Lincoln Electric IDEALARC SP-250 Uživatelský manuál

IDEALARC SP-250SERVICE MANUALSales and Service through Subsidiaries and Distributors Worldwide22801 St. Clair Ave. Cleveland, Ohio 44117-1199 U.S.A.

A-3INSTALLATION IDEALARC SP-250A-3FUSE AND WIRE SIZESProtect the input circuit with the super lag fuses ordelay type circuit breakers listed on the

TABLE OF CONTENTS- ELECTRICAL DIAGRAMS -Section GIDEALARC SP-250ELECTRICAL DIAGRAMS SECTION ... Section GG1992 CONTROL PC BOARD LA

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G-4NOTESG-4IDEALARC SP-250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master

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G-8NOTESG-8IDEALARC SP-250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master

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A-4INSTALLATION IDEALARC SP-250A-4For the 230/460/575V/ 60 HZ model which is notequipped with a plug, an input cord, or a receptacle,the input power

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A-5INSTALLATION IDEALARC SP-250A-511. Before opening the cylinder valve, turn the regula-tor adjusting knob counter clockwise until the pres-sure is

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A-7INSTALLATION IDEALARC SP-250A-7CONNECT OUTPUT COMPONENTSINSTALL THE WORK CLAMPAttach the work clamp to the cable which extends fromthe front of t

A-8INSTALLATION IDEALARC SP-250A-8GUN & CABLE INSTALLATIONWARNING: TURN THE WELDER POWER SWITCHOFF BEFORE INSTALLING GUN AND CABLE.____________

OPERATIONIDEALARC SP-250OPERATION SECTION ... Section BSafety Instructions...

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B-2OPERATIONB-2The system includes the following features:• 2-step or 4-step selectable trigger function (abovecode 9500 only).• both timed spot and s

B-3OPERATIONB-3DESIGN FEATURES AND ADVANTAGESUNIT FEATURES:Undercarriage for Hand Mobility - Heavy duty 10"(254mm) wheels and 4" (102mm) cas

iSAFETYiIDEALARC SP-250Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCPROTECT YOURSELF AND OTHERS FROM POSSIBLE SE

B-4OPERATIONB-4Gun and Cable (K524-1) - A 12.5 ft. (3.8) GMAW gunand cable assembly, rated 200 amps 60% duty, is pro-vided with the SP-250 and include

B-5OPERATIONB-5CONTROLS AND SETTINGSAll operator controls are located on the Front PanelKeypad/Nameplate. See Figure B.1 for the location ofeach cont

B-6OPERATIONB-6ARROW KEY OPERATION WHEN USED WITHPROCESS WIRE/GAS KEY:See Table B.1.Left Arrow Keys: Press to set Wire Type. Pressing theUP and DOWN a

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B-8OPERATIONB-87. MEMORY KEYS: Press memory key locationnumber in which you want to save a procedure orfrom which you want to recall a procedure fromm

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B-10OPERATIONB-10OPERATING STEPSBefore operating the machine, be sure you have all thematerials needed to perform the work. Be sure you arefamiliar w

B-11OPERATIONB-1110. If SPOT timing mode required.a. Press SPOT key.b. Press CENTER UP or DOWN ARROW keys toselect SPOT ON TIME required.c. Press SPOT

B-12OPERATIONB-124. Press the CENTER UP & DOWN ARROW keys toset the required Spot On time. Suggested initialsetting is 1.2 seconds.5. Press the S

B-13OPERATIONB-13LOADING THE WIRE REELTo mount a 22-30 lb. (10-14 kg) Readi-Reel- packageusing the Readi-Reel adapter provided:1. Pull the Readi-Reel

FOR ELECTRICALLYpowered equipment.6.a. Turn off input power using the disconnectswitch at the fuse box before working onthe equipment.6.b. Install equ

B-14OPERATIONB-14FEEDING ELECTRODEWhen inching, the electrode and drive mechanism arealways “hot” to work and ground. The electroderemains “hot” seve

ACCESSORIESIDEALARC SP-250ACCESSORIES SECTION ... Section COptions/Accessories ...

C-1ACCESSORIESC-1OPTIONS / ACCESSORIESReplacement Magnum 250-SP Gun and CableAssembliesThe following GMAW gun and cable assemblies areavailable for us

C-2ACCESSORIESC-2Figure C.2 - Spool Gun Module Board Installation.1. Remove input power to the machine before start-ing.2. Remove the six screws that

C-3ACCESSORIESC-3SPOOL GUN CONNECTION BOXINSTALLATIONNOTE: Model codes below 9900 require the additionof three holes to the front of the machine&apos

C-4ACCESSORIESC-4SPOOL GUN CONNECTIONCAUTION: The spool gun module is intended for usewith Lincoln Electric Magnum Spool Guns only. Usewith other un

C-5ACCESSORIESC-5SPOOL GUN INSTALLATION TO OLD K531 KIT.1. Slide the spool gun cable assembly through theopening in the louvers provided for the work

MAINTENANCEIDEALARC SP-250MAINTENANCE SECTION ... Section DSafety Precautions...

D-1MAINTENANCED-1SAFETY PRECAUTIONS•Have a qualified technician do the maintenanceand troubleshooting work. •Disconnect input power at main input sup

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iiiSAFETYiiiIDEALARC SP-250Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCMar. ‘93ELECTRIC AND MAG-NETIC FIELDSmay

THEORY OF OPERATIONIDEALARC SP-250Figure E.1 -Block Logic DiagramNOTE: Unshaded areas of Block LogicDiagram are the subject of discussionTHEORY OF OPE

E-1THEORY OF OPERATIONE-1IDEALARC SP-250INPUT LINE VOLTAGE AND MAIN TRANS-FORMERThe desired single phase input power is connected tothe SP-250 through

E-2THEORY OF OPERATIONE-2IDEALARC SP-250OUTPUT RECTIFICATION AND FEED-BACK CONTROLThe AC output from the main transformer secondaryweld winding is rec

E-3THEORY OF OPERATIONE-3IDEALARC SP-250CONSTANT VOLTAGE OUTPUTThe controlled DC output from the SCR rectifierassembly is filtered by the capacitor ba

E-4THEORY OF OPERATIONE-4IDEALARC SP-250WIRE DRIVE MOTOR AND FEEDBACKThe wire drive motor is controlled by the control board.A motor speed feedback si

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TROUBLESHOOTING & REPAIRIDEALARC SP-250TROUBLESHOOTING & REPAIR SECTION ... Section FHow to use Troubleshooting Guide ...

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ivSAFETYivIDEALARC SP-250Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCPRÉCAUTIONS DE SÛRETÉPourvotre propre prot

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F-11TROUBLESHOOTING & REPAIRF-11IDEALARC SP-250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Ma

F-12TROUBLESHOOTING & REPAIRF-12IDEALARC SP-250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Ma

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i - vInstallation . . . . .

F-13TROUBLESHOOTING & REPAIRF-13IDEALARC SP-250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Ma

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F-17TROUBLESHOOTING & REPAIRF-17IDEALARC SP-250G1992 (Code 9402 only):8. Turn OFF the machine9. Locate the following leads on PlugJ6 on the G2252

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INSTALLATIONIDEALARC SP-250INSTALLATION SECTION ... Section ATechnical Specifications ...

F-23TROUBLESHOOTING & REPAIRF-23IDEALARC SP-250TEST PROCEDURE1. Disconnect main AC input power tothe machine.2. Disconnect Molex Plugs J3 and J6fr

F-24TROUBLESHOOTING & REPAIRF-24IDEALARC SP-2507. Connect the Tester to the SCR 1 asshown in Figure F.7.a. Connect Tester lead (A) to theanode.b.

F-25TROUBLESHOOTING & REPAIRF-25IDEALARC SP-250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Ma

F-26TROUBLESHOOTING & REPAIRF-26IDEALARC SP-250TEST PROCEDURE1. Disconnect main input power to themachine.2. Remove the Case Top and SidePanels us

F-27TROUBLESHOOTING & REPAIRF-27IDEALARC SP-250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Ma

F-28TROUBLESHOOTING & REPAIRF-28IDEALARC SP-250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Ma

F-29TROUBLESHOOTING & REPAIRF-29IDEALARC SP-250TEST PROCEDURENOTE: POLARITY MUST BEOBSERVED FOR THESE TESTS.Test for Correct Wire Drive MotorArmat

F-30TROUBLESHOOTING & REPAIRF-30IDEALARC SP-250FIGURE F.10B - Plug J6 Location on G1992 PC Control Board (Code 9402 only.)NOTE: Plugs J5 and J6 ar

F-31TROUBLESHOOTING & REPAIRF-31IDEALARC SP-250Test for Supply Voltage toTachometer1. Test for 15 VDC between lead#515B (positive) and lead #206B(

F-32TROUBLESHOOTING & REPAIRF-32IDEALARC SP-250This is a typical DC output voltage wave-form generated from a properly operatingmachine. Note tha

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F-33TROUBLESHOOTING & REPAIRF-33IDEALARC SP-250This is a typical DC output voltage wave-form generated from a properly operatingmachine. Note tha

F-34TROUBLESHOOTING & REPAIRF-34IDEALARC SP-250This is NOT a typical DC output voltagewaveform. One output SCR is not function-ing. Note the incr

F-35TROUBLESHOOTING & REPAIRF-35IDEALARC SP-250This is NOT the typical DC output voltagewaveform. The output capacitors are notfunctioning. Note

F-36TROUBLESHOOTING & REPAIRF-36IDEALARC SP-250This is a typical SCR gate pulse voltagewaveform. The machine was in an open cir-cuit condition (n

F-37TROUBLESHOOTING & REPAIRF-37IDEALARC SP-250Printed Circuit Boards can be dam-aged by static electricity. Follow sta-tic handling guidelines de

F-38TROUBLESHOOTING & REPAIRF-38IDEALARC SP-2504. Remove the eight Phillips Headmounting screws using a PhillipsHead screwdriver. See Figure F.12

F-39TROUBLESHOOTING & REPAIRF-39IDEALARC SP-250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Ma

F-40TROUBLESHOOTING & REPAIRF-40IDEALARC SP-250PROCEDURENOTE: BEFORE REMOVING THEKEYPAD, PERFORM THE KEYPADRESISTANCE TEST TO BE SURE THEKEYPAD IS

F-41TROUBLESHOOTING & REPAIRF-41IDEALARC SP-250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Ma

F-42TROUBLESHOOTING & REPAIRF-42IDEALARC SP-250PROCEDURE1. Disconnect main input power to themachine.2. Remove the Case Top and SidePanels.3. Remo

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F-43TROUBLESHOOTING & REPAIRF-43IDEALARC SP-250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Ma

F-44TROUBLESHOOTING & REPAIRF-44IDEALARC SP-250PROCEDURE1. Disconnect lead #208 andTransformer Lead X1 from the heatsink on the left side of the m

F-45TROUBLESHOOTING & REPAIRF-45IDEALARC SP-250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Ma

F-46TROUBLESHOOTING & REPAIRF-46IDEALARC SP-250PROCEDURESee Figure F.17 for location of CapacitorBank Removal and Replacement com-ponents.FIGURE F

F-47TROUBLESHOOTING & REPAIRF-47IDEALARC SP-250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Ma

F-48TROUBLESHOOTING & REPAIRF-48IDEALARC SP-250PROCEDURE1. Disconnect main input power to themachine.2. Remove the Case Top and SidePanels.3. Perf

F-49TROUBLESHOOTING & REPAIRF-49IDEALARC SP-250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Ma

F-50TROUBLESHOOTING & REPAIRF-50IDEALARC SP-250PROCEDURESee Figure F.18 for fan motor and fanremoval components.FIGURE F.18 - Fan Motor and FanRem

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F-52TROUBLESHOOTING & REPAIRF-52IDEALARC SP-250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Ma