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IDEALARC SP-250
SVM 111-A
January, 1996
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 READING THIS MANUAL AND THE
SAFETY PRECAUTIONS CONTAINED THROUGHOUT. And,
most importantly, think before you
act and be careful.
9402
9546
9723
10001
10002
View Safety Info View Safety Info View Safety Info View Safety Info
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World's Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors
SERVICE MANUAL
Sales and Service through Subsidiaries and Distributors Worldwide
22801 St. Clair Ave. Cleveland, Ohio 44117-1199 U.S.A. Tel. (216) 481-8100
i
SAFETY
i
WARNING
ARC WELDING can be hazardous.
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN
AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American W elding Society, P .O. Box 351040,
Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the
Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THA T ALLINSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
ELECTRIC SHOCK can kill.
1.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.
1.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.
In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
1.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
1.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.
1.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
1.f.
Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
1.g. Never dip the electrode in water for cooling.
1.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.
1.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
1.j. Also see Items 4.c. and 6.
2.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
2.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
fumes and gases away from the breathing zone. When
welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.
3.b.
Do not weld in locations near chlorinated hydrocarbon
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
form phosgene, a highly toxic gas, and other irritating
products.
3.c. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
3.d. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
ARC RAYS can burn.
2.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.
FUMES AND GASES
can be dangerous.
3.a.Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases.When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
vapors
to
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3.e. Also see item 7b.
IDEALARC SP-250
Apr. ‘93
ii
SAFETY
ii
WELDING SPARKS can
cause fire or explosion.
4.a.
Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
the welding sparks from starting a fire.
materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.
4.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.
4.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact can
cause overheating and create a fire hazard.
4.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
4.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
4.f.
Sparks and spatter are thrown from the welding arc. Wear oil
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.
4.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate circuits.
This can create fire hazards or overheat lifting chains or
cables until they fail.
4.h. Also see item 7c.
Remember that welding sparks and hot
though
they have
Preparation
for Welding and Cutting of
CYLINDER may explode
if damaged.
5.a. Use only compressed gas cylinders
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
5.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
5.c. Cylinders should be located:
•Away from areas where they may be struck or subjected to
physical damage.
• A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
5.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
5.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
5.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
5.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
FOR ELECTRICALLY
powered equipment.
6.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
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.
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Feb. ‘95
IDEALARC SP-250
iii
SAFETY
iii
FOR ENGINE
powered equipment.
7.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
7.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.
____________________________________________________
7.c. Do not add the fuel near an open flame
welding arc or when the engine is running. Stop the engine and allow it to cool
before refueling to prevent spilled fuel
from vaporizing on contact with hot
engine parts and igniting. Do not spill
fuel when filling tank. If fuel is spilled,
wipe it up and do not start engine until
fumes have been eliminated.
____________________________________________________
7.d. Keep all equipment safety guards, covers
and devices in position and in good repair.
Keep hands, hair, clothing and tools away
from V-belts, gears, fans and all other
moving parts when starting, operating or
repairing equipment.
ELECTRIC AND MAGNETIC FIELDS
may be dangerous
8.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines
8.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
8.c. Exposure to EMF fields in welding may have other health
effects which are now not known.
8d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
8.d.1.
Route the electrode and work cables together - Secure
them with tape when possible.
8.d.2. Never coil the electrode lead around your body.
8.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.
8.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
8.d.5. Do not work next to welding power source.
____________________________________________________
7.e. In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.
7.f. Do not put your hands near the engine fan. Do not
attempt to override the governor or idler by pushing on
the throttle control rods while the engine is running.
7.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
___________________________________________________
7.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
Mar. ‘93
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IDEALARC SP-250
iv
SAFETY
iv
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 précautions de sûreté générales suivantes:
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble de
soudage et la machine à souder en bon et sûr état defonctionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
zones où l’on pique le laitier.
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
8. S’assurer que la masse est connectée le plus prés possible de
la zone de travail qu’il est pratique de le faire. Si on place la
masse sur la charpente de la construction ou d’autres endroits
éloignés de la zone de travail, on augmente le risque de voir
passer le courant de soudage par les chaines de levage,
câbles de grue, ou autres circuits. Cela peut provoquer des
risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté, voir
le code “Code for safety in welding and cutting” CSAStandard
W 117.2-1974.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie
du corps.
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du rayonnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
l‘arc.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pantalons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
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PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la debrancher à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
Mar. ‘93
IDEALARC SP-250
RETURN TO MAIN INDEX
TABLE OF CONTENTS
Page
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i - v
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Select Proper Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Input Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Reconnect Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
Connect Output Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-7 - A-9
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section B
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
Recommended Processes and Equipment . . . . . . . . . . . . . . . . . . . . . . .B-2
Operational Features and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
Design Features and Advantages . . . . . . . . . . . . . . . . . . . . . . . . . .B-3 - B-4
Machine Capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4
Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4 - B-9
Controls and Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5 - B-9
Operating Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-10 - B-14
vv
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section C
Options/Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section D
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1
Routine and Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section E
Power Supply Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-1 - E-4
Thermal Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-5
SCR Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-6
Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section F
How to use Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-1
PC Board Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . .F-2
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-3 - F-53
Error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-11 - F-13
Retest after Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-52
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section G
Parts Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-201
IDEALARC SP-250
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 - 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
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IDEALARC SP-250
A-1
INSTALLATION
TECHNICAL SPECIFICATIONS - Idealarc SP-250
INPUT - SINGLE PHASE/ 60 HERTZ ONLY
Standard Voltage Input Current at Rated Output
208/230/1/60 53/49 Amps
230/460/575 50/25/20 Amps
RATED OUTPUT
Duty Cycle Amps Volts at Rated Amps
100% 145 amps 26
60% 200 amps 28
35% 250 amps 26
OUTPUT
Current Range Maximum Open Circuit Voltage Wire Speed Range
A-1
30A - 250A 10V - 40V 50 - 600 IPM
(1.27-15.2 m./minute)
RECOMMENDED INPUT WIRE & FUSE SIZE
Input Voltage/ Fuse (Superlag) Type 750C wire in Type 750C Copper
Frequency or Breaker Size Copper conduit AWG Ground Wire in Conduit
(IEC Sizes)
Runs to Runs over
100ft. (30m.) 100ft.(30m.)
208/60 60 8 (10mm2) 6 (16mm2) 10 (6mm2)
230/60 60 10 (6mm2) 8 (10mm2) 10 (6mm2)
460/60 30 14 (2.5mm2) 12 (4mm2) 10 (6mm2)
575/60 25 14 (2.5mm2) 12 (4mm2) 10 (6mm2)
PHYSICAL DIMENSIONS
HEIGHT Width DEPTH WEIGHT
(W/GUN)
28.2” 18.8” 40.1” 222 lbs.
(719mm) (480mm) (1019mm) (101 Kg.)
OPERATING TEMPERATURE
STORAGE OPERATING
±400C -200C to 400C
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IDEALARC SP-250
A-2
INSTALLATION
A-2
Read entire Installation Section before installing
the IDEALARC SP-250
SAFETY PRECAUTIONS
ELECTRIC SHOCK CAN KILL.
WARNING
• Only qualified personnel should install
this machine.
• Turn the input power OFF at the disconnect switch or fuse box before
working on the equipment.
• Do not touch electrically hot parts.
• 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.
____________________________________
1. Before starting the installation, check with the local
power company to determine if there is any question about whether your power supply is adequate
for the voltage, amperes, phase, and frequency
specified on the welder nameplate. Also be sure
the planned installation will meet the U.S. National
Electrical Code and local code requirements. This
welder may be operated from a single-phase line
or from one phase of a three-phase line.
2. Models that have multiple input voltages specified
on the nameplate (e.g., 208/230) are shipped connected for the highest voltage. If the welder is to
be operated at a lower voltage, it must be reconnected according to the instructions on the inside
of the removable panel (Reconnect Access Door)
near the top left side of the Case Back Assembly.
Also see the Reconnect Section of this manual for
details on reconnecting the machine to operate at
different voltages.
3. Be sure the voltage, phase, and frequency of the
input power is as specified on the machine rating
plate. See Figure A.1 for the location of the
machine’s input cord entry, Reconnect Access
Door, Reconnect Panel, and Rear Nameplate.
SELECT PROPER LOCATION
Place the IDEALARC SP-250 where clean air can
freely circulate in through the front intake and out
through the rear louvers. Dirt, dust, or any foreign
material that can be drawn into the machine should be
kept at a minimum. Not following these precautions
can result in the nuisance shutdown of the machine
because of excessive operating temperatures.
STACKING
The IDEALARC SP-250 cannot be stacked.
INPUT CONNECTIONS
WARNING
All input power must be electrically
disconnected before proceeding.
FIGURE A.1 - Case Back Assembly: Input Power
Cable Entry Connections.
____________________________________
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IDEALARC SP-250
A-3
INSTALLATION
A-3
FUSE AND WIRE SIZES
Protect the input circuit with the super lag fuses or
delay type circuit breakers listed on the Specifications
page of this manual for the machine being used. The
tripping action of delay type circuit breakers decreases
as the magnitude of the current increases. They are
also called inverse time or thermal/magnetic circuit
breakers.
DO NOT use fuses or circuit breakers with a lower amp
rating than recommended. This can result in "nuisance" tripping caused by inrush current even when
machine is not being used for welding at high output
currents.
Use input and grounding wire sizes that meet local
electrical codes or see the Specifications page in this
manual.
INPUT POWER CONNECTIONS AND
GROUND CONNECTIONS
proper grounding of the welder frame when the
welder plug is inserted into the receptacle.
4. Use proper wire sizes. See the Specification table
for proper wire sizes. For cable lengths over 100
feet, larger copper wires should be used.
FIGURE A.2. - Ground Connections.
Have a qualified electrician connect the receptacle or
cable to the input power lines and the system ground
according to the U.S. National Electrical Code and any
applicable local codes.
1. Follow the Input Supply Connection Diagram on
the inside of the Reconnect Panel Access Door.
2. Use a single-phase line or one phase of a threephase line.
For the 208V/230V/ 60 HZ model SP 250 shipped with
a 10 ft. input cord and plug connected to the welder,
mount the matching receptacle supplied with the
machine.
1. Mount the receptacle in a suitable location using
the screws provided.
2. Locate the receptacle within reach of the 10 ft.
input cord attached to the welder.
3. Mount the receptacle with the grounding terminal
at the top. This allows the power cable to hang
down without bending. See Figure A.2.
a. The center terminal in the receptacle is for the
b. Fuse the two hot lines of the receptacle with
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grounding connection.
super lag type fuses as shown in Figure A.2. A
green wire in the input cord connects this terminal to the frame of the welder. This ensures
IDEALARC SP-250
A-4
INSTALLATION
A-4
For the 230/460/575V/ 60 HZ model which is not
equipped with a plug, an input cord, or a receptacle,
the input power supply leads are connected directly to
the Reconnect Panel as shown Figure A.3. Refer to the
specifications table at the beginning of this chapter for
proper wiring sizes.
1. Connect the input power leads to terminals L1 and
L2 on the Reconnect Panel Assembly.
a. For input power supply leads of 10 AWG or
smaller, connect leads to Reconnect Panel
using the ferrules (S19117-1) provided.
b. Strip fi" (13mm) of insulation from the input
power supply leads.
c. Place ferrule over wire.
e. Torque the terminal screws to 16 in.-lbs.
(1.8nm).
1. Set the gas cylinder on the rear platform of the SP
250.
2. Hook the chain in place to secure cylinder to rear
of welder.
3. Remove the cylinder cap.
4. Inspect the cylinder valves for damaged threads,
dirt, dust, oil or grease.
a. Remove dust and dirt with a clean cloth.
NOTE: DO NOT ATTACH THE REGULATOR IF OIL,
GREASE OR DAMAGE IS PRESENT! Inform your
gas supplier of this condition. Oil or grease in the presence of high pressure oxygen is explosive.
5. Stand to one side away from the outlet and open
the cylinder valve for an instant to blow away any
dust or dirt which may have accumulated in the
valve outlet.
BE SURE TO KEEP YOUR FACE AWAY FROM THE
VALVE OUTLET WHEN OPENING THE VALVE.
FIGURE A.3 - Ground Connection For 230/460/575
Volt Models
CONNECT SHIELDING GAS
Customer must provide cylinder of appropriate type of
shielding gas for gas metal arc welding for the process
being used. See Figure A.4 for the location of the components used to connect the air supply cylinder.
WARNING
GAS UNDER PRESSURE IS EXPLOSIVE. ALWAYS KEEP GAS CYLINDERS IN AN UPRIGHTPOSITION AND
ALWAYS KEEP CHAINED TO UNDERCARRIAGE OR STATIONARY SUPPORT.
6. Inspect the regulator for damaged threads, dirt,
dust, oil or grease.
a. Remove dust and dirt with a clean cloth.
NOTE: DO NOT USE THE REGULATOR IF OIL,
GREASE OR DAMAGE IS PRESENT! Have an
authorized repair station clean the regulator or repair
any damage.
7. Attach the flow regulator to the cylinder valve and
tighten the union nut(s) securely with a wrench.
a. NOTE: If connecting the flow regulator to
100% CO2 cylinder, insert regulator adapter
provided between regulator and cylinder valve.
If adapter is equipped with a plastic washer, be
sure it is seated properly to connect to the
CO2 cylinder.
8. Connect one end of the inlet gas hose to the outlet
fitting of the flow regulator.
9. Connect the other end of the inlet gas hose to the
SP-250 rear fitting.
10. Tighten both the union nuts securely with a
wrench.
____________________________________
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IDEALARC SP-250
A-5
INSTALLATION
A-5
11. Before opening the cylinder valve, turn the regulator adjusting knob counter clockwise until the pressure is released from the adjusting spring.
12. Open the cylinder valve slowly a fraction of a turn.
a. When the cylinder pressure gage pointer stops
moving, open the valve fully.
NEVER STAND DIRECTLY IN FRONT OF OR
BEHIND THE FLOW REGULATOR WHEN OPENING
THE CYLINDER VALVE. ALWAYS STAND TO ONE
SIDE.
13. Adjust the flow regulator for the flow rate recommended for the procedure and process being used
before making the weld.
RECONNECT PROCEDURE
Multiple voltage machines are shipped connected to
the highest input voltage listed on the machine's rating
plate. Before installing the machine, check that the
Reconnect Panel in the Input Box Assembly is connected for the proper voltage.
CAUTION
Failure to follow these instructions can cause immediate failure of components within the machine.
____________________________________
To reconnect a dual or triple voltage machine to a different voltage, change the position of the leads or links
on the Reconnect Panel based on the type of machine.
Follow The Input Supply Connection Diagram located
on the inside of the Case Back Reconnect Panel
Access Door.
FIGURE A.4 - Shielding Gas Supply Connections
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.
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IDEALARC SP-250
A-6
ALL MACHINES ARE SHIPPED FROM THE FACTORY CONNECTED FOR THE HIGHER OF THE TWO
INPUT VOLTAGES LISTED ON THE NAMEPLATE. TO CHANGE VOLTAGE CONNECTION PROCEED AS
FOLLOWS:
1. REMOVE THE OUTER STEEL HEX NUT FROM THE TERMINAL WHERE THE TRANSFORMER
INPUT LEAD IS CONNECTED.
2. SHIFT THE TRANSFORMER INPUT LEAD TO THE TERMINAL THAT THE UNIT IS TO OPERATE
ON AND FASTEN SECURELY WITH THE HEX NUT REMOVED IN STEP1. (MAKE CERTAIN THAT
BRASS NUTS ARE TIGHT.)
INSTALLATION
A-6
FIGURE A.5 - Reconnect Diagram For Codes 9402, 9723, and 10001 208/230/1/60 Machines.
1. ALL MACHINES ARE SHIPPED FROM THE FACTORY CONNECTED FOR THE HIGHEST NAMEPLA TED SINGLE PHASE INPUTVOLT AGE. TO CHANGE CONNECTIONS FOR ADIFFERENT INPUT
VOLTAGE, RECONNECT BOTH COPPER JUMPERS PER DIAGRAM BELOW. ALWAYS CONNECT
JUMPERS BETWEEN OUTER STEEL NUT AND INNER BRASS NUT ON TERMINAL STUDS.
2. CONNECT THE INPUT POWER TO THE INPUTTERMINALBLOCK, L1 AND L2 ATTHE UPPER CORNER 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 ( ) ON THE MACHINE NEAR THE TERMINAL BLOCK.
FIGURE A.6 - Reconnect Diagram For Codes 9546 & 10002 230/460/575/1/60 Machine.
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IDEALARC SP-250
A-7
INSTALLATION
A-7
CONNECT OUTPUT COMPONENTS
INSTALL THE WORK CLAMP
Attach the work clamp to the cable which extends from
the front of the machine using the following procedure:
1. Insert the lug on the end of the work cable through
the strain relief hole in the work clamp handle. See
Figure A.7.
2. Slide the work cable through the hole up to the bolt
and nut.
3. Fasten work cable using the bolt and nut provided.
GUN LINER & CONTACT TIP
INSTALLATION
The Magnum 250 SP gun and cable provided with the
SP-250 is factory installed with a liner for a .035” or
.045” (0.9 or 1.2mm) diameter electrode and an .035
(0.9mm) contact tip.
1. If a .045” diameter wire size is to be used, install
the .045” contact tip (also provided).
2. For other wire sizes, use the following procedure
for contact tip and gas nozzle installation. See
Figure A.8.
a. Choose the correct size contact tip for the
electrode being used (wire size is stenciled on
the side of the contact tip) and screw it snugly
into the gas diffuser.
b. Be sure the nozzle insulator is fully screwed
onto the gun tube and does not block the gas
holes in the diffuser.
FIGURE A.7 - Installing The Work Clamp
OUTPUT POLARITY CONNECTION
WARNING
WARNING: TURN THE WELDER POWER SWITCH
OFF BEFORE CHANGING OUTPUT CONNECTION.
____________________________________
The welder is shipped from the factory connected for
electrode positive (+) polarity . This is the normal polarity for GMA welding.
If negative (-) polarity is required, interchange the connection of the two cables located in the wire drive compartment near the front panel. The negative lead is the
lead closest to the front panel (where the leads come
out of the floor of the compartment) and should be
reconnected to the brass conductor tube of the gun
connector. The positive lead is stamped (+) on its terminal and should be reconnected to the work lead terminal.
c. Slip the appropriate gas nozzle onto the noz-
zle insulator. Either a standard .50" (12.7mm)
or optional .62” (15.9mm) I.D. slip on gas nozzle may be used and should be selected
based on the welding application.
d. Adjust the gas nozzle for the GMAW process
to be used.
For the short-circuiting transfer process, the contact
tip end should be flush to extended to .12" (3.2mm)
For the spray transfer process, the contact tip should
be flush to recessed .12" (3.2mm).
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FIGURE A.8 - Contact Tip and Electrode
Connections
IDEALARC SP-250
A-8
GUN & CABLE INSTALLATION
INSTALLATION
A-8
WARNING
WARNING: TURN THE WELDER POWER SWITCH
OFF BEFORE INSTALLING GUN AND CABLE.
____________________________________
1. Lay the cable out straight.
2. Make sure all pins on the gun cable connector are
aligned with the proper mating sockets on the front
panel gun connector and then join the connectors
and tighten the hand nut on the gun cable connector.
NOTE: If a gun and cable other than the Magnum 250
SP is to be used, it must conform to standard
European style connector (Magnum Fast Mate) specifications. See Figure A.9.
NOTE: The thumb switch functions available on the
Magnum 250 SP gun will only be operable from the
front panel keypad. The gun trigger switch must be
capable of switching 5 milliamps at 15 volts DC resistive.
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
insulated from the welding circuit. Improper operation 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.
____________________________________
FIGURE A.9 - European Style Connector
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IDEALARC SP-250
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 - B-4
Machine Capability...........................................................B-4
Limitations...............................................................B-4 - B-9
Controls and Settings..............................................B-5 - B-9
Power Switch...............................................................B-5
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
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IDEALARC SP-250
B-1
OPERATION
B-1
Read and understand this entire section before operating your Idealarc SP-250.
SAFETY INSTRUCTIONS
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts such
as output terminals or internal wiring.
• Insulate yourself from the work and
ground.
• Always wear dry insulating gloves.
------------------------------------------------------------------------
Only qualified personnel should operate this equipment.
ADDITIONAL SAFETY PRECAUTIONS
Proper welding setup is simple. You only need to
select the gauge size of the material to be welded and
enter the welding process to used. With that data, the
system
• automatically computes the proper wire feed
speed and arc voltage relationship for the process.
• selects the right procedure for optimum starting,
welding, and burnback.
The system allows you to store up to five separate
welding setup procedures. You can recall them at any
time at the touch of a single key . All active setup selections, as well as those stored in the memory locations,
are automatically saved when power is turned off or
disconnected. Whatever procedure was being used
when power was removed, will be recalled when power
is returned. The SP-250 does not require batteries to
maintain memory data.
Always operate the welder with the hinged door closed
and the side panels in place as these provide maximum protection from moving parts and insure proper
cooling air flow.
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 intelligent welding system.
Afront panel touch key entry system with audible feedback, along with a two-line, 32 character alphanumeric display, provide user friendly control of the system.
The system provides full range control from the keypad
or from the thumb switch built into the SP-250 welding
gun, which permits "on the fly" control while welding
Multi language display capability allows the SP-250 to
communicate with the user in any of the following five
languages: English, German, French, Spanish, or
Japanese (Katakana).
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IDEALARC SP-250
B-2
OPERATION
B-2
The system includes the following features:
• 2-step or 4-step selectable trigger function (above
code 9500 only).
• both timed spot and stitch welding selections.
• drop-in 2" (51mm) O.D. wire reel spindle with a 2230 lb. (10 - 13.6 kg) Readi-Reel- adapter.
• integral gas cylinder mounting undercarriage.
• 12.5 ft. (3.8m) Magnum 250SP GMAW gun and
cable.
• dual groove drive roll and a gun liner for .035
(0.9mm) and .045 (1.2mm) electrodes.
• one contact tip for each wire size.
• adjustable CO2or argon blend flow regulator with
cylinder pressure gauge.
• 10 ft. (3.0m) plug cable with receptacle.
• 12 ft. (3.6m) work cable with clamp.
RECOMMENDED PROCESSES AND
EQUIPMENT
The SP-250 is recommended for GMA welding
processes using 10 to 30 lb. (4.5 to 13.6 kg) 2" (51mm)
I.D. spools or Readi-Reel coils of
• .025" through .045" (0.61.2mm) solid steel using
CO2, ArCO2, or ArO2shielding gas
OPERATIONAL FEATURES AND
CONTROLS
Keypad - Consists of 20 membrane keys that have
large touch areas. The keys are spaced far enough
apart to provide easy selection, even if wearing welding gloves. An audible feedback beep is provided
whenever a key is pressed to ensure proper entry.
Display - Wide temperature range liquid crystal display
combines large 0.32" (8.1mm) high characters in a 2line by 16-character alphanumeric format. It has long
life LED backlighting and a non-glare cover for easy
viewing under bright or dark conditions. Multi language display capability permits the SP-250 to communicate in English, German, French, Spanish, or
Japanese (Katakana).
Auto Mode - Simply set the thickness of the material
being welded and the SP-250 automatically sets the
proper wire feed speed and arc voltage for the process
being used. This eliminates the need for look-up
tables, procedure slide rules, or notebooks to find the
proper settings. Auto Mode also provides one key control of the output by automatically adjusting both the
wire feed speed and arc voltage for an increase or
decrease in material thickness or wire feed speed.
This allows the operator to easily increase or decrease
his output without having to know how much to change
each parameter.
Thumb Switch on Gun - Allows the operator to set or
change the output of the machine, the wire feed speed,
or the arc voltage from the gun, even during welding.
This permits "on the fly" adjustment. In toggle operation mode, the thumb switch allows the operator to
toggle between two procedures stored in memory.
• .035" (0.9mm) stainless steel using ArO2or
HeArCO2shielding gas
• 3/64" (1.2mm) aluminum using Ar shielding gas
• .045" (1.2mm) Outershield- electrodes using CO
or ArCO2shielding gas
• .035" (0.9mm) and .045 (1.2mm) Innershield selfshielded electrodes.
The SP-250 is factory equipped to feed .035 (0.9mm)
and .045 (1.2mm) electrodes and includes a 200A,
60% duty cycle rated, 12.5 ft. (3.8m) GMA gun and
cable assembly equipped for these wire sizes. The
SP-250 is factory equipped with an adjustable CO2or
argon blend flow regulator. A supply of shielding gas is
required for GMAW processes.
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Memory - There are five separate memory locations
that the operator can use to save or recall a setup procedure. This eliminates dial marking and makes recalling a setup as simple as pushing one of the five memory keys for instant recall. Also, when power is
removed, these five memories as well as any current
2
setup in use is automatically saved. This feature does
not require batteries. When power is restored, the procedure in use will automatically return the unit to whatever was set up was being used when power was
removed.
Trigger Interlock (Above code 9500 only) - Selectable
four-step trigger interlock allows operator to release
gun trigger after weld current is established and continue welding. Breaking the arc or re-closing and then
releasing the gun trigger, stops the welding process.
IDEALARC SP-250
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 factory
installed along with the handle. Handle can be used for
hanging the welding gun and work cable.
Gas Cylinder Platform - Factory installed on undercarriage. It permits platform mounting and support of a
single gas cylinder. No full lifting of gas cylinder
required during loading.
Adjustable Flow Regulator - Accommodates CO2or
argon blend gas. Includes a cylinder pressure gauge
and a dual seal flow gauge.
Easy Accessability - Wire feeder enclosure protects
wire and wire drive from dirt, dust, and damage. Allows
easy top-access for "drop-in" wire reel loading and to
load or service the wire drive.
POWER SOURCE FEATURES:
10 Ft. (3.0m) Input Power Cable - Includes plug and
mating receptacle for 208/230V unit. Convenient rear
panel reconnect allows easy access for 208V re-connection.
Power Switch - Front panel toggle switch turns input
power on and off.
Thermostatically Controlled Fans - Provides cooling
of transformer and other components only when
required. When used intermittently or at low current
procedures, the fan motors stay off, reducing the
amount of dust and dirt drawn into the machine. Also
reduces power consumption.
Electronic Overload Protection - Protects machine
from short circuit or high current overloading.
Power Source Line Voltage Regulation - Precise
SCR phase control circuit holds the voltage setting
constant to maintain weld quality even when the input
voltage fluctuates +/-10%.
Solid State Contactor - Output is turned on and off by
SCR's instead of a mechanical contactor providing
extra long life in highly repetitive welding applications.
Automatic Burnback - Provides proper burnback of
the electrode to prevent it from sticking in the weld puddle at the end of a weld.
Output Terminals - Easily accessible in wire drive
section for quick cable connection and polarity reversal.
Work Cable - 10 ft. (3.0m) long with work clamp.
WIRE FEEDER FEATURES:
Drop-in Wire Loading - Wire spindle snaps into
Readi-Reel-Adapter, included with SP-250, or most
any 2" (51mm) I.D. wire spool. The wire spindle drops
into the top loading SP-250 case design.
Accommodating standard 12” (305mm) and 8”
(203mm) diameter coils, the unique spindle and support design automatically provides appropriate de-reeling drag to prevent wire reel overrun and loop-offs
without manual brake adjustments.
Tachometer Controlled Wire Drive - Precision control of permanent magnet motor provides proper wire
feed acceleration and speed accuracy, independent of
fluctuations in line voltage and wire loading. This
means reliable arc starting and weld consistency.
Low Speed Start - When the trigger is pulled, the wire
feeder feeds wire at low speed regardless of the set
wire feed speed until welding current is drawn or 2 seconds has expired. This feature enhances starting and
makes setting stick out a snap. The 2 second limit permits high speed loading of the gun and cable. In later
versions of the SP-250, a user selectable feature
allows the wire feeder to feed wire directly at the set
speed, thus bypassing the 2 second slow start.
Solid State Wire Feed Overload Protection - No circuit breaker to reset. Simply pull the trigger to resume
welding once the overload condition has been cleared.
Unique Drive Roll and Guide Tube Design - Long
life, precisely aligned guide tubes and drive rolls.
Quickly reloads by simply starting wire into ingoing
guide tube. Adjustable tension setting minimizes
'birdnesting', eliminates milling through the wire, and
gives positive feeding. The double groove, reversible
drive roll included with the SP-250 allows use of .030
(0.8mm) through .045 (1.2mm) diameter wire. Drive
Roll kits for other sizes and types of wire are also available.
Fast-Mate Gun Connector - European style gun connector provides electrode, shielding gas and gun con-
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IDEALARC SP-250
B-4
Gun and Cable (K524-1) - A 12.5 ft. (3.8) GMAW gun
and cable assembly, rated 200 amps 60% duty, is provided 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 connector with additional control lead connections for the
thumb activated 2 momentary position slide switch
control designed into the gun handle for use with SP-
250 remote control features.
OPERATION
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).
B-4
DUTY
CYCLE
100%
60%
35%
AMPS
145
200
250
VOLTS
26
28
26
LIMITATIONS
The SP-250 may not operate satisfactorily if powered
with a portable or in-plant generating system.
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IDEALARC SP-250
B-5
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.
B-5
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 ON
position the red LED backlighting of the LCD display lights and alphanumeric characters appear.
The welding setup in operation when the power
was shut off or disconnected is displayed when
power is restored.
2. SET UP ARROW KEYS: Press keys to
change the display selection directly above the
keys. See Figure B.1. Function of arrow keys
change depending on PROCESS KEY being used.
For function of arrow keys, refer to each process or
procedure. See Table B.1 for summary of arrow
key operation.
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3. PROCESS WIRE/GAS KEY: Press key to
display the Wire T ype, Wire Diameter , and W elding
Gas. Each combination of wire and gas dictates a
unique relationship between the wire feed speed
and the arc voltage. The SP-250 uses this unique
relationship, along with the metal thickness, to set
the proper values for wire feed speed and arc voltage. Therefore, it is very important that the wire
type, wire diameter, and welding gas displayed
match the actual wire type, wire diameter, and
welding gas being used for the weld.
IDEALARC SP-250
B-6
OPERATION
TABLE B.1 - Arrow Key Functions.
B-6
ARROW KEY OPERATION WHEN USED WITH
PROCESS WIRE/GAS KEY:
See Table B.1.
Left Arrow Keys: Press to set Wire T ype. Pressing the
UP and DOWN arrow keys changes the Wire Type displayed.
Center Arrow Keys: Press to set Wire Diameter.
Press the UP ( ) arrow key to increase the wire diameter displayed. Press the DOWN ( ) arrow key to
decrease the wire diameter displayed.
Right Arrow Keys: Press to select Welding Gas.
Pressing the UP and DOWN arrow keys changes the
Welding Gas displayed.
The following 16 processes are programmed into the
SP-250:
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Wire Type Wire Diameter Welding Gas
Solid Steel .025 (0.6mm) CO2
Solid Steel .025 (0.6mm) ArCO2
Solid Steel .030 (0.8mm) CO2
Solid Steel .030 (0.8mm) ArCO2
Solid Steel .035 (0.9mm) CO2
Solid Steel 035 (0.9mm) ArCO2
Solid Steel .035 (0.9mm) ArOxy
Solid Steel .045 (1.2mm) CO2
Solid Steel .045 (1.2mm) ArCO2
Stainless .035 (0.9mm) ArOxy
Stainless 035 (0.9mm) HeArCo2
Aluminum (5356) 3/64 (1.2mm) Argon
Outershield .045 (1.2mm) CO2
Outershield .045 (1.2mm) ArCO2
Innershield .035 (0.9mm) None
Innershield .045 (1.2mm) None
IDEALARC SP-250
B-7
OPERATION
4. AUTO KEY: Press for automatic welding set up
of recommended Wire Speed and Arc Voltage
based on Metal Thickness selected.
B-7
ARROW KEY OPERATION WHEN USED WITH
MANUAL KEY:
ARROW KEY OPERATION WHEN USED WITH
AUTO KEY:
See Table B.1.
Left Arrow Keys: Press to change the metal thickness
displayed. Press the UP ( )arrow key to increase
metal thickness. Press the DOWN ( ) arrow key to
decrease the metal thickness. Increasing or decreasing metal thickness automatically increases or
decreases both wire feed speed (IPM) and arc voltage
(VOLTS) simultaneously. See gauge chart on the
instruction label on the inside of SP-250 door for available sizes.
Center Arrow Keys: Press to change wire feed speed
setting. Press the UP ( ) arrow key to increase the
wire feed speed setting displayed. Press the DOWN
( ) arrow key to decrease the wire feed speed setting
displayed. Increasing or decreasing the wire feed
speed simultaneously causes an increase or decrease
in the arc voltage and can change the metal thickness
setting.
See Table B.1.
Left arrow keys: Do not function in Manual mode.
Center arrow keys: Press the UP ( ) arrow key to
increase wire feed speed. Press the DOWN ( ) arrow
key to decrease wire feed speed.
Right arrow key: Press the UP ( ) arrow key to
increase arc voltage. Press the DOWN ( ) arrow key
to decrease arc voltage.
NOTE: If the spot or stitch timers are ON, it will be indicated in the bottom left corner of the display. See
Figure B.2.
Right Arrow Keys: Press to change arc voltage setting. Press the UP ( ) arrow key to increase the arc
voltage setting displayed. Press the DOWN ( ) arrow
key to decrease arc voltage setting displayed. An up
arrow indicator appears below the V in VOLTS if the
arc voltage has been set higher than the recommended value. Adown arrow indicator appears below the V
in VOLTS if the arc voltage is below the recommended
value. No arrow indicates that you are set to the recommended value.
Pressing the AUTO key again resets the wire feed
speed and arc voltage settings to the recommended
values for the metal thickness displayed. (NOTE: If
the spot or stitch timers are on, metal thickness is not
displayed and, therefore, the reset function does not
work.)
5. MANUAL KEY: Press to set wire feed speed
and arc voltage for manual procedure setup. The
manual screen displays wire feed speed, arc voltage, and a cursor that indicates when the wire feed
speed or arc voltage is being controlled by the
thumb switch on the SP-250 gun.
FIGURE B.2 - Display when Stitch or Spot Weld
Timers are ON.
6. SAVE KEY: Press to save the current set up. The
process, procedure, and timer functions (if used)
are saved to one of five memory locations by
pressing one of the five memory keys. When the
Save key is pressed, a prompting message
instructing the operator to "PRESS MEMORY 1-5
TO SAVE SETUP" is displayed. See Figure B. 3
for sample SAVE sequence. This message
remains displayed until a memory number key is
selected or one of the other keys, such as Auto,
Manual, or Process, is pressed. If a memory number key is selected, a message will be displayed
for 2.5 seconds that confirms that the setup was
saved to that memory number.
The six arrow keys perform no function when saving a
setup.
NOTE: When a setup is saved to a memory location,
the previous contents of that memory is lost because it
is replaced by the present setup. Removing input
power does not effect the setup in memory.
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IDEALARC SP-250
B-8
OPERATION
B-8
7. MEMORY KEYS: Press memory key location
number in which you want to save a procedure or
from which you want to recall a procedure from
memory. See SAVE Key.
FIGURE B.3 - Sample SAVE Sequence.
8. SPOT KEY: Press to turn ON the Spot Weld
Timer and display the spot weld ON time.
Pressing the SPOT KEY a second time returns the
screen to the previous display without turning off
the spot timer. Anytime the Spot weld timer is on
and the display is in the Auto or Manual mode, the
word SPOT will appear in the bottom left corner of
the display. See Figure B.2.
Left arrow keys: Do not function.
Center arrow keys: Press UP ( ) arrow key to
increase Stitch time ON from 0.20 seconds to 2.50
seconds. Press the DOWN ( ) arrow key to decrease
Stitch ON time from 2.50 seconds to 0.20 seconds.
Right arrow keys: Press UP ( ) arrow key to increase
Stitch OFF time from 0.20 seconds to 2.50 seconds.
Press DOWN ( ) arrow key to decrease Stitch OFF
time from 2.50 seconds to 0.20 seconds.
10.TIMERS OFF KEY: Press to turn OFF both
Spot and Stitch timers. When the TIMERS OFF
key is pressed the indicating letters from the bottom left corner of the Auto and Manual mode display disappears.
The six arrow keys do not function with this key.
11.GUN SWITCH CONTROL IPM VOLTS
KEY: Press to engage the gun thumb switch to
control IPM or VOLTS. Pushing the gun thumb
switch forward (toward the tip) increases IPM or
VOLTS . Pulling gun thumb switch back decreases IPM or VOLTS. The underlining cursor always
indicates the selection being controlled by the gun
thumb switch. See Figure B.4.
ARROW KEY OPERATION WHEN USED WITH
SPOT KEY:
See Table B.1.
Left arrow keys: Do not function.
Center arrow keys: Press UP ( ) arrow key to
increase Spot Weld ON time from 0.20 seconds to 2.5
seconds. Press DOWN ( ) arrow key to decrease
Spot ON time from 2.5 seconds to 0.20 seconds.
Right arrow keys: - Do not function.
9. STITCH KEY: Press to turn Stitch Weld timers
ON and display the Stitch Weld ON and OFF
times. Pressing the STITCH key a second time
returns the screen to the previous display without
turning off the stitch timers. Anytime the Stitch
weld timers are on and the display is in the Auto or
Manual mode, the abbreviation STITCH will
appear in the bottom left corner of the display . See
Figure B.2.
If the cursor is not present, the gun thumb switch does
not function. This prevents any inadvertent actuations.
Each time this IPM VOLTS key is pressed, the cursor
moves in the following sequence: IPM to VOLTS to no
cursor. The sequence continues each time the key is
pressed.
NOTE: In Auto Mode, changing IPM changes arc voltage. This can result in a change in metal thickness
setting as well.
ARROW KEY OPERATION WHEN USED WITH
STITCH KEY:
See Table B.1.
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FIGURE B.4 - Using the IPM VOLTS key.
IDEALARC SP-250
B-9
OPERATION
B-9
12.TOGGLE KEY: When first pressed, this key
turns ON the TOGGLE MODE and recalls the weld
setup in memory 4. Pressing the key again switches to the weld setup in memory location 5. Each
time the key is pressed, it alternates between the
two memory locations. When the TOGGLE key is
pressed, the LED screen displays the memory
number the current setup was recalled from, indicates automatic (AUTO:) or manual (MAN:) mode,
displays wire gauge (Auto Mode), wire feed speed,
and arc voltage. The cursor underlines the memory number currently selected.
If in AUTO mode, an up or down arrow shows
whether the arc voltage has been adjusted above
or below the recommended level. Spot or Stitch
timer status is displayed in the lower left-hand corner if either timer is active.
The gun thumb switch functions as a Toggle key in
Toggle mode. Pushing the gun thumb switch forward (toward the tip) selects the setup in memory
5. Pulling gun thumb switch back selects the setup
in memory 4. The gun thumb switch also functions
with the trigger closed for "on the fly" changes during a weld. See Figure B.5.
Center arrow keys: Press the UP ( ) arrow key to
increase wire feed speed. Press DOWN ( ) arrow key
to decrease wire feed speed setting. If in Auto Mode,
increasing or decreasing wire feed speed simultaneously causes an increase or decrease in the arc voltage and can change the metal thickness setting.
Right arrow keys: Press the UP ( ) arrow key to
increases arc voltage setting. Press the DOWN ( )
arrow key to decrease the arc voltage setting. When
in the Auto Mode, an up arrow indicator appears below
the V in VOLTS if the arc voltage has been set higher
than the recommended value. Adown arrow indicator
appears below the V in VOLTS if the arc voltage is
below the recommended value. No arrow indicates
that you are set to the recommended value.
To turn the toggle mode off, press the AUTO, MANUAL, or any MEMORY Number key.
NOTE: Any changes made to settings in toggle mode
are not automatically saved when power is removed,
or if toggle mode is turned off. To save these changes
Press the SAVE key
Press the MEMORY number key that is currently displayed on the screen (4 or 5)
Press the SAVE key
Press other MEMORY Number key that was displayed
after the toggle (5 or 4).
When power is returned, the machine will not be in the
toggle mode. However, the weld setting placed in
memory when power was removed will return so you
may continue to weld right where you left off. Press the
TOGGLE key to return to toggle mode.
ARROW KEY OPERATION WHEN USED WITH THE
TOGGLE KEY (See Table B.1.)
Left arrow keys: If metal thickness is displayed, Press
the UP ( ) arrow key to increase metal thickness. Press
the DOWN ( ) arrow key to decrease metal thickness.
The Left arrow keys do not perform any function in any
other mode.
FIGURE B.5 - Using the TOGGLE Function.
4-STEP TRIGGER INTERLOCK KEYS
PROCESS
TOGGLE
Pressing and
WIRE/GAS
4 5
Controls whether 4-step trigger interlock is activated or
deactivated. (See
Function”
section)
“Using 4-Step Trigger Interlock
Note: 4-step Trigger is automatically deactivated if
either the spot or stitch timer mode is being used.
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IDEALARC SP-250
1/96
B-10
OPERATION
B-10
OPERATING STEPS
Before operating the machine, be sure you have all the
materials needed to perform the work. Be sure you are
familiar with and have taken all possible safety precautions before starting the work. It is important that
you follow these operating steps each time you use the
machine.
RUN-IN MODE
The IDEALARC SP-250 can operate in either a slow or
fast run-in mode. It is factory set to operate in the slow
run-in mode. In the slow run-in mode, the SP-250 initially feeds wire at the rate of 50 IPM until output current is reached or for 2 seconds, whichever condition is
reached first. When either of these conditions are
reached, the SP-250 accelerates to the preset wire
feed speed.
When the SP-250 is in the fast run-in mode, the wire
feed speed immediately accelerates to the preset wire
feed speed - (available on later codes only.)
CHANGING RUN-IN MODE (CODES 10001
AND ABOVE)
b. If run-in mode displayed is not the required
mode, repeat Step 1. By repeating Step 1, the
run-in mode changes. Pressing the TIMERS
OFF key and the PROCESS key allows you to
switch back and forth between the two run-in
modes.
You need only perform the above procedure when you
want to change the run-in mode. It is not necessary to
repeat the above procedure each time the unit is powered up. The unit will remember the run-in mode from
the previous power down and return you to that same
state on your next power up. When saving to Memory
locations 1-5, the run-in mode is saved at the same
time. All operators should be aware that when recalling
a procedure from a memory location, the run-in mode
in memory overrides any present run-in mode setting.
The run-in mode remains in effect until either the runin mode is changed using the double keystroke or until
a memorized procedure containing the opposite run-in
mode is recalled.
MAKING A WELD IN AUTO MODE
1. Check that the polarity is correct for the process
being used.
2. Turn the ON/OFF POWER SWITCH to ON.
NOTE: Arc starting characteristics may be affected
when using the fast run-in mode because normal starting processes are overridden.
1. Turn the ON/OFF POWER SWITCH to ON.
2. Press and hold both the TIMERS OFF key and the
PROCESS key.
NOTE: The order in which the TIMERS OFF key and
the PROCESS key are pressed does not matter.
3. Read the SP-250 LED display. One of two messages appear:
FAST INCH ENABLED = (Fast run-in mode)
FAST INCH DISABLED = (Slow run-in mode)
NOTE: The run-in message appears on the display for
2 seconds. Pressing the PROCESS key causes the
message to disappear immediately.
4. Select run-in mode required.
a. If run-in mode displayed is the required mode,
continue with weld process.
3. Press (PROCESS) key.
4. Press LEFT UP or DOWN ARROW Keys to select
wire type being used.
5. Press CENTER UP or DOWN ARROW Keys to
select wire diameter being used.
6. Press RIGHT UP or DOWN ARROW Keys to
select welding gas type being used.
7. Press AUTO key. When the AUTO key is pressed,
an alarm will beep three times. The following message is displayed for 2.5 seconds: PROCESS
MUST MATCH WIRE & GAS.
8. Press UP or DOWN ARROW Keys to select metal
thickness.
9. If SPOT or STITCH timing modes NOT required,
go to Step 12.
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IDEALARC SP-250
B-11
OPERATION
B-11
10. If SPOT timing mode required.
a. Press SPOT key.
b. Press CENTER UP or DOWN ARROW keys to
select SPOT ON TIME required.
c. Press SPOT key to return to previous display.
d. Go to Step 12.
11. If STITCH timing mode required.
a. Press STITCH key.
b. Press CENTER UP and DOWN ARROW keys
to select STITCH ON time required.
c. Press RIGHT UP or DOWN ARROW keys to
select STITCH OFF time required.
d. Press STITCH key to return to previous dis-
play.
e. Go to Step 12.
12. Inch the electrode through the gun and cable
13. Cut the electrode within approximately 3/8" of the
end of the contact tip (3/4" for Outershield).
NOTE: When the trigger is pulled, the wire feeder
feeds wire at low speed regardless of the set wire feed
speed until the welding arc starts or 2 seconds has
elapsed. This feature enhances starting and makes it
easier to set the stick out. The two-second limit permits high speed loading of the gun and cable. To
change Run-In Mode, see changing Run-In Mode section.
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 l/min.).
NOTE: When using an Innershield electrode, the gas
nozzle may be removed from the insulation on the end
of the gun. This will give improved visibility and eliminate the possibility of the gas nozzle overheating.
distance is about 3/8 inch (3/4" for Outershield).
18. To stop welding, release the gun trigger and then
pull the gun away from the work after the arc goes
out.
19. When no more welding is to be done, close valve
on gas cylinder (if used). Momentarily operate gun
trigger to release gas pressure.
20. Turn the ON/OFF POWER SWITCH to OFF.
USING THE 4-STEP INTERLOCK FUNCTION IN
AUTO MODE
When the 4-Step Interlock function is not activated, the
trigger functions in the normal mode so that welding
happens only when the trigger is closed.
When the 4-Step Interlock function is activated, it
functions as follows:
When the arc is struck, the gun trigger may be
released. The welding continues until welding is
stopped by either of these two methods:
1) The arc is extinguished by manually jerking the
gun away from the work.
2) The gun trigger is closed and then released at the
end of the weld. This action returns the trigger
function to the normal mode so the weld stops
when the trigger is released. Releasing the trigger
reinstates the trigger interlock function for the next
weld. This is the preferred Interlock mode
because it provides better control at the end of the
weld and allows automatic burnback to prevent
excessive wire feed speed overrun.
The 4-step trigger feature does not function when
using SPOT or STITCH timed welding modes.
15. Connect work clamp to metal to be welded. Work
clamp must make good electrical contact to the
work. The work must be grounded.
WARNING: WHEN USING AN OPEN ARC
PROCESS, IT IS NECESSARY TO USE CORRECT
EYE, HEAD, AND BODY PROTECTION.
____________________________________
16. Position electrode over joint. End of electrode may
be lightly touching the work.
17. Lower welding helmet, close gun trigger, and begin
welding. Hold the gun so the contact tip to work
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WARNING
MAKING A SPOT WELD IN AUTO MODE
Arc spot plug welds are used when continuous welds
are not needed or to hold thin sheet metal together
prior to stitch welding or continuous welding. Arc spot
plug welds are made by using a punch to make a 3/16
inch diameter hole in the top sheet and arc welding
through the hole into the back sheet.
To make an arc spot plug weld
1. Punch 3/16" hole in top sheet.
2. Set the procedure for the metal thickness to be
welded.
IDEALARC SP-250
B-12
OPERATION
B-12
4. Press the CENTER UP & DOWN ARROW keys to
set the required Spot On time. Suggested initial
setting is 1.2 seconds.
5. Press the SPOT key. Display returns to Auto
screen. Spot timer status is shown in bottom left
corner of screen.
6. Install spot weld nozzle (if available) on gun.
7. Press spot weld nozzle against the top sheet so
the top and bottom sheets are tight together. If a
spot weld nozzle is not used, smoother welds will
result by moving the welding wire in a small circle
while making the weld.
8. Close the trigger and hold it closed until the arc
goes out.
MAKING A STITCH WELD IN AUTO MODE
A stitch weld is used to weld thin material because
warpage and burnthrough are a problem. Properly
adjusting the ON and OFF times and arc travel speed,
permits welding thin sheet metal using small welds that
result in minimum distortion and no burnthrough.
USING THE GUN TRIGGER SWITCH
The Gun Trigger Switch turns on arc voltage, wire
feeder, and gas solenoid (except with Innershield)
when the Gun Trigger Switch is closed. When closed,
the LED screen displays the Auto or Manual screens,
depending on which mode is being used. When the
Gun Trigger Switch is released, or opened, arc voltage,
wire feeder, and gas solenoid are turned off.
NOTE: When the trigger is pulled, the wire feeder
feeds wire at low speed regardless of the set wire feed
speed until the welding arc starts or 2 seconds has
elapsed. This feature enhances starting and makes it
easier to set the stick out. The 2 second limit permits
high speed loading of the gun and cable.
USING THE GUN THUMB SWITCH
(MAGNUM SP-250 ONLY)
The Gun Thumb switch is used to control wire feed
speed, arc voltage, or to switch, or toggle, between
memory locations 4 and 5. See IPM VOLTS key and
TOGGLE key for control details. The Thumb switch is
used to increase or decrease IPM or VOLTS.
To make a stitch weld
1. Set the procedure for the metal thickness to be
welded.
2. Press STITCH key. Stitch screen is displayed.
3. Press CENTER ARROW keys to set Stitch ON
time. Start with a Stitch ON time setting of 0.5 seconds. Increase the Time ON setting to increase
penetration and weld size. Decrease the Time ON
setting to reduce burnthrough and distortion.
4. Press the RIGHT ARROW keys to set the Stitch
OFF time. Start with a Time OFF setting of 0.5
seconds. Increase the Time OFF setting to reduce
burnthrough. Decrease the Time OFF setting to
produce a flatter and smoother weld.
5. Press STITCH key. Auto screen is displayed.
Stitch timer status is display in lower left portion of
screen.
6. Close the gun trigger and hold it closed for the
length of seam. Hold gun in one place during ON
time and move gun just beyond edge of molten
metal during OFF time. For smoothest welds on
thinner metal, point gun slightly towards the direction of travel.
USING THE WIRE DRIVE ROLL
The drive roll provided with the SP-250 has two
grooves, one for .030”-.035” (0.8-0.9mm) solid steel
electrode, and the other for .045” (1.2mm) solid steel
electrode. The welder is shipped with the drive roll
installed in the .030”-.035” (0.8-0.9mm) position as
indicated by the stenciling on the exposed side of the
drive roll. If .045” (1.2mm) electrode is to be used or
one of the optional drive rolls is required, then the drive
roll must be reversed or changed per the instructions
provided on the instruction decal inside the SP-250
Drive Roll Access door.
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IDEALARC SP-250
B-13
OPERATION
B-13
LOADING THE WIRE REEL
To mount a 22-30 lb. (10-14 kg) Readi-Reel- package
using the Readi-Reel adapter provided:
1. Pull the Readi-Reel adapter and spindle up out of
the SP-250 spindle mounting clips (V-brackets).
2. Rotate the spindle and adapter so the retaining
spring is at the 12 o'clock position.
3. Position the Readi-Reel so that it will rotate in a
clockwise direction when wire is dereeled from the
top of the coil. See Figure B. 6.
7. Check that the mating surfaces of the spindle hubs
and spindle mounting clips (V-brackets) are clear
of dirt and debris and that the adapter is fully
engaged onto the spindle.
8. Lower the loaded spindle into the spindle mounting
clips (V brackets) so wire dereels from top of coil
toward wire drive.
NOTE: The retaining spring side of the adapter should
be facing the center (inner) panel of the SP-250.
9. To remove the Readi-Reel from Adapter, depress
retaining spring tab with thumb while pulling the
Readi-Reel cage from the molded adapter with
both hands. Do not remove adapter from spindle.
T o mount 10 to 30 lb. spools: (8" and 12" diameter):
1. Remove the Readi-Reel adapter shipped on the 2
inch diameter spindle.
2. Be sure that the mating surfaces of the spindle
hubs and spindle mounting clips (V-brackets) are
clear of dirt and debris.
FIGURE B. 6 - Wire Reel Loading
4. Set one of the Readi-Reel inside cage wires on the
slot in the retaining spring tab.
5. Lower the Readi-Reel to depress the retaining
spring and align the other inside cage wires with
the grooves in the molded adapter.
6. Slide the cage all the way onto the adapter until the
retaining spring "pops up" fully.
WARNING
WARNING: Check to be sure the the retaining spring
has fully returned to the locking position and has
securely locked the readi-reel cage in place. Retaining
spring must rest on the cage, not the welding electrode.
____________________________________
3. Place the spool on the spindle. Make certain the
brake driving pin enters one of the holes in the
back side of the spool.
4. Lower the loaded spindle into the spindle mounting
clips (V brackets) so the wire dereels from the top
of the reel toward the wire drive.
NOTE: The SP-250 Spindle was designed to mount
12"- (300mm) and 8"- (200mm) diameter spools meeting international spool size specifications. If the spool
being used is too narrow to keep the brake driving pin*
engaged with the spool pin hole, a 2" (51mm) I D shim
washer could be used between the spool and the spindle retaining clip to take up the space.
* A later spindle design uses a longer "D"-shaped pin
to assure engagement.
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IDEALARC SP-250
B-14
OPERATION
B-14
FEEDING ELECTRODE
WARNING
When inching, the electrode and drive mechanism are
always “hot” to work and ground. The electrode
remains “hot” several seconds after the gun trigger is
released.
____________________________________
NOTE: Check that the proper drive rolls and gun parts
are used for the wire size and wire type being used.
1. Turn the Readi-Reel or spool until the free end of
the electrode is accessible.
2. While tightly holding the electrode, cut off the bent
end and straighten the first six inches. Cut off the
first inch. (If the electrode is not properly straightened, it may not feed properly into the outgoing
guide tube or welding gun causing a "birdnest".)
3. Push the wire through the ingoing guide tube, then
press the gun trigger and push the electrode into
the drive roll. If the electrode fails to thread itself
into the outgoing guide tube of the wire drive, open
the quick release idle roll arm, thread the electrode
manually, and reclose the arm.
2. If the wire "birdnests", jams, or breaks at the drive
roll, the idle roll pressure is too great. Back the
wing screw out fi turn and run new wire through the
gun. Repeat above step.
3. If the drive roll slips, loosen the gun cable FastMate connection nut from the front of the SP-250.
Pull the gun cable forward about 6". There should
be a slight waviness in the exposed wire. If there
is no waviness, the pressure is too low. T ighten the
wing screw 1/4 turn and lock the gun cable in
place. Repeat the above procedure.
4. Inch the electrode through the gun.
NOTE: Due to the low speed starting feature of the
SP-250, the wire will feed at low speed for 2 seconds
while inching, then come up to the set speed.
5. Check that the welding process is set for the wire
type, diameter, and gas per instructions on nameplate.
SETTING IDLE ROLL PRESSURE
The idle roll pressure wing screw is set at the factory
backed out 2fi turns from full pressure. This is an
approximate setting. The optimum idle roll pressure
varies with type of wire, wire diameter, surface condition, lubrication, and hardness. As a general rule, hard
wires may require greater pressure, and soft, or aluminum wire, may require less pressure than the factory setting. The optimum idle roll setting can be determined as follows:
1. Press end of gun against a solid object that is electrically isolated from the welder output and press
the gun trigger for several seconds.
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IDEALARC SP-250
ACCESSORIES
TABLE OF CONTENTS
- ACCESSORIES SECTION -
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
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IDEALARC SP-250
C-1
ACCESSORIES
C-1
OPTIONS / ACCESSORIES
Replacement Magnum 250-SP Gun and Cable
Assemblies
The following GMAW gun and cable assemblies are
available for use with the SP-250. Each is rated at 200
amps at 60% duty cycle. Each is equipped with a FastMate connector and additional control lead connections for the thumb activated 2 momentary position
slide switch control designed into the gun handle to
use with the SP-250 remote control features:
K524-1 Gun and Cable -A 12.5 ft. (3.8m) GMAW gun
and cable assembly; includes a liner, dif fuser, and contact tips for .035 (0.9mm) and .045 (1.2mm) electrodes.
K524-2 Gun and Cable -A 12.5 ft. (3.8m) GMAW gun
and cable assembly; includes a liner, dif fuser, and contact tips for .025 (0.6mm) and .030 (0.8mm) electrodes.
K524-3 Gun and Cable -A 15 ft. (4.6m) GMAW gun
and cable assembly; includes a liner, diffuser and contact tips for .035 (0.9mm) and .045 (1.2mm) electrodes.
The connection box mounts to the front of the
machine's base and provides for inlet connection of the
spool gun gas supply hose. It provides up-front easy
connection of the spool gun gas line, control plug, and
electrode lead (using the T wist-Mate plug provided with
the kit). Installation and Operation Accessory Manual
(AM-105) is included with the kit.
SPOOL GUN MODULE BOARD
INSTALLATION
NOTE: The K607-1 Spool Gun Adapter Kit is designed
for use with SP-250, SP 250-I and Wire-matic 250
model codes above code 9900. Model Codes below
9900 may be used with the addition of holes to the
case as described in the installation instructions below.
SP-250 model code 9402 must have S19636-2 read
on display just after power switch is turned on.
WARNING
WARNING: HIGH VOLTAGE CAN KILL!
• Do not operate with covers removed.
K524-4 Gun and Cable -A 15 ft. (4.6m) GMAW gun
and cable assembly; includes a liner, dif fuser, and contact tips for .025 (0.6mm) and .030 (0.8mm) electrodes.
K607-1 Spool Gun adapter Kit
The K607-1 Spool Gun Adapter Kit provides "up front"
direct connection with the SP-250. It is used with the
K487 Spool Gun (with remote speed control) or the
K469 Spool Gun (requiring K518 Connection Adapter).
It also provides single switch transfer between the
machine's feeder gun or the spool gun for same polarity welding with different wire and gas processes. The
kit includes a spool gun module board, a connection
box assembly with connecting plug and lead harnesses, mounting hardware, and installation and operation
instructions.
SPOOL GUN ADAPTER KIT
INSTALLATION
(Option K607-1)
The spool gun module mounts inside the control section of the machine and provides control and inter-connection between the machine's control board and the
spool gun kit connection box.
• 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.
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IDEALARC SP-250
C-2
Figure C.2 - Spool Gun Module Board Installation.
1. Remove input power to the machine before starting.
2. Remove the six screws that hold the Case Side
Panels.
3. Locate the four snap-mount fasteners mounted to
the side panel of the control Board.
4. Position the spool gun module board over the
snap-mount fasteners, making sure that the lead
plug connectors are placed at the top.
ACCESSORIES
C-2
CAUTION
CAUTION: Collect metal filings with a rag to protect
against possible metal contamination of the control
board or other internal electrical components.
____________________________________
9. Fasten the panel receptacle to the case with the
three #6-32 x 3/8" self tapping screws provided.
Insert screws from wire drive side, through the
sheet metal, and into the receptacle mounting
plate holes.
10. Plug the 10-pin, 8-pin, and 6-pin connector plugs
from the other end of the receptacle lead harness
into the 10-, 8-and 6-pin connectors (J12, J11 and
J13) at the top of the spool gun module board.
Plug in the 8-pin connector at the opposite end of
this harness into the unused 8-pin connector on
the SP-250 control board (J4).
11. Disconnect the 4-pin gas solenoid plug from the
receptacle (J8) on the upper right corner of the
Control Board. See Figure C.2. Reconnect this
plug into the 4-pin receptacle (J14) on the top of
the Module Board.
12. Plug the 4-pin connector plug, included with the
panel receptacle harness connected in step 10
above, into the Control Board receptacle (J8), disconnected in step 11 above.
5. Gently press the board onto the fasteners, making
sure all of the fasteners snap into place.
6. On the wire drive side of the machine, remove the
hex-head screw from beneath the gas connector
releasing the metal cover. See Figure C-1.
7. Slide the metal cover out from behind the motor
bracket. Flip the cover over so that the screw hole
is in the top right corner, then reinstall as a spacer
plate with the hex head screw. See Figure C-1.
8. Find the panel receptacle lead harness included in
the kit. See Figure C-2. Insert the panel receptacle into the hole from the control board side of the
panel, making sure that the panel receptacle
mounting plate is positioned so that the grounding
screw is in the lower left corner of the plate.
NOTE: For model codes below 9900, small notches
may need to be filed at top and bottom of panel hole to
clear the plastic mounting ears of the receptacle.
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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
C-3
ACCESSORIES
C-3
SPOOL GUN CONNECTION BOX
INSTALLATION
NOTE: Model codes below 9900 require the addition
of three holes to the front of the machine's base as
shown in Fig C.3.
the machine connected for electrode positive,
(refer to instruction manual), remove the positive
electrode lead from its connection on the wire
drive. Then reconnect with the connection box
electrode lead on the bolt under the positive electrode lead so the connection box electrode lead is
sandwiched between the positive electrode lead
terminal and the wire drive contact surface.
Tighten snugly, being careful not to strip the
threads.
Figure C.3 - Spool Gun Connection Box Installation
Mounting Holes
1. Remove the plug button, if present, from the center hole in the front of the machine's base and partially thread the two #10 thread forming screws,
provided with kit, into the two small holes on both
sides of the center hole.
2. Route a user-provided gas supply hose, from the
flow regulator of the spool gun gas cylinder, over
the rear axle of the machine, and out to the front
through the center hole in the front of the base.
3. Connect the gas hose to the 5/8-18 female inert
gas fitting on the back of the connection box.
4. Slip the connection box mounting keyholes over
the screw heads (installed in Step 1 above) and
pivot the box clockwise to engage and level the
box, then tighten the screws.
5. Route the control cable of the connection box up
through the opening in the front louver provided for
the work lead, then up behind the wire drive, and
connect the plug to the kit receptacle installed in
the previous section A. See Figure C.4.
Figure C.4 - Spool Gun Connection Box
Installation.
6. Route the electrode lead of the connection box up
through the same opening in the front louver. With
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IDEALARC SP-250
C-4
ACCESSORIES
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 manual provided with the Magnum Spool Gun.
1. Connect the spool gun control cable 6-pin plug to
mating receptacle on the front of the spool gun
adapter connection box.
NOTE: If using a K469 spool gun with 4-pin plug, use
the K518 adapter.
2. Insert the Twist-Mate plug into the mating receptacle on the front of the connection box and twist to
lock the connection.
C-4
3. Attach the spool gun gas line to the gas outlet fitting on the front of the connection box.
4. Refer to the Instruction Manual included with the
K487 or K469 Spool Gun for more detail in Spool
Gun set-up and operation.
Figure C.5 - Spool Gun Connect.
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IDEALARC SP-250
C-5
ACCESSORIES
C-5
SPOOL GUN INSTALLATION TO OLD K531 KIT.
1. Slide the spool gun cable assembly through the
opening in the louvers provided for the work lead.
See Figure C.6.
2. Remove the SP-250 gas line from the gas line connector.
3. Screw the spool gun 6-pin plug into the new connector just below the gas line connector.
4. Attach the spool gun gas hose to the gas connector.
5. Tighten the gas hose tightly, being careful not to
strip the brass threads.
NOTE: If using a K469 Spool Gun with a 4-pin plug,
use the K518 adapter.
6. Thread the removed SP-250 gas line between the
new gas hose and spool gun cable. See Figure
C.6.
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.
7. Pull the SP-250 gas hose up and through until it
wedges between the cable connector and gas connector.
a. Make sure the SP-250 gas hose connector
does not touch the wire drive unit.
8. With the SP-250 connected electrode positive (+),
remove the positive electrode lead from the terminal on the wire drive.
9. Position the spool gun electrode lead on the terminal.
10. Place the SP-250 electrode lead on the terminal.
The spool gun electrode lead should be on the
inboard side.
11. Tighten the hex nut, being careful not to strip the
threads.
12. Confirm the spool gun has been connected properly.
a. Toggle the POWER SWITCH to the “ON” posi-
tion.
FIGURE C.6 - Spool Gun Connection.
b. If the spool gun cable has been installed prop-
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erly, the following display appears
SPOOL GUN HAS BEEN CONNECTED
PRESS MANUAL TO ENTER SETTINGS.
IDEALARC SP-250
MAINTENANCE
TABLE OF CONTENTS
- MAINTENANCE SECTION -
MAINTENANCE SECTION ...................................... Section D
Safety Precautions...........................................................D-1
Routine and Periodic Maintenance..................................D-1
Component Locations......................................................D-2
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IDEALARC SP-250
D-1
MAINTENANCE
D-1
SAFETY PRECAUTIONS
WARNING
•Have a qualified technician do the maintenance
and troubleshooting work.
•Disconnect input power at main input supply prior
to working inside machine.
____________________________________
Read the Safety Precautions in the front of this manual before working on this machine.
ROUTINE AND PERIODIC
MAINTENANCE
Disconnect input AC power supply lines to the machine
before performing periodic maintenance, tightening,
cleaning, or replacing parts. See Figure D.1.
Perform the following daily:
1. Check that no combustible materials are in the
welding or cutting area or around the machine.
Drive Rolls and Guide Tubes
After every coil of wire, inspect the wire drive mechanism. Clean it as necessary by blowing with low pressure compressed air. Do not use solvents for cleaning
the idle roll because it may wash the lubricant out of
the bearing. All drive rolls are stamped with the wire
sizes they will feed. If a wire size other than that
stamped on the roll is used, the drive roll must be
changed .
Drop-In Reel Spindle and Clips
Before loading a coil of wire into the SP-250 drop-in
spindle, inspect the mating surfaces of the spindle
hubs and the spindle mounting clips (V-brackets) and,
if necessary , wipe or blow out any dirt and debris which
may have deposited on these surfaces .
Cable Cleaning
Clean cable liner after using approximately 300
pounds (136 kg) of electrode. Remove the cable from
the wire feeder and lay it out straight on the floor.
Remove the contact tip from the gun. Using an air hose
and only partial pressure, gently blow out the cable
liner from the gas diffuser end.
2. Remove any debris, dust, dirt, or materials that
could block the air flow to the machine for cooling.
3. Inspect the electrode cables for any slits, punctures in the cable jacket, or any condition that
would affect the proper operation of the machine.
Perform Periodically:
Clean the inside of the machine with low pressure air
stream. Clean the following parts. Refer to Figure D-1.
Main transformer and choke.
Electrode and work cable connections.
SCR rectifier bridge and heat sink fins.
Control board.
Fan Assembly .
NOTE: The fan motor has sealed bearings which
require no maintenance.
CAUTION
Excessive pressure at the start may cause dirt to form
a plug.
____________________________________
Flex the cable over its entire length and again blow out
the cable. Repeat this procedure until no further dirt
comes out.
Gun Tubes and Nozzles
a. Replace worn contact tips as required.
b. Remove spatter from inside of gas nozzle and from
tip after each 10 minutes of arc time or as required.
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IDEALARC SP-250
D-2
MAINTENANCE
1
3
D-2
2
5
1
Control Board
2
Fan Assembly
3
SCR Rectifier
4
4
Choke
5
Main Transformer
Figure D.1 - Component Locations
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IDEALARC SP-250
THEORY OF OPERATION
TABLE OF CONTENTS
- THEORY OF OPERATION SECTION -
THEORY OF OPERATION SECTION ...................... Section E
Power Supply Operation ........................................E-1 - E-3
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 ............................................................... E-6
LINE
SWITCH
RECONNECT
FAN
MOTORS
LCD
DISPLAY
KEYPAD
MAIN
TRANSFORMER
PIEZO
ALARM
SOLENOID
CONTROL BOARD
G
A
T
E
S
I
G
N
A
L
SCR
RECTIFIER
GAS
WIRE
DRIVE
MOTOR
TACH
GUN TRIGGER AND THUMB SWITCH
FEEDBACK
POSITIVE
TERMINAL
C
A
P
A
C
I
T
O
R
S
SHUNT
F
E
E
D
B
A
C
K
CHOKE
NEGATIVE
TERMINAL
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Figure E.1 -Block Logic Diagram
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
IDEALARC SP-250
E-1
THEORY OF OPERATION
POWER SUPPLY OPERATION
E-1
LINE
SWITCH
RECONNECT
FAN
MOTORS
SCR
G
A
T
E
S
I
G
N
A
L
GAS
SOLENOID
WIRE
DRIVE
MOTOR
TACH
GUN TRIGGER AND THUMB SWITCH
FEEDBACK
C
A
P
A
C
I
T
O
R
S
SHUNT
F
E
E
D
B
A
C
K
CHOKE
LCD
DISPLAY
KEYPAD
MAIN
TRANSFORMER
PIEZO
ALARM
CONTROL BOARD
RECTIFIER
Figure E.2 - Input Line Voltage and Main Transformer
POSITIVE
TERMINAL
NEGATIVE
TERMINAL
INPUT LINE VOLTAGE AND MAIN TRANSFORMER
The desired single phase input power is connected to
the SP-250 through a line switch located on the front
panel.
A reconnect panel allows the user to configure the
machine for the desired input voltage. This AC input
voltage is applied to the primary of the main transformer and to the thermostatically controlled fan
motors. The transformer changes the high voltage, low
current input power to a low voltage, high current output. In addition, the main transformer also has an isolated center tapped 30VAC auxiliary winding that supplies power to the Control Board for SCR gate drive
and gas solenoid operation. The weld power windings
connect to the Control Board as well as to the main
SCR Rectifier.
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NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
IDEALARC SP-250
E-2
THEORY OF OPERATION
POWER SUPPLY OPERATION (CONTINUED)
E-2
LINE
SWITCH
RECONNECT
FAN
MOTORS
SCR
G
A
T
E
S
I
G
N
A
L
GAS
SOLENOID
WIRE
DRIVE
MOTOR
TACH
GUN TRIGGER AND THUMB SWITCH
FEEDBACK
C
A
P
A
C
I
T
O
R
S
SHUNT
F
E
E
D
B
A
C
K
CHOKE
LCD
DISPLAY
KEYPAD
MAIN
TRANSFORMER
PIEZO
ALARM
CONTROL BOARD
RECTIFIER
Figure E.3 - Output Rectification and Feedback Control
POSITIVE
TERMINAL
NEGATIVE
TERMINAL
OUTPUT RECTIFICATION AND FEEDBACK CONTROL
The AC output from the main transformer secondary
weld winding is rectified and controlled through the
SCR rectifier assembly. Output voltage and current
are sensed at the shunt and output terminals and fed
back to the control board. The control board compares
the commands of the keypad (or gun thumb switch)
with the feedback signals. The appropriate gate firing
pulses are generated by the control board and applied
to the SCR rectifier assembly. The control board controls the firing of the SCRs, thus controlling the output
of the machine. See SCR Operation. The control
board also powers and commands the keypad, the
LCD Display , the piezo alarm, the gas solenoid and the
wire drive motor.
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NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
IDEALARC SP-250
E-3
THEORY OF OPERATION
POWER SUPPLY OPERATION (CONTINUED)
E-3
LINE
SWITCH
RECONNECT
FAN
MOTORS
LCD
DISPLAY
KEYPAD
MAIN
TRANSFORMER
SCR
G
A
T
E
S
I
G
N
A
L
GAS
SOLENOID
WIRE
DRIVE
MOTOR
TACH
GUN TRIGGER AND THUMB SWITCH
FEEDBACK
C
A
P
A
C
I
T
O
R
S
SHUNT
F
E
E
D
B
A
C
K
CHOKE
PIEZO
ALARM
CONTROL BOARD
RECTIFIER
Figure E.4 - Constant Voltage Output
POSITIVE
TERMINAL
NEGATIVE
TERMINAL
CONSTANT VOLTAGE OUTPUT
The controlled DC output from the SCR rectifier
assembly is filtered by the capacitor bank and the output choke, which is in series with the gun and welding
load, resulting in a constant voltage output at the output terminals of the machine.
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NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
IDEALARC SP-250
E-4
THEORY OF OPERATION
POWER SUPPLY OPERATION (CONTINUED)
E-4
LINE
SWITCH
RECONNECT
FAN
MOTORS
LCD
DISPLAY
KEYPAD
MAIN
TRANSFORMER
SCR
G
A
T
E
S
I
G
N
A
L
GAS
SOLENOID
WIRE
DRIVE
MOTOR
TACH
GUN TRIGGER AND THUMB SWITCH
FEEDBACK
C
A
P
A
C
I
T
O
R
S
SHUNT
F
E
E
D
B
A
C
K
CHOKE
PIEZO
ALARM
CONTROL BOARD
RECTIFIER
Figure E.5 - Wire Drive Motor and Feedback
POSITIVE
TERMINAL
NEGATIVE
TERMINAL
WIRE DRIVE MOTOR AND FEEDBACK
The wire drive motor is controlled by the control board.
A motor speed feedback signal is generated at the
motor tach and sent to the control board. The control
board compares this feedback signal with the commands set forth by the keypad (or the gun thumb
switch) and sends the appropriate armature voltage to
the wire drive motor. The drive motor speed is thus
controlled which in turn regulates the electrode wire
feed speed through the gun.
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NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
IDEALARC SP-250
E-5
THEORY OF OPERATION
THERMAL PROTECTION
A thermostat protects the machine from excessive
operating temperatures.. Excessive operating temperatures 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-250
machine. One of the thermostats, located on the output choke, energizes the cooling fan motors when
required. The other choke thermostat "opens" the trigger circuit, preventing machine weld output and wire
feed, if excessive operating temperatures are detected. The third thermostat insures that the fan motors
are operating when required.
The thermostats are self-resetting once the machine
cools sufficiently. It the thermostat shutdown is caused
by excessive output or duty cycle and the fans are
operating normally, the power switch may be left on
and the reset should occur within a 15 minute period.
If the fans are not turning or the air intake louvers are
obstructed, then the input power must be removed and
the fan problem or air obstruction be corrected.
E-5
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IDEALARC SP-250
E-6
INPUT
CATHODE
THEORY OF OPERATION
SCR OPERATION
E-6
OUTPUT
ANODE
GATE
Figure E.6 - SCR Operation
A silicon controlled rectifier (SCR) is a three terminal
device used to control rather large currents to a load.
An SCR acts very much like a switch. When a gate signal is applied to the SCR it is turned ON and there is
current flow from anode to cathode. In the ON state the
SCR acts like a closed switch. When the SCR is turned
OFF there is no current flow from anode to cathode
thus the device acts like an open switch. As the name
suggests, the SCR is a rectifier, so it passes current
only during positive half cycles of the AC supply. The
positive half cycle is the portion of the sine wave in
which the anode of the SCR is more positive than the
cathode.
When an AC supply voltage is applied to the SCR, the
device spends a certain portion of the AC cycle time in
the off state and the remainder of the time in the on
state. The amount of time spent in the ON state is controlled by the gate.
NOTE: AS THE GATE
PULSE IS APPLIED
LATER IN THE CYCLE
THE SCR OUTPUT
IS DECREASED.
An SCR is fired by a short burst of current into the gate.
This gate pulse must be more positive than the cathode voltage. Since there is a standard PN junction
between gate and cathode, the voltage between these
terminals must be slightly greater than 0.6V. Once the
SCR has fired it is not necessary to continue the flow
of gate current. As long as current continues to flow
from anode to cathode the SCR will remain on. When
the anode to cathode current drops below a minimum
value, called holding current, the SCR will shut off. This
normally occurs as the AC supply voltage passes
through zero into the negative portion of the sine wave.
If the SCR is turned on early in the positive half cycle,
the conduction time is longer resulting in greater SCR
output. If the gate firing occurs later in the cycle the
conduction time is less resulting in lower SCR output.
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IDEALARC SP-250
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 - F10
Explanation of Prompting Error Messages ............F11 -F-13
Test Procedures
SP-250 Main Transformer Test............................F-14 - F-18
Static SCR Rectifier Test .....................................F-19 - F-21
Active SCR Rectifier Test.....................................F-22 - F-24
SP-250 Keypad Resistance Test.........................F-25 - F-27
Wire Drive Motor and Tach Feedback Test .........F-28 - F-31
Oscilloscope Waveforms.....................................F-32 - F-36
Replacement Procedures
Control Board Remove/Replace..........................F-37 - F-38
Keypad Remove/Replace....................................F-39 - F-40
Wire Drive Assembly Remove/Replace...............F-41 - F-42
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
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IDEALARC SP-250
F-1
TROUBLESHOOTING & REPAIR
F-1
HOW TO USE TROUBLESHOOTING GUIDE
WARNING
Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician and
machine operator and will invalidate your factory warranty. For your safety and to avoid
Electrical Shock, please observe all safety notes and precautions detailed throughout this
manual.
__________________________________________________________________________
This Troubleshooting Guide is provided to
help you locate and repair possible machine
malfunctions. Simply follow the three-step
procedure listed below.
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled “PROBLEM
(SYMPTOMS)”. This column describes possible symptoms that the machine may exhibit. Find the listing that best describes the
symptom that the machine is exhibiting.
Symptoms are grouped into the following
categories: output problems, function problems, wire feeding problems, and welding
problems.
Step 2. PERFORM EXTERNAL TESTS.
The second column labeled “POSSIBLE
AREAS OF MISADJUSTMENT(S)” lists the
obvious external possibilities that may contribute to the machine symptom. Perform
these tests/checks in the order listed. In
general, these tests can be conducted without removing the case wrap-around cover.
Step 3. RECOMMENDED COURSE OF
ACTION
The last column labeled “Recommended
Course of Action” lists the most likely components that may have failed in your
machine. It also specifies the appropriate
test procedure to verify that the subject component is either good or bad. If there are a
number of possible components, check the
components in the order listed to eliminate
one possibility at a time until you locate the
cause of your problem.
All of the referenced test procedures
referred to in the Troubleshooting Guide are
described in detail at the end of this chapter.
Refer to the Troubleshooting and Repair
Table of Contents to locate each specific
Test Procedure. All of the specified test
points, components, terminal strips, etc. can
be found on the referenced electrical wiring
diagrams and schematics. Refer to the
Electrical Diagrams Section Table of
Contents to locate the appropriate diagram.
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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 216-383-2531 or 1-800-833-9353.
_____________________________________________________________
IDEALARC SP-250
F-2
TROUBLESHOOTING & REPAIR
PC BOARD TROUBLESHOOTING PROCEDURES
- Remove the P.C. Board from the static-
WARNING
ELECTRIC SHOCK can
kill.
Have an electrician install and
service this equipment. Turn the
input power OFF at the fuse box
before working on equipment. Do
not touch electrically hot parts.
CAUTION: Sometimes machine failures
appear to be due to PC board failures. These
problems can sometimes be traced to poor
electrical connections. To avoid problems when
troubleshooting and replacing PC boards,
please use the following procedure:
1. Determine to the best of your technical ability that the PC board is the most likely component causing the failure symptom.
2. Check for loose connections at the PC
board to assure that the PC board is properly connected.
3. If the problem persists, replace the suspect
PC board using standard practices to avoid
static electrical damage and electrical
shock. Read the warning inside the static
resistant bag and perform the following procedures:
P.C. Board can be damaged by static electricity.
- Remove your body’s static charge before opening
the static-shielding bag.
ATTENTION
Static-Sensitive
Devices
Handle only at
Static-Safe
Workstations
Reusable
Container
Do Not Destroy
ment frame. Keep touching the frame to prevent static build-up. Be sure not to touch any
electrically live parts at the same time.
- Tools which come in contact with the P.C.
Board must be either conductive, anti-static or
static-dissipative.
Wear an anti-static wrist
strap. For safety, use a 1
Meg ohm resistive cord
connected to a grounded
part of the equipment
frame.
- If you don’t have a wrist
strap, touch an unpainted,
grounded, part of the equip-
shielding bag and place it directly into the
equipment. Don’t set the P.C. Board on or near
paper, plastic or cloth which could have a static charge. If the P.C. Board can’t be installed
immediately, put it back in the static-shielding
bag.
- If the P.C. Board uses protective shorting
jumpers, don’t remove them until installation is
complete.
- If you return a P.C. Board to The Lincoln
Electric Company for credit, it must be in the
static-shielding bag. This will prevent further
damage and allow proper failure analysis.
4. Test the machine to determine if the failure
symptom has been corrected by the
replacement PC board.
NOTE: It is desirable to have a spare (known
good) PC board available for PC board troubleshooting.
NOTE: Allow the machine to heat up so that
all electrical components can reach their operating temperature.
5. Remove the replacement PC board and
substitute it with the original PC board to
recreate the original problem.
a. If the original problem does not reappear
by substituting the original board, then
the PC board was not the problem.
Continue to look for bad connections in
the control wiring harness, junction
blocks, and terminal strips.
b. If the original problem is recreated by the
substitution of the original board, then
the PC board was the problem. Reinstall
the replacement PC board and test the
machine.
6. Always indicate that this procedure was followed when warranty reports are to be submitted.
NOTE: Following this procedure and writing
on the warranty report, “INSTALLED AND
SWITCHED PC BOARDS TO VERIFY PROBLEM,” will help avoid denial of legitimate PC
board warranty claims.
F-2
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IDEALARC SP-250
F-3
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual
F-3
PROBLEMS
(SYMPTOMS)
Major Physical or Electrical Damage is Evident
Machine is dead - No Open Circuit Voltage output and No Wire Feed when gun trigger is pulled. No Display.
No Open Circuit Voltage output but
wire feeds normally when gun trigger
is pulled. - Display lights properly.
POSSIBLE AREAS OF
MISADJUSTMENTS(S)
OUTPUT PROBLEMS
1. Contact your local Lincoln
Electric Authorized Field Service
Facility.
1. Make certain that the input
power switch is in the "ON" position.
2. Check the input voltage at the
machine. Input voltage must
match the rating plate and the
reconnect panel.
3. Blown or missing fuses in the
input line.
1. Check the input voltage at the
machine. Input voltage must
match the rating plate and the
reconnect panel - High or Low
Line message may be displayed.
RECOMMENDED
COURSE OF ACTION
1. Contact The Lincoln Electric
Service Dept. (216) 383-2531 or
1-800-833-9353 (WELD)
1. Check input power switch (S1).
It may be faulty.
2. Check for loose or broken wires
at the reconnect panel.
3. Perform Main Transformer Test.
1. Check for loose or broken connections at the output terminals,
the choke, the capacitor bank
and all heavy current carrying
leads.
2. The gun may be faulty . Check or
replace.
2. Make sure that the transformer
secondary leads are securely
connected to the SCR Rectifier
Assembly.
3. Perform the SCR Rectifier
Assembly Test.
4. The Control board may be faulty
- Replace.
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 216383-2531 or 1-800-833-9353
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CAUTION
IDEALARC SP-250
F-4
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual
F-4
PROBLEMS
(SYMPTOMS)
No Open Circuit Voltage output and
no wire feed when gun trigger is
pulled. Display is functioning properly .
Wire feeds but welding output is low
causing wire to "stub".
Welds are "cold". Machine cannot
obtain full rated output of 250 amps
at 26 volts.
POSSIBLE AREAS OF
MISADJUSTMENTS(S)
OUTPUT PROBLEMS
1. The thermostats may be open
due to machine overheating. If
machine operates normally after
a cooling off period then check
for proper fan operation and
ventilation. Make certain that
the machine's duty cycle is not
being exceeded.
2. Check the gun trigger circuit.
Leads #324 to #325 should have
continuity ( zero ohms) when the
gun trigger is pulled. If not then
the gun may be faulty - replace.
1. If an error message is displayed
on the display then proceed to
Explanation of Prompting and
Error Messages Section.
2. Make sure that the proper wire
and procedures are being used.
3. Check gun and work cable for
loose or faulty connections.
RECOMMENDED
COURSE OF ACTION
1. Check thermostats and associated leads for loose or broken
connections. See Wiring
Diagram.
2. Perform The Main Transformer
Test.
3. The control board may be faulty.
Replace.
1. Check for loose or faulty connections of the heavy current
carrying leads.
2. The output capacitor bank may
be faulty. Check for loose connections at the capacitors. Also
check for leaky capacitors.
Replace if necessary. WARNING: The liquid electrolyte in
these capacitors is toxic. Avoid
contact with any portion of your
body.
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 216383-2531 or 1-800-833-9353
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3. Perform the SCR Rectifier
Assembly Test.
4. Perform the Main Transformer
Test.
5. The control board may be faulty.
Replace.
CAUTION
IDEALARC SP-250
F-5
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual
F-5
PROBLEMS
(SYMPTOMS)
The output voltage and wire feed is present continuously or pulsing when gun trigger is NOT activated.
Output settings (voltage and/or wire
feed speed) are being changed even
though gun thumb switch or keypad
keys are not being activated.
POSSIBLE AREAS OF
MISADJUSTMENTS(S)
OUTPUT PROBLEMS
1. Remove the gun. If the problem
is resolved the gun trigger circuit
is faulty. Repair or replace.
2. If the problem is not resolved
then contact your Local Lincoln
Electric Authorized Field Service
Facility.
1. Remove the gun. If the problem
is resolved the gun thumb switch
circuit may be faulty. Repair or
replace.
2. If the problem persists after gun
removal then the keypad may be
faulty . Check for burned or damaged areas on the keypad.
RECOMMENDED
COURSE OF ACTION
1. Check the machine's internal
trigger leads for grounds or
shorts. See Wiring Diagram.
2. The control board may be faulty.
Replace.
1. Check leads #326 and #327 for
grounds or shorts. See Wiring
Diagram.
2. The Keypad may be faulty.
Perform the Keypad Test.
3. The control board may be faulty.
Replace.
No wire feed or open circuit voltage
when gun trigger is pulled. The display lights up but the audio alarm
and the display do not function properly.
1. Check the input voltage at the
machine. Input voltage must
match the rating plate and the
reconnect panel - High or Low
Line message may be displayed.
2. Remove the gun. If the problem
is resolved the gun is faulty.Replace.
1. Perform the Keypad Test.
2. Perform the Main Transformer
Test.
3. The control board may be faulty .Replace.
4. The LCD display may be faulty. Replace.
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 216383-2531 or 1-800-833-9353
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CAUTION
IDEALARC SP-250
F-6
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual
F-6
PROBLEMS
(SYMPTOMS)
The audio alarm does NOT sound when a key is pressed, but display changes.
The audio alarm does not sound
when a key is pressed, and the display does NOT change.
POSSIBLE AREAS OF
MISADJUSTMENTS(S)
FUNCTION PROBLEMS
1. The background noise may be
too loud for user to hear beeper.
1. Remove the gun. If the problem
is resolved the gun is faulty.Replace.
RECOMMENDED
COURSE OF ACTION
1. Check the voltage across pins
1J7 (+) to 2J7 (-) on the control
board. When the keys are
pressed there should be a brief
indication, or pulse, of a DC voltage. If the voltage "pulse" is present then the Piezo alarm may
be defective.- Replace.
If the DC voltage pulse is NOT
present when the keys are
pressed then the control board
may be defective.-Replace.
1. Perform the Keypad Test.
2. The control board may be faulty.
- Replace.
3. The LCD Display may be faulty.Replace.
There is no gas flow when gun trigger is pulled. Wire feeds and weld
voltage is present. The display functions properly.
No readable message on the display. Backlight is lit indicating there
is power to the machine.
1. Make certain that a process is
selected that requires gas flow.
2. Check gas source and hoses for
leaks or kinks.
1. Check the input voltage at the
machine. The input voltage
must match the rating plate and
the reconnect panel.
2. Turn the line switch (S1) off.
Wait a minute and turn power
on. If problem is not resolved
contact your local Lincoln
Electric Authorized Field Service
Facility.
1. Check the gas solenoid by disconnecting it from the control
board (Plug J8) and applying a
12VDC external supply to the
gas solenoid. If the solenoid
does NOT activate then it may
be faulty. - Replace.
2. The control board may be faulty .Replace.
1. The display board may be faulty.
Replace.
2. The control board may be faulty.
Replace.
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 216383-2531 or 1-800-833-9353
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CAUTION
IDEALARC SP-250
F-7
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual
F-7
PROBLEMS
(SYMPTOMS)
The display backlight does not function.
The machine stops feeding wire while welding and the MOTOR OVERLOAD message appears on the display.
POSSIBLE AREAS OF
MISADJUSTMENTS(S)
FUNCTION PROBLEMS
1. Check the input voltage at the
machine. Input voltage must
match the machine rating plate
and the reconnect panel.
1. Check for mechanical restrictions in the wire feeding path.
The gun cable may be clogged.
RECOMMENDED
COURSE OF ACTION
1. With the display board disconnected test for 12VDC from pins
1J1(+) to 2J1(-). If the 12VDC is
present and the display board
backlight does NOT function
then replace the display board.
See Wiring Diagram.
2. If the 12VDC is not present at
pins 1J1 to 2J1 then perform the
Main Transformer Test.
3. The control board may be faulty.
Replace.
1. Check the motor armature current. Normal armature current is
1.5 - 2.5 amps.
If the motor armature current is
normal the control board may be
faulty.-Replace.
2. If the motor armature current is
high (over 3 amps) and there are
NO restrictions in the wire feeding path then the motor or gear
box may be defective.-Replace.
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 216383-2531 or 1-800-833-9353
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CAUTION
IDEALARC SP-250
F-8
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual
F-8
PROBLEMS
(SYMPTOMS)
No control of wire feed speed. Other machine functions are normal.
There is no wire feed when gun trigger is pulled. Normal open circuit
voltage is present.
POSSIBLE AREAS OF
MISADJUSTMENTS(S)
WIRE FEEDING PROBLEMS
1. The thumb switch circuit in the
gun may be faulty. Check or
replace.
1. If the drive rolls are turning then
check for a mechanical restriction in the wire feed path.
2. The gun liner may be clogged.
Check or replace.
3. If the drive rolls are NOT turning
when the gun trigger is pulled
then contact your local Lincoln
Electric Authorized Field Service
Facility.
RECOMMENDED
COURSE OF ACTION
1. Perform the Wire Drive Motor
and Tach Feedback test.
2. The control board may be faulty .Replace.
1. Perform the Wire Drive Motor
and Tach Feedback Test.
2. The control board may be faulty.
- Replace.
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 216383-2531 or 1-800-833-9353
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CAUTION
IDEALARC SP-250
F-9
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual
F-9
PROBLEMS
(SYMPTOMS)
The arc is unstable and or "hunting".
POSSIBLE AREAS OF
MISADJUSTMENTS(S)
WELDING PROBLEMS
1. Check for worn or melted contact tip.
2. Check for loose or faulty connections on the work and electrode cables.
3. Make sure electrode polarity is
correct or welding process being
used.
4. Check for rusty or dirty wire.
5. Make sure machine settings and
gas are correct for process
being used.
RECOMMENDED
COURSE OF ACTION
1. Check for loose connections at
the output terminals, the choke,
the capacitor bank and all heavy
current carrying leads.
2. Make sure that the transformer
secondary leads are securely
connected to the SCR Rectifier
Assembly.
3. The output capacitor bank may
be faulty. Check for loose connections at the capacitors. Also
check for leaky capacitors.
Replace if necessary.
WARNING: The liquid electrolyte in these capacitors is
toxic. Avoid contact with any
portion of your body.
Weld bead is narrow or ropey. May
have porosity with electrode stubbing into plate.
1. Make sure the weld procedure
and electrode polarity is correct
for the process being used.
2. Make sure shielding gas is correct and flow is proper.
3. Make sure the weld joint is not
"contaminated".
4. The control board may be faulty.
Replace.
1. The output capacitor bank may
be faulty. Check for loose connections at the capacitors. Also
check for leaky capacitors.
Replace if necessary.
WARNING: The liquid electrolyte in these capacitors is
toxic. Avoid contact with any
portion of your body.
2. Perform the SCR Rectifier
Assembly Test.
3. The control board may be faulty.
Replace.
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 216383-2531 or 1-800-833-9353
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CAUTION
IDEALARC SP-250
F-10
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual
F-10
PROBLEMS
(SYMPTOMS)
The contact tip seizes in the gas diffuser.
POSSIBLE AREAS OF
MISADJUSTMENTS(S)
WELDING PROBLEMS
1. The tip is being over heated due
to excessive high current and /or
high duty cycle welding.
2. A light application of high temperature antisieze lubricant
(such as Lincoln E2607 Graphite
Grease) may be applied to the
contact tip threads.
RECOMMENDED
COURSE OF ACTION
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 216383-2531 or 1-800-833-9353
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CAUTION
IDEALARC SP-250
F-11
TROUBLESHOOTING & REPAIR
EXPLANATION OF PROMPTING AND ERROR MESSAGES
F-11
ON SCREEN ERROR MESSAGE
PROCESS MUST
MATCH WIRE & GAS
ONLY SET UP FOR
.035 STAINLESS
ONLY ARGON USED
WITH ALUMINUM
ONL Y SET UP FOR
. 045 OUTERSHIELD
NO GAS REQUIRED
WITH INNERSHIELD
MEMORY 1 NOW
CONTAINS SETUP
MESSAGE EXPLANATION
Reminder that in Auto mode the process entered with the Process key must
match the process installed in the machine .
Unit is only programmed for .035” (0.9mm) diameter in stainless steel wire.
Other wire diameters can be accommodated by using the Manual mode.
Unit is programmed to use only argon gas with aluminum electrodes. Other
gases can be accommodated by using the manual mode.
Unit is only programmed for .045” (1.1mm) diameter in Outershield® electrode wire. Other wire diameters within the SP-250 rating can be accommodated by using the Manual mode.
Innershield® electrode wire does not require a shielding gas. In the Auto
mode, the SP-250 automatically leaves the solenoid de-energized even
when the trigger is closed.
Verifies that the setup was saved to memory number 1. The actual memory number is determined by the memory number key that was pressed following Save.
MEMORY 2
IS EMPTY
MEMORY 4 DOESN’T
MATCH WIRE & GAS
REQ'S: STAINLESS
WIRE .035 Ar/O
PRESS PROCESS
WHEN INSTALLED
2
An attempt was made to recall a setup from a memory that does not contain one. The actual memory number is determined by the memory number key that was just pressed.
An attempt was made to enter Toggle mode and the process of the Auto
setup in memory 4 does not match the process in the machine. Press
memory 4 to find out what process is required. The memory number indicates which memory, 4 or 5, does not match.
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.
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IDEALARC SP-250
F-12
TROUBLESHOOTING & REPAIR
EXPLANATION OF PROMPTING AND ERROR MESSAGES (CONT’D)
F-12
ON SCREEN ERROR MESSAGE
DATA ***ERROR***
CHECK SETTINGS
PRESS PROCESS TO
CHECK SETTINGS
MOTOR OVERLOADED
CHECK GUN, DRIVE
XXXX ***ERROR***
CHECK SETTINGS
PRESS PROCESS TO
CHECK SETTINGS
MESSAGE EXPLANATION
An attempt was made to recall a setup from memory that has improper settings due to excessive electrical interference. The SP-250 will recall the
setup and reset the improper data to within machine limits. However, all
settings should be checked, properly set if needed, and then resaved to that
memory. This message alternates with the second message until the
Process key is pressed.
Unit shut down even though trigger was closed. There is an excessive current draw on the motor. Check for proper size tip, liner and drive rolls, for
any obstructions or bends in the gun cable, and any other factors that would
impede the wire feeding. To resume welding, simply pull the trigger.
Indicates that an error has occurred due to excessive electrical interference.
All of these error types turn off the arc voltage, wire feed speed, and solenoid. Press the Process key, per second message, and check all settings
before continuing to weld.
XXXX
IC3I
RTI
SWI
IOT
XIRQ
PWOF
DATA
This table shows all of the actual lettering which
appears in place of XXXX. There is no reason to
note which of these occurred unless it occurs frequently .
GUN SWITCH BEING
USED FOR TOGGLE
CONNECT FOR
NEG. POLARITY
LOW LINE: CHECK
RECONNECT PANEL
PRESS ANY KEY
TO STOP MESSAGE
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Reminds the operator that the gun switch is being used to toggle between
memory 4 and memory 5 and, therefore, is not able to control IPM or arc
VOLTS.
Reminds the operator to change the electrode polarity to negative when
Innershield wire type is selected.
Indicates to operator that the input line voltage is too low to obtain the output set on the machine. The operator can continue to weld, but the voltage
will be less than what is set on the machine. This message occurs when the
line voltage is less than 75% of nominal line or if the voltage level set on the
machine is not obtainable at that line voltage and load current. The operator should check if the reconnect panel is wired properly. Lowering the set
VOLTS and/or IPM can eliminate the message. Pressing any key or gun
switch when the operator is not welding will stop the message from being
displayed . Pressing any increment or decrement arrow keys or gun switch
while welding will temporarily stop the message from being displayed
(approximately 1.3 sec.) allowing the operator to view the increase or
decrease in that setting.
IDEALARC SP-250
F-13
TROUBLESHOOTING & REPAIR
EXPLANATION OF PROMPTING AND ERROR MESSAGES (CONT’D)
F-13
ON SCREEN ERROR MESSAGE
HIGH LINE: CHECK
RECONNECT PANEL
PRESS ANY KEY
TO STOP MESSAGE
CURRENT OVERLOAD
REDUCE OUTPUT
PRESS ANY KEY
TO STOP MESSAGE
MESSAGE EXPLANATION
Indicates to operator that the line voltage is too high, and the output voltage
has been reduced to protect the capacitor bank voltage rating limits. The
operator can continue to weld, but the voltage will be less than what is set
on the machine. This message occurs when the line voltage is greater than
121% of nominal line. The operator should check if the reconnect panel is
wired properly. Pressing any key or gun switch when the operator is not
welding will stop the message from being displayed. Pressing any 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.
Indicates to operator that too much current is being drawn from the
machine, and the output has been reduced to prevent the current from
exceeding safe levels. This will typically occur in Manual mode using .045"
(1.2mm) wire and WFS greater than 275 IPM (0.7m/min.). Lowering the
WFS will reduce the output requirement and allow operation within the
machine rating. Pressing any key or gun switch when the operator is not
welding will stop the message from being displayed. Pressing any increment or decrement arrow keys or gun switch while welding will temporarily
stop the message from being displayed (approximately 1.3 seconds) allowing the operator to view the increase or decrease in that setting.
SXXXXX -X
ROM ASSEMBL Y
C SXXXXX -X
ROM ASSEMBL Y
R
SPOOL GUN HAS
BEEN CONNECTED
PRESS MANUAL
TO ENTER SETTINGS
SPOOL GUN HAS
BEEN REMOVED
PRESS PROCESS TO
TO ENTER SETTINGS
Only displayed at power-up. Displays the part number of the ROM
ASSEMBLY currently on the PC board.
Indicates a checksum error in the software. Turn power off and back on
again. If this message persists, then replace the ROM assembly on the PC
board. Earlier units did not display the SXXXXX-X ROM ASSEMBLY number.
Indicates a fault in system RAM. Turn power off and back on again. If this
message persists, then replace the control PC board assembly.
Reminder that the Spool gun has been connected and the Manual key must
be pressed to enter any Spool gun welding procedures.
Reminder that the Spool gun has been removed and the Process key must
be pressed to enter SP-250 weld settings. This message may also be displayed if there is an open lead in the spool gun 6-pin plug assembly.
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IDEALARC SP-250
F-14
TROUBLESHOOTING & REPAIR
F-14
MAIN TRANSFORMER TEST
WARNING
Service and repair should be performed only by Lincoln Electric factory trained personnel. 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 precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform
the tests/repairs safely, contact the Lincoln Electric service department for technical
troubleshooting assistance before you proceed.
Call (216) 383-2531 or (800) 833-9353 (WELD).
TEST DESCRIPTION
This test will determine if the correct voltages are being
a. applied to the primary windings of the Main Transformer.
b. induced on the weld winding and auxiliary windings.
MATERIALS NEEDED
5/16" Nut Driver
Volt-Ohm Meter
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IDEALARC SP-250
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 proportionably with the primary input voltage.
1. Disconnect the main input power
supply to the machine.
2. Remove the Case Top and Side
Panels with a 5/16" nut driver.
3. Locate Plug J3 and Plug J6 on the
G2252 Control PC Board or Plug J3
on the G1992 (Code 9402 only)
Control PC Board. See Figures
F.1A and F.1B.
F-15
NOTE: The location of Plugs may vary
depending on the machine code.
J2
J7
J4
#206
(4J6)
J5
J6
#209
(7J6)
SP-250 CONTROL
G2252
J8
J9
#203
#204A
(3J3)
(2J3)
J3
#202
(1J3)
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#208
(16J6)
FIGURE F.1A - G2252 Control PC Board Main Transformer Test Points.
IDEALARC SP-250
F-16
TROUBLESHOOTING & REPAIR
MAIN TRANSFORMER TEST
SP-250 CONTROL
G1992
J2
J7
J4
F-16
J8
J5
J3
J6
#208
(1J3)
#209 (2J3)
#206 (3J3)
#204A (5J3)
#202 (6J3)
#203
(7J3)
J9
FIGURE F.1B - G1992 (Code 9402 Only) Control PC Board Main Transformer T est
Points. Note: Plugs J5 and J6 are on inboard non-component side of Control
Board.
4. Locate the following leads on Plug
J3:
G1992 (code 9402 only):
5. Connect main input power to the
LEAD
PLUG
machine.
LOCATION
6. Turn the IDEALARC SP-250
#202
#203
#204 A
1J3
3J3
2J3
ON/OFF POWER SWITCH to ON.
7. Make the following voltage tests at
Plug J3.
G2252:
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LEAD
#202
#203
#204 A
PLUG
LOCA TION
6J3
7J3
5J3
IDEALARC SP-250
FROM
LEAD
#202
(1J3)
#202
(1J3)
#203
(3J3)
TO
LEAD
#203
(3J3)
#204 A
(2J3)
#204 A
(2J3)
EXPECTED
VOL TAGE
30 VAC
15 VAC
15 VAC
F-17
TROUBLESHOOTING & REPAIR
MAIN TRANSFORMER TEST
F-17
G1992 (Code 9402 only):
FROM
LEAD
#202
(6J3)
#202
(6J3)
#203
(7J3)
8. Turn OFF the machine
9. Locate the following leads on Plug
J6 on the G2252 Control PC Board
or Plug J3 on the G1992 Control PC
Board. See Figures F.1A & F1.B.
G2252:
LEAD
#206
#208
#209
G1992 (Code 9402 only):
LEAD
#206
#208
#209
10.
Turn ON the machine.
11. Make the following voltage tests at
Plug J6 on the G2252 Control PC
Board, or at Plug J3 on the G1992
Control PC Board (Code 9402 only.)
a. Turn the machine OFF between
each test.
b. Carefully insert the meter
probes into the back of each
Molex Plug pin cavity to perform
the test.
TO
LEAD
#203
(7J3)
#204 A
(5J3)
#204 A
(5J3)
EXPECTED
VOL TAGE
30 VAC
15 VAC
15 VAC
PLUG
LOCATION
4J6
16J6
7J6
PLUG
LOCATION
3J3
1J3
2J3
G2252:
FROM
LEAD
#208
(16J6)
#208
(16J6)
#209
(7J6)
G1992 (Code 9402 only):
FROM
LEAD
#208
(1J3)
#208
(1J3)
#209
(2J3)
c. If any of the voltages tested are
incorrect, check for loose or broken leads between the test
points and the main transformer.
d. If ALL the voltages tested are
incorrect or missing, go to Step
12.
12. Test for correct nameplate input voltage between the H1 lead at the
ON/OFF POWER SWITCH to H2 or
H3 at the reconnect panel. Voltage
tested will vary depending on Input
Voltage Connection. See wiring diagram for test point locations.
a. If the voltage test is incorrect,
- check for loose or broken
leads between the reconnect
panel and the ON/OFF POWER
SWITCH.
- test the ON/OFF POWER
SWITCH for proper operation.
TO
LEAD
#209
(7J6)
#206
(4J6)
#206
(4J6)
TO
LEAD
#209
(2J3)
#206
(3J3)
#206
(3J3)
EXPECTED
VOLTAGE
60 VAC
30 VAC
30 VAC
EXPECTED
VOLTAGE
60 VAC
30 VAC
30 VAC
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IDEALARC SP-250
F-18
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.
F-18
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IDEALARC SP-250
F-19
TROUBLESHOOTING & REPAIR
F-19
STATIC SCR RECTIFIER ASSEMBLY TEST
WARNING
Service and repair should be performed only by Lincoln Electric factory trained personnel. 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 precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform
the tests/repairs safely, contact the Lincoln Electric service department for technical
troubleshooting assistance before you proceed.
Call (216) 383-2531 or (800) 833-9353 (WELD).
TEST DESCRIPTION
The Static SCR Test is used to quickly determine if an SCR is shorted or "leaky." See the
Waveform Section in this manual for normal and abnormal SCR waveforms.
MATERIALS NEEDED
Analog Ohmmeter (Multimeter)
IDEALARC SP-250 wiring diagrams (See Electrical Diagrams Section of this Manual).
5/16" Nut Driver
fi" open end or socket wrench
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IDEALARC SP-250
F-20
TROUBLESHOOTING & REPAIR
STATIC SCR RECTIFIER ASSEMBLY TEST
TEST PROCEDURE
F-20
1. Disconnect main AC input power to
the machine.
2. Disconnect Plugs J3 and J6 from
the G2252 Control Board or remove
Plug J3 from the G1992 Control
Board (Code 9402 only.) This electrically isolates the SCR bridge
assembly. See Figures F.2A and
F.2B.
SP-250 CONTROL
G2252
J2
J8
J7
J4
J9
J5
J6
J3
FIGURE F.2A - Remove Plugs J3 and
J6 to Perform Static SCR Rectifier
Assembly Test.
SP-250 CONTROL
G1992
3. Test with an Analog Volt-Ohm meter
that capacitors have completely discharged.
4. Disconnect leads X2 and X3 from
the negative capacitor bank using a
fi" open end wrench. See Figure F.3.
LEADS
X2 AND X3
NEGATIVE
CAPACITOR
BANK
BUSS BAR
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 contact. See Figure F.3.
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J2
J8
J7
J4
J5
J3
J9
J6
FIGURE F.2B - Remove Plug J3 to
Perform Static SCR Rectifier
Assembly Test.
IDEALARC SP-250
F-21
TROUBLESHOOTING & REPAIR
STATIC SCR RECTIFIER ASSEMBLY TEST
NOTE: DO NOT DISASSEMBLE THE
SCR RECTIFIER HEAT SINK ASSEMBLY.
6. Test for high or infinite resistance
from the anode to the cathode of
SCR 1. See Figure F.4. Use an
analog ohmmeter (Multimeter).
F-21
FIGURE F.4 - SCR 1 Test Points.
7. Test for high or infinite resistance
from the cathode to the anode of
SCR 1 by reversing the meter leads.
See Figure F.4.
a. If a high or infinite resistance is
indicated for both tests 6 and 7,
the SCR 1 is not “shorted”.
b. If a low resistance is indicated in
either tests 6 or 7, the SCR is
faulty. Replace SCR Assembly.
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 problem or to further test the SCR, go to
the Active SCR Test.
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IDEALARC SP-250
F-22
TROUBLESHOOTING & REPAIR
F-22
ACTIVE SCR RECTIFIER ASSEMBLY TEST
WARNING
Service and repair should be performed only by Lincoln Electric factory trained personnel. 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 precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform
the tests/repairs safely, contact the Lincoln Electric service department for technical
troubleshooting assistance before you proceed.
Call (216) 383-2531 or (800) 833-9353 (WELD).
TEST DESCRIPTION
The Active SCR Test will determine if the device is able to be gated ON and conduct current
from anode to cathode.
MATERIALS NEEDED
An SCR Tester as specified in this procedure.
IDEALARC SP-250 wiring diagrams (See Electrical Diagrams Section of this Manual).
SCR Heat Sink Assembly Drawings
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IDEALARC SP-250
F-23
TROUBLESHOOTING & REPAIR
ACTIVE SCR RECTIFIER ASSEMBLY TEST
F-23
TEST PROCEDURE
1. Disconnect main AC input power to
the machine.
2. Disconnect Molex Plugs J3 and J6
from the G2252 Control Board or
remove Plug J3 from G1992 Control
Board (Code 9402 only)
See Figures F.5A and F.5B.
SP-250 CONTROL
G2252
J2
J8
J7
J4
J9
J3
3. Test with an Analog Volt-Ohm meter
that capacitors have completely discharged.
4. Disconnect leads X2 and X3 from
the negative capacitor bank using a
fi" open end wrench.
See Figure F. 6.
LEADS
X2 AND X3
NEGATIVE
CAPACITOR
BANK
BUSS BAR
J5
J6
FIGURE F.5A - Control Board Molex
Plug Locations for G2252 PC Control
Board.
SP-250 CONTROL
G1992
J2
J8
J7
J4
J5
J3
J9
J6
FIGURE F.5B - Control Board Molex
Plug Locations for G1992 PC Control
Board (Code 9402 only.)
FIGURE F.6 - Location of Leads X2
and X3.
5. Separate leads X2 and X3 from the
negative capacitor bank buss bar.
Be sure there is no electrical contact. See Figure F6.
NOTE: DO NOT DISASSEMBLE THE
SCR RECTIFIER HEAT SINK ASSEMBLY.
6. Construct the circuit shown in Figure
F.8. One 6-volt lantern battery can
be used. R1 and R2 resistor values
are ±10%. Set voltmeter scale low,
at approximately 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. Battery
voltage should be 4.5 volts or
higher. If lower, replace the battery.
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IDEALARC SP-250
F-24
TROUBLESHOOTING & REPAIR
ACTIVE SCR RECTIFIER ASSEMBLY TEST
F-24
7. Connect the Tester to the SCR 1 as
shown in Figure F.7.
a. Connect Tester lead (A) to the
anode.
b. Connect Tester lead (C) to the
cathode.
c. Connect Tester lead (G) to the
gate.
a. If the voltage is 3 - 6 volts while
the switch is closed and after
the switch is open, the SCR is
functioning.
b. If the voltages is 3-6 volts only
when the switch is closed or
there is no voltage when the
switch is closed, the SCR is
defective.
NOTE: Be sure battery is functioning
properly. A low battery can affect the
results of the test. Repeat Battery Test
Procedure in Step 6 if needed.
12. Open switch SW-1.
13. Reconnect the Tester leads. See
Figure F.7.
a. Connect Tester lead (A) to the
cathode.
b. Connect Tester lead (C) to the
anode.
FIGURE F.7 - SCR Tester Circuit and
SCR connections.
8. Close switch SW-1.
NOTE: Switch SW-2 should be open.
9. Read meter for zero voltage.
a. If the voltage reading is higher
than zero, the SCR is shorted.
10. Close or keep closed switch SW-1
11. Close switch SW-2 for 2 seconds
and release and read meter.
c. Disconnect Test lead (G) from
the gate.
14. Close switch SW-1.
15. Read meter for zero voltage.
a. If the voltage is zero, the SCR is
functioning.
b. If the voltage is higher than
zero, the SCR is shorted.
16. Perform the Active Test Procedure
outlined in Steps 5-13 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.
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IDEALARC SP-250
F-25
TROUBLESHOOTING & REPAIR
F-25
SP-250 KEYPAD RESISTANCE TEST
WARNING
Service and repair should be performed only by Lincoln Electric factory trained personnel. 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 precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform
the tests/repairs safely, contact the Lincoln Electric service department for technical
troubleshooting assistance before you proceed.
Call (216) 383-2531 or (800) 833-9353 (WELD).
TEST DESCRIPTION
This test will determine if any key is not functioning properly.
MATERIALS NEEDED
5/16" Nut Driver
Analog volt-ohmmeter
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IDEALARC SP-250
F-26
TROUBLESHOOTING & REPAIR
SP-250 KEYPAD RESISTANCE TEST
TEST PROCEDURE
F-26
1. Disconnect main input power to the
machine.
2. Remove the Case Top and Side
Panels using the 5/16" nut driver.
3. Locate and disconnect Plug J2 connected to the Control PC Board.
See Figures F.8A and F8B.
SP-250 CONTROL
G2252
J2
J8
J7
J4
J9
J3
4. Measure the resistance of each key
at Plug J2 using an analog volt-ohm
meter as described in Table F.1.
a. The resistance measurements
are taken from the pin locations
on Plug J2. See Figure F.9 for
each pin location.
b. If any of the resistance tests are
not correct, the keypad may be
faulty. Replace.
J5
J6
FIGURE F.8A - Plug J2 Location on
G2252 PC Control Board.
SP-250 CONTROL
G1992
FIGURE F.9 - Plug J2 Test Points.
J2
J8
J7
J4
J5
J3
J6
J9
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FIGURE F.8B - Plug J2 Location on
G1992 PC Control Board (Code 9402
only).
IDEALARC SP-250
F-27
TROUBLESHOOTING & REPAIR
F-27
SP-250 KEYPAD RESISTANCE TEST
TABLE F.1 - SP-250 KEYPAD RESISTANCE TESTS
NOTE: THERE SHOULD NOT BE CONTINUITY BETWEEN PINS UNTIL A KEY IS PRESSED ON THE KEYPAD.
TEST POINTS KEY PRESSED MAXIMUM ALLOW ABLE
RESISTANCE
(TYPICAL RESISTANCE)
FROM PIN TO PIN
1J2 6J2 CENTER UP ARROW 100 OHMS (30 TYPICAL)
1J2 8J2 CENTER DOWN ARROW 100 OHMS (30 TYPICAL)
1J2 2J2 MEMORY 3 100 OHMS (30 TYPICAL)
1J2 4J2 SWITCH SET DISPLAY 100 OHMS (30 TYPICAL)
2J2 9J2 MEMORY 5 100 OHMS (30 TYPICAL)
2J2 7J2 MEMORY 4 100 OHMS (30 TYPICAL)
2J2 3J2 MEMORY 2 100 OHMS (30 TYPICAL)
2J2 5J2 MEMORY 1 100 OHMS (30 TYPICAL)
3J2 6J2 LEFT UP ARROW 100 OHMS (30 TYPICAL)
3J2 8J2 LEFT DOWN ARROW 100 OHMS (30 TYPICAL)
3J2 4J2 SPOT 100 OHMS (30 TYPICAL)
4J2 9J2 TOGGLE 100 OHMS (30 TYPICAL)
4J2 7J2 IMP VOLTS 100 OHMS (30 TYPICAL)
4J2 5J2 TIMERS OFF 100 OHMS (30 TYPICAL)
5J2 6J2 AUTO 100 OHMS (30 TYPICAL)
5J2 8J2 PROCESS WIRE/GAS 100 OHMS (30 TYPICAL)
6J2 9J2 MANUAL 100 OHMS (30 TYPICAL)
6J2 7J2 RIGHT UP ARROW 100 OHMS (30 TYPICAL)
7J2 8J2 RIGHT DOWN ARROW 100 OHMS (30 TYPICAL)
8J2 9J2 SAVE 100 OHMS (30 TYPICAL)
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IDEALARC SP-250
F-28
TROUBLESHOOTING & REPAIR
WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST
WARNING
Service and repair should be performed only by Lincoln Electric factory trained personnel. 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 precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform
the tests/repairs safely, contact the Lincoln Electric service department for technical
troubleshooting assistance before you proceed.
Call (216) 383-2531 or (800) 833-9353 (WELD).
F-28
TEST DESCRIPTION
This test will determine if the wire drive motor and voltage feedback circuit are functioning
properly.
MATERIALS NEEDED
5/16" Nut Driver
Volt-Ohmmeter
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IDEALARC SP-250
F-29
TROUBLESHOOTING & REPAIR
WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST
TEST PROCEDURE
NOTE: POLARITY MUST BE
OBSERVED FOR THESE TESTS.
Test for Correct Wire Drive Motor
Armature Voltage
1. Disconnect main input power to the
machine.
2. Remove the Case Top and Side
Panels using a 5/16" nut driver.
3. Locate Plug J5 on the G2252
Control Board, or Plug J6 on the
G1992 Control Board (Code 9402
only).. See Figures F.10A and
F.10B.
F-29
#515B
#515B
(3J5)
(3J5)
#206B
(2J5)
J5
J2
J7
J4
J6
SP-250 CONTROL
G2252
J8
J9
J3
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#555
(1J5)
FIGURE F.10A - Plug J5 Location on
G2252 PC Control Board.
#539
(8J5)
#541
(9J5)
IDEALARC SP-250
F-30
TROUBLESHOOTING & REPAIR
WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST
J2
F-30
J8
J7
J4
#206B
(4J6)
#515B
(1J6)
J5
J9
#555
(2J6)
J6
J3
#541
(6J6)
#539
(3J6)
FIGURE F.10B - Plug J6 Location on G1992 PC Control Board (Code 9402 only.)
NOTE: Plugs J5 and J6 are on the inboard non-component side of the Control
Board.
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4. Test for 2-25 VDC between lead
#539 (positive) and lead #541 (negative) to determine if the correct
armature voltage is being supplied.
See Figure F.10A or F.10B.
a. Insert probes in to the Molex pin
cavities.
5. Pull the gun trigger.
6. Read meter. Normal DC volts is
from 2 - 25 VDC. VDC varies
depending on wire feed speed.
a. If voltage to the wire drive motor
armature is zero, check the
wires between Plug J5 (J6 on
Code 9402) and the wire drive
motor.
IDEALARC SP-250
b. If the wires are okay and voltage
to the drive motor armature is
zero, the Control Board may be
faulty. Replace.
c. If the correct DC armature volt-
age is present at the wire drive
motor, the motor or motor brushes may be faulty. Test and/or
replace.
d. If the motor is running at high
speed and the armature voltage
is high and uncontrollable, proceed with the tachometer test.
F-31
TROUBLESHOOTING & REPAIR
WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST
Test for Supply Voltage to
Tachometer
1. Test for 15 VDC between lead
#515B (positive) and lead #206B
(negative). See Figure F. 10 for pin
locations.
a. Insert probes into Molex pin
cavities.
2. Pull gun trigger.
3. Read meter for 15 VDC.
a. If the 15 VDC is present, check
the leads to the tach circuit.
b. If the leads are okay and 15
VDC is present, the correct voltage is being received from the
Control Board. Go to Feedback
Test.
F-31
b. If the 1.5 - 3.5 VDC is not pre-
sent or not correct, the Control
Board is not receiving the proper feedback voltage from the
tach circuit. Check the leads
from the tach circuit to the
Control Board for loose or broken connections.
c. If the leads are okay, the Control
Board may be faulty. Replace.
c. If the 15 VDC is not present and
the leads are okay, the Control
Board may be faulty. Replace.
Test for Feedback Voltage to the
Control Board
1. Test for 1.5 - 3.5 VDC between lead
#555 (positive) and lead #206B
(negative). See Figure F.10 for pin
locations.
a. Insert probes into Molex pin
cavities.
2. Pull gun trigger.
3. Read meter for 1.5 - 3.5 VDC.
a. If the 1.5 - 3.5 VDC is present,
the tach circuit is sending the
correct feedback signal to the
Control Board.
NOTE: IF THE MOTOR IS NOT RUNNING, THE FEEDBACK VOL TAGE MAY
BE FROM 0 TO 5 VDC.
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IDEALARC SP-250
F-32
TROUBLESHOOTING & REPAIR
NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM
F-32
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This is a typical DC output voltage waveform generated from a properly operating
machine. Note that each vertical division
represents 20 volts and that each horizontal
division represents 2 milliseconds in time.
Note: Scope probes connected at machine
output terminals: (+) probe to electrode, (-)
probe to work.
IDEALARC SP-250
SCOPE SETTINGS
Volts/Div . . . . . . . . . . . . . . . . .20 V/Div.
Horizontal Sweep . . . . . . . . . .2 ms/Div.
Coupling . . . . . . . . . . . . . . . . . . . . .DC.
Trigger . . . . . . . . . . . . . . . . . . .Internal.
F-33
TROUBLESHOOTING & REPAIR
TYPICAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED
F-33
MACHINE LOADED TO 250 AMPS AT 26 VDC
This is a typical DC output voltage waveform generated from a properly operating
machine. Note that each vertical division
represents 20 volts and that each horizontal
division represents 5 milliseconds in time.
The machine was loaded with a resistance
grid bank.
Note: Scope probes connected at machine
output terminals: (+) probe to electrode, (-)
probe to work.
SCOPE SETTINGS
Volts/Div . . . . . . . . . . . . . . . . .20 V/Div.
Horizontal Sweep . . . . . . . . . .5 ms/Div.
Coupling . . . . . . . . . . . . . . . . . . . . .DC.
Trigger . . . . . . . . . . . . . . . . . . .Internal.
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IDEALARC SP-250
F-34
TROUBLESHOOTING & REPAIR
ABNORMAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED
ONE OUTPUT SCR NOT FUNCTIONING
F-34
MACHINE LOADED TO 220 AMPS AT 22 VDC
This is NOT a typical DC output voltage
waveform. One output SCR is not functioning. Note the increased ripple content. One
SCR gate was disconnected to simulate an
open or non-functioning output SCR. Each
vertical division represents 20 volts and
each horizontal division represents 5 milliseconds in time. The machine was loaded
with a resistance grid bank.
Note: Scope probes connected at machine
output terminals: (+) probe to electrode, (-)
probe to work.
SCOPE SETTINGS
Volts/Div . . . . . . . . . . . . . . . . .20 V/Div.
Horizontal Sweep . . . . . . . . . .5 ms/Div.
Coupling . . . . . . . . . . . . . . . . . . . . .DC.
Trigger . . . . . . . . . . . . . . . . . . .Internal.
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IDEALARC SP-250
F-35
TROUBLESHOOTING & REPAIR
ABNORMAL OPEN CIRCUIT VOLTAGE
OUTPUT CAPACITOR BANK NOT FUNCTIONING
F-35
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This is NOT the typical DC output voltage
waveform. The output capacitors are not
functioning. Note the lack of “filtering” in the
output waveform. The output capacitor
bank was disconnected. Each vertical division represents 20 volts and each horizontal
division represents 5 milliseconds in time.
Note: Scope probes connected at machine
output terminals: (+) probe to electrode, (-)
probe to work.
IDEALARC SP-250
SCOPE SETTINGS
Volts/Div . . . . . . . . . . . . . . . . .20 V/Div.
Horizontal Sweep . . . . . . . . . .5 ms/Div.
Coupling . . . . . . . . . . . . . . . . . . . . .DC.
Trigger . . . . . . . . . . . . . . . . . . .Internal.
F-36
TROUBLESHOOTING & REPAIR
TYPICAL SCR GATE VOLTAGE WAVEFORM
F-36
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This is a typical SCR gate pulse voltage
waveform. The machine was in an open circuit condition (no load) and operating properly. Note that each vertical division represents 2 volts and each horizontal division
represents 5 milliseconds in time.
Note: Scope probes connected at Plug J3
on the control board. The (+) probe to lead
G2, and the (-) probe to lead 204.
IDEALARC SP-250
SCOPE SETTINGS
Volts/Div . . . . . . . . . . . . . . . . . .2 V/Div.
Horizontal Sweep . . . . . . . . . .5 ms/Div.
Coupling . . . . . . . . . . . . . . . . . . . . .DC.
Trigger . . . . . . . . . . . . . . . . . . .Internal.
F-37
TROUBLESHOOTING & REPAIR
CONTROL PC BOARD REMOVAL AND REPLACEMENT
F-37
CAUTION
Printed Circuit Boards can be damaged by static electricity. Follow static handling guidelines detailed in
“PC Board Troubleshooting
Procedures” at the beginning of this
chapter.
_____________________________
REMOVAL AND REPLACEMENT
PROCEDURE
MATERIALS NEEDED
5/16" Nut Driver
Phillips Head Screwdriver
Static Electricity Grounding Strap
1. Disconnect main input power the
machine.
2. Remove the Case Top and Side
Panels using 5/16" nut driver.
J5
J2
J2
J7
J6
J4
SP-250 CONTROL
G2252
J8
J3
J9
SP-250 CONTROL
G1992
3. Disconnect all wiring harness
plugs and Molex Plugs connected to the Control Board. See
Figure F.11.
J7
J4
J5
J3
J6
FIGURE F.11 - Wiring Harness and
Molex Plug Locations.
J8
J9
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IDEALARC SP-250
F-38
TROUBLESHOOTING & REPAIR
CONTROL PC BOARD REMOVAL AND REPLACEMENT
4. Remove the eight Phillips Head
mounting screws using a Phillips
Head screwdriver. See Figure F.12.
F-38
FIGURE F.12 - Control Board
Mounting Screw Locations may
vary with different Code
Machines.
5. Lift the Control Board straight up
and out from the machine.
6. Replace all mounting screws and
wiring connections when
installing the Control Board.
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IDEALARC SP-250
F-39
TROUBLESHOOTING & REPAIR
F-39
KEYPAD REMOVAL AND REPLACEMENT
WARNING
Service and repair should be performed only by Lincoln Electric factory trained personnel. 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 precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform
the tests/repairs safely, contact the Lincoln Electric service department for technical
troubleshooting assistance before you proceed.
Call (216) 383-2531 or (800) 833-9353 (WELD).
MATERIALS NEEDED
5/16" Nut Driver
1/4" Nut Driver
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IDEALARC SP-250
F-40
TROUBLESHOOTING & REPAIR
KEYPAD REMOVAL AND REPLACEMENT
PROCEDURE
NOTE: BEFORE REMOVING THE
KEYPAD, PERFORM THE KEYPAD
RESISTANCE TEST TO BE SURE THE
KEYPAD IS FAULTY.
1. Disconnect main input power to the
machine.
2. Remove the Case Top and Side
Panels with 5/16" nut driver.
3. Disconnect Keypad Plug J2 from the
Control Panel.
4. Remove the two screws holding the
POWER SWITCH and bezel using a
1/4" nut driver.
F-40
5. Grasp the upper right hand corner of
the Keyboard and peel it off the front
panel.
a. The back of the Keypad is an
adhesive material that bonds
the Keypad to the Front Panel.
6. Install a new Keypad.
a. Remove the paper backing from
the new Keypad to uncover the
adhesive backing.
b. Install the new Keypad by care-
fully pressing the Keypad to the
Front Panel. Be sure to smooth
out any air bubbles that become
trapped under the Keypad.
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IDEALARC SP-250
F-41
TROUBLESHOOTING & REPAIR
WIRE DRIVE ASSEMBLY REMOVAL AND REPLACEMENT
WARNING
Service and repair should be performed only by Lincoln Electric factory trained personnel. 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 precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform
the tests/repairs safely, contact the Lincoln Electric service department for technical
troubleshooting assistance before you proceed.
Call (216) 383-2531 or (800) 833-9353 (WELD).
F-41
MATERIALS NEEDED
Large slot head screwdriver
5/16" Nut Driver
Small slot head screwdriver
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IDEALARC SP-250
F-42
TROUBLESHOOTING & REPAIR
WIRE DRIVE ASSEMBLY REMOVAL AND REPLACEMENT
PROCEDURE
1. Disconnect main input power to the
machine.
2. Remove the Case Top and Side
Panels.
3. Remove the large mounting screw
with a large slot head screwdriver
located in front of the drive roll. See
Figure F.13.
a. Note the placement of the insu-
lators and washers for replacement.
F-42
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FIGURE F.13 - Wire Drive Assembly
Removal
4. Using a small slot head screw driver,
loosen the set screw holding the out
going guide tube into the drive roll
assembly. Carefully slide out the
wire drive assembly.
5. Disconnect the six pin plug from the
vertical baffle connector.
IDEALARC SP-250
a. The six pin plug contains the
wire feed drive motor wires.
6. Remove carefully the drive motor
and drive roll assembly.
F-43
TROUBLESHOOTING & REPAIR
F-43
SCR OUTPUT RECTIFIER REMOVAL
WARNING
Service and repair should be performed only by Lincoln Electric factory trained personnel. 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 precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform
the tests/repairs safely, contact the Lincoln Electric service department for technical
troubleshooting assistance before you proceed.
Call (216) 383-2531 or (800) 833-9353 (WELD).
MATERIALS NEEDED
5/16" Nut Driver
1/2" Open End Wrench
1/2" Socket wrench, universal tool, and extension
3/8" Open End Wrench
Slot head screwdriver
Wire cutters
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IDEALARC SP-250
F-44
TROUBLESHOOTING & REPAIR
SCR OUTPUT RECTIFIER REMOVAL
F-44
PROCEDURE
1. Disconnect lead #208 and
Transformer Lead X1 from the heat
sink on the left side of the machine
(facing the front) using a 1/2" socket
wrench. See Figure F.14.
a. Thin lead is always on the out-
board side of the connection.
4. Cut the SCR gate leads G1 and G2
(see wire markers and wiring diagram) using wire cutters.
a. The easiest access to these
leads is from the right side of the
machine.
b. Cut any necessary cable ties.
5. Remove the four screws holding the
SCR Assembly to the floor of the
machine using a 5/16" nut driver.
6. Pivot the SCR Assembly counterclockwise to provide access to the
right side heat sink.
See Figure F.16.
FIGURE F.14 - Heat Sink lead disconnection.
2. Disconnect lead #204 and heavy
lead from the middle heat sink with a
1/2" socket wrench and 1/2" open
end wrench. See Figure F. 15.
3. Remove the diode lead from the
negative capacitor band buss bar on
the right side of the machine using a
slot head screwdriver and 3/8" open
end wrench.
FIGURE F.16 - Heat Sink Lead
Disconnection
7. Remove lead #209 and Transformer
Lead X4 from the right side heat sink
using a 1/2" socket wrench and 1/2"
open end wrench.
8. Clear the leads and carefully
remove the SCR Rectifier Assembly.
NOTE: When installing the SCR
Rectifier Assembly, apply a thin coating
of Dow Corning #340 Compound to the
electrical connections.
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FIGURE F.15 - Heat Sink lead disconnection.
IDEALARC SP-250
F-45
TROUBLESHOOTING & REPAIR
CAPACITOR BANK REMOVAL AND REPLACEMENT
WARNING
Service and repair should be performed only by Lincoln Electric factory trained personnel. 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 precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform
the tests/repairs safely, contact the Lincoln Electric service department for technical
troubleshooting assistance before you proceed.
Call (216) 383-2531 or (800) 833-9353 (WELD).
F-45
WARNING
THE LIQUID ELECTROLYTE IN THE CAPACITORS IS TOXIC. DO NOT TOUCH THE
CAPACITORS WITH ANY PART OF YOUR BODY.
MATERIALS NEEDED
5/16" Nut driver
5/16" socket wrench, extension, and universal tool
1/2" Open end wrench
3/8" open end wrench
Slot head screwdriver
Wiring diagram
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IDEALARC SP-250
F-46
TROUBLESHOOTING & REPAIR
CAPACITOR BANK REMOVAL AND REPLACEMENT
PROCEDURE
See Figure F.17 for location of Capacitor
Bank Removal and Replacement components.
F-46
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FIGURE F.17 - Location of Capacitor
Bank Removal and Replacement
Components
1. Disconnect main input power to the
machine.
2. Test that the capacitors are discharged using a volt ohmmeter.
Polarity must be observed.
3. Remove the two transformer secondary leads (X2 and X3) for the
negative capacitor bank buss bar
using two fi" open end wrenches.
4. Remove the output choke lead and
the heavy lead extending from the
SCR Rectifier Assembly to the positive capacitor bank buss bar using a
fi" open end wrench.
5. Remove lead #206 and the D1
diode lead from the negative capacitor bank buss bar using a slot head
screwdriver and 3/8" open end
wrench.
IDEALARC SP-250
6. Remove the #204 lead from the positive buss bar.
7. Remove the shunt from the negative
capacitor bank buss bar using a 1/2"
socket wrench with a universal tool
adapter.
a. Two people may be required to
remove the shunt. One person
may have to reach through from
the left side of the machine to
keep the bolt in position while
the other person loosens the
nut.
b. There is no shunt on machine
code 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 assembly from the machine.
F-47
TROUBLESHOOTING & REPAIR
MAIN TRANSFORMER REMOVAL AND REPLACEMENT
WARNING
Service and repair should be performed only by Lincoln Electric factory trained personnel. 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 precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform
the tests/repairs safely, contact the Lincoln Electric service department for technical
troubleshooting assistance before you proceed.
Call (216) 383-2531 or (800) 833-9353 (WELD).
F-47
MATERIALS NEEDED
5/16" Nut Driver
1/2" Open end wrench
3/8" Open end wrench
1/2" Socket wrench, extender, universal adapter
Wire cutters
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IDEALARC SP-250
F-48
TROUBLESHOOTING & REPAIR
MAIN TRANSFORMER REMOVAL AND REPLACEMENT
F-48
PROCEDURE
1. Disconnect main input power to the
machine.
2. Remove the Case Top and Side
Panels.
3. Perform the Capacitor Bank
Removal Procedure.
4. Remove lead X1 from the left side
SCR heat sink assembly using a
1/2" socket wrench, extender and
universal adapter.
5. Remove lead X4 from the right side
heat sink assembly using a 1/2"
socket wrench, extender and universal adapter.
6. Disconnect all leads from the reconnect panel using a 3/8" open end
wrench.
12. Disconnect the positive output lead
at the wire drive motor.
13. Remove the strain relief grommet
through which the positive output
lead passes through the horizontal
baffle of the machine.
14. Pull down on the positive output
lead until it slides out the hole in the
baffle.
15. Carefully remove the main transformer.
a. Be sure all leads are clear.
7. Disconnect all leads from the
POWER SWITCH.
8. Remove the POWER SWITCH.
9. Label and cut leads #202, #203,
#204A.
a. Cut lead #204A at a point just in
front of the transformer.
b. These leads must be re-spliced
during reassembly.
c. An alternative to cutting these
leads is to remove them from
Molex Plug J3 and pull them
free of any wire bundles.
10. Remove all cable ties, wire mounts,
- and any harness tape that could
get in the way during transformer
removal using wire cutters and
screwdriver.
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11. Remove the four screws mounting
the transformer to the floor of the
machine using a 5/16" nut driver.
IDEALARC SP-250
F-49
TROUBLESHOOTING & REPAIR
FAN MOTOR AND FAN REMOVAL AND REPLACEMENT
WARNING
Service and repair should be performed only by Lincoln Electric factory trained personnel. 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 precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform
the tests/repairs safely, contact the Lincoln Electric service department for technical
troubleshooting assistance before you proceed.
Call (216) 383-2531 or (800) 833-9353 (WELD).
F-49
MATERIALS NEEDED
3/4" Open end wrench
1/2" Socket wrench with extension
Phillips head screwdriver
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IDEALARC SP-250
F-50
TROUBLESHOOTING & REPAIR
FAN MOTOR AND FAN REMOVAL AND REPLACEMENT
PROCEDURE
See Figure F.18 for fan motor and fan
removal components.
F-50
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FIGURE F.18 - Fan Motor and Fan
Removal Components
1. Remove the Case Back screws.
2. Remove the gas solenoid using a
3/4" open end wrench.
3. Using a 5/16” wrench, remove the 5
screws holding the fan motor mounting bracket to the case back.
4. Tilt the Case Back away from the
machine and remove the screws
holding the Case Back to the floor of
the machine using a 1/2" socket
wrench with extension.
IDEALARC SP-250
5. Loosen the two screws holding the
reconnect panel in place and a slide
the reconnect panel from the frame.
6. Remove the fan blade. Note fan
blade position on motor shaft for reference for replacing fan.
a. Pry the fan blade off the motor.
b. Slide the fan blade off the motor
shaft.
F-51
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 slot head screw
driver.
b. When the motor is free from the
mounting bracket, place it carefully on the bottom of the
machine.
c. Cut any necessary wire wraps
bundling the motor leads.
d. Remove the leads from the fan
motor.
8. Install the replacement motor in the
reverse order of removal.
F-51
9. Install the fan blade. When
installing the fan blade, the blade is
flush with the end of the motor shaft.
a. Spin the fan to be sure it is free
to rotate.
10. Reassemble the remaining components in reverse order of removal.
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IDEALARC SP-250
F-52
TROUBLESHOOTING & REPAIR
RETEST AFTER REPAIR
INPUT IDLE AMPS AND WATTS
OPEN CIRCUIT VOLTAGE
F-52
Maximum Idle WattsMaximum Idle AmpsInput Volts/Hertz
3756.4230/60
10 to 40 VDC
35-40 VDC Strike Voltage
WIRE SPEED RANGE
50 - 600 IPM (1.27 - 15.2 m/minute)
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IDEALARC SP-250
TABLE OF CONTENTS
- ELECTRICAL DIAGRAMS -
ELECTRICAL DIAGRAMS SECTION ...................... Section G
G1992 CONTROL PC BOARD LAYOUT .....................G - 1
G2252 CONTROL PC BOARD LAYOUT......................G - 5
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
Section G
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IDEALARC SP-250
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