Lincoln Electric IDEALARC SP-250 Service Manual
  1. Manuals
  2. Brands
  3. Lincoln Electric Manuals
  4. Welding System
  5. IDEALARC SP-250
  6. Service manual
Lincoln Electric IDEALARC SP-250 Service Manual

Lincoln Electric IDEALARC SP-250 Service Manual

Lincoln electric welding system user manual
Hide thumbs
Table of Contents

Advertisement

Quick Links

For use with machines having Code Numbers:
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.
World's Leader in Welding and Cutting Products
22801 St. Clair Ave. Cleveland, Ohio 44117-1199 U.S.A. Tel. (216) 481-8100
RETURN TO MAIN INDEX
IDEALARC SP-250
9402
9546
9723
10001
10002
SERVICE MANUAL
Sales and Service through Subsidiaries and Distributors Worldwide
SVM 111-A
Premier Manufacturer of Industrial Motors
January, 1996

Advertisement

Table of Contents
loading

Related Manuals for Lincoln Electric IDEALARC SP-250

Summary of Contents for Lincoln Electric IDEALARC SP-250

  • Page 1 IDEALARC SP-250 For use with machines having Code Numbers: 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.

  • Page 2: Safety

    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. BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PER- FORMED ONLY BY QUALIFIED INDIVIDUALS.
  • Page 3 6.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations. 6.c. Ground the equipment in accordance with the U.S. National Electrical Code and the manufacturer’s recommendations. Feb. ‘95 IDEALARC SP-250 compressed cylinders...
  • Page 4 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. Mar. ‘93 Remove complete. IDEALARC SP-250...
  • Page 5 électricien qualifié. 3. Avant de faires des travaux à l’interieur de poste, la debranch- er à l’interrupteur à la boite de fusibles. 4. Garder tous les couvercles et dispositifs de sûreté à leur place. IDEALARC SP-250 Mar. ‘93...

  • Page 6: Table Of Contents

    Parts Manual ..........P-201 RETURN TO MAIN INDEX TABLE OF CONTENTS IDEALARC SP-250 Page...

  • Page 7: Installation

    Fuse and Wire Sizes ...A-3 Input Power Connections and Ground Connections...A-3 Connect Shielding Gas...A-4 Reconnect Procedure...A-5 Connect Output Components...A-7 - A-9 Install the Work Clamp ...A-7 Output Polarity Connection ...A-7 Gun Liner & Contact Tip Installation ...A-7 Gun and Cable Connection...A-8 IDEALARC SP-250...

  • Page 8: Technical Specifications

    TECHNICAL SPECIFICATIONS - Idealarc SP-250 INPUT - SINGLE PHASE/ 60 HERTZ ONLY Standard Voltage 208/230/1/60 230/460/575 Duty Cycle 100% Current Range 30A - 250A RECOMMENDED INPUT WIRE & FUSE SIZE Input Voltage/ Fuse (Superlag) Frequency or Breaker Size 208/60 230/60...

  • Page 9: Safety Precautions

    Always connect the IDEALARC SP-250 grounding terminal (located on the side of the Case Back Assembly) to a good electrical earth ground. • Set the IDEALARC SP-250 Power switch to the OFF position when connecting power cord to input power. ____________________________________...

  • Page 10: Fuse And Wire Sizes

    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. FIGURE A.2. - Ground Connections. IDEALARC SP-250...

  • Page 11: Connect Shielding Gas

    8. Connect one end of the inlet gas hose to the outlet fitting of the flow regulator. 9. Connect the 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 Have an...

  • Page 12: Reconnect Procedure

    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, see Figure A.5. For codes 9546 and 10002 230/460/575/1/60 machines, see Figure A.6. IDEALARC SP-250 CAUTION...
  • Page 13 NER OF THE PANEL. FOR INPUT LEADS 10AWG AND SMALLER USE FERRULES PROVIDED. TORQUE TO 16 IN-LBS. 3. CONNECT A GROUNDING LEAD TO THE GROUND STUD ( MINAL BLOCK. FIGURE A.6 - Reconnect Diagram For Codes 9546 & 10002 230/460/575/1/60 Machine. INSTALLATION ) ON THE MACHINE NEAR THE TER- IDEALARC SP-250...

  • Page 14: Connect Output Components

    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). FIGURE A.8 Contact Connections IDEALARC SP-250 Electrode...
  • Page 15 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 CAUTION...

  • Page 16: Operation

    Set Up Arrow Keys ...B-5 Process Wire/Gas Key ...B-5 Auto Key...B-7 Manual Key ...B-7 Save Key ...B-7 Memory Keys ...B-8 Spot Key...B-8 Stitch Key ...B-8 Timers Off Key...B-8 Gun Switch Control IPM Volts Key...B-8 Toggle Key...B-9 Operating Steps ...B-10 - B-14 IDEALARC SP-250...

  • Page 17: Safety Precautions

    GENERAL DESCRIPTION Product Description The 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.

  • Page 18: Recommended Processes And Equipment

    Breaking the arc or re-closing and then releasing the gun trigger, stops the welding process. IDEALARC SP-250 FEATURES AND Multi lan- Also, when power is...

  • Page 19: Design Features And Advantages

    (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 SP-250 case design. This...

  • Page 20: Machine Capability

    SP- 250 remote control features. MACHINE CAPABILITY The IDEALARC SP-250 is rated at the following duty cycles based upon 10 minute time period (i.e., for 60% duty cycle, it is 6 minutes on and 4 minutes off).

  • Page 21: Controls And Settings

    Therefore, it is very important that the wire type, wire diameter, and welding gas displayed Press keys to match the actual wire type, wire diameter, and welding gas being used for the weld. IDEALARC SP-250 Press key to...
  • Page 22 Solid Steel Solid Steel Solid Steel Solid Steel Solid Steel Stainless Stainless Aluminum (5356) 3/64 (1.2mm) Outershield Outershield Innershield Innershield IDEALARC SP-250 Wire Diameter Welding Gas .025 (0.6mm) .025 (0.6mm) ArCO .030 (0.8mm) .030 (0.8mm) ArCO .035 (0.9mm) 035 (0.9mm) ArCO .035 (0.9mm)

  • Page 23: Auto Key

    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. power does not effect the setup in memory. IDEALARC SP-250 ) arrow key to This message Removing input...

  • Page 24: Memory Keys

    NOTE: In Auto Mode, changing IPM changes arc volt- age. This can result in a change in metal thickness setting as well. FIGURE B.4 - Using the IPM VOLTS key. IDEALARC SP-250 ) arrow key to Press to turn OFF both...

  • Page 25: Toggle Key

    PROCESS Pressing WIRE/GAS Controls whether 4-step trigger interlock is activated or deactivated. (See “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. IDEALARC SP-250 TOGGLE 1/96...

  • Page 26: Operating Steps

    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-...
  • Page 27 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 B-11...
  • Page 28 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 B-12 THUMB SWITCH...
  • Page 29 2" (51mm) I 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 assure engagement. IDEALARC SP-250 B-13...
  • Page 30 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 B-14...

  • Page 31: Accessories

    ACCESSORIES SECTION ... Section C Options/Accessories ...C-1 Replacement Magnum 250-SP Gun and Cable Assemblies...C-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...

  • Page 32: Options/Accessories

    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 C-2. Figure C.1 - Spool Gun Installation. IDEALARC SP-250 WARNING...
  • Page 33 11 above. 13. 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. 14. Replace the Case. IDEALARC SP-250 CAUTION...

  • Page 34: Spool Gun Connection Box Installation

    Tighten snugly, being careful not to strip the threads. Figure Spool Installation. IDEALARC SP-250 Connection...

  • Page 35: Spool Gun Connection

    SPOOL GUN CONNECTION 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.

  • Page 36: Spool Gun Installation To Old K531

    ACCESSORIES c. Press the MANUAL key for spool gun welding mode. Refer to the Instruction Manual for the K487 or K469 spool gun for information on spool gun set up and operation. FIGURE C.6 - Spool Gun Connection. IDEALARC SP-250...

  • Page 37: Maintenance

    MAINTENANCE TABLE OF CONTENTS - MAINTENANCE SECTION - MAINTENANCE SECTION ... Section D Safety Precautions ...D-1 Routine and Periodic Maintenance ...D-1 Component Locations ...D-2 IDEALARC SP-250...

  • Page 38: Safety Precautions

    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 CAUTION...
  • Page 39 MAINTENANCE Control Board Choke Main Transformer Fan Assembly SCR Rectifier Figure D.1 - Component Locations IDEALARC SP-250...

  • Page 40: Theory Of Operation

    SWITCH RECONNECT MOTORS Figure E.1 -Block Logic Diagram NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion SOLENOID WIRE DRIVE MOTOR TACH GUN TRIGGER AND THUMB SWITCH FEEDBACK POSITIVE TERMINAL CHOKE RECTIFIER NEGATIVE TERMINAL SHUNT IDEALARC SP-250...

  • Page 41: Power Supply Operation

    Control Board as well as to the main SCR Rectifier. PIEZO ALARM SOLENOID WIRE DRIVE MOTOR CONTROL BOARD TACH GUN TRIGGER AND THUMB SWITCH FEEDBACK CHOKE RECTIFIER SHUNT NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion IDEALARC SP-250 POSITIVE TERMINAL NEGATIVE TERMINAL...
  • Page 42 PIEZO ALARM SOLENOID WIRE DRIVE MOTOR CONTROL BOARD TACH GUN TRIGGER AND THUMB SWITCH FEEDBACK CHOKE RECTIFIER SHUNT The control NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion IDEALARC SP-250 POSITIVE TERMINAL NEGATIVE TERMINAL...
  • Page 43 SOLENOID WIRE DRIVE MOTOR CONTROL BOARD TACH GUN TRIGGER AND THUMB SWITCH FEEDBACK CHOKE RECTIFIER SHUNT Figure E.4 - Constant Voltage Output NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion IDEALARC SP-250 POSITIVE TERMINAL NEGATIVE TERMINAL...

  • Page 44: Wire Drive Motor And Feedback

    PIEZO ALARM SOLENOID WIRE DRIVE MOTOR CONTROL BOARD TACH GUN TRIGGER AND THUMB SWITCH FEEDBACK CHOKE RECTIFIER SHUNT NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion IDEALARC SP-250 POSITIVE TERMINAL NEGATIVE TERMINAL...

  • Page 45: Thermal Protection

    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. IDEALARC SP-250...

  • Page 46: Scr Operation

    SCR output. If the gate firing occurs later in the cycle the conduction time is less resulting in lower SCR output. IDEALARC SP-250 NOTE: AS THE GATE PULSE IS APPLIED LATER IN THE CYCLE THE SCR OUTPUT IS DECREASED.

  • Page 47: Retest After Repair

    Keypad Remove/Replace ...F-39 - F-40 Wire Drive Assembly Remove/Replace...F-41 - F-42 SCR Output Rectifier Remove/Replace ...F-43 - F-44 Capacitor 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 Repair ...F-52 IDEALARC SP-250...

  • Page 48: Troubleshooting And Repair

    TROUBLESHOOTING & REPAIR HOW TO USE TROUBLESHOOTING GUIDE 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.

  • Page 49: Pc Board Troubleshooting Procedures

    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. IDEALARC SP-250...

  • Page 50: Troubleshooting Guide

    - Display lights properly. 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...

  • Page 51: Error Messages

    26 volts. 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...
  • Page 52 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 POSSIBLE AREAS OF...
  • Page 53 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...
  • Page 54 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...
  • Page 55 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...
  • Page 56 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...
  • Page 57 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 POSSIBLE AREAS OF...

  • Page 58: Explanation Of Prompting And Error Messages

    An attempt was made to recall from memory an Auto setup whose process 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. IDEALARC SP-250 F-11...
  • Page 59 . 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 F-12...
  • Page 60 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 F-13...

  • Page 61: Main Transformer Test

    TROUBLESHOOTING & REPAIR MAIN TRANSFORMER TEST 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.
  • Page 62 NOTE: The location of Plugs may vary depending on the machine code. #208 (16J6) FIGURE F.1A - G2252 Control PC Board Main Transformer Test Points. SP-250 CONTROL G2252 #206 #203 #204A #202 (4J6) (1J3) (3J3) (2J3) #209 (7J6) IDEALARC SP-250 F-15...
  • Page 63 ON/OFF POWER SWITCH to ON. 7. Make the following voltage tests at Plug J3. PLUG FROM LOCATION LEAD #202 (1J3) #202 (1J3) #203 (3J3) IDEALARC SP-250 F-16 IDEALARC SP-250 EXPECTED LEAD VOLTAGE #203 30 VAC (3J3) #204 A 15 VAC (2J3)
  • Page 64 If the voltage test is incorrect, check for loose or broken leads between the reconnect meter panel and the ON/OFF POWER SWITCH. test the ON/OFF POWER SWITCH for proper operation. IDEALARC SP-250 F-17 EXPECTED VOLTAGE 60 VAC 30 VAC 30 VAC EXPECTED...
  • Page 65 TROUBLESHOOTING & REPAIR MAIN TRANSFORMER TEST b. If the correct nameplate voltage is being applied to the main transformer and one or more of the secondary voltages are missing or are incorrect, the main transformer may faulty. Replace. IDEALARC SP-250...

  • Page 66: Static Scr Rectifier Assembly Test

    TROUBLESHOOTING & REPAIR STATIC SCR RECTIFIER ASSEMBLY TEST 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.
  • Page 67 FIGURE F.3 - 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 F.3. SP-250 CONTROL G1992 Rectifier IDEALARC SP-250 F-20 LEADS X2 AND X3...
  • Page 68 8. Repeat Steps #7 to test SCR 2. 9. Reconnect leads X2 and X3. 10. Reconnect Plugs J3 and J6. 11. If this test did not identify the prob- lem or to further test the SCR, go to the Active SCR Test. IDEALARC SP-250 F-21...

  • Page 69: Active Scr Rectifier Assembly Test

    ACTIVE SCR RECTIFIER ASSEMBLY TEST 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.
  • Page 70 0-5 volts or 5-10 volts. a. Test the voltage level of the bat- tery. Short leads (A) and (C). Close switch SW-1. voltage should be 4.5 volts or higher. If lower, replace the bat- tery. IDEALARC SP-250 F-23 LEADS X2 AND X3 Battery...
  • Page 71 16. Perform the Active Test Procedure outlined in Steps 5-13 for 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 X3. IDEALARC SP-250 F-24...
  • Page 72 TROUBLESHOOTING & REPAIR SP-250 KEYPAD RESISTANCE TEST 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.
  • Page 73 If any of the resistance tests are SP-250 CONTROL G2252 SP-250 CONTROL G1992 FIGURE F.9 - Plug J2 Test Points. IDEALARC SP-250 F-26 are taken from the pin locations on Plug J2. See Figure F.9 for each pin location. not correct, the keypad may be...
  • Page 74 100 OHMS (30 TYPICAL) 100 OHMS (30 TYPICAL) 100 OHMS (30 TYPICAL) 100 OHMS (30 TYPICAL) 100 OHMS (30 TYPICAL) 100 OHMS (30 TYPICAL) 100 OHMS (30 TYPICAL) 100 OHMS (30 TYPICAL) 100 OHMS (30 TYPICAL) IDEALARC SP-250 F-27 RESISTANCE...

  • Page 75: Wire Drive Motor And Tachometer Feedback Test

    TROUBLESHOOTING & REPAIR WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST 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.
  • Page 76 G1992 Control Board (Code 9402 only).. See Figures F.10A and F.10B. #515B #515B (3J5) (3J5) #206B (2J5) #539 #555 (8J5) (1J5) FIGURE F.10A - Plug J5 Location on G2252 PC Control Board. SP-250 CONTROL G2252 #541 (9J5) IDEALARC SP-250 F-29...
  • Page 77 If the wires are okay and voltage c. If the correct DC armature volt- Normal DC volts is d. If the motor is running at high VDC varies IDEALARC SP-250 F-30 to the drive motor armature is zero, the Control Board may be faulty. Replace.
  • Page 78 Check the leads from the tach circuit to the Control Board for loose or bro- ken connections. c. If the leads are okay, the Control Board may be faulty. Replace. IDEALARC SP-250 F-31...

  • Page 79: Normal Open Circuit Voltage Waveform

    Coupling .....DC. Trigger ....Internal. IDEALARC SP-250 F-32...
  • Page 80 Coupling .....DC. Trigger ....Internal. IDEALARC SP-250 F-33...
  • Page 81 Coupling .....DC. Trigger ....Internal. IDEALARC SP-250 F-34...
  • Page 82 Coupling .....DC. Trigger ....Internal. IDEALARC SP-250 F-35...

  • Page 83: Typical Scr Gate Voltage Waveform

    Coupling .....DC. Trigger ....Internal. IDEALARC SP-250 F-36...
  • Page 84 Panels using 5/16" nut driver. 3. Disconnect all wiring harness plugs and Molex Plugs connect- ed to the Control Board. Figure F.11. FIGURE F.11 - Wiring Harness and Molex Plug Locations. IDEALARC SP-250 F-37 SP-250 CONTROL G2252 SP-250 CONTROL G1992...
  • Page 85 FIGURE F.12 - Control Board Mounting Screw Locations may vary with Machines. 5. Lift the Control Board straight up and out from the machine. 6. Replace all mounting screws and wiring connections installing the Control Board. different Code when IDEALARC SP-250 F-38...
  • Page 86 TROUBLESHOOTING & REPAIR KEYPAD REMOVAL AND REPLACEMENT 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.
  • Page 87 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. IDEALARC SP-250 F-40...

  • Page 88: Wire Drive Assembly Removal And Replacement

    TROUBLESHOOTING & REPAIR WIRE DRIVE ASSEMBLY REMOVAL AND REPLACEMENT 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.
  • Page 89 Carefully slide out the wire drive assembly. 5. Disconnect the six pin plug from the vertical baffle connector. a. The six pin plug contains the wire feed drive motor wires. 6. Remove carefully the drive motor and drive roll assembly. IDEALARC SP-250 F-42...
  • Page 90 TROUBLESHOOTING & REPAIR SCR OUTPUT RECTIFIER REMOVAL 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.
  • Page 91 1/2" socket wrench and 1/2" open end wrench. 8. Clear the leads and carefully remove the SCR Rectifier Assembly. NOTE: When Rectifier Assembly, apply a thin coating of Dow Corning #340 Compound to the electrical connections. IDEALARC SP-250 F-44 installing...

  • Page 92: Capacitor Bank Removal And Replacement

    TROUBLESHOOTING & REPAIR CAPACITOR BANK REMOVAL AND REPLACEMENT 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.
  • Page 93 9402. 8. Remove the two screws holding the capacitor bank to the floor of the machine using a 5/16" nut driver. 9. Clear the leads and carefully remove the capacitor bank assem- bly from the machine. IDEALARC SP-250 F-46...
  • Page 94 TROUBLESHOOTING & REPAIR MAIN TRANSFORMER REMOVAL AND REPLACEMENT 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.
  • Page 95 14. Pull down on the positive output Capacitor Bank lead until it slides out the hole in the baffle. 15. Carefully remove the main trans- former. a. Be sure all leads are clear. IDEALARC SP-250 F-48...
  • Page 96 TROUBLESHOOTING & REPAIR FAN MOTOR AND FAN REMOVAL AND REPLACEMENT 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.
  • Page 97 6. Remove the fan blade. blade position on motor shaft for ref- erence for replacing fan. a. Pry the fan blade off the motor. b. Slide the fan blade off the motor shaft. IDEALARC SP-250 F-50 Note fan...
  • Page 98 Spin the fan to be sure it is free to rotate. 10. Reassemble the remaining compo- nents in reverse order of removal. When IDEALARC SP-250 F-51...

  • Page 99: Retest After Repair

    RETEST AFTER REPAIR INPUT IDLE AMPS AND WATTS Input Volts/Hertz Maximum Idle Amps Maximum Idle Watts 230/60 OPEN CIRCUIT VOLTAGE 10 to 40 VDC 35-40 VDC Strike Voltage WIRE SPEED RANGE 50 - 600 IPM (1.27 - 15.2 m/minute) IDEALARC SP-250...
  • Page 100 WIRING DIAGRAM (Code 9402) ...G - 9 WIRING DIAGRAM (Code 9546 & 10002)...G - 10 WIRING DIAGRAM (Code 9723 & 10001) ...G - 11 G1992 CONTROL PC BOARD SCHEMATIC ...G - 12 G2252 CONTROL PC BOARD SCHEMATIC ...G - 13 IDEALARC SP-250...
  • Page 101 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.
  • Page 102 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.
  • Page 103 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.
  • Page 104 NOTES IDEALARC SP-250...
  • Page 105 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.
  • Page 106 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.
  • Page 107 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.
  • Page 108 NOTES IDEALARC SP-250...
  • Page 109 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 ELECTRICAL DIAGRAMS...
  • Page 110 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 ELECTRICAL DIAGRAMS WIRING DIAGRAM FOR CODE 9546 &...
  • Page 111 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 ELECTRICAL DIAGRAMS WIRING DIAGRAM FOR CODE 9723 &...

  • Page 112: Electrical Diagrams

    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.
  • Page 113 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.

Table of Contents