Page 2 - SAFETY; ELECTRIC SHOCK can kill.; WARNING; ARC WELDING can be hazardous.
i SAFETY i IDEALARC SP-250 Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDRENAWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING. Read and understand the follow...
Page 3 - ii
FOR ELECTRICALLYpowered equipment. 6.a. Turn off input power using the disconnect switch at the fuse box before working onthe equipment. 6.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’srecommendations. 6.c. Ground the equipment in ac...
Page 4 - iii
iii SAFETY iii IDEALARC SP-250 Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Mar. ‘93 ELECTRIC AND MAG-NETIC FIELDSmay be dangerous 8.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creat...
Page 5 - iv; PRÉCAUTIONS DE SÛRETÉ
iv SAFETY iv IDEALARC SP-250 Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les ...
Page 6 - Parts Manual; TABLE OF CONTENTS; RETURN TO MAIN INDEX
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i - v Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . ...
Page 7 - INSTALLATION
INSTALLATION IDEALARC SP-250 INSTALLATION SECTION ........................................ Section A Technical Specifications ...................................................A-1Safety Precautions ...........................................................A-2Select Proper Location ...................
Page 8 - TECHNICAL SPECIFICATIONS - Idealarc SP-250; RATED OUTPUT
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Duty Cycle Amps Volts at Rated Amps 100% 145 amps 26 60% 200 amps 28 35% 250 amps 26 Current Range Maximum Open Circuit ...
Page 9 - SAFETY PRECAUTIONS; ELECTRIC SHOCK CAN KILL.; Do not touch electrically hot parts.; SELECT PROPER LOCATION; STACKING; INPUT CONNECTIONS
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Read entire Installation Section before installingthe IDEALARC SP-250 SAFETY PRECAUTIONS ELECTRIC SHOCK CAN KILL. • Only...
Page 10 - FUSE AND WIRE SIZES
A-3 INSTALLATION IDEALARC SP-250 A-3 FUSE AND WIRE SIZES Protect the input circuit with the super lag fuses ordelay type circuit breakers listed on the Specificationspage of this manual for the machine being used. Thetripping action of delay type circuit breakers decreasesas the magnitude of the cur...
Page 11 - CONNECT SHIELDING GAS
A-4 INSTALLATION IDEALARC SP-250 A-4 For the 230/460/575V/ 60 HZ model which is notequipped with a plug, an input cord, or a receptacle,the input power supply leads are connected directly tothe Reconnect Panel as shown Figure A.3. Refer to thespecifications table at the beginning of this chapter for...
Page 12 - Open the cylinder valve slowly a fraction of a turn.; FIGURE A.4 - Shielding Gas Supply Connections; RECONNECT PROCEDURE
A-5 INSTALLATION IDEALARC SP-250 A-5 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 stopsmoving...
Page 13 - INPUT LEAD IS CONNECTED.
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC A-6 INSTALLATION IDEALARC SP-250 A-6 FIGURE A.5 - Reconnect Diagram For Codes 9402, 9723, and 10001 208/230/1/60 Machine...
Page 14 - CONNECT OUTPUT COMPONENTS; INSTALL THE WORK CLAMP; Insert the lug on the end of the work cable through; OUTPUT POLARITY CONNECTION; b. Be sure the nozzle insulator is fully screwed
A-7 INSTALLATION IDEALARC SP-250 A-7 CONNECT OUTPUT COMPONENTS INSTALL THE WORK CLAMP Attach the work clamp to the cable which extends fromthe 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. S...
Page 15 - GUN & CABLE INSTALLATION; Lay the cable out straight.; CAUTION
A-8 INSTALLATION IDEALARC SP-250 A-8 GUN & CABLE INSTALLATION WARNING: TURN THE WELDER POWER SWITCHOFF BEFORE INSTALLING GUN AND CABLE. ____________________________________ 1. Lay the cable out straight. 2. Make sure all pins on the gun cable connector arealigned with the proper mating sockets o...
Page 16 - OPERATION
OPERATION IDEALARC SP-250 OPERATION SECTION ............................................ Section B Safety Instructions ............................................................B-1General Description..........................................................B-1Recommended Processes and Equipment .....
Page 17 - SAFETY INSTRUCTIONS; • Do not touch electrically live parts such; ADDITIONAL SAFETY PRECAUTIONS; GENERAL DESCRIPTION; Product Description
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC B-1 OPERATION B-1 Read and understand this entire section before operat-ing your Idealarc SP-250. SAFETY INSTRUCTIONS EL...
Page 18 - The system includes the following features:; both timed spot and stitch welding selections.; OPERATIONAL
B-2 OPERATION B-2 The system includes the following features: • 2-step or 4-step selectable trigger function (abovecode 9500 only). • both timed spot and stitch welding selections. • drop-in 2" (51mm) O.D. wire reel spindle with a 22-30 lb. (10 - 13.6 kg) Readi-Reel- adapter. • integral gas cyli...
Page 19 - Adjustable Flow Regulator - Accommodates CO; or; POWER SOURCE FEATURES:
B-3 OPERATION B-3 DESIGN FEATURES AND ADVANTAGES UNIT FEATURES: Undercarriage for Hand Mobility - Heavy duty 10"(254mm) wheels and 4" (102mm) casters are factoryinstalled along with the handle. Handle can be used forhanging the welding gun and work cable. Gas Cylinder Platform - Factory inst...
Page 20 - control designed into the gun handle for use with SP-; MACHINE CAPABILITY; DUTY
B-4 OPERATION B-4 Gun and Cable (K524-1) - A 12.5 ft. (3.8) GMAW gunand cable assembly, rated 200 amps 60% duty, is pro-vided with the SP-250 and 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 c...
Page 21 - CONTROLS AND SETTINGS; Toggle switch to turn input
B-5 OPERATION B-5 CONTROLS AND SETTINGS All operator controls are located on the Front PanelKeypad/Nameplate. See Figure B.1 for the location ofeach control. FIGURE B.1 - SP-250 Control Panel Keys 1. POWER SWITCH: Toggle switch to turn input power ON and OFF. When the switch is in the ONposition the...
Page 22 - Wire Type
B-6 OPERATION B-6 ARROW KEY OPERATION WHEN USED WITHPROCESS WIRE/GAS KEY: See Table B.1. Left Arrow Keys: Press to set Wire Type. Pressing theUP and DOWN arrow keys changes the Wire Type dis-played. Center Arrow Keys: Press to set Wire Diameter.Press the UP ( ) arrow key to increase the wire diam-et...
Page 23 - Left arrow keys: Do not function in Manual mode.; Press for automatic welding set up
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC ARROW KEY OPERATION WHEN USED WITHMANUAL KEY: See Table B.1. Left arrow keys: Do not function in Manual mode. Center arr...
Page 24 - GUN SWITCH CONTROL IPM VOLTS
B-8 OPERATION B-8 7. MEMORY KEYS: Press memory key location number in which you want to save a procedure orfrom which you want to recall a procedure frommemory. See SAVE Key. FIGURE B.3 - Sample SAVE Sequence. 8. SPOT KEY: Press to turn ON the Spot Weld Timer and display the spot weld ON time.Pressi...
Page 25 - -STEP TRIGGER INTERLOCK KEYS; Pressing; “Using 4-Step Trigger Interlock
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC 12. TOGGLE KEY : When first pressed, this key turns ON the TOGGLE MODE and recalls the weldsetup in memory 4. Pressing t...
Page 26 - OPERATING STEPS; MAKING A WELD IN AUTO MODE
B-10 OPERATION B-10 OPERATING STEPS Before operating the machine, be sure you have all thematerials needed to perform the work. Be sure you arefamiliar with and have taken all possible safety pre-cautions before starting the work. It is important thatyou follow these operating steps each time you us...
Page 27 - MAKING A SPOT WELD IN AUTO MODE
B-11 OPERATION B-11 10. If SPOT timing mode required. a. Press SPOT key. b. Press CENTER UP or DOWN ARROW keys toselect SPOT ON TIME required. c. Press SPOT key to return to previous display. d. Go to Step 12. 11. If STITCH timing mode required. a. Press STITCH key. b. Press CENTER UP and DOWN ARROW...
Page 28 - MAKING A STITCH WELD IN AUTO MODE; Press STITCH key. Stitch screen is displayed.; USING THE GUN TRIGGER SWITCH; USING THE WIRE DRIVE ROLL
B-12 OPERATION B-12 4. Press the CENTER UP & DOWN ARROW keys toset the required Spot On time. Suggested initialsetting is 1.2 seconds. 5. Press the SPOT key. Display returns to Autoscreen. Spot timer status is shown in bottom leftcorner of screen. 6. Install spot weld nozzle (if available) on gu...
Page 29 - LOADING THE WIRE REEL; NOTE: The retaining spring side of the adapter should
B-13 OPERATION B-13 LOADING THE WIRE REEL To mount a 22-30 lb. (10-14 kg) Readi-Reel- packageusing the Readi-Reel adapter provided: 1. Pull the Readi-Reel adapter and spindle up out ofthe SP-250 spindle mounting clips (V-brackets). 2. Rotate the spindle and adapter so the retainingspring is at the 1...
Page 30 - FEEDING ELECTRODE; Inch the electrode through the gun.; SETTING IDLE ROLL PRESSURE
B-14 OPERATION B-14 FEEDING ELECTRODE When inching, the electrode and drive mechanism arealways “hot” to work and ground. The electroderemains “hot” several seconds after the gun trigger isreleased. ____________________________________ NOTE: Check that the proper drive rolls and gun partsare used fo...
Page 31 - ACCESSORIES
ACCESSORIES IDEALARC SP-250 ACCESSORIES SECTION ....................................... Section C Options/Accessories ........................................................C-1 Replacement Magnum 250-SP Gun andCable Assemblies........................................................C-1Spool Gun Adap...
Page 32 - OPTIONS / ACCESSORIES; K607-1 Spool Gun adapter Kit; • Do not operate with covers removed.
C-1 ACCESSORIES C-1 OPTIONS / ACCESSORIES Replacement Magnum 250-SP Gun and CableAssemblies The following GMAW gun and cable assemblies areavailable for use with the SP-250. Each is rated at 200amps at 60% duty cycle. Each is equipped with a Fast-Mate connector and additional control lead connec-tio...
Page 33 - Disconnect the 4-pin gas solenoid plug from the
C-2 ACCESSORIES C-2 Figure C.2 - Spool Gun Module Board Installation. 1. Remove input power to the machine before start-ing. 2. Remove the six screws that hold the Case SidePanels. 3. Locate the four snap-mount fasteners mounted tothe side panel of the control Board. 4. Position the spool gun module...
Page 35 - SPOOL GUN CONNECTION
C-4 ACCESSORIES C-4 SPOOL GUN CONNECTION CAUTION: The spool gun module is intended for usewith Lincoln Electric Magnum Spool Guns only. Usewith 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 s...
Page 36 - SPOOL GUN INSTALLATION TO OLD K531 KIT.; Tighten the hex nut, being careful not to strip the
C-5 ACCESSORIES C-5 SPOOL GUN INSTALLATION TO OLD K531 KIT. 1. Slide the spool gun cable assembly through theopening in the louvers provided for the work lead.See Figure C.6. 2. Remove the SP-250 gas line from the gas line con-nector. 3. Screw the spool gun 6-pin plug into the new con-nector just be...
Page 37 - MAINTENANCE
MAINTENANCE IDEALARC SP-250 MAINTENANCE SECTION ...................................... Section D Safety Precautions ...........................................................D-1Routine and Periodic Maintenance ..................................D-1Component Locations ...................................
Page 38 - •Have a qualified technician do the maintenance; Replace worn contact tips as required.
D-1 MAINTENANCE D-1 SAFETY PRECAUTIONS •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 ...
Page 39 - Control Board
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC D-2 MAINTENANCE D-2 Figure D.1 - Component Locations IDEALARC SP-250 2 1 3 4 5 5 4 3 1 2 Control Board Fan Assembly SCR ...
Page 40 - THEORY OF OPERATION; NOTE: Unshaded areas of Block Logic
THEORY OF OPERATION IDEALARC SP-250 Figure E.1 -Block Logic Diagram NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion THEORY OF OPERATION SECTION ...................... Section E Power Supply Operation ........................................E-1 - E-3 Input Line Voltage and M...
Page 41 - Figure E.2 - Input Line Voltage and Main Transformer; POWER SUPPLY OPERATION
E-1 THEORY OF OPERATION E-1 IDEALARC SP-250 INPUT LINE VOLTAGE AND MAIN TRANS-FORMER The desired single phase input power is connected tothe SP-250 through a line switch located on the frontpanel. A reconnect panel allows the user to configure themachine for the desired input voltage. This AC inputv...
Page 42 - Figure E.3 - Output Rectification and Feedback Control
E-2 THEORY OF OPERATION E-2 IDEALARC SP-250 OUTPUT RECTIFICATION AND FEED-BACK CONTROL The AC output from the main transformer secondaryweld winding is rectified and controlled through theSCR rectifier assembly. Output voltage and currentare sensed at the shunt and output terminals and fedback to th...
Page 43 - CONSTANT VOLTAGE OUTPUT
E-3 THEORY OF OPERATION E-3 IDEALARC SP-250 CONSTANT VOLTAGE OUTPUT The controlled DC output from the SCR rectifierassembly is filtered by the capacitor bank and the out-put choke, which is in series with the gun and weldingload, resulting in a constant voltage output at the out-put terminals of the...
Page 44 - WIRE DRIVE MOTOR AND FEEDBACK; Figure E.5 - Wire Drive Motor and Feedback
E-4 THEORY OF OPERATION E-4 IDEALARC SP-250 WIRE DRIVE MOTOR AND FEEDBACK The wire drive motor is controlled by the control board.A motor speed feedback signal is generated at themotor tach and sent to the control board. The controlboard compares this feedback signal with the com-mands set forth by ...
Page 45 - THERMAL PROTECTION
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC E-5 THEORY OF OPERATION E-5 IDEALARC SP-250 A thermostat protects the machine from excessiveoperating temperatures.. Exc...
Page 46 - SCR OPERATION
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC E-6 THEORY OF OPERATION E-6 IDEALARC SP-250 A silicon controlled rectifier (SCR) is a three terminaldevice used to contr...
Page 47 - TROUBLESHOOTING & REPAIR; Test Procedures
TROUBLESHOOTING & REPAIR IDEALARC SP-250 TROUBLESHOOTING & REPAIR SECTION ........... Section F How to use Troubleshooting Guide ..................................F-1PC Board Troubleshooting Procedures ............................F-2Troubleshooting Guide.........................................
Page 48 - HOW TO USE TROUBLESHOOTING GUIDE
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC F-1 TROUBLESHOOTING & REPAIR F-1 IDEALARC SP-250 This Troubleshooting Guide is provided tohelp you locate and repair...
Page 49 - PC BOARD TROUBLESHOOTING PROCEDURES
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC F-2 TROUBLESHOOTING & REPAIR F-2 IDEALARC SP-250 CAUTION: Sometimes machine failures appear to be due to PC board fa...
Page 50 - OUTPUT PROBLEMS; Perform Main Transformer Test.
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC F-3 TROUBLESHOOTING & REPAIR F-3 IDEALARC SP-250 TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed thro...
Page 52 - Perform the Keypad Test.
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC F-5 TROUBLESHOOTING & REPAIR F-5 IDEALARC SP-250 TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed thro...
Page 53 - FUNCTION PROBLEMS
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC F-6 TROUBLESHOOTING & REPAIR F-6 IDEALARC SP-250 TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed thro...
Page 55 - WIRE FEEDING PROBLEMS
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC F-8 TROUBLESHOOTING & REPAIR F-8 IDEALARC SP-250 TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed thro...
Page 56 - WELDING PROBLEMS; Check for rusty or dirty wire.
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC F-9 TROUBLESHOOTING & REPAIR F-9 IDEALARC SP-250 TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed thro...
Page 58 - EXPLANATION OF PROMPTING AND ERROR MESSAGES; ON SCREEN ERROR MESSAGE
F-11 TROUBLESHOOTING & REPAIR F-11 IDEALARC SP-250 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC EXPLANATION OF PROMPTING AND ERROR MESSAGES ON SCREEN ERROR MESSA...
Page 59 - EXPLANATION OF PROMPTING AND ERROR MESSAGES (CONT’D)
F-12 TROUBLESHOOTING & REPAIR F-12 IDEALARC SP-250 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC EXPLANATION OF PROMPTING AND ERROR MESSAGES (CONT’D) ON SCREEN ER...
Page 61 - TEST DESCRIPTION; This test will determine if the correct voltages are being; MATERIALS NEEDED
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC F-14 TROUBLESHOOTING & REPAIR F-14 IDEALARC SP-250 TEST DESCRIPTION This test will determine if the correct voltages...
Page 62 - TEST PROCEDURE; Disconnect the main input power; FIGURE F.1A - G2252 Control PC Board Main Transformer Test Points.; MAIN TRANSFORMER TEST
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC F-15 TROUBLESHOOTING & REPAIR F-15 IDEALARC SP-250 TEST PROCEDURE The ON/OFF POWER SWITCH will be"hot" durin...
Page 63 - Locate the following leads on Plug
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC F-16 TROUBLESHOOTING & REPAIR F-16 IDEALARC SP-250 G1992 (code 9402 only): 5. Connect main input power to themachine...
Page 64 - Turn OFF the machine
F-17 TROUBLESHOOTING & REPAIR F-17 IDEALARC SP-250 G1992 (Code 9402 only): 8. Turn OFF the machine 9. Locate the following leads on Plug J6 on the G2252 Control PC Boardor Plug J3 on the G1992 Control PCBoard. See Figures F.1A & F1.B.G2252: G1992 (Code 9402 only): 10. Turn ON the machine. 11...
Page 65 - b. If the correct nameplate voltage
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC F-18 TROUBLESHOOTING & REPAIR F-18 IDEALARC SP-250 MAIN TRANSFORMER TEST b. If the correct nameplate voltage is bein...
Page 67 - STATIC SCR RECTIFIER ASSEMBLY TEST
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC FIGURE F.2B - Remove Plug J3 toPerform Static SCR RectifierAssembly Test. TEST PROCEDURE 1. Disconnect main AC input pow...
Page 68 - Reconnect leads X2 and X3.
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC F-21 TROUBLESHOOTING & REPAIR F-21 IDEALARC SP-250 NOTE: DO NOT DISASSEMBLE THESCR RECTIFIER HEAT SINK ASSEM-BLY. 6....
Page 71 - ACTIVE SCR RECTIFIER ASSEMBLY TEST
F-24 TROUBLESHOOTING & REPAIR F-24 IDEALARC SP-250 7. Connect the Tester to the SCR 1 asshown in Figure F.7. a. Connect Tester lead (A) to theanode. b. Connect Tester lead (C) to thecathode. c. Connect Tester lead (G) to thegate. FIGURE F.7 - SCR Tester Circuit andSCR connections. 8. Close switc...
Page 72 - This test will determine if any key is not functioning properly.
F-25 TROUBLESHOOTING & REPAIR F-25 IDEALARC SP-250 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TEST DESCRIPTION This test will determine if any key is not funct...
Page 74 - TEST POINTS
F-27 TROUBLESHOOTING & REPAIR F-27 IDEALARC SP-250 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TEST POINTS KEY PRESSED MAXIMUM ALLOWABLE RESISTANCE (TYPICAL RES...
Page 76 - MUST; WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST
F-29 TROUBLESHOOTING & REPAIR F-29 IDEALARC SP-250 TEST PROCEDURE NOTE: POLARITY MUST BE OBSERVED FOR THESE TESTS. Test for Correct Wire Drive MotorArmature Voltage 1. Disconnect main input power to themachine. 2. Remove the Case Top and SidePanels using a 5/16" nut driver. 3. Locate Plug J5...
Page 77 - a. Insert probes in to the Molex pin; Pull the gun trigger.
F-30 TROUBLESHOOTING & REPAIR F-30 IDEALARC SP-250 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 ControlBoard. 4. Test for 2-25 VDC between lead#539 (positive) and lead #541 (neg-ative) to determine i...
Page 78 - Read meter for 15 VDC.
F-31 TROUBLESHOOTING & REPAIR F-31 IDEALARC SP-250 Test for Supply Voltage toTachometer 1. Test for 15 VDC between lead#515B (positive) and lead #206B(negative). See Figure F. 10 for pinlocations. a. Insert probes into Molex pincavities. 2. Pull gun trigger. 3. Read meter for 15 VDC. a. If the 1...
Page 79 - SCOPE SETTINGS; NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM
F-32 TROUBLESHOOTING & REPAIR F-32 IDEALARC SP-250 This is a typical DC output voltage wave-form generated from a properly operatingmachine. Note that each vertical divisionrepresents 20 volts and that each horizontaldivision represents 2 milliseconds in time. Note: Scope probes connected at mac...
Page 80 - TYPICAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED
F-33 TROUBLESHOOTING & REPAIR F-33 IDEALARC SP-250 This is a typical DC output voltage wave-form generated from a properly operatingmachine. Note that each vertical divisionrepresents 20 volts and that each horizontaldivision represents 5 milliseconds in time.The machine was loaded with a resist...
Page 81 - ABNORMAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED
F-34 TROUBLESHOOTING & REPAIR F-34 IDEALARC SP-250 This is NOT a typical DC output voltagewaveform. One output SCR is not function-ing. Note the increased ripple content. OneSCR gate was disconnected to simulate anopen or non-functioning output SCR. Eachvertical division represents 20 volts ande...
Page 82 - ABNORMAL OPEN CIRCUIT VOLTAGE
F-35 TROUBLESHOOTING & REPAIR F-35 IDEALARC SP-250 This is NOT the typical DC output voltagewaveform. The output capacitors are notfunctioning. Note the lack of “filtering” in theoutput waveform. The output capacitorbank was disconnected. Each vertical divi-sion represents 20 volts and each hori...
Page 83 - TYPICAL SCR GATE VOLTAGE WAVEFORM
F-36 TROUBLESHOOTING & REPAIR F-36 IDEALARC SP-250 This is a typical SCR gate pulse voltagewaveform. 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 divisionrepresents 5 milliseconds in time...
Page 84 - Disconnect main input power the; CONTROL PC BOARD REMOVAL AND REPLACEMENT
F-37 TROUBLESHOOTING & REPAIR F-37 IDEALARC SP-250 Printed Circuit Boards can be dam-aged by static electricity. Follow sta-tic handling guidelines detailed in“PC Board TroubleshootingProcedures” at the beginning of thischapter. _____________________________ REMOVAL AND REPLACEMENTPROCEDURE MATE...
Page 85 - Lift the Control Board straight up
F-38 TROUBLESHOOTING & REPAIR F-38 IDEALARC SP-250 4. Remove the eight Phillips Headmounting screws using a PhillipsHead screwdriver. See Figure F.12. FIGURE F.12 - Control BoardMounting Screw Locations mayvary with different CodeMachines. 5. Lift the Control Board straight up and out from the m...
Page 87 - PROCEDURE; Install a new Keypad.; KEYPAD REMOVAL AND REPLACEMENT
F-40 TROUBLESHOOTING & REPAIR F-40 IDEALARC SP-250 PROCEDURE NOTE: BEFORE REMOVING THEKEYPAD, PERFORM THE KEYPADRESISTANCE TEST TO BE SURE THEKEYPAD IS FAULTY. 1. Disconnect main input power to themachine. 2. Remove the Case Top and SidePanels with 5/16" nut driver. 3. Disconnect Keypad Plug...
Page 91 - Cut any necessary cable ties.; SCR OUTPUT RECTIFIER REMOVAL
F-44 TROUBLESHOOTING & REPAIR F-44 IDEALARC SP-250 PROCEDURE 1. Disconnect lead #208 andTransformer Lead X1 from the heatsink on the left side of the machine(facing the front) using a 1/2" socketwrench. See Figure F.14. a. Thin lead is always on the out-board side of the connection. FIGURE F...
Page 97 - Remove the Case Back screws.; FAN MOTOR AND FAN REMOVAL AND REPLACEMENT
F-50 TROUBLESHOOTING & REPAIR F-50 IDEALARC SP-250 PROCEDURE See Figure F.18 for fan motor and fanremoval components. FIGURE F.18 - Fan Motor and FanRemoval Components 1. Remove the Case Back screws. 2. Remove the gas solenoid using a3/4" open end wrench. 3. Using a 5/16” wrench, remove the ...
Page 98 - Remove the fan motor.
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC F-51 TROUBLESHOOTING & REPAIR F-51 IDEALARC SP-250 7. Remove the fan motor. a. Loosen and remove the twoscrews from ...
Page 99 - INPUT IDLE AMPS AND WATTS; Maximum Idle Watts
F-52 TROUBLESHOOTING & REPAIR F-52 IDEALARC SP-250 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC INPUT IDLE AMPS AND WATTS WIRE SPEED RANGE OPEN CIRCUIT VOLTAGE R...
Page 100 - Section G
TABLE OF CONTENTS - ELECTRICAL DIAGRAMS - Section G IDEALARC SP-250 ELECTRICAL DIAGRAMS SECTION ...................... Section G G1992 CONTROL PC BOARD LAYOUT .....................G - 1G2252 CONTROL PC BOARD LAYOUT ......................G - 5WIRING DIAGRAM (Code 9402) ..................................
Page 101 - ELECTRICAL DIAGRAMS
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC J 5 J 6 J 3 J 4 C 1 6 C 1 8 X 1 4 R47 C 1 9 D Z 3 R 4 0 R 8 9 R 9 0 R 4 8 R 5 0 C 2 3 C 2 2 D 2 4 D 2 5 D 2 6 D 2 7 D 2 ...
Page 104 - NOTES
G-4 NOTES G-4 IDEALARC SP-250 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC
Page 109 - WIRING DIAGRAM FOR CODE 9402; N O T E S
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC G-9 G-9 IDEALARC SP-250 IDEALARC SP-250 ELECTRICAL DIAGRAMS WIRING DIAGRAM FOR CODE 9402 NOTE: This diagram is for reference onl...
Page 112 - G1992 CONTROL PC BOARD SCHEMATIC
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC G-12 ELECTRICAL DIAGRAMS G-12 G1992 CONTROL PC BOARD SCHEMATIC NOTE: Lincoln Electric assumes no responsibility for liablilities...
Page 113 - G2252 CONTROL PC BOARD SCHEMATIC
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC G-13 ELECTRICAL DIAGRAMS G-13 G2252 CONTROL PC BOARD SCHEMATIC NOTE: Lincoln Electric assumes no responsibility for liablilities...
