Lincoln Electric IDEALARC AC/DC 250 Service Manual
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Lincoln Electric IDEALARC AC/DC 250 Service Manual

Lincoln Electric IDEALARC AC/DC 250 Service Manual

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IDEALARC
AC/DC 250
®
For use with machines having Code Numbers:
9646; 9670; 9712; 9713; 9738; 9755; 9992; 9993; 9994; 9995; 9996;
9997; 9998; 11094; 11100; 11101; 11102; 11103; 11104
SERVICE MANUAL
SVM228-A
| Issue D ate 13-Jan
© 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.
9491; 9512; 9513; 9514; 9548; 9645;

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Summary of Contents for Lincoln Electric IDEALARC AC/DC 250

  • 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 AC/DC 250 ® 9491; 9512; 9513; 9514; 9548; 9645; For use with machines having Code Numbers: 9646;...
  • 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 PERFORMED 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 and properly operating this is not possible, cover them to prevent the welding sparks regulators designed for the gas and 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 activities 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 recommen- dations.

  • Page 8: Table Of Contents

    - MASTER TABLE OF CONTENTS FOR ALL SECTIONS - Page Safety ................i-vi Installation .
  • Page 9 TABLE OF CONTENTS - INSTALLATION SECTION Installation ................A-1 Technical Specifications .

  • Page 10: Installation

    INSTALLATION TECHNICAL SPECIFICATIONS: IDEALARC AC/DC 250 INPUT - OUTPUT RATINGS Model AC/DC 250 AC/DC 250 Type K1053 K1054 AC Input Frequency Output Rating NEMA CLASS II (60) IEC 974 Amperes Volts Duty Cycle Current Range 35-300 40-250 35-250 40-250 Max O.C.V.
  • Page 11 Electrical Code and any applicable local codes. is provided for this purpose. See the U.S. National Electrical Code for details on proper grounding meth- • Turn the power switch on the IDEALARC AC/DC 250 ods. “OFF” before connecting or disconnecting output cables or other equipment.
  • Page 12 INSTALLATION TABLE A.1 – RECOMMENDED INPUT WIRE, GROUND WIRE AND FUSE SIZES RECOMMENDED INPUT WIRE, GROUND WIRE AND FUSE SIZES 200 Amp Output and 50% Duty Cycle Copper Wire Sizes Fuse Size Input Amps 75ºC in Conduit (Super Lag) Input Frequency With Without...
  • Page 13 TABLE OF CONTENTS - OPERATION SECTION Operation ................B-1 General Description .

  • Page 14: Operation

    OPERATION GENERAL DESCRIPTION • Submersion dipping of assembled transformer and choke in special sealing/insulating material gives The IDEALARC AC/DC 250 is a single phase constant extra protection against moisture and corrosive current arc welding power source available in an atmosphere.
  • Page 15 WELDING SPARKS can cause fire or explosion. C. TIG Welding • Keep flammable material away. The IDEALARC AC/DC 250 with the optional Hi-Freq is • Do not weld on closed containers. an inexpensive equipment combination for part-time production or repair TIG welding of aluminum, magne- ------------------------------------------------------------------------ sium, thin stainless steel and many space-age metals.
  • Page 16 NOTES IDEALARC ® AC/DC 250...
  • Page 17 TABLE OF CONTENTS - ACCESSORIES SECTION Accessories ................C-1 Options / Accessories and Compatible Lincoln Equipment .

  • Page 18: Accessories

    • Power Factor Capacitors panel. The 60 Hz IDEALARC AC/DC 250 provides (Reduce input amps by 30% at rated load) 1/2” studs for weld cable connections. The 50 Hz IDE- ALARC AC/DC 250 provides European weld cable •...
  • Page 19 TABLE OF CONTENTS - MAINTENANCE SECTION Maintenance ................D-1 Safety Precautions .

  • Page 20: Maintenance

    MAINTENANCE MAINTENANCE SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill. • Have a qualified individual install and service this equipment. • Turn the input power off at the fuse box before working on equipment. • Do not touch electrically hot parts. --------------------------------------------------------------------- GENERAL MAINTENANCE 1.
  • Page 21 TABLE OF CONTENTS-THEORY OF OPERATION SECTION Theory of Operation ..............E-1 General Description .

  • Page 22: Theory Of Operation

    RECTIFIER CHOKE GENERAL DESCRIPTION The IDEALARC AC/DC 250 is a single phase constant current arc welder power source available in a AC/DC model only. Designed for stick welding, it may be used for TIG welding DC or AC with an add on kit.
  • Page 23 On older codes Power Factor correction capacitors are The desired single phase input power is connected to factory installed. On later codes they are field installed the IDEALARC AC/DC 250 through the input recon- options. nect panel, located near the lower left of the machine.
  • Page 24 THEORY OF OPERATION FIGURE E.4 - OUTPUT VOLTAGE RECTIFICATION POLARITY SWITCH, OVER CURRENT PROTECTION AND STABILIZER CIRCUIT LINE SWITCH OPTIONAL POWER FACTOR CAPACITORS STABILIZER CIRCUIT INPUT LEADS OVERLOAD THERMOSTAT RECONNECT PANEL ELECTRODE SUPPRESSOR CIRCUIT ARC POLARITY SWITCH POWER WORK RECTIFIER CHOKE OUTPUT VOLTAGE RECTIFICATION POLARITY SWITCH, OVER...
  • Page 25 THEORY OF OPERATION FIGURE E.5 - CONTROL REACTOR AND CHOKE LINE SWITCH OPTIONAL POWER FACTOR CAPACITORS STABILIZER CIRCUIT INPUT LEADS OVERLOAD THERMOSTAT RECONNECT PANEL ELECTRODE SUPPRESSOR CIRCUIT ARC POLARITY SWITCH POWER WORK RECTIFIER CHOKE CONTROL REACTOR AND CHOKE The control reactor is the only means of increasing or With the crank set to maximum output (max air gap) decreasing the weld current of this machine.
  • Page 26 COMPONENT IDENTIFICATION FIGURE E.6 – MAIN TRANSFORMER ASSEMBLY REAR VIEW REACTOR WINDINGS REACTOR BRAKE MAIN TRANSFORMER ASSEMBLY FIGURE E.7 – MAIN TRANSFORMER ASSEMBLY FRONT VIEW WELD CHOKE REACTOR CRANK SHAFT REACTOR CRANK LEVER PRIMARY WINDINGS SECONDARY WINDINGS (UNDER SECONDARY) IDEALARC ®...
  • Page 27 TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR Troubleshooting and Repair ............. .F-1 How to Use Troubleshooting Guide .
  • Page 28 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.
  • Page 29 Do not touch electrically hot parts. - If you return a PC board to The Lincoln Electric Company for credit, it must be in the static-shielding bag. This will prevent further damage and allow prop- CAUTION er failure analysis.

  • Page 30: Troubleshooting And Repair

    6. Carefully clean in naptha. or replace thermostat. 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 ®...
  • Page 31 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 ®...
  • Page 32 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 ®...

  • Page 33: Main Transformer Test

    MAIN TRANSFORMER TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 34 TROUBLESHOOTING AND REPAIR MAIN TRANSFORMER TEST (continued) PROCEDURE GROUNDED PRIMARY COILS 1. Switch the volt meter to X 100 ohms. Check the WARNING H1 lead on the load side of the on / off switch to ELECTRIC SHOCK can kill. a good clean (rust/paint free) area on the case. Generally one of the removed case side screw •...

  • Page 35: Output Rectifier Bridge Test

    OUTPUT RECTIFIER BRIDGE TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 36 TROUBLESHOOTING AND REPAIR F-10 F-10 OUTPUT RECTIFIER BRIDGE TEST (continued) FIGURE F.1 – OUTPUT RECTIFIER TEST POINTS DC- OUTPUT DC+ OUTPUT (BLUE DOT OR - MARK) (RED DOT OR + MARK) AC INPUT (CENTER) AC INPUT LEAD #1 & #4 AC INPUT (CENTER) (CENTER)
  • Page 37 TROUBLESHOOTING AND REPAIR F-11 F-11 OUTPUT RECTIFIER BRIDGE TEST (continued) FIGURE F.2 – OUTPUT RECTIFIER SCHEMATIC MEASURE SCHEMATIC – MEASURE IDEALARC ® AC/DC 250...
  • Page 38 NOTES F-12 F-12 IDEALARC ® AC/DC 250...

  • Page 39: Control Reactor Test

    CONTROL REACTOR TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 40 TROUBLESHOOTING AND REPAIR F-14 F-14 CONTROL REACTOR TEST (continued) FIGURE F.3 – CONTROL REACTOR TEST READINGS MAX. MIN. OUTPUT OUTPUT INPUT TYPE VOLTS AMPS VOLTS AMPS VOLTS SHORT CIRCUIT CONDITION LOAD BANK CONDITION PROCEDURE Factors that can cause the above testing to WARNING result in error: ELECTRIC SHOCK can kill.

  • Page 41: Test For Grounded Circuits

    TEST FOR GROUNDED CIRCUITS WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 42 TROUBLESHOOTING AND REPAIR F-16 F-16 TEST FOR GROUNDED CIRCUITS (continued) PROCEDURE WARNING 4. Touch the electrode lead to the piece of ELECTRIC SHOCK can kill. attached bare sheet metal. The electrode should not create a weld arc. Small sparks can • Have a qualified individual be normal (typical leakage).

  • Page 43: Polarity Switch Removal And Replacement Procedure

    POLARITY SWITCH REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 44 TROUBLESHOOTING AND REPAIR F-18 F-18 POLARITY SWITCH REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.4 – POLARITY SWITCH MOUNTING BOLTS MOUNTING BOLTS MOUNTING BOLTS REMOVAL PROCEDURE 3. Locate the polarity switch in the top front right WARNING area. Make note of where the leads and ELECTRIC SHOCK can kill.
  • Page 45 TROUBLESHOOTING AND REPAIR F-19 F-19 POLARITY SWITCH REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.5 – POLARITY SWITCH CONNECTIONS VIEWED FROM THE REAR TO AC2 RECTIFIER & AC SECONDARY JUMPER ONLY TO NEGATIVE WELD STUD (WORK) WELD CHOKE LEAD JUMPER ONLY TO NEGATIVE RECTIFIER TO POSITIVE...
  • Page 46 NOTES F-20 F-20 IDEALARC ® AC/DC 250...

  • Page 47: Output Rectifier Bridge Removal And Replacement Procedure

    REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 48 TROUBLESHOOTING AND REPAIR F-22 F-22 OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.6 – OUTPUT RECTIFIER LEAD LOCATIONS AND MOUNTING BOLTS REMOVE ALL ELECTRICAL CONNECTIONS IN THIS TOP AREA REMOVE BOTH BRACKET MOUNTING NUTS 3.75 PMS 48/2/4 L11523 RIGHT SIDE VIEW REAR TOP VIEW OF WELDER FAN BAFFLE SHEET METAL...
  • Page 49 TROUBLESHOOTING AND REPAIR F-23 F-23 OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT PROCEDURE (continued) REPLACEMENT PROCEDURE 1. Perform a visual inspection of the snubber net- work for missing or burnt components. Replace if necessary before installing the new bridge rectifier. 2. Apply a thin coating of joint compound (Penetrox A-13 Lincoln Part #E2529) to all elec- trical mating surfaces.
  • Page 50 NOTES F-24 F-24 IDEALARC ® AC/DC 250...

  • Page 51: Case Front Current Indicator Removal Procedure

    REMOVAL PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 52 TROUBLESHOOTING AND REPAIR F-26 F-26 CASE FRONT CURRENT INDICATOR REMOVAL PROCEDURE (continued) FIGURE F.7 – ACTUATOR MOUNTING POINTS ACTUATOR ARM (TOP) ACTUATOR DRIVE SCREW POST PIVOT POINT ACTUATOR ARM SLOT SIDE VIEW FRONT VIEW (BOTTOM) PROCEDURE 1. Remove input power to the machine. 1.

  • Page 53: Control Reactor Crank Brake Adjustment Procedure

    CONTROL REACTOR CRANK BRAKE ADJUSTMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 54 TROUBLESHOOTING AND REPAIR F-28 F-28 CONTROL REACTOR CRANK BRAKE ADJUSTMENT PROCEDURE (continued) FIGURE F.8 – CONTROL REACTOR ADJUSTMENT POINTS BRAKE MOUNTING BOLTS (8) REACTOR RIGHT SHIM PIVOT POINTS GAP AREA ADJUSTMENT PROCEDURE This area of adjustment will prevent movement of WARNING the welders’...
  • Page 55 TROUBLESHOOTING AND REPAIR F-29 F-29 CONTROL REACTOR CRANK BRAKE ADJUSTMENT PROCEDURE (continued) If adjusting these 4 points does not help with your particular problem, then the brake assemblies need to be replaced. If the brakes are replaced, the air gap on both sides of the reactor must be maintained.

  • Page 56: Retest After Repair

    TROUBLESHOOTING AND REPAIR F-30 F-30 RETEST AFTER REPAIR Should a machine under test be rejected for any reason requiring the removal of any mechanical part that could effect the machines electrical characteristics, or if any electrical components are repaired or replaced, the machine must be retested.
  • Page 57 TABLE OF CONTENTS - DIAGRAM SECTION Electrical Diagrams ..............G-1 Wiring Diagram (60 Hz or 50/60 Hz Machines ONLY) .
  • Page 58 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine. IdEaLaRC aC/dC 250...
  • Page 59 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine. IdEaLaRC aC/dC 250...

This manual is also suitable for:

949195129513951495489645 ... Show all

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