Lincoln Electric IDEALARC SP-255 Service Manual
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Lincoln Electric IDEALARC SP-255 Service Manual

Lincoln Electric IDEALARC SP-255 Service Manual

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IDEALARC
SP-255
®
For use with machines having Code Numbers:
10164, 10165
SERVICE MANUAL
SVM115-A
| Issue D ate 12, Apr
© Lincoln Global, Inc. All Rights Reserved.
NOTE: This manual will cover most of the troubleshooting and repair
procedures for the code numbers listed. Some variances may exist when
troubleshooting/repairing later code numbers.

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Summary of Contents for Lincoln Electric IDEALARC SP-255

  • Page 1 NOTE: This manual will cover most of the troubleshooting and repair procedures for the code numbers listed. Some variances may exist when troubleshooting/repairing later code numbers. IDEALARC SP-255 ® For use with machines having Code Numbers: 10164, 10165 SERVICE MANUAL SVM115-A | Issue D ate 12, Apr ©...
  • Page 2 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 SAFETY ELECTRIC SHOCK can kill. ARC RAYS can burn. 3.a. The electrode and work (or ground) circuits 4.a. Use a shield with the proper filter and cover are electrically “hot” when the welder is on. plates to protect your eyes from sparks and Do not touch these “hot”...
  • Page 4 SAFETY WELDING and CUTTING CYLINDER may explode SPARKS can cause fire or if damaged. explosion. 7.a. Use only compressed cylinders containing the correct shielding gas for the 6.a. Remove fire hazards from the welding area.If process used properly operating this is not possible, cover them to prevent the welding sparks regulators designed from starting a fire.
  • Page 5 SAFETY 6. Eloigner les matériaux inflammables ou les recouvrir afin de PRÉCAUTIONS DE SÛRETÉ prévenir tout risque d’incendie dû aux étincelles. Pour votre propre protection lire et observer toutes les instructions 7. Quand on ne soude pas, poser la pince à une endroit isolé de et les précautions de sûreté...
  • Page 6 2004/108/EC. It was manufactured in conformity with a national standard that implements a harmonized standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment. It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use. Introduction All electrical equipment generates small amounts of electromagnetic emission.

  • Page 7: Safety

    SAFETY Electromagnetic Compatibility (EMC) The size of the surrounding area to be considered will depend on the structure of the building and other ac- tivities that are taking place. The surrounding area may extend beyond the boundaries of the premises. Methods of Reducing Emissions Mains Supply Welding equipment should be connected to the mains supply according to the manufacturer’s recommenda-...

  • Page 8: Table Of Contents

    RETURN TO MAIN INDEX TABLE OF CONTENTS Page Safety ............i- vi Installation .

  • Page 9: Installation

    INSTALLATION TABLE OF CONTENTS - INSTALLATION SECTION - INSTALLATION SECTION ........Section A Technical Specifications ...........A-1 Safety Precautions ............A-2 Select Proper Location .............A-2 Stacking...............A-2 Input Electrical Connections..........A-2 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 Install the Work Clamp ..........A-7...

  • Page 10: Technical Specifications

    INSTALLATION TECHNICAL SPECIFICATIONS - Idealarc SP-255 ® INPUT - SINGLE PHASE/ 60 HERTZ ONLY Standard Voltage Input Current at Rated Output 208/230/60 53/49 Amps 230/460/575 50/25/20 Amps RATED OUTPUT Duty Cycle Amps Volts at Rated Amps 100% 145 amps 200 amps 250 amps OUTPUT Current Range...

  • Page 11: Safety Precautions

    INSTALLATION Read entire Installation Section before installing the 1. Before starting the installation, check with the local Idealarc SP-255 power company to determine if there is any ques- ® tion about whether your power supply is adequate SAFETY PRECAUTIONS for the voltage, amperes, phase, and frequency specified on the welder nameplate.

  • Page 12: Fuse And Wire Sizes

    INSTALLATION FUSE AND WIRE SIZES 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 Protect the input circuit with the super lag fuses or delay proper grounding of the welder frame when the type circuit breakers listed on the Technical Specifica- welder plug is inserted into the receptacle.

  • Page 13: Connect Shielding Gas

    INSTALLATION For the 230/460/575V/ 60 HZ model which is not BE SURE TO KEEP YOUR FACE AWAY FROM THE equipped with a plug, an input cord, or a receptacle, the VALVE OUTLET WHEN OPENING THE VALVE. input power supply leads are connected directly to the Reconnect Panel as shown Figure A.3.

  • Page 14: Reconnect Procedure

    INSTALLATION RECONNECT PROCEDURE 11. Before opening the cylinder valve, turn the regulator adjusting knob counter clockwise until the pressure is released from the adjusting spring. Multiple voltage machines are shipped connected to the highest input voltage listed on the machine's rating 12.
  • Page 15 INSTALLATION 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.

  • Page 16: Connect Output Components

    INSTALLATION CONNECT OUTPUT COMPONENTS GUN LINER & CONTACT TIP The Magnum 250 SP gun and cable provided with the INSTALL THE WORK CLAMP SP-255 is factory installed with a liner for a .035” or .045” (0.9 or 1.2mm) diameter electrode and an .035 Attach the work clamp to the cable which extends from (0.9mm) contact tip.
  • Page 17 INSTALLATION CAUTION The gun trigger switch connected to the gun trigger control cable must be a normally open momentary switch. The terminals of the switch must be insu- lated from the welding circuit. Improper operation of or damage to the SP-255 might result if this switch is common to an electrical circuit other than the SP-255 trigger circuit.

  • Page 18: Operation

    OPERATION TABLE OF CONTENTS - OPERATION SECTION - OPERATION SECTION ..........Section B Safety Instructions............B-1 General Description............B-1 Recommended Processes and Equipment ......B-2 Operational Features and Controls ........B-2 Design Features and Advantages ........B-3 Machine Capability ............B-4 Limitations ................B-4 Controls and Settings ............B-5 Power Switch...............B-5 Arrow Keys ..............B-5 Process Wire/Gas Key ..........B-5...

  • Page 19: Safety Instructions

    OPERATION Read and understand this entire section before operat- ADDITIONAL SAFETY PRECAUTIONS ing your Idealarc SP-255. ® Always operate the welder with the hinged door closed SAFETY INSTRUCTIONS and the side panels in place as these provide maximum protection from moving parts and insure proper cooling air flow.

  • Page 20: Recommended Processes And Equipment

    OPERATION RECOMMENDED PROCESSES AND Auto Mode - Simply set the thickness of the material being welded and the SP-255 automatically sets the EQUIPMENT proper wire feed speed and arc voltage for the process being used. This eliminates the need for look-up tables, The SP-255 is recommended for GMA welding procedure slide rules, or notebooks to find the proper processes using 10 to 44 lb.

  • Page 21: Design Features And Advantages

    OPERATION DESIGN FEATURES AND Output Terminals - Easily accessible in wire drive sec- tion for quick cable connection and polarity reversal. ADVANTAGES Work Cable - 10 ft. (3.0m) long with work clamp. UNIT FEATURES: Undercarriage for Hand Mobility - Heavy duty 10" WIRE FEEDER FEATURES: (254mm) wheels and 4"...

  • Page 22: Machine Capability

    OPERATION Gun and Cable - A 12.5 ft. (3.8) GMAW gun and cable assembly, rated 200 amps 60% duty, is provided with the SP-255 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 connector with addi- tional control lead connections for the thumb activated 2 momentary position slide switch control designed into...

  • Page 23: Controls And Settings

    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. ARROW KEYS maintaining an excellent resolution. However, FIGURE B.1 - SP-255 Control Panel Keys when the trigger is closed, the changes will be at a steady, moderate rate to allow for proper “on the fly”...
  • Page 24 OPERATION TABLE B.1 - Arrow Key Functions. ARROW KEY OPERATION WHEN USED WITH Wire Type Wire Diameter Welding Gas PROCESS WIRE/GAS KEY: Solid Steel .025 (0.6mm) Solid Steel .025 (0.6mm) ArCO See Table B.1. Solid Steel .030 (0.8mm) Solid Steel .030 (0.8mm) ArCO Left Arrow Keys: Press to set Wire Type.

  • Page 25: Auto Key

    OPERATION 4. AUTO KEY: ARROW KEY OPERATION WHEN USED WITH MAN- Press for automatic welding set up UAL KEY: of recommended Wire Speed and Arc Voltage based on Metal Thickness selected. See Table B.1. ARROW KEY OPERATION WHEN USED WITH AUTO Left arrow keys: Do not function in Manual mode.

  • Page 26: Memory Keys

    OPERATION 7. MEMORY KEYS: Center arrow keys: Press UP ( ) arrow key to in- Press memory key location crease Stitch time ON from 0.20 seconds to 2.50 sec- number in which you want to save a procedure or onds. Press the DOWN ( ) arrow key to decrease from which you want to recall a procedure from Stitch ON time from 2.50 seconds to 0.20 seconds.

  • Page 27: Toggle Key

    OPERATION 12. TOGGLE KEY : When first pressed, this key Center arrow keys: Press the UP ( ) arrow key to in- turns ON the TOGGLE MODE and recalls the weld crease wire feed speed. Press DOWN ( ) arrow key setup in memory 4.

  • Page 28: Operating Steps

    B-10 B-10 OPERATION OPERATING STEPS Run-In Speed The SP-255 is factory set for FAST run-in (Figure B.6) where the wire feed will accelerate directly to Before operating the machine, be sure you have all the the preset speed. SLOW run-in will initially feed at materials needed to perform the work.

  • Page 29: Loading The Wire Reel

    B-11 B-11 OPERATION LOADING THE WIRE REEL NOTE: The retaining spring side of the adapter should be facing the center (inner) panel of the SP-255. To mount a 22-30 lb. (10-14 kg) Readi-Reel package 7. To remove the Readi-Reel from Adapter, depress using the Readi-Reel adapter provided: retaining spring tab with thumb while pulling the Readi-Reel cage from the molded adapter with both...

  • Page 30: Feeding Electrode

    B-12 B-12 OPERATION FEEDING ELECTRODE 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. WARNING 2. If the wire "birdnests", jams, or breaks at the drive When inching, the electrode and drive mechanism are roll, the idle roll pressure is too great.

  • Page 31: Making A Weld In Auto Mode

    B-13 B-13 OPERATION MAKING A WELD IN AUTO MODE 14. If welding gas is to be used, turn on the gas supply and set the required flow rate (typically 25-35 CFH/12-16.5 l/min.). 1. Check that the polarity is correct for the process being used.
  • Page 32 B-14 B-14 OPERATION USING THE 4-STEP INTERLOCK FUNCTION IN 7. Press spot weld nozzle against the top sheet so the AUTO MODE top and bottom sheets are tight together. If a spot weld nozzle is not used, smoother welds will result When the 4-Step Interlock function is not activated, the by moving the welding wire in a small circle while trigger functions in the normal mode so that welding...

  • Page 33: Fan Control

    B-15 B-15 OPERATION MAKING A STITCH WELD IN AUTO MODE USING THE GUN THUMB SWITCH (MAG- NUM 250SP GUN ONLY) A stitch weld is used to weld thin material because warpage and burnthrough are a problem. Properly ad- The Gun Thumb switch is used to control wire feed justing the ON and OFF times and arc travel speed, per- speed, arc voltage, or to switch, or toggle, between mits welding thin sheet metal using small welds that...

  • Page 34: Wire Feed Overload Protection

    B-16 B-16 OPERATION WIRE FEED OVERLOAD PROTECTION The SP-255 has solid state overload protection of the wire drive motor. If the motor becomes overloaded, the protection circuitry turns off the arc voltage, wire feed speed and gas solenoid and then causes the alarm to beep 3 times.

  • Page 35: Accessories

    ACCESSORIES TABLE OF CONTENTS - ACCESSORIES SECTION - ACCESSORIES SECTION ........Section C Options/Accessories ............C-1 Making a Weld with the Spool Gun Adapter and Spool Gun Installed...........C-1 Spot Key..............C-2 Stitch Key ..............C-3 Toggle Key..............C-3 Disabling Spool Gun............C-3 IDEALARC SP-255 ®...

  • Page 36: Making A Weld With The Spool Gun Adapter And Spool Gun Installed

    ACCESSORIES DRIVE ROLL KITS (OPTIONAL K672-1) The K672-1 Spool Gun Adapter Kit provides recessed Drive Rolls available to feed different sizes and types of panel “up front” direct connection for use of the recom- electrode: mended K487 Spool Gun (with remote speed control), or the optional K469 Spool Gun (requires K518 Con- nection Adapter).
  • Page 37 ACCESSORIES Transfer switch in FEEDER position: crease (down arrow) arc voltage. a. Disables spool gun trigger, wire feed and gas d. Procedure settings may be stored in memory output. for later recall. (See Memory Keys in Opera- tion Section.) b. Closing feeder gun trigger starts feeder gun welding and makes both electrodes electrically 4.
  • Page 38 ACCESSORIES STITCH KEY TYPICAL TOGGLE KEY PRESS SEQUENCE Anytime the Stitch weld timers are on and the display is Spool screen is displayed prior to pressing Toggle key. in Spool Mode, the abbreviation STCH will appear in the Toggle key is pressed, memory 4 is recalled and ap- bottom left corner of the display.

  • Page 39: Maintenance

    MAINTENANCE TABLE OF CONTENTS - MAINTENANCE SECTION - MAINTENANCE SECTION ........Section D Safety Precautions ............D-1 Routine and Periodic Maintenance ........D-1 Contact Tip and Gas Nozzle Installation ......D-3 Liner Removal and Replacement........D-3 Liner Removal, Installation, and Trimming Instructions for Magnum 250SP ............D-4 Gun Handle Disassembly..........D-5 Magnum 250SP Gun Parts and Accessories ....D-6 IDEALARC...

  • Page 40: Safety Precautions

    MAINTENANCE SAFETY PRECAUTIONS Drive Rolls and Guide Tubes After every coil of wire, inspect the wire drive mecha- WARNING nism. Clean it as necessary by blowing with low pres- sure compressed air. Do not use solvents for cleaning • Have a qualified technician do the maintenance the idle roll because it may wash the lubricant out of the and troubleshooting work.
  • Page 41 MAINTENANCE 7 Wire Drive Unit Control Board Choke Fan Assembly Main Transformer SCR Rectifier Capacitor Bank Figure D.1 - Component Locations IDEALARC SP-255 ®...

  • Page 42: Contact Tip And Gas Nozzle Installation

    MAINTENANCE CONTACT TIP AND GAS NOZZLE INSTALLATION 1. Choose the correct size contact tip for the elec- trodes being used (wire size is stenciled on the side of the contact tip) and screw it snugly into the gas diffuser. 2. Screw the appropriate fixed gas nozzle fully onto the diffuser.

  • Page 43: Liner Removal, Installation, And Trimming Instructions For Magnum 250Sp

    MAINTENANCE LINER REMOVAL, INSTALLATION, AND TRIMMING INSTRUCTIONS FOR MAGNUM 250SP NOTICE: The variation in cable lengths prevents the in- terchange ability of liners between guns. Once a liner has been cut for a particular gun, it should not be in- stalled in another gun unless it can meet the liner cutoff length requirement.

  • Page 44: Gun Handle Disassembly

    MAINTENANCE LINER ASSEMBLY (LINER BUSHING 1-1/4" TO BE TIGHTLY SEATED) (31.8MM) FEEDER END FAST-MATE LINER TRIM CONNECTOR ASSEMBLY LENGTH SET SCREW GAS DIFFUSER LINER NUT NOZZLE INSULATOR (IF USED) GAS NOZZLE Figure D.2 - Liner Trim Length for the 250SP Gun. GUN HANDLE DISASSEMBLY The internal parts of the gun handle may be inspected or serviced if necessary.

  • Page 45: Magnum 250Sp Gun Parts And Accessories

    MAINTENANCE MAGNUM 250SP GUN PARTS AND ACCESSORIES Description Part Number English Size Metric Size CABLE LINER For 15’ (4.5 m) KP1934-1 .025 - .030” 0.6 - 0.8 mm or shorter Cable KP1934-1* .035-.045” 0.9 - 1.2 mm KP1955-1** 3/64” 1.2 mm (Alum.

  • Page 46: Theory Of Operation

    THEORY OF OPERATION TABLE OF CONTENTS - THEORY OF OPERATION SECTION - THEORY OF OPERATION SECTION ...... Section E Power Supply Operation ..........E-1 Input Line Voltage and Main Transformer ....E-1 Output Rectification and Feedback Control....E-2 Constant Voltage Output ..........E-3 Wire Drive Motor and Feedback........E-4 Thermal Protection ............E-5 SCR Operation ...............

  • Page 47: Power Supply Operation

    THEORY OF OPERATION POWER SUPPLY OPERATION PIEZO ALARM SOLENOID DISPLAY WIRE DRIVE MOTOR KEYPAD CONTROL BOARD TACH GUN TRIGGER AND THUMB SWITCH MAIN LINE TRANSFORMER SWITCH FEEDBACK RECONNECT POSITIVE TERMINAL CHOKE RECTIFIER NEGATIVE MOTORS TERMINAL SHUNT Figure E.2 - Input Line Voltage and Main Transformer INPUT LINE VOLTAGE AND MAIN TRANS- FORMER The desired single phase input power is connected to...
  • Page 48 THEORY OF OPERATION POWER SUPPLY OPERATION (CONTINUED) PIEZO ALARM SOLENOID DISPLAY WIRE DRIVE MOTOR KEYPAD CONTROL BOARD TACH GUN TRIGGER AND THUMB SWITCH MAIN LINE TRANSFORMER SWITCH FEEDBACK RECONNECT POSITIVE TERMINAL CHOKE RECTIFIER NEGATIVE MOTORS TERMINAL SHUNT Figure E.3 - Output Rectification and Feedback Control OUTPUT RECTIFICATION AND FEED- BACK CONTROL The AC output from the main transformer secondary...
  • Page 49 THEORY OF OPERATION POWER SUPPLY OPERATION (CONTINUED) PIEZO ALARM SOLENOID DISPLAY WIRE DRIVE MOTOR KEYPAD CONTROL BOARD TACH GUN TRIGGER AND THUMB SWITCH MAIN LINE TRANSFORMER SWITCH FEEDBACK RECONNECT POSITIVE TERMINAL CHOKE RECTIFIER NEGATIVE MOTORS TERMINAL SHUNT Figure E.4 - Constant Voltage Output CONSTANT VOLTAGE OUTPUT The controlled DC output from the SCR rectifier assem- bly is filtered by the capacitor bank and the output...
  • Page 50 THEORY OF OPERATION POWER SUPPLY OPERATION (CONTINUED) PIEZO ALARM SOLENOID DISPLAY WIRE DRIVE MOTOR KEYPAD CONTROL BOARD TACH GUN TRIGGER AND THUMB SWITCH MAIN LINE TRANSFORMER SWITCH FEEDBACK RECONNECT POSITIVE TERMINAL CHOKE RECTIFIER NEGATIVE MOTORS TERMINAL SHUNT Figure E.5 - Wire Drive Motor and Feedback WIRE DRIVE MOTOR AND FEEDBACK The wire drive motor is controlled by the control board.

  • Page 51: Thermal Protection

    THEORY OF OPERATION THERMAL PROTECTION A thermostat protects the machine from excessive op- erating temperatures.. Excessive operating tempera- tures may be caused by a lack of cooling air or operating the machine beyond the duty cycle and output rating. There are three thermostats within the SP-255 machine.

  • Page 52: Scr Operation

    THEORY OF OPERATION SCR OPERATION INPUT CATHODE OUTPUT NOTE: AS THE GATE PULSE IS APPLIED ANODE LATER IN THE CYCLE THE SCR OUTPUT IS DECREASED. GATE Figure E.6 - SCR Operation A silicon controlled rectifier (SCR) is a three terminal de- This gate pulse must be more positive than the cathode vice used to control rather large currents to a load.

  • Page 53: Test Procedures

    TROUBLESHOOTING & REPAIR TABLE OF CONTENTS - TROUBLESHOOTING & REPAIR SECTION - TROUBLESHOOTING & REPAIR SECTION .... Section F How to use Troubleshooting Guide ........F-1 PC Board Troubleshooting Procedures ......F-2 Troubleshooting Guide .............F-3 Explanation of Prompting Error Messages .....F-11 Test Procedures SP-255 Main Transformer Test ........F-14 Static SCR Rectifier Assembly Test ........F-17 Active SCR Rectifier Assembly Test .......F-20...

  • Page 54: How To Use Troubleshooting Guide

    HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and repair should be performed by only 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 55: Pc Board Troubleshooting Procedures

    OFF at the fuse box before working on equipment. Do - If you return a PC board to The Lincoln Electric Com- not touch electrically hot parts. pany for credit, it must be in the static-shielding bag.
  • Page 56 4. 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, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. IDEALARC SP-255 ®...
  • Page 57 5. 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, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. IDEALARC SP-255 ®...
  • Page 58 4. The LCD display may be faulty. - place. Replace. CAUTION 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 1-888-935-3877. IDEALARC SP-255...
  • Page 59 Field Service Facility. CAUTION 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 1-888-935-3877. IDEALARC SP-255 ®...

  • Page 60: Main Transformer Test

    4. Check output capacitors. CAUTION 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 1-888-935-3877. IDEALARC SP-255 ®...
  • Page 61 Electric Authorized Field Service Facility. CAUTION 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 1-888-935-3877. IDEALARC SP-255 ®...
  • Page 62 3. 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, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. IDEALARC SP-255 ®...
  • Page 63 CAUTION 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 1-888-935-3877. IDEALARC SP-255 ®...
  • Page 64 F-11 F-11 TROUBLESHOOTING & REPAIR EXPLANATION OF PROMPTING AND ERROR MESSAGES MESSAGE EXPLANATION ON SCREEN ERROR MESSAGE Reminder that in Auto mode the process entered with the Process key must PROCESS MUST match the process installed in the machine . MATCH WIRE &...
  • Page 65 F-12 F-12 TROUBLESHOOTING & REPAIR EXPLANATION OF PROMPTING AND ERROR MESSAGES (CONT’D) MESSAGE EXPLANATION ON SCREEN ERROR MESSAGE An attempt was made to recall a setup from memory that has improper set- DATA ***ERROR*** tings due to excessive electrical interference. The SP-255 will recall the CHECK SETTINGS setup and reset the improper data to within machine limits.
  • Page 66 F-13 F-13 TROUBLESHOOTING & REPAIR EXPLANATION OF PROMPTING AND ERROR MESSAGES (CONT’D) MESSAGE EXPLANATION ON SCREEN ERROR MESSAGE 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 op- HIGH LINE: CHECK erator can continue to weld, but the voltage will be less than what is set on RECONNECT PANEL...
  • Page 67 MAIN TRANSFORMER 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 precau- tions detailed throughout this manual.
  • Page 68 F-15 F-15 TROUBLESHOOTING & REPAIR MAIN TRANSFORMER TEST TEST PROCEDURE WARNING The ON/OFF POWER SWITCH will be "hot" during these tests. __________________________ NOTE: Secondary voltages will vary pro- portionably with the primary input volt- age. 1. Disconnect the main input power supply to the machine.
  • Page 69 F-16 F-16 TROUBLESHOOTING & REPAIR MAIN TRANSFORMER TEST 4. Locate the following leads on Plug J3 a. Turn the machine OFF between on the Control Board. each test. G2801: b. Carefully insert the meter probes LEAD PLUG into the back of each Molex Plug LOCATION pin cavity to perform the test.

  • Page 70: Static Scr Rectifier Assembly Test

    STATIC 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 precau- tions detailed throughout this manual.
  • Page 71 F-18 F-18 TROUBLESHOOTING & REPAIR STATIC SCR RECTIFIER ASSEMBLY TEST TEST PROCEDURE 1. Disconnect main AC input power to the machine. 2. Disconnect Plugs J3 and J6 from the G2801 Control Board. This electri- cally isolates the SCR bridge assem- bly.
  • Page 72 F-19 F-19 TROUBLESHOOTING & 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 ana- log ohmmeter (Multimeter).

  • Page 73: 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 precau- tions detailed throughout this manual.
  • Page 74 F-21 F-21 TROUBLESHOOTING & REPAIR ACTIVE SCR RECTIFIER ASSEMBLY TEST TEST PROCEDURE 1. Disconnect main AC input power to the machine. 2. Disconnect Molex Plugs J3 and J6 from the G2801 Control Board. See Figure F.5. LEADS X2 AND X3 SP-255 CONTROL NEGATIVE G2801...
  • Page 75 F-22 F-22 TROUBLESHOOTING & REPAIR ACTIVE SCR RECTIFIER ASSEMBLY TEST 7. Connect the Tester to the SCR 1 as a. If the voltage is 3 - 6 volts while shown in Figure F.7. the switch is closed and after the switch is open, the SCR is func- a.

  • Page 76: Keypad Resistance Test

    SP-255 KEYPAD RESISTANCE 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 precau- tions detailed throughout this manual.
  • Page 77 F-24 F-24 TROUBLESHOOTING & REPAIR SP-255 KEYPAD RESISTANCE TEST TEST PROCEDURE 1. Disconnect main input power to the machine. 2. Remove the Case Top and Side Pan- els using the 5/16” nut driver. 3. Locate and disconnect Plug J2 con- nected to the Control PC Board.
  • Page 78 F-25 F-25 TROUBLESHOOTING & REPAIR SP-255 KEYPAD RESISTANCE TEST TABLE F.1 - SP-255 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 (TYPICAL RESISTANCE) FROM PIN TO PIN CENTER UP ARROW...
  • Page 79 WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK 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 precau- tions detailed throughout this manual.
  • Page 80 F-27 F-27 TROUBLESHOOTING & REPAIR WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST TEST PROCEDURE NOTE: POLARITY MUST BE OB- SERVED FOR THESE TESTS. Test for Correct Wire Drive Motor Arma- ture Voltage 1. Disconnect main input power to the machine. 2.
  • Page 81 F-28 F-28 TROUBLESHOOTING & REPAIR WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST 4. Test for 2-25 VDC between lead being received from the Control #539(B) (positive) and lead #541(W) Board. Go to Feedback Test. (negative) to determine if the correct armature voltage is being supplied.
  • Page 82 F-29 F-29 TROUBLESHOOTING & REPAIR NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM SCOPE SETTINGS This is a typical DC output voltage waveform generated from a properly operating ma- Volts/Div ....20 V/Div. chine.
  • Page 83 F-30 F-30 TROUBLESHOOTING & REPAIR TYPICAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED MACHINE LOADED TO 250 AMPS AT 26 VDC SCOPE SETTINGS This is a typical DC output voltage waveform generated from a properly operating ma- Volts/Div ....20 V/Div. chine.
  • Page 84 F-31 F-31 TROUBLESHOOTING & REPAIR ABNORMAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED ONE OUTPUT SCR NOT FUNCTIONING 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 .
  • Page 85 F-32 F-32 TROUBLESHOOTING & REPAIR ABNORMAL OPEN CIRCUIT VOLTAGE OUTPUT CAPACITOR BANK NOT FUNCTIONING SCOPE SETTINGS This is NOT the typical DC output voltage waveform. The output capacitors are not Volts/Div ....20 V/Div. functioning.
  • Page 86 F-33 F-33 TROUBLESHOOTING & REPAIR TYPICAL SCR GATE VOLTAGE WAVEFORM SCOPE SETTINGS This is a typical SCR gate pulse voltage waveform. The machine was in an open cir- Volts/Div ....2 V/Div. cuit condition (no load) and operating prop- erly.
  • Page 87 F-34 F-34 TROUBLESHOOTING & REPAIR CONTROL PC BOARD REMOVAL AND REPLACEMENT CAUTION Printed Circuit Boards can be dam- aged by static electricity. Follow static handling guidelines detailed in “PC Board Troubleshooting Proce- dures” at the beginning of this chap- ter. _____________________________ REMOVAL AND REPLACEMENT PROCEDURE...
  • Page 88 F-35 F-35 TROUBLESHOOTING & REPAIR CONTROL PC BOARD REMOVAL AND REPLACEMENT 4. Carefully remove P.C. Board from mounting standoffs. See Figure F.12. FIGURE F.12 - Control Board Mounting Locations may vary with different Code Machines. 5. Lift the Control Board straight up and out from the machine.
  • Page 89 KEYPAD REMOVAL AND REPLACEMENT 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 precau- tions detailed throughout this manual.
  • Page 90 F-37 F-37 TROUBLESHOOTING & REPAIR KEYPAD REMOVAL AND REPLACEMENT PROCEDURE NOTE: BEFORE REMOVING THE KEY- PAD, PERFORM THE KEYPAD RE- SISTANCE TEST TO BE SURE THE KEYPAD IS FAULTY. 1. Disconnect main input power to the machine. 2. Remove the Case Top and Side Pan- els with 5/16”...
  • Page 91 WIRE DRIVE ASSEMBLY REMOVAL AND REPLACEMENT 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 precau- tions detailed throughout this manual.
  • Page 92 F-39 F-39 TROUBLESHOOTING & REPAIR WIRE DRIVE ASSEMBLY REMOVAL AND REPLACEMENT PROCEDURE 1. Disconnect main input power to the machine. 2. Remove the Case Top and Side Pan- els. 3. Remove the drive roll. See Figure F.13. a. Remove the thumb screw, drive hub, and the spacer.
  • Page 93 F-40 F-40 TROUBLESHOOTING & REPAIR WIRE DRIVE ASSEMBLY REMOVAL AND REPLACEMENT 5. Remove the screw holding the gun connector assembly to the Case Front Panel. See Figure F.14. FIGURE F.14 - Location of Screw Hold- ing the Gun Connector Assembly to the Case Front Panel.
  • Page 94 SCR OUTPUT RECTIFIER REMOVAL 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 precau- tions detailed throughout this manual.
  • Page 95 F-42 F-42 TROUBLESHOOTING & REPAIR SCR OUTPUT RECTIFIER REMOVAL PROCEDURE 4. Cut the SCR gate leads G1 and G2 (see wire markers and wiring dia- gram) using wire cutters. 1. Disconnect lead #208 and Trans- former Lead X1 from the heat sink on a.
  • Page 96 CAPACITOR BANK REMOVAL AND REPLACEMENT 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 precau- tions detailed throughout this manual.
  • Page 97 F-44 F-44 TROUBLESHOOTING & REPAIR CAPACITOR BANK REMOVAL AND REPLACEMENT PROCEDURE See Figure F.18 for location of Capacitor Bank Removal and Replacement compo- nents. FIGURE F.18 - Location of Capacitor Bank Removal and Replacement Components 6. Remove the #204 lead from the pos- 1.
  • Page 98 MAIN TRANSFORMER REMOVAL AND REPLACEMENT 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 precau- tions detailed throughout this manual.
  • Page 99 F-46 F-46 TROUBLESHOOTING & REPAIR MAIN TRANSFORMER REMOVAL AND REPLACEMENT PROCEDURE 12. Carefully remove the main trans- 1. Disconnect main input power to the former. machine. a. Be sure all leads are clear. 2. Remove the Case Top and Side Pan- els.
  • Page 100 FAN MOTOR AND FAN REMOVAL AND REPLACEMENT 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 precau- tions detailed throughout this manual.
  • Page 101 F-48 F-48 TROUBLESHOOTING & REPAIR FAN MOTOR AND FAN REMOVAL AND REPLACEMENT PROCEDURE See Figure F.19 for fan motor and fan re- moval components. FIGURE F.19 - Fan Motor and Fan Re- moval Components the machine using a 5/16” socket wrench with extension.
  • Page 102 F-49 F-49 TROUBLESHOOTING & REPAIR 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 phillips head screw driver. b. When the motor is free from the mounting bracket, place it care- fully on the bottom of the ma- chine.
  • Page 103 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-255...
  • Page 104 F-51 F-51 NOTES IDEALARC ® SP-255...

  • Page 105: Electrical Diagrams

    ELECTRICAL DIAGRAMS TABLE OF CONTENTS - ELECTRICAL DIAGRAMS SECTION - ELECTRICAL DIAGRAMS SECTION ....... Section G WIRING DIAGRAM (Code 10164) (L9688) ....G - 2 WIRING DIAGRAM (Code 10165) (L9689) ....G - 3 SCHEMATIC CONTROL PC BOARD (G2799) ....G - 4 IDEALARC ®...
  • Page 106 ElEcTrical DiaGramS WiriNG DiaGram - (cODE 10164) (l9688) SP - 255 (DUAL VOLTAGE) GENERAL INFORMATION CONTROL BOARD (J7) ELECTRICAL SYMBOLS PER E1537 (J8) 2 LINE X 16 CHAR. (J4) COLOR CODE: ALPHA-NUMERI C B - BLACK W - WHIT E (J9) R - RE D LCD DISPLAY...
  • Page 107 ElEcTrical DiaGramS WiriNG DiaGram - (cODE 10165) (l9689) SP-255 (230 / 460 / 575V) CONTROL BOARD (J7) GENERAL INFORMATION (J8) 2 LINE X 16 CHAR. (J4) ELECTRICAL SYMBOLS PER E1537 ALPHA-NUMERI C COLOR CODE: (J9) B - BLACK LCD DISPLAY W - WHIT E R - RE D (J1)
  • Page 108 ElEcTrical DiaGramS SchEmaTic - cOmPlETE machiNE (G2799) ENGINEERING CONTROLLED CHANGE DETAIL: SCR1 AND SCR2 , REVISED AMPS MANUFACTURER: THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED PROPRIETARY & CONFIDENTIAL: TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC. UNLESS OTHERWISE SPECIFIED TOLERANCE DESIGN INFORMATION REFERENCE:...

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