Lincoln Electric SP-250 User Manual

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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

SAFETY

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

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3.e. Also see item 7b.

IDEALARC SP-250

Apr. ‘93

SAFETY

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

SAFETY

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

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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

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

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

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