575 50 25 20 Amps RATED OUTPUT OUTPUT Current Range Maximum Open Circuit Voltage Wire Speed Range 30A 250A 10V 40V 50 600 IPM 1 27 15 2 m minute RECOMMENDED INPUT WIRE amp FUSE SIZE Input Voltage Fuse Superlag Type 75 C wire in Type 75 C Copper Frequency or Breaker Size Copper conduit AWG Ground Wire in Conduit IEC Sizes Runs to Runs over 100ft 30m 100ft 30m 208 60 8 10mm 6 16mm 230 60 10 6mm 8 10mm 460
121. ne wave If the SCR is turned on early in the positive half cycle the conduction time is longer resulting in greater SCR output If the gate firing occurs later in the cycle the conduction time is less resulting in lower SCR output IDEALARC SP 250 LINCOLN TROUBLESHOOTING amp REPAIR Y TABLE OF CONTENTS TROUBLESHOOTING amp REPAIR SECTION gt TROUBLESHOOTING amp REPAIR SECTION Section F How to use Troubleshooting Guide F 1 PC Board Troubleshooting 5 F 2 Troubleshooting oco t oes F 3 F10 Explanation of Prompting Error Messages F11 F 13 Test Procedures SP 250 Main Transformer Test F 14 F 18 Static SCR Rectifier F 19 F 21 Active SCR Rectifier F 22 F 24 SP 250 Keypad Resistance Test F 25 F 27 5 Wire Drive Motor and Tach Feedback Test F 28 F 31 a Oscilloscope Waveforms F 32 F 36 9 Replacement Procedures Control Board Remove Replace F 37 F 38 Keypad Remove Replace F 39 F 40 Wire Drive Assembly Remove Replace F 41 F 42 8 SCR Output Rectifier Remove Replace F 43 F 44 Capa
122. nformation 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 LINCOLN NOTES M IDEALARC SP 250 LINCOLN amp G 4 DOL ISe W uinjeu DOL 5 W DOL 4 1 DOL JSE W uino DOL 5 DOL uonoes 03 uumey 301 uonoes 03 DOL uonoes 6 5 ELECTRICAL DIAGRAMS G 5 9 2252 CONTROL PC BOARD oic ee SP 250 CONTROL lt cle gt 62252 2 c S lt gt a C61 R77 07 Nzj we 072 b DAE 194 4 RI33 Nm FRS7 076 C6 577 052 8135 D75 274 C8 Rn C74 077 079
123. ng that best describes the symptom that the machine is exhibiting Symptoms are grouped into the following categories output problems function prob lems wire feeding problems and welding problems Step 2 PERFORM EXTERNAL TESTS The second column labeled POSSIBLE AREAS OF MISADJUSTMENT S lists the obvious external possibilities that may con tribute to the machine symptom Perform these tests checks in the order listed In general these tests can be conducted with out removing the case wrap around cover Step 3 RECOMMENDED COURSE OF ACTION The last column labeled Recommended Course of Action lists the most likely com ponents that may have failed in your machine It also specifies the appropriate test procedure to verify that the subject com ponent is either good or bad If there are a number of possible components check the components in the order listed to eliminate one possibility at a time until you locate the cause of your problem All of the referenced test procedures referred to in the Troubleshooting Guide are described in detail at the end of this chapter Refer to the Troubleshooting and Repair Table of Contents to locate each specific Test Procedure All of the specified test points components terminal strips etc can be found on the referenced electrical wiring diagrams and schematics Refer to the Electrical Diagrams Section Table of Contents to locate the appropriate diagram CAUTION If
124. ns depending on which mode is being used When the Gun Trigger Switch is released or opened arc voltage wire feeder and gas solenoid are turned off NOTE When the trigger is pulled the wire feeder feeds wire at low speed regardless of the set wire feed speed until the welding arc starts or 2 seconds has elapsed This feature enhances starting and makes it easier to set the stick out The 2 second limit permits high speed loading of the gun and cable USING THE GUN THUMB SWITCH MAGNUM SP 250 ONLY The Gun Thumb switch is used to control wire feed speed arc voltage or to switch or toggle between memory locations 4 and 5 See IPM VOLTS key and TOGGLE key for control details The Thumb switch is used to increase or decrease IPM or VOLTS USING THE WIRE DRIVE ROLL The drive roll provided with the SP 250 has two grooves one for 030 035 0 8 0 9mm solid steel electrode and the other for 045 1 2mm solid steel electrode The welder is shipped with the drive roll installed in the 030 035 0 8 0 9mm position as indicated by the stenciling on the exposed side of the drive roll If 045 1 2mm electrode is to be used or one of the optional drive rolls is required then the drive roll must be reversed or changed per the instructions provided on the instruction decal inside the SP 250 Drive Roll Access door IDEALARC SP 250 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to M
125. ntact tip and screw it snugly into the gas diffuser b Be sure the nozzle insulator is fully screwed onto the gun tube and does not block the gas holes in the diffuser c Slip the appropriate gas nozzle onto the noz zle insulator Either a standard 50 12 7mm or optional 62 15 9mm 1 0 slip on gas noz zle may be used and should be selected based on the welding application d Adjust the gas nozzle for the GMAW process to be used For the short circuiting transfer process the contact tip end should be flush to extended to 12 3 2mm For the spray transfer process the contact tip should be flush to recessed 12 3 2mm CONTACT TIP FIGURE 8 Connections Contact Tip Electrode IDEALARC SP 250 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC c T o dei I Return to Section TOC Return to Master TOC Q O H f 4 c 5 a INSTALLATION ial GUN amp CABLE INSTALLATION WARNING WARNING TURN THE WELDER POWER SWITCH OFF BEFORE INSTALLING GUN AND CABLE 1 Lay the cable out straight 2 Make sure all pins on the gun cable connector are aligned with the proper mating sockets on the front panel gun connector and then join the connectors and tighten the hand nut on the gun cable connec tor NOTE Ifa gun and cable other than the Magnum 25
126. o Master TOC Return to Section TOC Return to Master TOC lu 2 nile 818 EJE 5 o Return to Section Return to Master TOC IDEALARC SP 250 LINCOLN TROUBLESHOOTING 4 REPAIR inis STATIC SCR RECTIFIER ASSEMBLY TEST A WARNING Service and repair should be performed only by Lincoln Electric factory trained per sonnel Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and pre cautions detailed throughout this manual Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 216 383 2531 or 800 833 9353 WELD Return to Section TOC Return to Master TOC TEST DESCRIPTION The Static SCR Test is used to quickly determine if an SCR is shorted or leaky See the Waveform Section in this manual for normal and abnormal SCR waveforms MATERIALS NEEDED Analog Ohmmeter Multimeter IDEALARC SP 250 wiring diagrams See Electrical Diagrams Section of this Manual 5 16 Nut Driver fi open end or socket wrench lu 2 nile 818 EJE o
127. o set Wire Type Pressing the Solid Steel 030 0 8mm 2 UP and DOWN arrow keys changes the Wire dis Solid Steel 035 0 9mm CO2 played Solid Steel 035 0 9mm ArCO2 Solid Steel 035 0 9mm ArOxy Center Arrow Keys Press to set Wire Diameter Solid Steel 045 1 2mm 2 Press the UP arrow key to increase the wire diam Solid Steel 045 1 2mm ArCO2 eter displayed Press the DOWN arrow key to T decrease the wire diameter displayed Stainless 035 0 9mm ArOxy 5 Stainless 035 0 9mm HeArCo2 Right Arrow Keys Press to select Welding Gas 8 Pressing the UP and DOWN arrow keys changes the ADIs Argon 915 Welding Gas displayed Outershield 045 1 2mm CO2 cla Outershield 045 1 2mm ArCO2 s p The following 16 processes are programmed into the 515 SP 250 Innershield 035 0 9mm None 9 Innershield 045 1 2mm None Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 5 9 E 9 4 ac Return to Section TOC Return to Master TOC Q O H 4 c 5 4 AUTO KEY Press for automatic welding set up of recommended Wire Speed and Arc Voltage based on Metal Thickness selected ARROW KEY OPERATION WHEN USED WITH AUTO KEY See Table 8 1 Left Arrow Keys Press to change the metal thickness displayed Press the UP A arrow key to increase metal thickness P
128. ociety P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is available from the Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 Return to Master TOC BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE PER FORMED ONLY BY QUALIFIED INDIVIDUALS Return to Master TOC Q 7 4 4 c 5 Return to Master TOC K 1 b ELECTRIC SHOCK can kill 1 a The electrode and work or ground circuits are electrically hot when the welder is on Do not touch these hot parts with your bare skin or wet clothing Wear dry hole free gloves to insulate hands Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground In addition to the normal safety precautions if welding must be performed under electrically hazardous conditions in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying if there is a high risk of unavoidable or accidental contact with the workpiece or ground use the following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In semia
129. oltage is greater than 121 of nominal line The operator should check if the reconnect panel is wired properly Pressing any key or gun switch when the operator is not welding will stop the message from being displayed Pressing any incre ment or decrement arrow keys or gun switch while welding will temporarily stop the message from being displayed approximately 1 3 sec allowing the operator to view the increase or decrease in that setting Indicates to operator that too much current is being drawn from the machine and the output has been reduced to prevent the current from exceeding safe levels This will typically occur in Manual mode using 045 1 2mm wire and WFS greater than 275 IPM 0 7m min Lowering the WFS will reduce the output requirement and allow operation within the machine rating Pressing any key or gun switch when the operator is not welding will stop the message from being displayed Pressing any incre ment or decrement arrow keys or gun switch while welding will temporarily stop the message from being displayed approximately 1 3 seconds allow ing the operator to view the increase or decrease in that setting Only displayed at power up Displays the part number of the ROM ASSEMBLY currently on the PC board Indicates a checksum error in the software Turn power off and back on again If this message persists then replace the ROM assembly on the PC board Earlier units did not display the SXXXXX X ROM ASSEMBLY num
130. om 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 LINCOLN NOTES as IDEALARC SP 250 LINCOLN amp G 8 DOL ISe W uinjeu DOL 5 W DOL 4 1 DOL JSE W uino DOL 5 oj DOL uonoes 301 uonoes 03 DOL uonoes ELECTRICAL DIAGRAMS WIRING DIAGRAM FOR CODE 9402 SP 250 DUAL VOLTAGE WIRING DIAGRAM G 9 G 9 ae i CONTROL BOARD 1 J8 322 X 2 LINE X 16 CHAR 413 p 3 321 ALPHA NUMERIC E gt 3258 l F 3248 pA ii SP 250 SPOOL GUN OPTIONAL SPOOL OR PULL GUN RECEPTACLE fex MODULE SOLENOID 5418 321 3 432048 6 5308 208 lt 1 822 209 2 206 3 z PROCESS GND lt 4 MBE 204A K 5 202 6 GENERAL INFORMATION 203 AK 7 lt HP ELECTRICAL SYMBOLS PER E1537 MEMORY 2045 9 COLOR CODE 1 207 x 10 320 lt 116 B BLACK W WHITE 204 lt 126 RED Return to Section TOC Return to Master TOC ONDAN SPOT switch 0175 81 U BLUE RF CHO
131. on o o aic IDEALARC SP 250 LINCOLN ds TROUBLESHOOTING amp REPAIR in CAPACITOR BANK REMOVAL AND REPLACEMENT A WARNING Service and repair should be performed only by Lincoln Electric factory trained per sonnel Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and pre cautions detailed throughout this manual Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 216 383 2531 or 800 833 9353 WELD Return to Section TOC Return to Master TOC A WARNING THE LIQUID ELECTROLYTE IN THE CAPACITORS IS TOXIC DO NOT TOUCH THE CAPACITORS WITH ANY PART OF YOUR BODY MATERIALS NEEDED 5 16 Nut driver 5 16 socket wrench extension and universal tool 1 2 Open end wrench 3 8 open end wrench Slot head screwdriver Wiring diagram lu 2 nile 818 EJE o iac Return to Section TOC Return to Master TOC IDEALARC SP 250 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC E 9 AM o n 9 HM
132. on TOC lu 2 nile 818 EJE 5 o Return to Section Return to Master TOC Return to Master TOC F 48 TROUBLESHOOTING amp REPAIR MAIN TRANSFORMER REMOVAL AND REPLACEMENT PROCEDURE Disconnect main input power to the machine Remove the Case Top and Side Panels Perform the Capacitor Bank Removal Procedure Remove lead X1 from the left side SCR heat sink assembly using a 1 2 socket wrench extender and universal adapter Remove lead X4 from the right side heat sink assembly using a 1 2 socket wrench extender and univer sal adapter Disconnect all leads from the recon nect panel using a 3 8 open end wrench Disconnect all leads from the POWER SWITCH Remove the POWER SWITCH Label and cut leads 202 203 204 a lead 204A at a point just in front of the transformer b These leads must be re spliced during reassembly c An alternative to cutting these leads is to remove them from Molex Plug J3 and pull them free of any wire bundles Remove all cable ties wire mounts and any harness tape that could get in the way during transformer removal using wire cutters and screwdriver Remove the four screws mounting the transformer to the floor of the machine using a 5 16 nut driver 12 13 14 15 IDEALARC SP 250 LINCOLN Disconnect the positive output lead at the wire drive motor Remove the
133. ontrol Board IDEALARC SP 250 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 9 E 9 4 ac Return to Section TOC Q O H f 5 Return to Master F 39 TROUBLESHOOTING amp REPAIR F 39 KEYPAD REMOVAL AND REPLACEMENT A WARNING Service and repair should be performed only by Lincoln Electric factory trained per sonnel Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and pre cautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 216 383 2531 or 800 833 9353 WELD MATERIALS NEEDED 5 16 Nut Driver 1 4 Nut Driver IDEALARC SP 250 LINCOLN EU TROUBLESHOOTING amp REPAIR cot KEYPAD REMOVAL AND REPLACEMENT PROCEDURE NOTE BEFORE REMOVING THE KEYPAD PERFORM THE KEYPAD RESISTANCE TEST TO BE SURE THE KEYPAD IS FAULTY Return to Section TOC Return to Master TOC 1 Disconnect main input power to the machine 2 Remove the Case Top and Side Panels with 5 1
134. ossible de la zone de travail qu il est pratique de le faire Si on place la masse sur la charpente de la construction ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de levage c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants Si on utilise la machine souder comme une source de 11 Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se prot ger contre les chutes dans le cas ou on recoit un choc Ne jamais PR CAUTIONS DE S RET POU R enrouler le c ble lectrode autour de n importe quelle parti
135. oubleshooting 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 LINCOLN Return to Section TOC Return to Master TOC 6 7 ELECTRICAL DIAGRAMS G 7 G2252 CONTROL PC BOARD Item Identification R97 R110 R160 R161 R171 R172 R188 R189 RESISTOR MF 1 4W 1 50K 1 R23 R115 R147 R187 RESISTOR MF 1 4W 15 0K 1 Item Identification Q1 Q2 Q3 Q4 Q5 TRANSISTOR N T226 0 5A 40V 2N4401 010 012 014 022 023 040 041 Q13 Q25 TRANSISTOR P T226 0 5A 40V 2N4403 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC RESISTOR MF 1 4W 16 5K 196 RESISTOR MF 1 4W 475K 1 R11 R15 R18 R166 R177 RESISTOR MF 1 4W 2 21K 1 YT Ges ead nd pee CRYSTAL QUARTZ 4 000MHZ R46 RA7 R102 R111 RESISTOR MF 1 4W 22 1K 196 2 0 OPTOCOUPLER TRIAC DRIVER R118 cue kr ess RESISTOR MF 1 4W 267 1 SCR1 SCR2 4 A 400 VOLT SCR BIA RESISTOR MF 1 4W 2 67K 1 RIOS RESISTOR MF 1 4W 26 7K 1 R165 R170 RESISTOR MF 1 4W 26 7 1 R120 R123 R130 R135 RESISTOR MF 1 4W 28 0K 196 H150 iR RESISTOR MF 1 4W 3 01K 196 849 882 RESISTOR MF 1 4W 332 1 R33 R34 R35 R36 R37 RE
136. oud for user to hear beeper Remove the gun If the problem is resolved the gun is faulty Replace Make certain that a process is selected that requires gas flow Check gas source and hoses for leaks or kinks Check the input voltage at the machine The input voltage must match the rating plate and the reconnect panel Turn the line switch S1 off Wait a minute and turn power on If problem is not resolved contact your local Lincoln Electric Authorized Field Service Facility Check the voltage across pins 147 to 2J7 on the control board When the keys are pressed there should be a brief indication or pulse of a DC volt age If the voltage pulse is pre sent then the Piezo alarm may be defective Replace If the DC voltage pulse is NOT present when the keys are pressed then the control board may be defective Replace Perform Keypad Test The control board may be faulty Replace The LCD Display may be faulty Replace Check the gas solenoid by dis connecting it from the control board Plug J8 and applying a 12VDC external supply to the gas solenoid If the solenoid does NOT activate then it may be faulty Replace The control board may be faulty Replace The display board may be faulty Replace The control board may be faulty Replace A CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely con
137. our employer s safety practices MSDS forms are available from your welding distributor or from the manufacturer Apr 93 IDEALARC SP 250 LINCOLN Return to Master TOC Return to Master TOC Q 2 gt a a Return to Master TOC SAFETY WELDING SPARKS gt cause fire or explosion 4 a Remove fire hazards from the welding area If this is not possible cover them to prevent the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Welding and Cutting ANSI Standard Z49 1 and the operating information for the equipment being used When not welding make certain no part of the electrode circuit is touching the work or ground Accidental contact can cause overheating and create a fire hazard Do not heat cut or weld tanks drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside They can cause an explosion even though they have been cleaned For information purchase Recommended Safe Practices for the Preparation
138. ps for 025 0 6mm and 030 0 8mm elec trodes K524 3 Gun and Cable A 15 ft 4 6m GMAW gun and cable assembly includes a liner diffuser and con tact tips for 035 0 9mm and 045 1 2mm elec trodes K524 4 Gun and Cable A 15 ft 4 6m GMAW gun and cable assembly includes a liner diffuser and con tact tips for 025 0 6mm and 030 0 8mm elec trodes K607 1 Spool Gun adapter Kit The K607 1 Spool Gun Adapter Kit provides up front direct connection with the SP 250 It is used with the K487 Spool Gun with remote speed control or the K469 Spool Gun requiring K518 Connection Adapter It also provides single switch transfer between the machine s feeder gun or the spool gun for same polar ity welding with different wire and gas processes The kit includes a spool gun module board a connection box assembly with connecting plug and lead harness es mounting hardware and installation and operation instructions SPOOL GUN ADAPTER KIT INSTALLATION Option K607 1 The spool gun module mounts inside the control sec tion of the machine and provides control and inter con nection between the machine s control board and the spool gun kit connection box als ACCESSORIES a The connection box mounts to the front of the machine s base and provides for inlet connection of the spool gun gas supply hose It provides up front easy connection of the spool gun gas line control plug and electrode lead using the Twi
139. r 1 800 833 9353 IDEALARC SP 250 LINCOLN dinis TROUBLESHOOTING amp REPAIR FM TROUBLESHOOTING GUIDE Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENTS S COURSE OF ACTION WELDING PROBLEMS The contact tip seizes in the gas dif 1 The tip is being over heated due to excessive high current and or high duty cycle welding Return to Section TOC Return to Master TOC A light application of high tem perature antisieze lubricant such as Lincoln E2607 Graphite Grease may be applied to the contact tip threads Return to Section TOC Return to Master TOC 2 nile 818 EJE iac CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely con tact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed call 216 383 2531 or 1 800 833 9353 Return to Section TOC Return to Master TOC IDEALARC SP 250 LINCOLN TROUBLESHOOTING amp REPAIR gg EXPLANATION OF PROMPTING AND ERROR MESSAGES ae 918 5 SCREEN ERROR MESSAGE MESSAGE EXPLANATION PROCESS MUST Reminder that in Auto mode the process entered with the Process key must 5 5 MATCH WIRE GAS match the process installed in the machine gle ONLY SET UP FOR Unit is only programmed for
140. r any reason you do not understand the test procedures or are unable to perform the tests repairs safely con tact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed call 216 383 2531 or 1 800 833 9353 IDEALARC SP 250 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC T o dei I Return to Section TOC Return to Master TOC Q O H 5 ac dn TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENTS S COURSE OF ACTION No Open Circuit Voltage output and 1 no wire feed when gun trigger is pulled Display is functioning proper ly Wire feeds but welding output is low 1 causing wire to stub Welds are cold Machine cannot obtain full rated output of 250 amps at 26 volts OUTPUT PROBLEMS The thermostats may be open 1 due to machine overheating If machine operates normally after a cooling off period then check for proper fan operation and ventilation Make certain that the machine s duty cycle is not being exceeded Check the gun trigger circuit Leads 324 to 325 should have continuity zero ohms when the gun trigger is pulled If not then the gun may be faulty replace I
141. r is connected to the SP 250 through a line switch located on the front panel E 2 nile 818 EJE E Bi ic A reconnect panel allows the user to configure the machine for the desired input voltage This AC input voltage is applied to the primary of the main trans former and to the thermostatically controlled fan motors The transformer changes the high voltage low current input power to a low voltage high current out put In addition the main transformer also has an iso lated center tapped 30VAC auxiliary winding that sup plies power to the Control Board for SCR gate drive and gas solenoid operation The weld power windings connect to the Control Board as well as to the main SCR Rectifier NOTE Unshaded areas of Block Logic Diagram are the subject of discussion IDEALARC SP 250 LINCOLN Return to Section TOC Return to Master TOC THEORY OPERATION ERE POWER SUPPLY OPERATION CONTINUED Return to Section TOC Return to Master TOC LINE SWITCH FEEDBACK POSITIVE TERMINAL SCR RECTIFIER vDo NEGATIVE TERMINAL Return to Section TOC Return to Master TOC Figure E 3 Output Rectification and Feedback Control OUTPUT RECTIFICATION AND FEED BACK CONTROL The AC output from the main transformer secondary weld winding is rectified and controlled through the SCR rectifier assembly Output voltage and current are sensed at the shunt
142. re was being used when power was removed will be recalled when power is returned The SP 250 does not require batteries to maintain memory data IDEALARC SP 250 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 9 E 9 4 ac Return to Section TOC Return to Master TOC Q O H f 5 ac The system includes the following features e 2 step or 4 step selectable trigger function above code 9500 only both timed spot and stitch welding selections e drop in 2 51mm O D wire reel spindle with a 22 30 Ib 10 13 6 kg Readi Reel adapter integral gas cylinder mounting undercarriage 12 5 ft 3 8m Magnum 250SP GMAW gun and cable dual groove drive roll and a gun liner for 035 0 9mm and 045 1 2mm electrodes e contact tip for each wire size e adjustable CO or argon blend flow regulator with cylinder pressure gauge 101 3 0m plug cable with receptacle 121 3 6m work cable with clamp RECOMMENDED PROCESSES AND EQUIPMENT The SP 250 is recommended for GMA welding processes using 10 to 30 Ib 4 5 to 13 6 kg 2 51mm 1 0 spools or Readi Reel coils of 025 through 045 0 61 2mm solid steel using CO ArCO or ArO shielding gas e 035 0 9mm stainless steel using ArOo or HeArCO shielding gas 3 64 1
143. ress the DOWN arrow key to decrease the metal thickness Increasing or decreas ing metal thickness automatically increases decreases both wire feed speed IPM and arc voltage VOLTS simultaneously See gauge chart on the instruction label on the inside of SP 250 door for avail able sizes Center Arrow Keys Press to change wire feed speed setting Press the UP A arrow key to increase the wire feed speed setting displayed Press the DOWN v arrow key to decrease the wire feed speed setting displayed Increasing or decreasing the wire feed speed simultaneously causes an increase or decrease in the arc voltage and can change the metal thickness setting Right Arrow Keys Press to change arc voltage set ting Press the UP A arrow key to increase the arc voltage setting displayed Press the DOWN y arrow key to decrease arc voltage setting displayed An up arrow indicator appears below the V in VOLTS if the arc voltage has been set higher than the recommend ed value A down arrow indicator appears below the V in VOLTS if the arc voltage is below the recommended value No arrow indicates that you are set to the rec ommended value Pressing the AUTO key again resets the wire feed speed and arc voltage settings to the recommended values for the metal thickness displayed NOTE If the spot or stitch timers are on metal thickness is not displayed and therefore the reset function does not Work 5 MANUAL KEY Press to se
144. rrow keys Do not function Center arrow keys Press UP A arrow key to increase Spot Weld ON time from 0 20 seconds to 2 5 seconds Press DOWN v arrow key to decrease Spot ON time from 2 5 seconds to 0 20 seconds Right arrow keys Do not function 9 STITCH KEY Press to turn Stitch Weld timers ON and display the Stitch Weld ON and OFF times Pressing the STITCH key a second time returns the screen to the previous display without turning off the stitch timers Anytime the Stitch weld timers are on and the display is in the Auto or Manual mode the abbreviation STITCH will appear in the bottom left corner of the display See ARROW KEY OPERATION WHEN USED WITH STITCH KEY Sed Table 8 1 cix OPERATION Left arrow keys Do not function Center arrow keys Press UP A arrow key to increase Stitch time ON from 0 20 seconds to 2 50 seconds Press the DOWN arrow key to decrease Stitch ON time from 2 50 seconds to 0 20 seconds Right arrow keys Press UP A arrow key to increase Stitch OFF time from 0 20 seconds to 2 50 seconds Press DOWN arrow key to decrease Stitch OFF time from 2 50 seconds to 0 20 seconds 10 TIMERS OFF KEY Press to turn OFF both Spot and Stitch timers When the TIMERS OFF key is pressed the indicating letters from the bot tom left corner of the Auto and Manual mode dis play disappears The six arrow keys do not function with this key 11 GUN SWITCH CONTROL IPM VOLTS KEY Pres
145. s are clear of dirt and debris and that the adapter is fully engaged onto the spindle 8 Lower the loaded spindle into the spindle mounting clips V brackets so wire dereels from top of coil toward wire drive NOTE The retaining spring side of the adapter should be facing the center inner panel of the SP 250 9 To remove the Readi Reel from Adapter depress retaining spring tab with thumb while pulling the Readi Reel cage from the molded adapter with both hands Do not remove adapter from spindle To mount 10 to 30 Ib spools 8 and 12 diameter 1 Remove the Readi Reel adapter shipped on the 2 inch diameter spindle 2 Be sure that the mating surfaces of the spindle hubs and spindle mounting clips V brackets are clear of dirt and debris 3 Place the spool on the spindle Make certain the brake driving pin enters one of the holes in the back side of the spool 4 Lower the loaded spindle into the spindle mounting clips V brackets so the wire dereels from the top of the reel toward the wire drive NOTE The SP 250 Spindle was designed to mount 12 300mm and 8 200mm diameter spools meet ing international spool size specifications If the spool being used is too narrow to keep the brake driving pin engaged with the spool pin hole a 2 51mm D shim washer could be used between the spool and the spin dle retaining clip to take up the space A later spindle design uses a longer D shaped pin to ass
146. s are NOT turning when the gun trigger is pulled then contact your local Lincoln Electric Authorized Field Service Facility Wire Drive and Tach Feedback test The control board may be faulty Replace Motor Perform the Wire Drive Motor and Tach Feedback Test The control board may be faulty Replace CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely con tact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed call 216 383 2531 or 1 800 833 9353 IDEALARC SP 250 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC c T o dei I Return to Section TOC Return to Master TOC Q O H f 5 ac F 9 TROUBLESHOOTING amp REPAIR F 9 TROUBLESHOOTING GUIDE Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENTS S COURSE OF ACTION The arc is unstable and or hunting Weld bead is narrow or May 1 have porosity with electrode stub bing into plate WELDING PROBLEMS Check for worn or melted con tact tip Check for loose or faulty con nections on the work and elec trode cables Make sure electrode polarity is correct or welding process being
147. s key is pressed Unit shut down even though trigger was closed There is an excessive cur rent draw on the motor Check for proper size tip liner and drive rolls for any obstructions or bends in the gun cable and any other factors that would impede the wire feeding To resume welding simply pull the trigger Indicates that an error has occurred due to excessive electrical interference All of these error types turn off the arc voltage wire feed speed and sole noid Press the Process key per second message and check all settings before continuing to weld XXXX This table shows all of the actual lettering which appears in place of There is no reason to RTI note which of these occurred unless it occurs fre SWI quently XIRQ PWOF DATA Reminds the operator that the gun switch is being used to toggle between memory 4 and memory 5 and therefore is not able to control IPM or arc VOLTS Reminds the operator to change the electrode polarity to negative when Innershield wire type is selected Indicates to operator that the input line voltage is too low to obtain the out put set on the machine The operator can continue to weld but the voltage will be less than what is set on the machine This message occurs when the line voltage is less than 75 of nominal line or if the voltage level set on the machine is not obtainable at that line voltage and load current The opera tor should check if the reconnect pan
148. s to engage the gun thumb switch to control IPM or VOLTS Pushing the gun thumb switch forward toward the tip increases IPM or VOLTS Pulling gun thumb switch back decreas es IPM or VOLTS The underlining cursor always indicates the selection being controlled by the gun thumb switch See Figure B 4 If the cursor is not present the gun thumb switch does not function This prevents any inadvertent actuations Each time this IPM VOLTS key is pressed the cursor moves in the following sequence IPM to VOLTS to no cursor The sequence continues each time the key is pressed NOTE In Auto Mode changing IPM changes arc volt age This can result in a change in metal thickness setting as well Press IPM VOLTS AUTO IPM VOLTS 14GA 229 17 8 gt lt AUTO IPM VOLTS 14GA 229 178 Press IPM VOLTS IPM ere 229 178 Press VOLTS FIGURE 4 Using the IPM VOLTS key IDEALARC SP 250 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC FE au 2 nile 818 EJE iac Return to Section TOC Return to Master TOC Return to Master TOC 12 TOGGLE KEY When first pressed this key turns ON the TOGGLE MODE and recalls the weld setup in memory 4 Pressing the key again switch es to the weld setup in memory location 5 Each time the key is pressed it alternates between the two memory locations When the TOGGLE
149. sed to weld thin material because warpage and burnthrough are a problem Properly adjusting the ON and OFF times and arc travel speed permits welding thin sheet metal using small welds that result in minimum distortion and no burnthrough To make a stitch weld 1 Set the procedure for the metal thickness to be welded 2 Press STITCH key Stitch screen is displayed 3 Press CENTER ARROW keys to set Stitch ON time Start with a Stitch ON time setting of 0 5 sec onds Increase the Time ON setting to increase penetration and weld size Decrease the Time ON setting to reduce burnthrough and distortion 4 Press the RIGHT ARROW keys to set the Stitch OFF time Start with a Time OFF setting of 0 5 seconds Increase the Time OFF setting to reduce burnthrough Decrease the Time OFF setting to produce a flatter and smoother weld 5 Press STITCH key Auto screen is displayed Stitch timer status is display in lower left portion of Screen 6 Close the gun trigger and hold it closed for the length of seam Hold gun in one place during ON time and move gun just beyond edge of molten metal during OFF time For smoothest welds on thinner metal point gun slightly towards the direc tion of travel OPERATION USING THE GUN TRIGGER SWITCH The Gun Trigger Switch turns on arc voltage wire feeder and gas solenoid except with Innershield when the Gun Trigger Switch is closed When closed the LED screen displays the Auto or Manual scree
150. st Mate plug provided with the kit Installation and Operation Accessory Manual AM 105 is included with the kit SPOOL GUN MODULE BOARD INSTALLATION NOTE The K607 1 Spool Gun Adapter Kit is designed for use with SP 250 SP 250 and Wire matic 250 model codes above code 9900 Model Codes below 9900 may be used with the addition of holes to the case as described in the installation instructions below SP 250 model code 9402 must have 519636 2 read on display just after power switch is turned on A WARNING o WARNING HIGH VOLTAGE CAN KILL Do not operate with covers removed Disconnect input power before servicing Only qualified persons should install use or service this equipment See Figures C 1 and 2 WIRE Figure C 1 Spool Gun Installation IDEALARC SP 250 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC FE E lu 2 nile 818 EJE iac Return to Section TOC Return to Master TOC Return to Master TOC STEP 14 350 gt 5 4 88 9 STEP 10 RECEPTACLE gt LEAD HARNESS SNAP MOUNT CONTROL BOARD FASTENERS LEAD HARNESS 4 TOTAL SP 250 SPOOL STEP 3 Figure C 2 Spool Gun Module Board Installation 1 Remove input pow
151. t wire feed speed and arc voltage for manual procedure setup The manual screen displays wire feed speed arc volt age and a cursor that indicates when the wire feed speed or arc voltage is being controlled by the thumb switch on the SP 250 gun B7 OPERATION B7 ARROW KEY OPERATION WHEN USED WITH MANUAL KEY See Table B 1 Left arrow keys Do not function in Manual mode Center arrow keys Press the UP A arrow key to increase wire feed speed Press the DOWN y arrow key to decrease wire feed speed Right arrow key Press the UP A arrow key to increase arc voltage Press the DOWN y arrow key to decrease arc voltage NOTE If the spot or stitch timers are ON it will be indi cated in the bottom left corner of the display See Figure B 2 4 VOLTS SPOT 229 17 8 4 IPM VOLTS 150 201 SPOT 4 STCH TIME ON DISPLAY FIGURE B 2 Display when Stitch or Spot Weld Timers are ON 6 SAVE KEY Press to save the current set up The process procedure and timer functions if used are saved to one of five memory locations by pressing one of the five memory keys When the Save key is pressed a prompting message instructing the operator to PRESS MEMORY 1 TO SAVE SETUP is displayed See Figure B 3 for sample SAVE sequence This message remains displayed until a memory number key is selected or one of the other keys such as Auto Manual or Process is pressed If a memory num ber key
152. tact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed call 216 383 2531 or 1 800 833 9353 IDEALARC SP 250 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC c T o dei I Return to Section TOC Return to Master TOC Q O H f 4 c TROUBLESHOOTING amp REPAIR E TROUBLESHOOTING GUIDE Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENTS S COURSE OF ACTION FUNCTION PROBLEMS The display backlight does not 1 Check the input voltage at the 1 With the display board discon machine Input voltage must nected test for 12VDC from pins match the machine rating plate 1J1 to 2J1 If the 12VDC is and the reconnect panel present and the display board backlight does NOT function then replace the display board See Wiring Diagram 2 If the 12VDC is not present at pins 1J1 to 2J1 then perform the Main Transformer Test The control board may be faulty Replace The machine stops feeding wire 1 Check for mechanical restric 1 Check the motor armature cur while welding and the MOTOR tions in the wire feeding path rent Normal armature current is OVERLOAD message appears on The gun cable may be clogged 1 5 2 5 amps the display If the
153. tion TOC Return to Master TOC E 9 AM o n 9 HM Return to Section TOC Return to Master TOC Q O H ks 4 c 5 F 31 Test for TROUBLESHOOTING amp REPAIR WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST Supply Voltage to Tachometer 1 Test for 15 VDC between lead 5158 positive and lead 2068 negative Figure F 10 for pin locations a Insert probes into Molex pin cavities Pull gun trigger Read meter for 15 VDC a Ifthe 15 VDC is present check the leads to the tach circuit b the leads are okay and 15 VDC is present the correct volt age is being received from the Control Board Go to Feedback Test Ifthe 15 VDC is not present and the leads are okay the Control Board may be faulty Replace Test for Feedback Voltage to the Control Board 1 Test for 1 5 3 5 VDC between lead 555 positive and lead 2068 negative See Figure F 10 for pin locations a Insert probes into Molex pin cavities Pull gun trigger Read meter for 1 5 3 5 VDC a If the 1 5 3 5 VDC is present the tach circuit is sending the correct feedback signal to the Control Board NOTE IF THE MOTOR IS NOT RUN NING THE FEEDBACK VOLTAGE MAY BE FROM 0 TO 5 VDC b If the 1 5 3 5 VDC is not pre sent or not correct the Control Board is not receiving the prop er feedback voltage from the t
154. ure engagement IDEALARC SP 250 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC FE E lu 2 nile 818 EJE iac Return to Section TOC Return to Master TOC Return to Master TOC B 14 FEEDING ELECTRODE A WARNING When inching the electrode and drive mechanism are always hot to work and ground The electrode remains hot several seconds after the gun trigger is released NOTE Check that the proper drive rolls and gun parts are used for the wire size and wire type being used 1 Turn the Readi Reel or spool until the free end of the electrode is accessible 2 While tightly holding the electrode cut off the bent end and straighten the first six inches Cut off the first inch If the electrode is not properly straight ened it may not feed properly into the outgoing guide tube or welding gun causing a birdnest 3 Push the wire through the ingoing guide tube then press the gun trigger and push the electrode into the drive roll If the electrode fails to thread itself into the outgoing guide tube of the wire drive open the quick release idle roll arm thread the electrode manually and reclose the arm 4 Inch the electrode through the gun NOTE Due to the low speed starting feature of the SP 250 the wire will feed at low speed for 2 seconds while inching then come up to the set speed 5 Check that the welding process is set
155. utomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot Always be sure the work cable makes a good electrical connection with the metal being welded The connection should be as close as possible to the area being welded Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 4 c and 6 3 e Also see item 7b ARC RAYS can burn 2 a Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding Headshield and filter lens should conform to ANSI Z87 standards 2 b Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose th
156. w battery can affect the results of the test Repeat Battery Test Procedure in Step 6 if needed 12 Open switch SW 1 13 Reconnect the Tester leads See Figure F 7 a Connect Tester lead A to the cathode b Connect Tester lead C to the anode c Disconnect Test lead G from the gate 14 Close switch SW 1 15 Read meter for zero voltage a If the voltage is zero the SCR is functioning b If the voltage is higher than zero the SCR is shorted 16 Perform the Active Test Procedure outlined in Steps 5 13 SCR 2 17 Replace all SCR assemblies that do not pass the above tests 18 Replace all Molex Plugs onto the Control Board and connect leads X2 and IDEALARC SP 250 LINCOLN F 24 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 9 E 9 4 ac Return to Section TOC Q O H f 5 Return to Master F 25 TROUBLESHOOTING amp REPAIR F 25 SP 250 KEYPAD RESISTANCE TEST A WARNING Service and repair should be performed only by Lincoln Electric factory trained per sonnel Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and pre cautions detailed throughout
157. w current procedures the fan motors stay off reducing the amount of dust and dirt drawn into the machine Also reduces power consumption Electronic Overload Protection Protects machine from short circuit or high current overloading Power Source Line Voltage Regulation Precise SCR phase control circuit holds the voltage setting constant to maintain weld quality even when the input voltage fluctuates 10 Solid State Contactor Output is turned on and off by SCR s instead of a mechanical contactor providing extra long life in highly repetitive welding applications 2 OPERATION si Automatic Burnback Provides proper burnback of the electrode to prevent it from sticking in the weld pud dle at the end of a weld Output Terminals Easily accessible in wire drive section for quick cable connection and polarity rever sal Work Cable 10 ft 3 0m long with work clamp WIRE FEEDER FEATURES Drop in Wire Loading Wire spindle snaps into Readi Reel Adapter included with SP 250 or most any 2 51mm 1 0 wire spool The wire spindle drops into the top loading SP 250 case design Accommodating standard 12 305mm and 8 203mm diameter coils the unique spindle and sup port design automatically provides appropriate de reel ing drag to prevent wire reel overrun and loop offs without manual brake adjustments Tachometer Controlled Wire Drive Precision con trol of permanent magnet motor provides proper wire fee

Lincoln Electric IDEALARC SP-250 User's Manual

Contents

Download Pdf Manuals

Related Search

Related Contents