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SVM 111-A
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SERVICE MANUAL
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World's Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors
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22801 St. Clair Ave. Cleveland, Ohio 44117-1199 U.S.A. Tel. (216) 481-8100
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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 Welding 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 THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PER-
FORMED ONLY BY QUALIFIED INDIVIDUALS.
skin or wet clothing. Wear dry, hole-free open arc welding. Headshield and filter lens
gloves to insulate hands. should conform to ANSI Z87. I standards.
1.b. Insulate yourself from work and ground using dry insulation. 2.b. Use suitable clothing made from durable flame-resistant
Make certain the insulation is large enough to cover your full material to protect your skin and that of your helpers from
area of physical contact with work and ground. the arc rays.
In addition to the normal safety precautions, if welding 2.c. Protect other nearby personnel with suitable, non-flammable
must be performed under electrically hazardous screening and/or warn them not to watch the arc nor expose
conditions (in damp locations or while wearing wet themselves to the arc rays or to hot spatter or metal.
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 FUMES AND GASES
accidental contact with the workpiece or ground) use
the following equipment: can be dangerous.
• Semiautomatic DC Constant Voltage (Wire) Welder. 3.a. Welding may produce fumes and gases
• DC Manual (Stick) Welder. hazardous to health. Avoid breathing these
• AC Welder with Reduced Voltage Control. fumes and gases.When welding, keep
your head out of the fume. Use enough
1.c. In semiautomatic or automatic wire welding, the electrode, ventilation and/or exhaust at the arc to keep
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electrode reel, welding head, nozzle or semiautomatic fumes and gases away from the breathing zone. When
welding gun are also electrically “hot”. welding with electrodes which require special
ventilation such as stainless or hard facing (see
1.d. Always be sure the work cable makes a good electrical instructions on container or MSDS) or on lead or
connection with the metal being welded. The connection cadmium plated steel and other metals or coatings
should be as close as possible to the area being welded. which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
1.e. Ground the work or metal to be welded to a good electrical using local exhaust or mechanical ventilation. In
(earth) ground. confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
1.f. Maintain the electrode holder, work clamp, welding cable and also required when welding on galvanized steel.
welding machine in good, safe operating condition. Replace
3.b. Do not weld in locations near chlorinated hydrocarbon vapors
damaged insulation.
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors to
1.g. Never dip the electrode in water for cooling.
form phosgene, a highly toxic gas, and other irritating
products.
1.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
3.c. Shielding gases used for arc welding can displace air and
between the two can be the total of the open circuit voltage
cause injury or death. Always use enough ventilation,
of both welders.
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4.b. Where compressed gases are to be used at the job site, 5.b. Always keep cylinders in an upright position securely
special precautions should be used to prevent hazardous chained to an undercarriage or fixed support.
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the 5.c. Cylinders should be located:
equipment being used. • Away from areas where they may be struck or subjected to
physical damage.
4.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact can • A safe distance from arc welding or cutting operations and
cause overheating and create a fire hazard. any other source of heat, sparks, or flame.
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4.d. Do not heat, cut or weld tanks, drums or containers until the 5.d. Never allow the electrode, electrode holder or any other
proper steps have been taken to insure that such procedures electrically “hot” parts to touch a cylinder.
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even though they have 5.e. Keep your head and face away from the cylinder valve outlet
been “cleaned”. For information, purchase “Recommended when opening the cylinder valve.
Safe Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous 5.f. Valve protection caps should always be in place and hand
Substances”, AWS F4.1 from the American Welding Society tight except when the cylinder is in use or connected for
use.
(see address above).
5.g. Read and follow the instructions on compressed gas
4.e. Vent hollow castings or containers before heating, cutting or
cylinders, associated equipment, and CGA publication P-l,
welding. They may explode.
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
4.f. Sparks and spatter are thrown from the welding arc. Wear oil
1235 Jefferson Davis Highway, Arlington, VA 22202.
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 FOR ELECTRICALLY
welding area. powered equipment.
4.g. Connect the work cable to the work as close to the welding
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Feb. ‘95
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IDEALARC SP-250
____________________________________________________ 8.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right
7.d. Keep all equipment safety guards, covers side, the work cable should also be on your right side.
and devices in position and in good repair.
Keep hands, hair, clothing and tools away 8.d.4. Connect the work cable to the workpiece as close as
from V-belts, gears, fans and all other possible to the area being welded.
moving parts when starting, operating or
repairing equipment. 8.d.5. Do not work next to welding power source.
____________________________________________________
Mar. ‘93
7.e. In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove
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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.
___________________________________________________
hot.
IDEALARC SP-250
IDEALARC SP-250
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
IDEALARC SP-250
- INSTALLATION SECTION -
IDEALARC SP-250
OPERATING TEMPERATURE
STORAGE OPERATING
± 400C -200C to 400C
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IDEALARC SP-250
STACKING
INPUT CONNECTIONS
WARNING
FIGURE A.1 - Case Back Assembly: Input Power
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____________________________________
IDEALARC SP-250
phase line.
any damage.
FIGURE A.3 - Ground Connection For 230/460/575 7. Attach the flow regulator to the cylinder valve and
Volt Models tighten the union nut(s) securely with a wrench.
GAS UNDER PRESSURE IS EXPLO- 9. Connect the other end of the inlet gas hose to the
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____________________________________
IDEALARC SP-250
IDEALARC SP-250
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.)
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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 NAME-
PLATED SINGLE PHASE INPUT VOLTAGE. TO CHANGE CONNECTIONS FOR A DIFFERENT INPUT
VOLTAGE, RECONNECT BOTH COPPER JUMPERS PER DIAGRAM BELOW. ALWAYS CONNECT
JUMPERS BETWEEN OUTER STEEL NUT AND INNER BRASS NUT ON TERMINAL STUDS.
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2. CONNECT THE INPUT POWER TO THE INPUT TERMINAL BLOCK, L1 AND L2 AT THE UPPER COR-
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NER 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 TER-
MINAL BLOCK.
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FIGURE A.6 - Reconnect Diagram For Codes 9546 & 10002 230/460/575/1/60 Machine.
IDEALARC SP-250
INSTALLATION
INSTALL THE WORK CLAMP
The Magnum 250 SP gun and cable provided with the
Attach the work clamp to the cable which extends from SP-250 is factory installed with a liner for a .035” or
the front of the machine using the following procedure: .045” (0.9 or 1.2mm) diameter electrode and an .035
(0.9mm) contact tip.
1. Insert the lug on the end of the work cable through
the strain relief hole in the work clamp handle. See 1. If a .045” diameter wire size is to be used, install
Figure A.7. the .045” contact tip (also provided).
2. Slide the work cable through the hole up to the bolt 2. For other wire sizes, use the following procedure
and nut. for contact tip and gas nozzle installation. See
Figure A.8.
3. Fasten work cable using the bolt and nut provided.
a. Choose the correct size contact tip for the
electrode being used (wire size is stenciled on
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WARNING: TURN THE WELDER POWER SWITCH For the spray transfer process, the contact tip should
OFF BEFORE CHANGING OUTPUT CONNECTION. be flush to recessed .12" (3.2mm).
____________________________________
IDEALARC SP-250
WARNING CAUTION
WARNING: TURN THE WELDER POWER SWITCH
OFF BEFORE INSTALLING GUN AND CABLE. The gun trigger switch connected to the gun trig-
____________________________________ ger control cable must be a normally open momen-
tary switch. The terminals of the switch must be
1. Lay the cable out straight. insulated from the welding circuit. Improper opera-
tion of or damage to the SP-250 might result if this
2. Make sure all pins on the gun cable connector are switch is common to an electrical circuit other than
aligned with the proper mating sockets on the front the SP-250 trigger circuit.
panel gun connector and then join the connectors ____________________________________
and tighten the hand nut on the gun cable connec-
tor.
IDEALARC SP-250
- OPERATION SECTION -
IDEALARC SP-250
ing your Idealarc SP-250. select the gauge size of the material to be welded and
enter the welding process to used. With that data, the
SAFETY INSTRUCTIONS system
ELECTRIC SHOCK can kill. • selects the right procedure for optimum starting,
welding, and burnback.
• Do not touch electrically live parts such
as output terminals or internal wiring. The system allows you to store up to five separate
welding setup procedures. You can recall them at any
• Insulate yourself from the work and time at the touch of a single key. All active setup selec-
ground. tions, as well as those stored in the memory locations,
are automatically saved when power is turned off or
• Always wear dry insulating gloves. disconnected. Whatever procedure was being used
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GENERAL DESCRIPTION
Product Description
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Japanese (Katakana).
IDEALARC SP-250
• integral gas cylinder mounting undercarriage. Display - Wide temperature range liquid crystal display
combines large 0.32" (8.1mm) high characters in a 2-
• 12.5 ft. (3.8m) Magnum 250SP GMAW gun and line by 16-character alphanumeric format. It has long
cable. life LED backlighting and a non-glare cover for easy
viewing under bright or dark conditions. Multi lan-
• dual groove drive roll and a gun liner for .035 guage display capability permits the SP-250 to com-
(0.9mm) and .045 (1.2mm) electrodes. municate in English, German, French, Spanish, or
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Japanese (Katakana).
• one contact tip for each wire size.
Auto Mode - Simply set the thickness of the material
• adjustable CO2 or argon blend flow regulator with being welded and the SP-250 automatically sets the
proper wire feed speed and arc voltage for the process
cylinder pressure gauge.
being used. This eliminates the need for look-up
tables, procedure slide rules, or notebooks to find the
• 10 ft. (3.0m) plug cable with receptacle.
proper settings. Auto Mode also provides one key con-
trol of the output by automatically adjusting both the
• 12 ft. (3.6m) work cable with clamp.
wire feed speed and arc voltage for an increase or
decrease in material thickness or wire feed speed.
RECOMMENDED PROCESSES AND This allows the operator to easily increase or decrease
EQUIPMENT his output without having to know how much to change
each parameter.
The SP-250 is recommended for GMA welding
processes using 10 to 30 lb. (4.5 to 13.6 kg) 2" (51mm) Thumb Switch on Gun - Allows the operator to set or
change the output of the machine, the wire feed speed,
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The SP-250 is factory equipped to feed .035 (0.9mm) Trigger Interlock (Above code 9500 only) - Selectable
and .045 (1.2mm) electrodes and includes a 200A, four-step trigger interlock allows operator to release
60% duty cycle rated, 12.5 ft. (3.8m) GMA gun and gun trigger after weld current is established and con-
cable assembly equipped for these wire sizes. The tinue welding. Breaking the arc or re-closing and then
SP-250 is factory equipped with an adjustable CO2 or releasing the gun trigger, stops the welding process.
argon blend flow regulator. A supply of shielding gas is
required for GMAW processes.
IDEALARC SP-250
Undercarriage for Hand Mobility - Heavy duty 10" Work Cable - 10 ft. (3.0m) long with work clamp.
(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. WIRE FEEDER FEATURES:
Gas Cylinder Platform - Factory installed on under- Drop-in Wire Loading - Wire spindle snaps into
carriage. It permits platform mounting and support of a Readi-Reel-Adapter, included with SP-250, or most
single gas cylinder. No full lifting of gas cylinder any 2" (51mm) I.D. wire spool. The wire spindle drops
required during loading. into the top loading SP-250 case design.
Accommodating standard 12” (305mm) and 8”
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Adjustable Flow Regulator - Accommodates CO2 or (203mm) diameter coils, the unique spindle and sup-
argon blend gas. Includes a cylinder pressure gauge port design automatically provides appropriate de-reel-
and a dual seal flow gauge. ing drag to prevent wire reel overrun and loop-offs
without manual brake adjustments.
Easy Accessability - Wire feeder enclosure protects
wire and wire drive from dirt, dust, and damage. Allows Tachometer Controlled Wire Drive - Precision con-
easy top-access for "drop-in" wire reel loading and to trol of permanent magnet motor provides proper wire
load or service the wire drive. feed acceleration and speed accuracy, independent of
fluctuations in line voltage and wire loading. This
means reliable arc starting and weld consistency.
POWER SOURCE FEATURES:
Low Speed Start - When the trigger is pulled, the wire
10 Ft. (3.0m) Input Power Cable - Includes plug and feeder feeds wire at low speed regardless of the set
mating receptacle for 208/230V unit. Convenient rear wire feed speed until welding current is drawn or 2 sec-
panel reconnect allows easy access for 208V re-con- onds has expired. This feature enhances starting and
nection. makes setting stick out a snap. The 2 second limit per-
mits high speed loading of the gun and cable. In later
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Power Switch - Front panel toggle switch turns input versions of the SP-250, a user selectable feature
power on and off. allows the wire feeder to feed wire directly at the set
speed, thus bypassing the 2 second slow start.
Thermostatically Controlled Fans - Provides cooling
of transformer and other components only when Solid State Wire Feed Overload Protection - No cir-
required. When used intermittently or at low current cuit breaker to reset. Simply pull the trigger to resume
procedures, the fan motors stay off, reducing the welding once the overload condition has been cleared.
amount of dust and dirt drawn into the machine. Also
reduces power consumption. Unique Drive Roll and Guide Tube Design - Long
life, precisely aligned guide tubes and drive rolls.
Electronic Overload Protection - Protects machine Quickly reloads by simply starting wire into ingoing
from short circuit or high current overloading. guide tube. Adjustable tension setting minimizes
'birdnesting', eliminates milling through the wire, and
Power Source Line Voltage Regulation - Precise gives positive feeding. The double groove, reversible
SCR phase control circuit holds the voltage setting drive roll included with the SP-250 allows use of .030
constant to maintain weld quality even when the input (0.8mm) through .045 (1.2mm) diameter wire. Drive
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voltage fluctuates +/-10%. Roll kits for other sizes and types of wire are also avail-
able.
Solid State Contactor - Output is turned on and off by
SCR's instead of a mechanical contactor providing Fast-Mate Gun Connector - European style gun con-
extra long life in highly repetitive welding applications. nector provides electrode, shielding gas and gun con-
IDEALARC SP-250
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).
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100% 145 26
60% 200 28
35% 250 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
1. POWER SWITCH: Toggle switch to turn input 3. PROCESS WIRE/GAS KEY: Press key to
power ON and OFF. When the switch is in the ON display the Wire Type, Wire Diameter, and Welding
position the red LED backlighting of the LCD dis- Gas. Each combination of wire and gas dictates a
play lights and alphanumeric characters appear. unique relationship between the wire feed speed
The welding setup in operation when the power and the arc voltage. The SP-250 uses this unique
was shut off or disconnected is displayed when relationship, along with the metal thickness, to set
power is restored. the proper values for wire feed speed and arc volt-
age. Therefore, it is very important that the wire
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2. SET UP ARROW KEYS: Press keys to type, wire diameter, and welding gas displayed
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change the display selection directly above the match the actual wire type, wire diameter, and
keys. See Figure B.1. Function of arrow keys welding gas being used for the weld.
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.
IDEALARC SP-250
ARROW KEY OPERATION WHEN USED WITH Wire Type Wire Diameter Welding Gas
PROCESS WIRE/GAS KEY:
Solid Steel .025 (0.6mm) CO2
See Table B.1. Solid Steel .025 (0.6mm) ArCO2
Solid Steel .030 (0.8mm) CO2
Left Arrow Keys: Press to set Wire Type. Pressing the Solid Steel .030 (0.8mm) ArCO2
UP and DOWN arrow keys changes the Wire Type dis- Solid Steel .035 (0.9mm) CO2
played. Solid Steel 035 (0.9mm) ArCO2
Solid Steel .035 (0.9mm) ArOxy
Center Arrow Keys: Press to set Wire Diameter. Solid Steel .045 (1.2mm) CO2
Press the UP ( ) arrow key to increase the wire diam- Solid Steel .045 (1.2mm) ArCO2
eter displayed. Press the DOWN ( ) arrow key to
decrease the wire diameter displayed. Stainless .035 (0.9mm) ArOxy
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of recommended Wire Speed and Arc Voltage ARROW KEY OPERATION WHEN USED WITH
based on Metal Thickness selected. MANUAL KEY:
able sizes. cated in the bottom left corner of the display. See
Figure B.2.
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.
5. MANUAL KEY: Press to set wire feed speed The six arrow keys perform no function when saving a
and arc voltage for manual procedure setup. The setup.
manual screen displays wire feed speed, arc volt-
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age, and a cursor that indicates when the wire feed NOTE: When a setup is saved to a memory location,
speed or arc voltage is being controlled by the the previous contents of that memory is lost because it
thumb switch on the SP-250 gun. is replaced by the present setup. Removing input
power does not effect the setup in memory.
IDEALARC SP-250
number in which you want to save a procedure or Center arrow keys: Press UP ( ) arrow key to
from which you want to recall a procedure from increase Stitch time ON from 0.20 seconds to 2.50
memory. See SAVE Key. seconds. Press the DOWN ( ) arrow key to decrease
Stitch ON time from 2.50 seconds to 0.20 seconds.
FIGURE B.3 - Sample SAVE Sequence. The six arrow keys do not function with this key.
8. SPOT KEY: Press to turn ON the Spot Weld 11. GUN SWITCH CONTROL IPM VOLTS
Timer and display the spot weld ON time. KEY: Press to engage the gun thumb switch to
Pressing the SPOT KEY a second time returns the control IPM or VOLTS. Pushing the gun thumb
screen to the previous display without turning off switch forward (toward the tip) increases IPM or
the spot timer. Anytime the Spot weld timer is on VOLTS . Pulling gun thumb switch back decreas-
and the display is in the Auto or Manual mode, the es IPM or VOLTS. The underlining cursor always
word SPOT will appear in the bottom left corner of indicates the selection being controlled by the gun
the display. See Figure B.2. thumb switch. See Figure B.4.
ARROW KEY OPERATION WHEN USED WITH If the cursor is not present, the gun thumb switch does
SPOT KEY: not function. This prevents any inadvertent actuations.
Each time this IPM VOLTS key is pressed, the cursor
See Table B.1. moves in the following sequence: IPM to VOLTS to no
cursor. The sequence continues each time the key is
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Center arrow keys: Press UP ( ) arrow key to NOTE: In Auto Mode, changing IPM changes arc volt-
increase Spot Weld ON time from 0.20 seconds to 2.5 age. This can result in a change in metal thickness
seconds. Press DOWN ( ) arrow key to decrease setting as well.
Spot ON time from 2.5 seconds to 0.20 seconds.
Figure B.2.
IDEALARC SP-250
turns ON the TOGGLE MODE and recalls the weld increase wire feed speed. Press DOWN ( ) arrow key
setup in memory 4. Pressing the key again switch- to decrease wire feed speed setting. If in Auto Mode,
es to the weld setup in memory location 5. Each increasing or decreasing wire feed speed simultane-
time the key is pressed, it alternates between the ously causes an increase or decrease in the arc volt-
two memory locations. When the TOGGLE key is age and can change the metal thickness setting.
pressed, the LED screen displays the memory
number the current setup was recalled from, indi- Right arrow keys: Press the UP ( ) arrow key to
cates automatic (AUTO:) or manual (MAN:) mode, increases arc voltage setting. Press the DOWN ( )
displays wire gauge (Auto Mode), wire feed speed, arrow key to decrease the arc voltage setting. When
and arc voltage. The cursor underlines the mem- in the Auto Mode, an up arrow indicator appears below
ory number currently selected. the V in VOLTS if the arc voltage has been set higher
than the recommended value. A down arrow indicator
If in AUTO mode, an up or down arrow shows appears below the V in VOLTS if the arc voltage is
whether the arc voltage has been adjusted above below the recommended value. No arrow indicates
or below the recommended level. Spot or Stitch that you are set to the recommended value.
timer status is displayed in the lower left-hand cor-
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ARROW KEY OPERATION WHEN USED WITH THE Note: 4-step Trigger is automatically deactivated if
TOGGLE KEY (See Table B.1.) either the spot or stitch timer mode is being used.
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1/96
IDEALARC SP-250
rent is reached or for 2 seconds, whichever condition is The run-in mode remains in effect until either the run-
reached first. When either of these conditions are in mode is changed using the double keystroke or until
reached, the SP-250 accelerates to the preset wire a memorized procedure containing the opposite run-in
feed speed. mode is recalled.
go to Step 12.
4. Select run-in mode required.
a. If run-in mode displayed is the required mode,
continue with weld process.
IDEALARC SP-250
a. Press SPOT key. 18. To stop welding, release the gun trigger and then
b. Press CENTER UP or DOWN ARROW keys to pull the gun away from the work after the arc goes
select SPOT ON TIME required. out.
c. Press SPOT key to return to previous display.
d. Go to Step 12. 19. When no more welding is to be done, close valve
on gas cylinder (if used). Momentarily operate gun
11. If STITCH timing mode required. trigger to release gas pressure.
a. Press STITCH key.
b. Press CENTER UP and DOWN ARROW keys 20. Turn the ON/OFF POWER SWITCH to OFF.
to select STITCH ON time required.
c. Press RIGHT UP or DOWN ARROW keys to
select STITCH OFF time required. USING THE 4-STEP INTERLOCK FUNCTION IN
d. Press STITCH key to return to previous dis- AUTO MODE
play.
e. Go to Step 12. When the 4-Step Interlock function is not activated, the
trigger functions in the normal mode so that welding
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12. Inch the electrode through the gun and cable happens only when the trigger is closed.
13. Cut the electrode within approximately 3/8" of the When the 4-Step Interlock function is activated, it
end of the contact tip (3/4" for Outershield). functions as follows:
15. Connect work clamp to metal to be welded. Work MAKING A SPOT WELD IN AUTO MODE
clamp must make good electrical contact to the
Arc spot plug welds are used when continuous welds
WARNING are not needed or to hold thin sheet metal together
prior to stitch welding or continuous welding. Arc spot
work. The work must be grounded. plug welds are made by using a punch to make a 3/16
WARNING: WHEN USING AN OPEN ARC inch diameter hole in the top sheet and arc welding
PROCESS, IT IS NECESSARY TO USE CORRECT through the hole into the back sheet.
EYE, HEAD, AND BODY PROTECTION.
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16. Position electrode over joint. End of electrode may 1. Punch 3/16" hole in top sheet.
be lightly touching the work.
2. Set the procedure for the metal thickness to be
17. Lower welding helmet, close gun trigger, and begin welded.
welding. Hold the gun so the contact tip to work
IDEALARC SP-250
7. Press spot weld nozzle against the top sheet so NOTE: When the trigger is pulled, the wire feeder
the top and bottom sheets are tight together. If a feeds wire at low speed regardless of the set wire feed
spot weld nozzle is not used, smoother welds will speed until the welding arc starts or 2 seconds has
result by moving the welding wire in a small circle elapsed. This feature enhances starting and makes it
while making the weld. easier to set the stick out. The 2 second limit permits
high speed loading of the gun and cable.
8. Close the trigger and hold it closed until the arc
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1. Set the procedure for the metal thickness to be The drive roll provided with the SP-250 has two
welded. grooves, one for .030”-.035” (0.8-0.9mm) solid steel
electrode, and the other for .045” (1.2mm) solid steel
2. Press STITCH key. Stitch screen is displayed. electrode. The welder is shipped with the drive roll
installed in the .030”-.035” (0.8-0.9mm) position as
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3. Press CENTER ARROW keys to set Stitch ON indicated by the stenciling on the exposed side of the
time. Start with a Stitch ON time setting of 0.5 sec- drive roll. If .045” (1.2mm) electrode is to be used or
onds. Increase the Time ON setting to increase one of the optional drive rolls is required, then the drive
penetration and weld size. Decrease the Time ON roll must be reversed or changed per the instructions
setting to reduce burnthrough and distortion. provided on the instruction decal inside the SP-250
Drive Roll Access door.
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.
IDEALARC SP-250
1. Pull the Readi-Reel adapter and spindle up out of 8. Lower the loaded spindle into the spindle mounting
the SP-250 spindle mounting clips (V-brackets). clips (V brackets) so wire dereels from top of coil
toward wire drive.
2. Rotate the spindle and adapter so the retaining
spring is at the 12 o'clock position. NOTE: The retaining spring side of the adapter should
be facing the center (inner) panel of the SP-250.
3. Position the Readi-Reel so that it will rotate in a
clockwise direction when wire is dereeled from the 9. To remove the Readi-Reel from Adapter, depress
top of the coil. See Figure B. 6. retaining spring tab with thumb while pulling the
Readi-Reel cage from the molded adapter with
both hands. Do not remove adapter from spindle.
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6. Slide the cage all the way onto the adapter until the * A later spindle design uses a longer "D"-shaped pin
retaining spring "pops up" fully. to assure engagement.
WARNING
IDEALARC SP-250
end and straighten the first six inches. Cut off the
first inch. (If the electrode is not properly straight-
ened, it may not feed properly into the outgoing
guide tube or welding gun causing a "birdnest".)
mined as follows:
IDEALARC SP-250
- ACCESSORIES SECTION -
IDEALARC SP-250
K524-2 Gun and Cable -A 12.5 ft. (3.8m) GMAW gun SP-250 model code 9402 must have S19636-2 read
and cable assembly; includes a liner, diffuser, and con- on display just after power switch is turned on.
tact tips for .025 (0.6mm) and .030 (0.8mm) elec-
trodes. WARNING
K524-3 Gun and Cable -A 15 ft. (4.6m) GMAW gun
and cable assembly; includes a liner, diffuser and con- WARNING: HIGH VOLTAGE CAN KILL!
tact tips for .035 (0.9mm) and .045 (1.2mm) elec-
trodes. • Do not operate with covers removed.
K524-4 Gun and Cable -A 15 ft. (4.6m) GMAW gun • Disconnect input power before servicing
and cable assembly; includes a liner, diffuser, and con-
tact tips for .025 (0.6mm) and .030 (0.8mm) elec- • Only qualified persons should install, use or service
trodes. this equipment.
____________________________________
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K607-1 Spool Gun adapter Kit See Figures C-1 and C-2.
(Option K607-1)
IDEALARC SP-250
CAUTION
CAUTION: Collect metal filings with a rag to protect
against possible metal contamination of the control
board or other internal electrical components.
____________________________________
5. Gently press the board onto the fasteners, making 13. Using the cable tie included in the kit, tie the two
sure all of the fasteners snap into place. harnesses together approximately 3.50 inches
(88.9mm) from the end of the lead plugs as shown
6. On the wire drive side of the machine, remove the in Figure C.2.
hex-head screw from beneath the gas connector
releasing the metal cover. See Figure C-1. 14. Replace the Case.
IDEALARC SP-250
IDEALARC SP-250
CAUTION
3. Attach the spool gun gas line to the gas outlet fit-
ting on the front of the connection box.
IDEALARC SP-250
mode.
1. Slide the spool gun cable assembly through the
opening in the louvers provided for the work lead. Refer to the Instruction Manual for the K487 or K469
See Figure C.6. spool gun for information on spool gun set up and
operation.
2. Remove the SP-250 gas line from the gas line con-
nector.
3. Screw the spool gun 6-pin plug into the new con-
nector just below the gas line connector.
11. Tighten the hex nut, being careful not to strip the
threads.
tion.
IDEALARC SP-250
- MAINTENANCE SECTION -
IDEALARC SP-250
WARNING After every coil of wire, inspect the wire drive mecha-
nism. Clean it as necessary by blowing with low pres-
•Have a qualified technician do the maintenance sure compressed air. Do not use solvents for cleaning
and troubleshooting work. the idle roll because it may wash the lubricant out of
the bearing. All drive rolls are stamped with the wire
•Disconnect input power at main input supply prior sizes they will feed. If a wire size other than that
to working inside machine. stamped on the roll is used, the drive roll must be
____________________________________ changed .
Flex the cable over its entire length and again blow out
Perform Periodically: the cable. Repeat this procedure until no further dirt
comes out.
Clean the inside of the machine with low pressure air
stream. Clean the following parts. Refer to Figure D-1.
Gun Tubes and Nozzles
Main transformer and choke.
Electrode and work cable connections. a. Replace worn contact tips as required.
SCR rectifier bridge and heat sink fins.
Control board. b. Remove spatter from inside of gas nozzle and from
Fan Assembly. tip after each 10 minutes of arc time or as required.
NOTE: The fan motor has sealed bearings which
require no maintenance.
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IDEALARC SP-250
3
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5
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IDEALARC SP-250
PIEZO GAS
LCD ALARM SOLENOID
DISPLAY
WIRE
DRIVE
MOTOR
KEYPAD
CONTROL BOARD
TACH
G
A
T
E GUN TRIGGER AND THUMB SWITCH
LINE MAIN
TRANSFORMER S
SWITCH I
G FEEDBACK
N
A
L
RECONNECT
POSITIVE
TERMINAL
C CHOKE
A F
P E
A E
C D
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SCR I B
RECTIFIER T A
O C
R K
FAN S NEGATIVE
MOTORS TERMINAL
SHUNT
IDEALARC SP-250
PIEZO GAS
LCD ALARM SOLENOID
DISPLAY
WIRE
DRIVE
MOTOR
KEYPAD
CONTROL BOARD
TACH
G
A
T
E GUN TRIGGER AND THUMB SWITCH
LINE MAIN
TRANSFORMER S
SWITCH I
G FEEDBACK
N
A
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L
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RECONNECT
POSITIVE
TERMINAL
C CHOKE
A F
P E
A E
C D
SCR I B
RECTIFIER T A
O C
R K
FAN S NEGATIVE
MOTORS TERMINAL
SHUNT
IDEALARC SP-250
PIEZO GAS
LCD ALARM SOLENOID
DISPLAY
WIRE
DRIVE
MOTOR
KEYPAD
CONTROL BOARD
TACH
G
A
T
E GUN TRIGGER AND THUMB SWITCH
LINE MAIN
TRANSFORMER S
SWITCH I
G FEEDBACK
N
A
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L
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RECONNECT
POSITIVE
TERMINAL
C CHOKE
A F
P E
A E
C D
SCR I B
RECTIFIER T A
O C
R K
FAN S NEGATIVE
MOTORS TERMINAL
SHUNT
IDEALARC SP-250
PIEZO GAS
LCD ALARM SOLENOID
DISPLAY
WIRE
DRIVE
MOTOR
KEYPAD
CONTROL BOARD
TACH
G
A
T
E GUN TRIGGER AND THUMB SWITCH
LINE MAIN
TRANSFORMER S
SWITCH I
G FEEDBACK
N
A
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L
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RECONNECT
POSITIVE
TERMINAL
C CHOKE
A F
P E
A E
C D
SCR I B
RECTIFIER T A
O C
R K
FAN S NEGATIVE
MOTORS TERMINAL
SHUNT
IDEALARC SP-250
PIEZO GAS
LCD ALARM SOLENOID
DISPLAY
WIRE
DRIVE
MOTOR
KEYPAD
CONTROL BOARD
TACH
G
A
T
E GUN TRIGGER AND THUMB SWITCH
LINE MAIN
TRANSFORMER S
SWITCH I
G FEEDBACK
N
A
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L
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RECONNECT
POSITIVE
TERMINAL
C CHOKE
A F
P E
A E
C D
SCR I B
RECTIFIER T A
O C
R K
FAN S NEGATIVE
MOTORS TERMINAL
SHUNT
IDEALARC SP-250
IDEALARC SP-250
INPUT
CATHODE
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OUTPUT
NOTE: AS THE GATE
PULSE IS APPLIED
ANODE LATER IN THE CYCLE
THE SCR OUTPUT
IS DECREASED.
GATE
A silicon controlled rectifier (SCR) is a three terminal An SCR is fired by a short burst of current into the gate.
device used to control rather large currents to a load. This gate pulse must be more positive than the cath-
An SCR acts very much like a switch. When a gate sig- ode voltage. Since there is a standard PN junction
nal is applied to the SCR it is turned ON and there is between gate and cathode, the voltage between these
current flow from anode to cathode. In the ON state the terminals must be slightly greater than 0.6V. Once the
SCR acts like a closed switch. When the SCR is turned SCR has fired it is not necessary to continue the flow
OFF there is no current flow from anode to cathode of gate current. As long as current continues to flow
thus the device acts like an open switch. As the name from anode to cathode the SCR will remain on. When
suggests, the SCR is a rectifier, so it passes current the anode to cathode current drops below a minimum
only during positive half cycles of the AC supply. The value, called holding current, the SCR will shut off. This
positive half cycle is the portion of the sine wave in normally occurs as the AC supply voltage passes
which the anode of the SCR is more positive than the through zero into the negative portion of the sine wave.
cathode. If the SCR is turned on early in the positive half cycle,
the conduction time is longer resulting in greater SCR
When an AC supply voltage is applied to the SCR, the output. If the gate firing occurs later in the cycle the
device spends a certain portion of the AC cycle time in conduction time is less resulting in lower SCR output.
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IDEALARC SP-250
IDEALARC SP-250
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 trou-
bleshooting assistance before you proceed call 216-383-2531 or 1-800-833-9353.
_____________________________________________________________
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IDEALARC SP-250
troubleshooting and replacing PC boards, damage and allow proper failure analysis.
please use the following procedure:
4. Test the machine to determine if the failure
1. Determine to the best of your technical abil- symptom has been corrected by the
ity that the PC board is the most likely com- replacement PC board.
ponent causing the failure symptom.
NOTE: It is desirable to have a spare (known
2. Check for loose connections at the PC good) PC board available for PC board trou-
board to assure that the PC board is proper- bleshooting.
ly connected.
NOTE: Allow the machine to heat up so that
3. If the problem persists, replace the suspect all electrical components can reach their oper-
PC board using standard practices to avoid ating temperature.
static electrical damage and electrical
shock. Read the warning inside the static 5. Remove the replacement PC board and
resistant bag and perform the following pro- substitute it with the original PC board to
recreate the original problem.
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cedures:
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IDEALARC SP-250
OUTPUT PROBLEMS
Major Physical or Electrical Damage 1. Contact your local Lincoln 1. Contact The Lincoln Electric
is Evident Electric Authorized Field Service Service Dept. (216) 383-2531 or
Facility. 1-800-833-9353 (WELD)
Machine is dead - No Open Circuit 1. Make certain that the input 1. Check input power switch (S1).
Voltage output and No Wire Feed power switch is in the "ON" posi- It may be faulty.
when gun trigger is pulled. No tion.
Display. 2. Check for loose or broken wires
2. Check the input voltage at the at the reconnect panel.
machine. Input voltage must
match the rating plate and the 3. Perform Main Transformer Test.
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reconnect panel.
No Open Circuit Voltage output but 1. Check the input voltage at the 1. Check for loose or broken con-
wire feeds normally when gun trigger machine. Input voltage must nections at the output terminals,
is pulled. - Display lights properly. match the rating plate and the the choke, the capacitor bank
reconnect panel - High or Low and all heavy current carrying
Line message may be displayed. leads.
2. The gun may be faulty. Check or 2. Make sure that the transformer
replace. secondary leads are securely
connected to the SCR Rectifier
Assembly.
Assembly Test.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con-
tact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed call 216-
383-2531 or 1-800-833-9353
IDEALARC SP-250
OUTPUT PROBLEMS
No Open Circuit Voltage output and 1. The thermostats may be open 1. Check thermostats and associ-
no wire feed when gun trigger is due to machine overheating. If ated leads for loose or broken
pulled. Display is functioning proper- machine operates normally after connections. See Wiring
ly. a cooling off period then check Diagram.
for proper fan operation and
ventilation. Make certain that 2. Perform The Main Transformer
the machine's duty cycle is not Test.
being exceeded.
3. The control board may be faulty.
2. Check the gun trigger circuit. Replace.
Leads #324 to #325 should have
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Wire feeds but welding output is low 1. If an error message is displayed 1. Check for loose or faulty con-
causing wire to "stub". on the display then proceed to nections of the heavy current
Welds are "cold". Machine cannot Explanation of Prompting and carrying leads.
obtain full rated output of 250 amps Error Messages Section.
at 26 volts. 2. The output capacitor bank may
2. Make sure that the proper wire be faulty. Check for loose con-
and procedures are being used. nections at the capacitors. Also
check for leaky capacitors.
3. Check gun and work cable for Replace if necessary. WARN-
loose or faulty connections. ING: The liquid electrolyte in
these capacitors is toxic. Avoid
contact with any portion of your
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body.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con-
tact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed call 216-
383-2531 or 1-800-833-9353
IDEALARC SP-250
OUTPUT PROBLEMS
The output voltage and wire feed is 1. Remove the gun. If the problem 1. Check the machine's internal
present continuously or pulsing is resolved the gun trigger circuit trigger leads for grounds or
when gun trigger is NOT activated. is faulty. Repair or replace. shorts. See Wiring Diagram.
Output settings (voltage and/or wire 1. Remove the gun. If the problem 1. Check leads #326 and #327 for
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feed speed) are being changed even is resolved the gun thumb switch grounds or shorts. See Wiring
though gun thumb switch or keypad circuit may be faulty. Repair or Diagram.
keys are not being activated. replace.
2. The Keypad may be faulty.
2. If the problem persists after gun Perform the Keypad Test.
removal then the keypad may be
faulty. Check for burned or dam- 3. The control board may be faulty.
aged areas on the keypad. Replace.
No wire feed or open circuit voltage 1. Check the input voltage at the 1. Perform the Keypad Test.
when gun trigger is pulled. The dis- machine. Input voltage must
play lights up but the audio alarm match the rating plate and the 2. Perform the Main Transformer
and the display do not function prop- reconnect panel - High or Low Test.
erly. Line message may be displayed.
3. The control board may be faulty.-
2. Remove the gun. If the problem Replace.
is resolved the gun is faulty.-
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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, con-
tact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed call 216-
383-2531 or 1-800-833-9353
IDEALARC SP-250
FUNCTION PROBLEMS
The audio alarm does NOT sound 1. The background noise may be 1. Check the voltage across pins
when a key is pressed, but display too loud for user to hear beeper. 1J7 (+) to 2J7 (-) on the control
changes. board. When the keys are
pressed there should be a brief
indication, or pulse, of a DC volt-
age. If the voltage "pulse" is pre-
sent 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
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may be defective.-Replace.
The audio alarm does not sound 1. Remove the gun. If the problem 1. Perform the Keypad Test.
when a key is pressed, and the dis- is resolved the gun is faulty.-
play does NOT change. Replace. 2. The control board may be faulty.
- Replace.
No readable message on the dis- 1. Check the input voltage at the 1. The display board may be faulty.
play. Backlight is lit indicating there machine. The input voltage Replace.
is power to the machine. must match the rating plate and
the reconnect panel. 2. The control board may be faulty.
Replace.
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.
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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, con-
tact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed call 216-
383-2531 or 1-800-833-9353
IDEALARC SP-250
FUNCTION PROBLEMS
The display backlight does not func- 1. Check the input voltage at the 1. With the display board discon-
tion. machine. Input voltage must nected test for 12VDC from pins
match the machine rating plate 1J1(+) to 2J1(-). If the 12VDC is
and the reconnect panel. present and the display board
backlight does NOT function
then replace the display board.
See Wiring Diagram.
The machine stops feeding wire 1. Check for mechanical restric- 1. Check the motor armature cur-
while welding and the MOTOR tions in the wire feeding path. rent. Normal armature current is
OVERLOAD message appears on The gun cable may be clogged. 1.5 - 2.5 amps.
the display. If the motor armature current is
normal the control board may be
faulty.-Replace.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con-
tact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed call 216-
383-2531 or 1-800-833-9353
IDEALARC SP-250
There is no wire feed when gun trig- 1. If the drive rolls are turning then 1. Perform the Wire Drive Motor
ger is pulled. Normal open circuit check for a mechanical restric- and Tach Feedback Test.
voltage is present. tion in the wire feed path.
2. The control board may be faulty.
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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, con-
tact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed call 216-
383-2531 or 1-800-833-9353
IDEALARC SP-250
WELDING PROBLEMS
The arc is unstable and or "hunting". 1. Check for worn or melted con- 1. Check for loose connections at
tact tip. the output terminals, the choke,
the capacitor bank and all heavy
2. Check for loose or faulty con- current carrying leads.
nections on the work and elec-
trode cables. 2. Make sure that the transformer
secondary leads are securely
3. Make sure electrode polarity is connected to the SCR Rectifier
correct or welding process being Assembly.
used.
3. The output capacitor bank may
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4. Check for rusty or dirty wire. be faulty. Check for loose con-
nections at the capacitors. Also
5. Make sure machine settings and check for leaky capacitors.
gas are correct for process Replace if necessary.
being used. WARNING: The liquid elec-
trolyte in these capacitors is
toxic. Avoid contact with any
portion of your body.
Weld bead is narrow or ropey. May 1. Make sure the weld procedure 1. The output capacitor bank may
have porosity with electrode stub- and electrode polarity is correct be faulty. Check for loose con-
bing into plate. for the process being used. nections at the capacitors. Also
check for leaky capacitors.
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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, con-
tact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed call 216-
383-2531 or 1-800-833-9353
IDEALARC SP-250
WELDING PROBLEMS
The contact tip seizes in the gas dif- 1. The tip is being over heated due
fuser. to excessive high current and /or
high duty cycle welding.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con-
tact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed call 216-
383-2531 or 1-800-833-9353
IDEALARC SP-250
PROCESS MUST Reminder that in Auto mode the process entered with the Process key must
MATCH WIRE & GAS match the process installed in the machine .
ONLY SET UP FOR Unit is only programmed for .035” (0.9mm) diameter in stainless steel wire.
.035 STAINLESS Other wire diameters can be accommodated by using the Manual mode.
ONLY ARGON USED Unit is programmed to use only argon gas with aluminum electrodes. Other
WITH ALUMINUM gases can be accommodated by using the manual mode.
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ONLY SET UP FOR Unit is only programmed for .045” (1.1mm) diameter in Outershield® elec-
. 045 OUTERSHIELD trode wire. Other wire diameters within the SP-250 rating can be accom-
modated by using the Manual mode.
NO GAS REQUIRED Innershield® electrode wire does not require a shielding gas. In the Auto
WITH INNERSHIELD mode, the SP-250 automatically leaves the solenoid de-energized even
when the trigger is closed.
MEMORY 1 NOW Verifies that the setup was saved to memory number 1. The actual memo-
CONTAINS SETUP ry number is determined by the memory number key that was pressed fol-
lowing Save.
MEMORY 2 An attempt was made to recall a setup from a memory that does not con-
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IS EMPTY tain one. The actual memory number is determined by the memory num-
ber key that was just pressed.
MEMORY 4 DOESN’T An attempt was made to enter Toggle mode and the process of the Auto
MATCH WIRE & GAS 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 indi-
cates which memory, 4 or 5, does not match.
REQ'S: STAINLESS An attempt was made to recall from memory an Auto setup whose process
WIRE .035 Ar/O2 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.
PRESS PROCESS
WHEN INSTALLED
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IDEALARC SP-250
DATA ***ERROR*** An attempt was made to recall a setup from memory that has improper set-
CHECK SETTINGS tings 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
PRESS PROCESS TO memory. This message alternates with the second message until the
CHECK SETTINGS Process key is pressed.
MOTOR OVERLOADED Unit shut down even though trigger was closed. There is an excessive cur-
CHECK GUN, DRIVE rent 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
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impede the wire feeding. To resume welding, simply pull the trigger.
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XXXX ***ERROR*** Indicates that an error has occurred due to excessive electrical interference.
CHECK SETTINGS All of these error types turn off the arc voltage, wire feed speed, and sole-
noid. Press the Process key, per second message, and check all settings
before continuing to weld.
PRESS PROCESS TO XXXX This table shows all of the actual lettering which
CHECK SETTINGS IC3I appears in place of XXXX. There is no reason to
RTI note which of these occurred unless it occurs fre-
SWI quently.
IOT
XIRQ
PWOF
DATA
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GUN SWITCH BEING Reminds the operator that the gun switch is being used to toggle between
USED FOR TOGGLE memory 4 and memory 5 and, therefore, is not able to control IPM or arc
VOLTS.
CONNECT FOR Reminds the operator to change the electrode polarity to negative when
NEG. POLARITY Innershield wire type is selected.
LOW LINE: CHECK Indicates to operator that the input line voltage is too low to obtain the out-
RECONNECT PANEL put 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
PRESS ANY KEY machine is not obtainable at that line voltage and load current. The opera-
TO STOP MESSAGE tor should check if the reconnect panel is wired properly. Lowering the set
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VOLTS and/or IPM can eliminate the message. Pressing any key or gun
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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
Indicates to operator that the line voltage is too high, and the output voltage
HIGH LINE: CHECK has been reduced to protect the capacitor bank voltage rating limits. The
RECONNECT PANEL 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
PRESS ANY KEY wired properly. Pressing any key or gun switch when the operator is not
TO STOP MESSAGE welding will stop the message from being displayed. Pressing any incre-
ment 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.
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CURRENT OVERLOAD Indicates to operator that too much current is being drawn from the
REDUCE OUTPUT 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
PRESS ANY KEY WFS will reduce the output requirement and allow operation within the
TO STOP MESSAGE machine rating. Pressing any key or gun switch when the operator is not
welding will stop the message from being displayed. Pressing any incre-
ment or decrement arrow keys or gun switch while welding will temporarily
stop the message from being displayed (approximately 1.3 seconds) allow-
ing the operator to view the increase or decrease in that setting.
SXXXXX -X Only displayed at power-up. Displays the part number of the ROM
ROM ASSEMBLY ASSEMBLY currently on the PC board.
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C SXXXXX -X Indicates a checksum error in the software. Turn power off and back on
ROM ASSEMBLY again. If this message persists, then replace the ROM assembly on the PC
board. Earlier units did not display the SXXXXX-X ROM ASSEMBLY num-
ber.
R Indicates a fault in system RAM. Turn power off and back on again. If this
message persists, then replace the control PC board assembly.
SPOOL GUN HAS Reminder that the Spool gun has been connected and the Manual key must
BEEN CONNECTED be pressed to enter any Spool gun welding procedures.
PRESS MANUAL
TO ENTER SETTINGS
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SPOOL GUN HAS Reminder that the Spool gun has been removed and the Process key must
BEEN REMOVED be pressed to enter SP-250 weld settings. This message may also be dis-
played if there is an open lead in the spool gun 6-pin plug assembly.
PRESS PROCESS TO
TO ENTER SETTINGS
IDEALARC SP-250
WARNING
Service and repair should be performed only by Lincoln Electric factory trained per-
sonnel. 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 pre-
cautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform
Return to Section TOC
Return to Master TOC
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
MATERIALS NEEDED
5/16" Nut Driver
Volt-Ohm Meter
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IDEALARC SP-250
TEST PROCEDURE
WARNING
The ON/OFF POWER SWITCH will be
"hot" during these tests.
__________________________
SP-250 CONTROL
G2252
J2
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J8
J7
J3
J4
J9
#206
#203 #204A #202
(4J6)
(3J3) (2J3) (1J3)
#209
(7J6)
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J5 J6
#208
(16J6)
IDEALARC SP-250
SP-250 CONTROL
G1992
J2
J8
J7
J4
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J6 J9
J5
#208
(1J3)
J3 #209 (2J3)
#206 (3J3)
#204A (5J3)
#202 (6J3)
#203
(7J3)
FIGURE F.1B - G1992 (Code 9402 Only) Control PC Board Main Transformer Test
Points. Note: Plugs J5 and J6 are on inboard non-component side of Control
Board.
4. Locate the following leads on Plug
J3:
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IDEALARC SP-250
IDEALARC SP-250
IDEALARC SP-250
WARNING
Service and repair should be performed only by Lincoln Electric factory trained per-
sonnel. 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 pre-
cautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform
Return to Section TOC
Return to Master TOC
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.
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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
TEST PROCEDURE
1. Disconnect main AC input power to 3. Test with an Analog Volt-Ohm meter
the machine. that capacitors have completely dis-
charged.
2. Disconnect Plugs J3 and J6 from
the G2252 Control Board or remove 4. Disconnect leads X2 and X3 from
Plug J3 from the G1992 Control the negative capacitor bank using a
Board (Code 9402 only.) This elec- fi" open end wrench. See Figure F.3.
trically isolates the SCR bridge
assembly. See Figures F.2A and
F.2B.
SP-250 CONTROL
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G2252
J2
J8
LEADS
J7
X2 AND X3
J4
NEGATIVE
J9 J3
CAPACITOR
BANK
J5 J6
BUSS BAR
FIGURE F.3 - Location of Leads X2
FIGURE F.2A - Remove Plugs J3 and and X3.
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J2
J8
J7
J4
J9
J5
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J3 J6
IDEALARC SP-250
IDEALARC SP-250
WARNING
Service and repair should be performed only by Lincoln Electric factory trained per-
sonnel. 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 pre-
cautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform
Return to Section TOC
Return to Master TOC
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.
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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
SP-250 CONTROL
G2252
Return to Section TOC
J2
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J8
LEADS
J7 X2 AND X3
J4
NEGATIVE
J3
CAPACITOR
J9
BANK
BUSS BAR
J5 J6
FIGURE F.6 - Location of Leads X2
and X3.
FIGURE F.5A - Control Board Molex
Plug Locations for G2252 PC Control 5. Separate leads X2 and X3 from the
negative capacitor bank buss bar.
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Board.
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IDEALARC SP-250
FIGURE F.7 - SCR Tester Circuit and b. If the voltage is higher than
SCR connections. zero, the SCR is shorted.
9. Read meter for zero voltage. 17. Replace all SCR assemblies that do
not pass the above tests.
a. If the voltage reading is higher
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than zero, the SCR is shorted. 18. Replace all Molex Plugs onto the
Control Board and connect leads X2
10. Close or keep closed switch SW-1 and X3.
IDEALARC SP-250
WARNING
Service and repair should be performed only by Lincoln Electric factory trained per-
sonnel. 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 pre-
cautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform
Return to Section TOC
Return to Master TOC
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
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IDEALARC SP-250
TEST PROCEDURE
1. Disconnect main input power to the 4. Measure the resistance of each key
machine. at Plug J2 using an analog volt-ohm
meter as described in Table F.1.
2. Remove the Case Top and Side
Panels using the 5/16" nut driver. a. The resistance measurements
are taken from the pin locations
3. Locate and disconnect Plug J2 con- on Plug J2. See Figure F.9 for
nected to the Control PC Board. each pin location.
See Figures F.8A and F8B.
b. If any of the resistance tests are
not correct, the keypad may be
SP-250 CONTROL faulty. Replace.
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G2252
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J2
J8
J7
J4
J9 J3
J5 J6
SP-250 CONTROL
G1992
J7
J4
J9
J5
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J3 J6
IDEALARC SP-250
NOTE: THERE SHOULD NOT BE CONTINUITY BETWEEN PINS UNTIL A KEY IS PRESSED ON THE KEYPAD.
IDEALARC SP-250
WARNING
Service and repair should be performed only by Lincoln Electric factory trained per-
sonnel. 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 pre-
cautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform
Return to Section TOC
Return to Master TOC
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 wire drive motor and voltage feedback circuit are functioning
properly.
MATERIALS NEEDED
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IDEALARC SP-250
TEST PROCEDURE
NOTE: POLARITY MUST BE
OBSERVED FOR THESE TESTS.
SP-250 CONTROL
G2252
J2
J8
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J7
J4
J5 J9 J3
#515B
(3J5)
#206B
(2J5) J6
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IDEALARC SP-250
J2
J8
J7
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J4
#206B
(4J6) #515B
(1J6)
J5
J9
#555
(2J6)
J6 J3
#541
(6J6)
#539
(3J6)
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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.
4. Test for 2-25 VDC between lead b. If the wires are okay and voltage
#539 (positive) and lead #541 (neg- to the drive motor armature is
ative) to determine if the correct zero, the Control Board may be
armature voltage is being supplied. faulty. Replace.
See Figure F.10A or F.10B.
c. If the correct DC armature volt-
a. Insert probes in to the Molex pin age is present at the wire drive
cavities. motor, the motor or motor brush-
es may be faulty. Test and/or
5. Pull the gun trigger. replace.
IDEALARC SP-250
IDEALARC SP-250
SCOPE SETTINGS
IDEALARC SP-250
SCOPE SETTINGS
IDEALARC SP-250
SCOPE SETTINGS
probe to work.
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IDEALARC SP-250
SCOPE SETTINGS
IDEALARC SP-250
SCOPE SETTINGS
IDEALARC SP-250
J9
MATERIALS NEEDED
J8
3. Disconnect all wiring harness
plugs and Molex Plugs connect- J7
ed to the Control Board. See
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Figure F.11.
J4
J6 J9
J5
J3
IDEALARC SP-250
IDEALARC SP-250
WARNING
Service and repair should be performed only by Lincoln Electric factory trained per-
sonnel. 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 pre-
cautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform
Return to Section TOC
Return to Master TOC
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
IDEALARC SP-250
PROCEDURE
NOTE: BEFORE REMOVING THE
KEYPAD, PERFORM THE KEYPAD
RESISTANCE TEST TO BE SURE THE
KEYPAD IS FAULTY.
Control Panel.
IDEALARC SP-250
WARNING
Service and repair should be performed only by Lincoln Electric factory trained per-
sonnel. 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 pre-
cautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform
Return to Section TOC
Return to Master TOC
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
IDEALARC SP-250
PROCEDURE
1. Disconnect main input power to the
machine.
4. Using a small slot head screw driver, a. The six pin plug contains the
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loosen the set screw holding the out wire feed drive motor wires.
going guide tube into the drive roll
assembly. Carefully slide out the 6. Remove carefully the drive motor
wire drive assembly. and drive roll assembly.
IDEALARC SP-250
WARNING
Service and repair should be performed only by Lincoln Electric factory trained per-
sonnel. 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 pre-
cautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform
Return to Section TOC
Return to Master TOC
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
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IDEALARC SP-250
a. Thin lead is always on the out- b. Cut any necessary cable ties.
board side of the connection.
5. Remove the four screws holding the
SCR Assembly to the floor of the
machine using a 5/16" nut driver.
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3. Remove the diode lead from the FIGURE F.16 - Heat Sink Lead
negative capacitor band buss bar on Disconnection
the right side of the machine using a
slot head screwdriver and 3/8" open 7. Remove lead #209 and Transformer
end wrench. Lead X4 from the right side heat sink
using a 1/2" socket wrench and 1/2"
open end wrench.
electrical connections.
IDEALARC SP-250
WARNING
Service and repair should be performed only by Lincoln Electric factory trained per-
sonnel. 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 pre-
cautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform
Return to Section TOC
Return to Master TOC
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).
WARNING
THE LIQUID ELECTROLYTE IN THE CAPACITORS IS TOXIC. DO NOT TOUCH THE
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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
PROCEDURE
See Figure F.17 for location of Capacitor
Bank Removal and Replacement com-
ponents.
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IDEALARC SP-250
WARNING
Service and repair should be performed only by Lincoln Electric factory trained per-
sonnel. 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 pre-
cautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform
Return to Section TOC
Return to Master TOC
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
3/8" Open end wrench
1/2" Socket wrench, extender, universal adapter
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Return to Master TOC
Wire cutters
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IDEALARC SP-250
3. Perform the Capacitor Bank 14. Pull down on the positive output
Removal Procedure. lead until it slides out the hole in the
baffle.
4. Remove lead X1 from the left side
SCR heat sink assembly using a 15. Carefully remove the main trans-
1/2" socket wrench, extender and former.
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IDEALARC SP-250
WARNING
Service and repair should be performed only by Lincoln Electric factory trained per-
sonnel. 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 pre-
cautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform
Return to Section TOC
Return to Master TOC
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
3/4" Open end wrench
1/2" Socket wrench with extension
Phillips head screwdriver
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IDEALARC SP-250
PROCEDURE
See Figure F.18 for fan motor and fan
removal components.
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1. Remove the Case Back screws. 5. Loosen the two screws holding the
reconnect panel in place and a slide
2. Remove the gas solenoid using a the reconnect panel from the frame.
3/4" open end wrench.
6. Remove the fan blade. Note fan
3. Using a 5/16” wrench, remove the 5 blade position on motor shaft for ref-
screws holding the fan motor mount- erence for replacing fan.
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IDEALARC SP-250
IDEALARC SP-250
IDEALARC SP-250
IDEALARC SP-250
SP-250 CONTROL
R132
R130
R129
C11
R131
C88
C87
C86
C85
X21
G1992-2
R100
X17
R138
C95
B J8
C81
C84
C83
C82
R128
R127
R126
R125
C35 C34 R97 R67 R139
J1 R68 R106
R108
D57
X5 Y1 C27
D2 R53
R107
R16 C28 R52
D54
X4 C6 R65 R54
R61 D53
C8
C91
C90
R135
R133
R134
R3
R1
R5
R6
R7
D37
R111
D20
C4
X6 C47 R4
D38 D69
C5 X1
R18 D50
R58
L7
Q14
R104 R70
R57
R95
Q20
Q18
X7 R91
C33
C32
X20 X2 X3
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R8
C17
R11
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D32
Q19
R123
C78
R19
D34
R10 R117
D47
D45
D70
R55
R49
D48
D46
D71
Q3 C36
Q10
Q1 Q4
C37
R9
J2
C26
Q2
D31
C24
D30
X9
D27
R101
C52
C7
D29
D26
D25 D28 C25
D24
D72 R140
D1
R12 R109
R13 R76
R14 X8 R77 R121
Q6
R15 R79 Q7
R20
R122
C44
J7
C29 D73 C38
C31 X16 R44 X15
R31
R80 D44
C20
C21
DZ7
D43
D51 DZ6
A
D39
D40
DZ3
X13 D75 R43
C50
R47
R118
C2
X11
R22
D76
R83
R46
R23
C19
R81
R82
R78
C14
C56
R37 C55
C9 R36
C43
X10
C13 X14 X18
Q13
R35
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R120
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D58
R38
C48
D41
X12 R39
R32 R112 Q12
R25
Q21
C16
C15
Q11
C3
R115
R114
R113
R56
R51
C49
D61
D60
D59
D62
J4 Q9 DZ2
C R94 R87 R71
R40
R28
R116
R30
D35
L5 L4 L6 L3
J6
J5
C40
C30
D67
D66
L2
R74
DZ4
R92
R86
C39
TP3
TP5
R72
R73
D68
D65
Q16
Q15
TP1
TP2
Q17
R136
R137
R84 J3
DZ5
R75
D63
C79
C80
L1
R48 R50
R90
R103
D55
D56
R89
R102
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NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshoot-
ing. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components
are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric
discourages board level troubleshooting and repair since it may compromise the quality of the design
and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result
in damage to the machine.
IDEALARC SP-250
R40 . . . . . . . . . . . . . . . . . . .RESISTOR-WW,7W,0.25,1%
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C19 . . . . . . . . . . . .CAPACITOR-ALEL,3300,50V,+30/-10%
OCI2,OCI3 OPTOCOUPLER-PHOTO-SCR,400V,MCS2401 DZ5 . . . . . . . . . . . . .ZENER DIODE-1W,16V,5%,1N4745A
OCI1 . . . . . . . . . . .OPTOCOUPLER-PHOTO-Q,30V,4N35 DZ4 . . . . . . . . . . . . .ZENER DIODE-1W,15V,5%,1N4744A
X10 . . . . . . . . .IC-CMOS,INVERTER,SCHMITT,HEX,4584 DZ3 . . . . . . . . . . . . .ZENER DIODE-5W,10V,5%,1N5347B
X14,X17,X18 . . . . . . .IC-VOLTREF,ADJ,PRECISION,431I DZ7 . . . . . . . . . . . .ZENER DIODE-1W,6.2V,5%,1N4735A
X16 . . . . . . . . . . . . . . . .IC-VOLTREG,FIXED,3-T,(-),1A,5V DZ1,DZ2,DZ6 . . . . .ZENER DIODE-1W,18V,5%,1N4746A
R3 . . . . . . . . . . . . .TRIMMER-MT,1/2W,10K,10%,LINEAR Q9,Q16 . . . . . . . .TRANSISTOR-P,T226,0.2A,30V,2N4125
R100 . . . . . . . . .RESISTOR-NETWORK,100,8-RESISTOR Q17 . . . . . . . .TRANSISTOR-NMF,T220,15A,60V,15N06E
C6,C8 . . . . . . . . . . . . . .CAPACITOR-CEMO,22P,100V,5% D20 . . . . . . . . . . . . . .DIODE-AXLDS,1A,30V,SCHOTTKY
R66 . . . . . . . . . . . . . . . . . . . .RESISTOR-MF,1/2W,1K,2%
C11,C32,C33,C34, . . . . .CAPACITOR-CEMO,0.1,50V,10% R35 . . . . . . . . . . . . . . . . . . .RESISTOR-MF,1/2W,2.7K,2%
C35,C36,C37,C38,C51,C52,C77,C78 R87,R94 . . . . . . . . . . . . . . . .RESISTOR-MF,1/2W,330,2%
R123 . . . . . . . . . . . . . . . . . .RESISTOR-MF,1/2W,6.8K,2%
C81,C82,C83,C846, . .CAPACITOR-CEMO,100P,100V,5% R22,R70 . . . . . . . . . . . . . . .RESISTOR-MF,1/2W,3.9K,2%
C85,C8,C87,C88,C90,C91 R47 . . . . . . . . . . . . . . . . . . . .RESISTOR-MF,1/2W,3K,2%
R121 . . . . . . . . . . . . . . . . . .RESISTOR-MF,1/2W,27K,2%
C17 . . . . . . . . . . . . . . .CAPACITOR-CEMO,2700P,50V,5%
R5,R6,R7,R30,R75,R99, . . . .RESISTOR-MF,1/2W,100,2%
C1,C2,C3,C4,C5,C7, . .CAPACITOR-CEMO,.022,50V,20% R113,R114,R115,R120
Return to Section TOC
Return to Master TOC
C9,C10,C27,C28,C31,C43,C44,C48,C49,C50,C56
R37,R122 . . . . . . . . . . . . . . .RESISTOR-MF,1/2W,750,2%
J2 . . . . . . . . . . . . .CONNECTOR,PCB,WW,MALE,DIL,1X9 R52,R57 . . . . . . . . . . . . . . .RESISTOR-MF,1/2W,1.8K,2%
Q12 . . . . . . . . . . . . . . . . . . . . . . . . . . .HEATSINK ASBLY R118 . . . . . . . . . . . . . . . . . . . .RESISTOR-MF,1/2W,68,2%
DD1 . . . . . . . . . .MULTIPLE DIODE & HEAT SINK ASBLY R89,R90 . . . . . . . . . . . . . . . .RESISTOR-MF,1/2W,270,2%
J9 . . . . . . . . . . . .CONNECTOR,MOLEX,MINI,PCB,10-PIN R31 . . . . . . . . . . . . . . . . . . .RESISTOR-MF,1/2W,1.5K,2%
J3 . . . . . . . . . . . .CONNECTOR,MOLEX,MINI,PCB,14-PIN R62 . . . . . . . . . . . . . . . . . . .RESISTOR-MF,1/2W,10K,2%
J5,J7,J8 . . . . . . . .CONNECTOR,MOLEX,MINI,PCB,4-PIN R1 . . . . . . . . . . . . . . . . . . . .RESISTOR-MF,1/2W,18K,2%
J6 . . . . . . . . . . . . .CONNECTOR,MOLEX,MINI,PCB,6-PIN R86,R92 . . . . . . . . . . . . . . . . .RESISTOR-MF,1/2W,15,2%
J4 . . . . . . . . . . . . .CONNECTOR,MOLEX,MINI,PCB,8-PIN R51,R56 . . . . . . . . . . . . . . . .RESISTOR-MF,1/2W,56K,2%
R103 . . . . . . . .THERMISTOR-PTC,.02-0.47 OHMS,0.90A R71 . . . . . . . . . . . . . . . . . . .RESISTOR-MF,1/2W,470,2%
X15 . . . . . . . . .POS VOLTAGE REG & HEAT SINK ASBLY R48,R50 . . . . . . . . . . . . . . . . .RESISTOR-CC,2W,10,10%
Q11 . . . . . . . . . . . . . .TRANSISTOR & HEAT SINK ASBLY R43 . . . . . . . . . . . . . . . . . . .RESISTOR-WW,5W,3.3K,5%
J1 . . . . . . . . . .CONNECTOR,PCB,WW,VERTICAL,16-PIN TP3,TP5 . . . . . . . . . . . . . . . . . .MOV-50VRMS,15J,14MM
R138 . . . . . . . . . . . . .TRIMMER-ST,1/2W,1K,10%,LINEAR TP1,TP2 . . . . . . . . . . . . . . . . . .MOV-75VRMS,22J,14MM
C29 . . . . . . . . . . . . . . . .CAPACITOR-PEF,0.22,100V,10% R106 . . . . . . . . . . . . . . . . . . . .RESISTOR-MF 102K 1/4W
C22,C23 . . . . . .CAPACITOR-PPEF,0.68,400V,10%,RIGID R49,R55,R67,R69,R139 . . . . . .RESISTOR-MF 10K 1/4W
Return to Section TOC
Return to Master TOC
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshoot-
ing. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components
are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric
discourages board level troubleshooting and repair since it may compromise the quality of the design
and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result
in damage to the machine.
IDEALARC SP-250
2/95
G1992 CONTROL PC BOARD
Return to Section TOC
Return to Master TOC
Item Identification
R16 . . . . . . . . . . . . . . . . . . .RESISTOR-CC,1/2W,10M,5%
R32,R54,R119 . . . . . . . . . . . . . .RESISTOR-MF 22K 1/4W
R60,R81,R82,R83,R91,R95 . . .RESISTOR-MF 2.2K 1/4W
R2,R116 . . . . . . . . . . . . . . . . . .RESISTOR-MF 330 1/4W
R61,R107,R108 . . . . . . . . . . . . .RESISTOR-MF 100 1/4W
R112 . . . . . . . . . . . . . . . . . . . . .RESISTOR-MF 270 1/4W
X12 . . . . . . . . . .IC-CMOS,SWITCH,ANALOG,QUAD,4066
X1 . . . . . . . . . . .IC-OP-AMP,QUAD,GEN-PURPOSE,224N
Y1 . . . . . . . . . . . . . . . . . . .CRYSTAL-QUARTZ,4.000MHZ
X3 . . . . . . . .IC-CMOS,GATE,NAND,2-INPUT,QUAD,HC00
X5 . . . . . . . . .IC-CMOS,LATCH,3-STATE,OCTAL,HC373A
X2,X20 . . . . .IC-CMOS,INVERTER,SCHMITT,HEX,HC14A
X7 . . . . . . . . . . . .IC-CMOS,REGISTER,SHFT,SI/PO,8-BIT
X11,X13,X19 . . . . . . . . . .IC-COMPARATOR,QUAD,2901N
X8 . . . . . . . . . .IC-CMOS REGISTER,SHFT,S-PI/SO,8-BIT
X21 . . . . . . . .IC-CMOS,TRNSCVR,BUS,3-STATE,OCTAL
Q1,Q2,Q3,Q4,Q6, TRANSISTOR-N,T226,0.2A,30V,2N4123
Q8,Q10,Q14,Q15,Q18,Q19,Q20
Q7,Q13 . . . . .TRANSISTOR-N,T226,0.5A,300V,MPS-A42
Return to Section TOC
Return to Master TOC
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshoot-
ing. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components
are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric
discourages board level troubleshooting and repair since it may compromise the quality of the design
and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result
in damage to the machine.
IDEALARC SP-250
IDEALARC SP-250
G-4
G-5 ELECTRICAL DIAGRAMS G-5
Return to Section TOC
SP 250 CONTROL
G2252- 2
16
1
Return to Section TOC
9
Return to Master TOC
1
Return to Section TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshoot-
ing. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components
are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric
discourages board level troubleshooting and repair since it may compromise the quality of the design
and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result
in damage to the machine.
IDEALARC SP-250
R79 . . . . . . . . . . . . . TRIMMER-ST,1/2W,1K,10%,LINEAR
Return to Master TOC
C2,C3,C4,C5,C33, . . . CAPACITOR-CEMO,.022,50V,20%
C40,C41,C52,C53,C57,C60,C62,C63,C100,C101,C102, C42 . . . . . . . . . . . . . . . . CAPACITOR-PEF,0.22,100V,10%
C103,C104,C105,C106,C107,C117 C70,C75 . . . . . . CAPACITOR-PPEF,0.68,400V,10%,RIGID
R74,R153 . . . . . . . . . . . . . RESISTOR-WW,5W,1K,5%,SQ
D9,D10,D11,D12,D13,D14 . . . . DIODE-AXLDS,1A,1000V R145,R162,R175 . . . . . . . RESISTOR-WW,5W,50,5%,SQ
R57,R58 . . . . . . . . . . . . . . RESISTOR-WW,5W,20,5%,SQ
L1,L4,L5,L6,L7,L8, CHOKE-330UH,10%,110MA,MOLDED C50 . . . . . . . . . . . . . . CAPACITOR-PEMF,.047,100V,10%
L10,L11,L12,L13,L14 C74 . . . . . . . . . . . . . . . . . CAPACITOR-TAEL,39,20V,10%
C78 . . . . . . . . . . . CAPACITOR-ALEL,2200,63V,+30/-10%
L2,L3 . . . . . . . . CHOKE-390UH,5%,225MA,CONFORMAL
R143 . . . . . . . . . . . . . . . . . . RESISTOR-WW,5W,3.3K,5% R14,R17,R20,R30,R31,R32, RESISTOR-MF,1/4W,100,1%
TP1,TP2 . . . . . . . . . . . . . . . . . . MOV-75VRMS,22J,14MM R41,R42,R43,R44,R45,R54,R55,R56,R65,R94,
R70 . . . . . . . . . . . . . . . . . . RESISTOR-CC,1/2W,10M,5% R103,R108,R121,R129,R148,R192,R193
R140,R141 . . . . . . . . . . RESISTOR-WW,7W,0.25,5%,SQ
C21,C34 . . . . . . . . . . . . . CAPACITOR-TAEL,4.7,35V,10% R6,R7,R8,R9,R60,R62, . . RESISTOR-MF,1/4W,1.00K,1%
C56 . . . . . . . . . . . . . . . . . CAPACITOR-TAEL,39,10V,10% R63,R64,R72,R163,R176
C55,C79 . . . . . . . . . . . . . CAPACITOR-TAEL,18,15V,10%
C91,C92 . . . . . . . . . . . . . CAPACITOR-TAEL,1.0,35V,10% R1,R2,R3,R4,R5,R13, . . . RESISTOR-MF,1/4W,10.0K,1%
C51 . . . . . . . . . . . . . CAPACITOR-ALEL,20,50V,+75/-10% R16,R19,R24,R25,R78,R80,R93,R96,R124,R134
C54 . . . . . . . . . . . . . . . . CAPACITOR-PEF,.001,400V,10%
Return to Section TOC
Return to Master TOC
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshoot-
ing. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components
are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric
discourages board level troubleshooting and repair since it may compromise the quality of the design
and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result
in damage to the machine.
IDEALARC SP-250
R150 . . . . . . . . . . . . . . . . RESISTOR-MF,1/4W,3.01K,1%
R49,R82 . . . . . . . . . . . . . . . RESISTOR-MF,1/4W,332,1%
R33,R34,R35,R36,R37, . . RESISTOR-MF,1/4W,3.32K,1%
R38,R39,R40,R50,R51,R52,R53,R92,R112
R100,R101,R164,R169 . . . . RESISTOR-MF,1/4W,33.2,1%
R66,R146 . . . . . . . . . . . . . RESISTOR-MF,1/4W,3.92K,1%
R89 . . . . . . . . . . . . . . . . . . . RESISTOR-MF,1/4W,475,1%
R71,R81,R90,R91, . . . . . . RESISTOR-MF,1/4W,4.75K,1%
R136,R190
R116 . . . . . . . . . . . . . . . . RESISTOR-MF,1/4W,47.5K,1%
R125,R127 . . . . . . . . . . . . . RESISTOR-MF,1/4W,511,1%
R126,R131 . . . . . . . . . . . . RESISTOR-MF,1/4W,51.1K,1%
R167,R168,R173,R174 . . . . RESISTOR-MF,1/4W,562,1%
R10,R68,R104,R106 . . . . RESISTOR-MF,1/4W,5.62K,1%
Return to Section TOC
Return to Master TOC
R77,R109,R113,R122, . . . RESISTOR-MF,1/4W,6.81K,1%
R133,R149
R107,R117 . . . . . . . . . . . . . RESISTOR-MF,1/4W,750,1%
X6 . . . . . . . . . . IC-CMOS,MCU,NO-ROM,DIP,68HC11A1P
X9 . . . . . IC-CMOS,UNDERVOLT-SENSING,RESET,MCU
X12 . . . . . . . . . IC-CMOS,SWITCH,ANALOG,QUAD,4066
X1 . . . . . . . . . . IC-OP-AMP,QUAD,GEN-PURPOSE,224N
X3 . . . . . . . IC-CMOS,GATE,NAND,2-INPUT,QUAD,HC00
X5 . . . . . . . . IC-CMOS,LATCH,3-STATE,OCTAL,HC373A
X2,X20 . . . . IC-CMOS,INVERTER,SCHMITT,HEX,HC14A
X7 . . . . . . . . . . . IC-CMOS,REGISTER,SHFT,SI/PO,8-BIT
OCI1 . . . . . . . . OPTOCOUPLER-PHOTO-Q,70V,CNY17-3
X11,X13,X19 . . . . . . . . . IC-COMPARATOR,QUAD,2901N
X8 . . . . . . . . . IC-CMOS REGISTER,SHFT,S-PI/SO,8-BIT
X21 . . . . . . . . IC-CMOS,TRNSCVR,BUS,3-STATE,OCTAL
Q21,Q31 . . . . TRANSISTOR-N,T226,0.5A,300V,MPS-A42
Return to Section TOC
Return to Master TOC
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshoot-
ing. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components
are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric
discourages board level troubleshooting and repair since it may compromise the quality of the design
and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result
in damage to the machine.
IDEALARC SP-250
IDEALARC SP-250
G-8
G-9
ELECTRICAL DIAGRAMS G-9
Return to Section TOC
A 541B
B 539B
1 (J7)* CONTROL BOARD 1
2
C 322 (J8)
*
2
2 LINE X 16 CHAR. (J13) 3
D 321
3
4
ALPHA-NUMERIC E 325B
4 *
1 2 3 4 *
F 324B (J4) (J9)
5
OPTIONAL SPOOL OR PULL SP - 250
LCD DISPLAY 6
GUN RECEPTACLE SPOOL GUN GAS
R
7
(J1) B MODULE SOLENOID
8 * 1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8 9 10
9 1 541B
10 2 321
541A
325
515
495
542
324
543
206
12 6 539B
208 1 7 322
13 (J12)
N.D. *
14 209 2 8 325B
(J6)
15
* N.D. 206 3 4
(J5)
*
16 GND 4 5
PROCESS SAVE
Return to Section TOC
Return to Master TOC
204A 5 9
WIRE/
5
GAS
202 6 10 GENERAL INFORMATION
3 1 2 3 4 1 2 3 4 5 6 203 7
(J3)
ELECTRICAL SYMBOLS PER E1537
*
1
325 8 (J11)
(J2)
*
MEMORY 7 204S
*
9
COLOR CODE:
541
515
555
206
539
9
325
327
1 2 3 4 5
326
324
207 10
6
320 11 B - BLACK
8 W - WHITE
204 12
2 1 2 3 4 5 6 7 8 R - RED
IPM G1 13
SPOT SWITCH VOLTS TOGGLE U - BLUE
4
G2 14
TIMERS SET SET 4 5
OFF DISPLAY DISPLAY
RF CHOKE
AS'BLY
* INDICATES CONNECTOR CAVITY NO.
B R
541A
515
325
324
495
542
543
206
KEYPAD MATRIX PIEZO
N.F.
ALARM
TO NOTES
WORK
N.A. N.C. N.A. WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE
W 541
MOTOR/ CURRENT AND DUTY CYCLE OF IMMEDIATE AND
T R 515
327 GEARBOX A
FUTURE APPLICATIONS.
P.M. 555
U
C
324 206 GND
N.J. H B N.B. THIS DIAGRAM SHOWS THE "ELECTRODE" POLARITY
325 B 539 "POSITIVE". TO CHANGE POLARITY, TURN THE UNIT
206 207
326 N.B.
OFF AND REVERSE LEAD CONNECTIONS AT CABLE
THUMB
CONDUCTOR STRAP AND WORK STUD.
SWITCH 327
320 326 325
N.E. R.F. TOROID AS'BLY. N.C. CONNECTOR SHOWN GEARBOX SIDE VIEW.
INC. DEC. TO SINGLE PHASE
N.G.
R.F. FILTER
Return to Section TOC
SUPPLY LINE
Return to Master TOC
THERMOSTAT THERMOSTAT
N.D. CONNECTORS MOUNTED ON NON-COMPONENT SIDE
326 L1 OF BOARD.
324 S3 S4
N.E. THERMOSTATS MOUNTED ON CHOKE COIL .
TRIGGER S2 MOUNTED CLOSEST TO FAN; S3 MOUNTED CLOSEST TO
325 L2
X5 POWER TRANSFORMER.
202
H4 N.F. KEYPAD MATRIX SHOWN FRONT VIEW.
X6 W
204A GND
H2 H3 N.G. THERMOSTAT S4 MOUNTED ON FAN SENSOR BRACKET
TO GROUND PER
X7 208 L1
T1 203 LOW V.
NATIONAL ELECTRICAL N.H. RESISTOR R2 MOUNTED ON FAN SENSOR BRACKET.
X1 G1 HIGH V.
CODE
H1 H1 SCR 1 B N.J. CONNECTOR SHOWN PIN SIDE VIEW.
250V
204 470A
L2
CAVITY NUMBERING SEQUENCE
L1 L2 X2 SCR HEATSINK
ASBLY
(COMPONENT SIDE OF P.C. BOARD)
H2 GND. RECONNECT PANEL 1 16 1 9
H2 X3 SCR 2
J1 J2
250V G
470A
P2 X4
H3 G2
H1 H4
H3 209 1 7 1 5 1 4
POWER TRANSFORMER D1 J4
300V J3 J9
85A N.E.
J11
H1 P2
8 14 6 10 5 8
LINE
T1 T2
SWITCH P1 P2
1 2 1 3
S1 206
FAN J7
S2 J12
MOTORS
THERMOSTAT J8
15 OHMS
Return to Section TOC
Return to Master TOC
R1
100 W 3 4 4 6
C1 C2 C3 C4
C1 THRU C4
30,000 MFD (NON-COMPONENT SIDE OF BOARD)
+ + + +
50V OUTPUT 1 2 1 3
CHOKE R2
207 2.5K J5 J6
N.H. 10W
204S
3 4 4 6
10-19-90N
L7976
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels.
A 541B
B 539B
1 (J7)
* CONTROL BOARD 1
2
C 322 * (J8)
*
2
2 LINE X 16 CHAR. (J13) (J4) 3
D 321
3
4
ALPHA-NUMERIC E 325B 4
1 2 3 4 *
F 324B
5 (J9)
OPTIONAL SPOOL OR PULL 1 2 3 4 5 6 7 8
LCD DISPLAY 6
GUN RECEPTACLE
R
7 GAS
(J1) B SP - 250
8 * 541A
324A
325A
206A
SOLENOID
515
495
542
543
1 2 3 4 5 6 SPOOL GUN
9 GENERAL INFORMATION
MODULE
10
1 541B ELECTRICAL SYMBOLS PER E1537
AUTO MANUAL 11
12 2 321
GND COLOR CODE:
13 3 324B
6 539B B - BLACK
14 1
202 1 W - WHITE
15 1 555 2 7 322
(J12)
* R - RED
204A 2
2 206B 3 8 325B
PROCESS SAVE 16 U - BLUE
203 3
3 515B 206 4 4
WIRE/
GAS
5
4 325 207 5
4
5 * INDICATES CONNECTOR CAVITY NO.
3 G1 5
5 GND 6 9
Return to Section TOC
1 204
Return to Master TOC
MEMORY 7
(J2)
* * 6 326 209 7
G2 7
(J3)
* 10
(J5) 324
7 8 (J11)
*
1 2 3 4 5 9
* 8
8 539 9
6 (J6) 9
9 541 10
8 10
10 205 11
2 11 1 2 3 4 5 6 7 8
IPM VOLTS 11 12
SPOT STITCH TOGGLE 12
4
TIMERS SET SET 4 5 12 206S 13
541A
325A
324A
206A
515
495
542
543
208 16
KEYPAD MATRIX
N.F.
GND
R.F. CHOKE AS'BLY.
B R
515B 1 515B
TO
541 6 541
NOTES
N.A. WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE
WORK
CURRENT AND DUTY CYCLE OF IMMEDIATE AND
N.A. N.C. FUTURE APPLICATIONS.
W 541
MOTOR/ N.B. THIS DIAGRAM SHOWS THE "ELECTRODE" POLARITY
T R 515B
327 GEARBOX "POSITIVE". TO CHANGE POLARITY, TURN THE UNIT
P.M. A
U 555 OFF AND REVERSE LEAD CONNECTIONS AT CABLE
C
CONDUCTOR STRAP AND WORK STUD.
N.J. 324 H B 206B
Return to Section TOC
Return to Master TOC
SWITCH 327
320 328 325A N.F. KEYPAD MATRIX SHOWN FRONT VIEW.
N.E.
N.G. TO SINGLE PHASE N.G. THERMOSTAT S4 MOUNTED ON FAN SENSOR BRACKET.
R.F. FILTER SUPPLY LINE
INC. DEC. THERMOSTAT THERMOSTAT N.H. RESISTOR R2 MOUNTED ON FAN SENSOR BRACKET.
S3 S4 L1
N.J. CONNECTOR SHOWN PIN SIDE VIEW.
326
324 L2
X5
202
5
TRIGGER X6
H5
204A GND
325 L1 L2
TO GROUND PER
X7 208
T1
X1
203
G1 4 2 H2
NATIONAL ELECTRICAL CAVITY NUMBERING SEQUENCE
CODE
H1 SCR 1 (COMPONENT SIDE OF P.C. BOARD)
H2
P2 250V J1 TOP
470A 1 16
H2 204 1 9
1 3 H4
L1 L2 H5 X2 SCR HEATSINK J2
ASBLY H3
H3
X3 SCR 2 H1 J3
250V 1 6 1 5 1 4
470A RECONNECT PANEL (SHOWN CONNECTED
GND. J4
X4 FOR 230 VOLT.)
G2 J12
H1 H4
H4 209
G J11
SHUNT POWER TRANSFORMER D1
7 12 6 10 5 8
300V N.E.
+ 85A
H1 - P2 1 2 1 3
LINE 206 T1 T2 J7
P1 P2 J9
SWITCH
J8
S1 FAN
Return to Section TOC
205
Return to Master TOC
15 OHMS S2
MOTORS 3 4 4 6
R1
100 W THERMOSTAT
C1 THRU C4
206S C1 C2 C3 C4
30,000 MFD
+ + + + 50V 204
OUTPUT
1 7 1 8
CHOKE R2
2.5K
207 J5 J6
N.H. 10W
8 14 9 16
2-28-92B
L7977
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels.
A 541B
B 539B
1 (J7)
* CONTROL BOARD 1
2
C 322 * (J8)
*
2
2 LINE X 16 CHAR. (J13) (J4) 3
D 321
3
4
ALPHA-NUMERIC E 325B 4
1 2 3 4 *
F 324B
5 (J9)
OPTIONAL SPOOL OR PULL 1 2 3 4 5 6 7 8
LCD DISPLAY 6
GUN RECEPTACLE
R
7 GAS
(J1) B SP - 250
8 *
541A
324A
325A
206A SOLENOID
515
495
542
543
1 2 3 4 5 6 SPOOL GUN
9 GENERAL INFORMATION
MODULE
10
1 541B ELECTRICAL SYMBOLS PER E1537
AUTO MANUAL 11
12 2 321
GND COLOR CODE:
13 3 324B
6 539B B - BLACK
14 1
202 1 W - WHITE
15 1 555 2 7 322
(J12)
* R - RED
204A 2
2 206B 3 8 325B
PROCESS SAVE 16 U - BLUE
203 3
3 515B 206 4 4
WIRE/
GAS
5
4 325 207 5
4
5 * INDICATES CONNECTOR CAVITY NO.
3 G1 5
5 GND 6 9
204
Return to Section TOC
1 6
*
Return to Master TOC
*
1 2 3 4 5 9
* 8
8 539 9
6 (J6) 9
9 541 10
8 10
10 205 11
2 11 1 2 3 4 5 6 7 8
IPM VOLTS 11 12
SPOT STITCH TOGGLE 12
4
TIMERS SET SET 4 5 12 206S 13
541A
325A
324A
206A
515
495
542
543
208 16
KEYPAD MATRIX
N.F.
GND
R.F. CHOKE AS'BLY.
B R
515B 1 515B
TO
541 6 541
NOTES
WORK N.A. WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE
CURRENT AND DUTY CYCLE OF IMMEDIATE AND
N.A. N.C.
W 541 FUTURE APPLICATIONS.
MOTOR/
T R 515B N.B. THIS DIAGRAM SHOWS THE "ELECTRODE" POLARITY
327 GEARBOX P.M. A
U 555 "POSITIVE". TO CHANGE POLARITY, TURN THE UNIT
C
N.J. 324 H B 206B
OFF AND REVERSE LEAD CONNECTIONS AT CABLE
Return to Section TOC
Return to Master TOC
S3 S4 L1
N.G. THERMOSTAT S4 MOUNTED ON FAN SENSOR BRACKET
15 OHMS
3 4 4 6
R1
100 W
C1 THRU C4
206S C1 C2 C3 C4 R2
30,000 MFD
2.5K
+ + + + 50V 204
OUTPUT N.H. 10W
1 7 1 8
CHOKE
207 J5 J6
8 14 9 16
2-28-92B
L8423
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels.
G-12
+5 V
IDEALARC SP-250
P2 J2 L7
1
Q4
2N4123 .33mH
P2 J2 R11
3
10K 3.3K 3.3K 3.3K 3.3K 3.3K 3.3K 3.3K 3.3K
Q1
R125
R126
R127
R128
R129
R130
R131
R132
2N4123 +5 V
R8 3 Q A
P2 J2 11 9 9 8
5 B1 A1
X7 R100 9 D0
10K 4 Q B
Q2 12 8 10 7 J1 P1
B2 A2
X21 10 D1
2N4123 5 Q C A1 1
R9 13 7 11 6 J1 P1
P2 J2 B3 A3
11 D2
7 6 2
10K Q D A2 14 6 12 5 J1 P1
B4 A4
Q3 RES. NTWK. 12 D3
10 Q E 8
2N4123 CLK X2 E 15 5 13 4 J1 P1
12 13 B5 A5
P2 J2 R10 100 13 D4
11 Q F 9
9 R 16 4 14 3 J1 P1
10K B6 A6 .19W 14 D5
12 Q G Q H 13
17 3 15 2 J1 P1
B7 A7
Q20 74HC164 15 D6
KEYPAD R104 74HC245 J1 P1
2N4123 18 B8 A8 2 16 1
16 D7
10K J1 P1
DIR OUT EN C82 C83 C84 C85 C86 C87
20 C81 100p 100p 100p 100p 100p 100p
3 0D Vcc 1 19 100p 100V 100V 100V 100V 100V 100V LCD
+5 V C88
11 A CLK1 2 4 1D X5 0Q 2 100V
100p
12 9 7 5 R54 100V
DISPLAY
B X8 Q H 2D 1Q
13 C SS/PL 1 8 3D 2Q 6 22K
D24 D25 D26 D27
14 D Q H 7 13 4D 3Q 9
R12
R13
R14
R15
1K 1K 1K 1K 3 E CLK2 15 14 5D 4Q 12 R1 5 Vo
CW
J1 P1
4 F SA 10 17 6D 5Q 15 18K
P2 J2 10
2 1/2W
5 6 18 7D 6Q 16
R3
P2 J2 G H 8
4
10K
74HC165 X1 R2 4 VDD
11 /LE 7Q 19
P2 J2 9 A J1 P1
6 330 30V
10 1
P2 J2 GND 74HC373 /OE 1.0A
8
D20
3.3K 3.3K 3.3K
R135
R134
R133
D28 D29 D30 D31 2.7K
R4
11 28
D0 Vcc R5 6 RS
J1 P1
12 D1 A0 10 100
7 R/W
1/2W J1 P1
13 D2 A1 9 D69
+15 V R6 8 E
+5 V 15 8
D3 X4 A2 J1 P1
C90 C91 C11
100
16 D4 A3 7 100p 100p 0.1
-5 V 1/2W
100V 100V 50V
17 D5 A4 6
R7
3 VSS
18 D6 A5 5 L1
100 J1 P1
2.2K 10K 10K 5 6 9 8 .39mH
19 4 X20 X20 1/2W
R81
R78
D7 A6 +5 V 2 -LEDB
R76
A B J1 P1
25 A8 A7 3 R124
11
R113 D37
24 A9 Vpp 1 20
D58 13
100 X13 5W
1N4007 21 A10 CE 20 13 12 11 10 1 +LEDB
1/2W 10 A X20 X20
2.2K L2 J1 P1
D64 23 22 C D 204
R82
A11 OE
1N4007 .39mH
10K
C48 2 27
R77
A12 A14
9 14 1
R114 GND 27C64 A13 26
3 5 6 20 +15 V
14 X3 X2
100 D59 2 D63
X13 5W
R102
1N4007 A A 3
1/2W 8 B R66 J8 P8
D62 2.2K
1K
R83
10K .25 C30 DZ4
+t
1N4007 470 1/2W D57 SOL.
C49
R79
60V 1/2W 4.7 15V
7 4 202
R103
R71
R115 35V 1W
6
1 X3
100 D60 5 R72
X13 D55 OCI1 4
1N4007 B J8 P8
1/2W 6 C 1 4N35 5
+5 V 1K
+5 V
203
D61 9 Q15 204
1N4007 8 2N4123
C50 C31 X3 D56 Q17
10
33K 15A
C 2 6 4
R80
10K R75 60V
10K
R97
R98
13 100K 100
11 3 4 Q14 1/2W SOLENOID
X3 X2 R70 Q16
1 2 12 DZ5
2N4123
R73
X2 D C 2N4125 DRIVER
3.9K 5.6K 16V
B
R74
C6 1/2W 1W
22p CIRCUITRY
100V CRYSTAL 45 48
L3 46 SCK A7/D7 38
+15 V
FOR OPTION PLUG
44 37 D75
INCR 1 MISO A6/D6
10M R118 541A 204
P5 J5 .33mH 4.0MHz 47 36
J4 Y1 1/2W I/O X6 A5/D5
R16
130 68
24 35 1 5 7 8 4 6
MODB A4/D4 1/2W J9 J9 J6 P6
3 22K 10 5 6
25 34 +5 V C45
MODA A3/D3 J4 J4 J4 J4 J4 J4 D 541
L4
R119
P4 +15 V .047
533 30 XTAL A2/D2 33 14
C8 C55 100V
DECR 3 Q21
22p 29 32 20 18A
P5 J5 .33mH EXTAL A1/D1 X Y G PM
100V 50V X10 R120 200V
TO OPTIONAL 40 31 541A -5 V
/XIRQ A0/D0
+5 V 4.7K 7 100
PULL GUN 39 26 S
/RES AS
R20
+5 V C56 1/2W J9 J6 P6 539
+15 V 9 4 3
L5 4.7K 22 16
TRIGGER VRH A8 D76 J9
DZ1
TRIG 4 R18 6 15
IC1 A9 18V
533A P4 P5 J5 .33mH 6 539A
20 A/D A10 14 1W
1K X19
D72 1
2
R101
18 A/D A11 13 A 5.6K
IN 4.7K
R25
7
R109
COM C52 X9 RES 17 A/D A12 12
J4 2
0.1 6 +15 V
P5 J5 4 11
OC4 A13
Operator or Technician. Improper PC board repairs could result in damage to the machine.
50V
1
L6 GND C7 3 OC3 R/W 28 X11 R121
C44 D73 Q7
7 A R28
7 IC2 E 27 27K 500mA
R84
.33mH 1/2W 300V 5.6K
19 A/D A14 10 Q8
1K 5 2N4123
J3 J3 41 9
5W /IRQ A15
Q6
2
8 11 43 I/O I/O 5 X19 2N4123 D
+15 V 68HC11A1 4 B Q11
8 42 D35
RESET I/O I/O
325 320 6.8K 750 G 18A
23 2
Vss OC2 R30 200V
R68 1/2W S
R122
THERM. LD. CONN. 21 1 5 100
VRL I/O
Q9
1/2W
10K 2 2N4125
X11
R67
4 B DZ2
6.8K
18V
_ 1/2W
+ 1 1W
R123
C95 1K +15 V
X17 8 PIEZO
A/D 4.7 BUZZER
REF
R138
TL431 1.5K
35V CW + C9 MOTOR
SUPPLY - 6 1/2W
R31
P7 P7 CONTROL
22K
R32
10K
CIRCUITRY
2 1 6 12
R69
J7 J7 9 8 10 11
R34 X12 X12
Q10
A B
200mA 3.3K
30V +15 V
+5 V R117
3.3K R38
9
+5 V X11 +15 V 6.8K
14 2.7K C13
+15 V C
1/2W .001
8 5
R35
400V
4.7K
PIEZO BUZZER CIRCUITRY
D32 3 4
R19
1 X12 R39
P6 J6 330 15K
4.7K C
R36
47K
R33
555 9 8
TACH 2 R116 X2
P6 J6 D
C17 13
206 C51 11
D34 2700p X11
4 0.1
50V 13
P6 J6 50V D 2 1
+5 V X12
+5 V 10
D
C10
+5 V
10K
R139
C14 .25
D51 750 18 270 7W
10K
R112
R40
R63
R37
R62
.22 541A
100 4 6 10V
P3 J3 100V
D71
56K
1/2W D47 2
R56
+5 V ZERO-CROSSING 2
1 D41
X1 R105 DETECTOR LINE SENSING
ELECTRICAL DIAGRAMS
3 100 DD1
R61
B R59
6.8K 16A
13 6.8K D49 400V 50 +15 V
R57 1 3
P3 J3 J9 J9 3.3K Q12 5W
14
R43
R55
2.2K D38 .25 150V
50V TP1 D42
7W C94 C22
75V .68 3.9K
D50 .0047
20J 400V 1/2W
C47 1400V
R22
1.8K
D44
1/2W 4.7 Q13
6.8K 10K P3 J3 J9 J9 15K
R58
35V
R52
R111
R46
2 R137 2 8 500mA +5 V
209A 300V
204S 209 .25 8 X15
9 DZ6
+15 V +5 V 7W C93 C23 D40 IN
P3 J3 1 6 18V OUT
.0047 .68 X18
G1992 CONTROL PC BOARD SCHEMATIC
1W
1400V 400V
D39 R99 C21
56K TP2 C19 GND
D53 1 TL431 39
1/2W D45 6 75V 100 3300 DZ7
10 20V
R51
20J 1/2W 8 50V 6.2V
R48
7 X14
2W 1W
X1 R53 R65
5 C TL431
common
6.8K 10K C16 6
D54 C28 3K
2200
6.8K 1/2W
63V
R23
R47
C24
CT. MAIN C20
10K .27 D46
18
R49
50V P3 J3 J9 J9
3 1 6 GND
VOLTAGE AND CURRENT 15V
206 206A
-5 V
SENSING CIRCUITRY C92 DZ3
1K C18 X16
.0047 10V
10 50 IN OUT
1400V 5W
R44
R50
2W 25V 5W
P3 J3
4
D43
204
NOTES : POWER SUPPLIES
N.A. SINCE COMPONENTS OR CIRCUITRY ON A PRINTED
G2 +15 V
202
330
1/2W
R87
202 OCI2
P3 J3 5 4 H11C4 J3 P3
204 6 13 3 3 3 14 4
R85
G1
202 50 D65 R88
AUX TRANSFORMER 6
5W
DR.
C43 C1 C2
10K X19 X11 X13 C3 X1 C4
C79 1 2 X12
15 D66
.0047 1/2W 270
R86
203 R91
TP3 Q18 12 12 12 7 11
2.2K
50V 2N4123
15J C39
1.0
35V C5
P3 J3 J3 P3
LABELS 5 12
LAST NO. USED
204
204A
SUPPLY VOLTAGE NET R- 140 CT. AUX. +15 V
C40 -5 V
TP5 1.0
C- 95
50V 35V 204
POWER SUPPLY SOURCE POINT D- 58 15J 270
330 1/2W
R90
1400V
OCI3
FRAME CONNECTION 3 4 1 2
P3 J3 5 4 H11C4 J3 P3 X20 A
7 R96 14
G2 E
203 50 D68 R93
EARTH GROUND CONNECTION 203 6
5W
10K
1 2 1 2 3 B 4
GATE DRIVE X20
F
GENERAL INFORMATION CIRCUITRY Q19
R95
2N4123
2.2K 11 10 5 6
ELECTRICAL SYMBOLS PER E-1537 +5 V X2 C
X Y
F
CAPS. = ufd (.022/50V UNLESS OTHERWISE SPECIFIED)
RESISTORS = Ohms (1/4W UNLESS OTHERWISE SPECIFIED)
9
9 8
DIODES = 1A, 400V (UNLESS OTHERWISE SPECIFIED) D
14
X19
1 7 20 14 14 14 28 20 48 14 16
1 2 1 3 8 C
J5 , J6 J3 X21 11 10
SP 250
C77 C78 C32 C33 X4 C34 X5 C35 X6 C36 X7 C37 X8 C38 E
10-19-90N
X20 X2 X3
J7,J8 11
0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1
SCHEMATIC
74HC245 HEXINV HEXINV NAND
50V 50V 50V 50V 50V 74HC373 50V 68HC11A1 50V 74HC164 50V 74HC165 50V
4 8 14 27C64 13
3 4 6 X19
1 4 1 5 10 D 13 12
10 7 7 7 14 10 23 7 8 F
G 1922
J4 J9
5 8 6 10
IDEALARC SP-250
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from
Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine
G-12
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
G-13
+5 V
P2 J2 R30 L1
11 B1 A1 9
1 100
100
IDEALARC SP-250
12 B2 A2 8
Q1 X21 R31 .33mH
600mA R1 13 B3 A3 7
P2 J2 R32
3 40V 3.32K 3.32K 3.32K 3.32K 3.32K 3.32K 3.32K 3.32K
10K 14 B4 A4 6
100
R33
R34
R35
R36
R37
R38
R39
R40
Q2
15 B5 A5 5
600mA R2 3 +5 V
P2 J2 Q A 100
5 40V 16 4 9 D0
10K 4 X7 B6 A6
Q B R41 J1 P1
Q3 17 B7 A7 3 10 D1
5 Q C A1 1
600mA R3 J1 P1
P2 J2 18 74HC245 2 100 11 D2
7 6 2 B8 A8
40V Q D A2 J1 P1
10K
DIR OUT EN R42 12 D3
Q4 10 Q E 8 13
CLK X2 J1 P1
600mA R4 12 100 13 D4
P2 J2 11 9 1 19
9 40V Q F R J1 P1
10K R43 14 D5
12 Q G Q H 13
Q5 J1 P1
74HC164 R44 15 D6
KEYPAD 600mA R5 J1 P1
40V 100 16 D7
10K R45 J1 P1
C11 C12 C13 C14 C15 C16
20 100 C10 100p 100p 100p 100p 100p 100p
13 0D Vcc
100p 100V 100V 100V 100V 100V 100V LCD
+5 V C17
11 A CLK1 2 8 1D X5 0Q 12 100V
100p
12 B X8 Q H 9 14 2D 1Q 9 R46 100V
DISPLAY
D1 D2 D3 D4 13 C SS/PL 1 7 3D 2Q 15 22.1K
14 D Q H 7 17 4D 3Q 6
R6
R7
R8
R9
1.00K 1.00K 1.00K 1.00K 3 E CLK2 15 4 5D 4Q 16 R47 5 Vo
CW
J1 P1
4 F SA 10 18 6D 5Q 5 22.1K
P2 J2 12
2
5 6 3 7D 6Q 19
R48
P2 J2 G H 14
4
10K
74HC165 X1 R49 4 VDD
11 /LE 7Q 2
P2 J2 13 A J1 P1
6 332 30V
10 1
P2 J2 GND 74HC373 /OE 1.0A
8
D20 3.32K
R50
R51
R52
3.32K
D5 D6 D7 D8 3.32K 3.32K
R53
11 28
D0 Vcc R54 6 RS
J1 P1
12 D1 A0 10 100
+15 V 7 R/W
13 9 D21 J1 P1
D2 A1
+5 V R55 8 E
15 D3 X4 A2 8
R190 C18 C19 C20 J1 P1
C117 100
16 D4 A3 7 100p 100p 0.1
4.75K -5 V 100V 100V 50V
17 D5 A4 6
R56
+5 V 3 VSS
2.21K 18 D6 A5 5 L2
100 J1 P1
R11
R10
10K 5 6 9 8 .39mH
5.62K 19 D7 A6 4 X20 X20
2 -LEDB
R13
C D J1 P1
25 A8 A7 3 R57
11
R14 L3 D22
24 A9 Vpp 1 20
D9 13
100 2.21K X13 5W
1N4007 21 A10 CE 20 13 12 11 10 1 +LEDB
10 A X20 X20 .39mH J1 P1
D10 23 22 F E 204
R15
10K A11 OE
1N4007 C2
2 27
R16
A12 A14
9 12 +15 V
14 26
R17 GND 27C256 A13 20
11 3 4
14 X3 X20 5W
100 D11 13 D33
X13
R58
1N4007 2.21K D B 3
8 B R60 J8 P8
D12 10K 1.00K 1.00K
R18
.25 C21 DZ1
+t
1N4007 D34 SOL.
R19
C3 60V 4.7 15V
R62
R63
7 1
R61
R20 202 203 1.00K 1W
35V
3
1 X3 R64
100 D13 2
X13 4
1N4007 A J8 P8
6 C D24 1 5 1.00K
+5 V OCI1
Q10
D14 D23 600mA
CNY17-3 204
1N4007 9 40V
C4 C5 Q11
15.0K 8
X3 15A
10 2 6 4
R23
R65 60V
C
100
Q12 475K SOLENOID
4
R66 600mA
6 1 2 DZ2
X3 X20 40V Q13
5 6 5 3.92K 5.62K 16V DRIVER
X2 B A 600mA
R68
R191
+5 V 1W
C 40V CIRCUITRY
45 48
MOSI Vdd
46 38 +15 V
515
543
542
495
541A
44 37
206A
10K 10K MISO A6/D6 TO 541A
R100 204
47 36 OPTIONAL
R24
R25
I/O X6 A5/D5
24 35 SPOOL GUN 1 5 7 8 4 6 J5 J5 J5
MODB A4/D4 22.1K 13 10 9
C50 541
25 MODA A3/D3 34
R102
J4 J4 J4 J4 J4 J4 R101 1
.047 D
C30 +15 V 14
L4 30 XTAL A2/D2 33 33.2 100V Q20
22p CRYSTAL X Y
J5 +5 V G 18A PM
100V 29 EXTAL A1/D1 32
INCR 6 X10 R103 200V
.33mH -5 V 2 S
J4 326 40 /XIRQ A0/D0 31 C51 3
541A 7 100
20 J5 J5 539
39 /RES AS 26 C52 8
+5 V 50V 12 11
3 10M
4.0MHz D61 J5
Y1 1/2W 22 VRH A8 16 4.75K DZ3
R70
L5 130 475
R90
P4 6 15 18V
R89
324A J5 IC1 A9
DECR 14 +15 V 1W
.33mH 20 A/D A10 14
327
TO OPTIONAL 18 13 D50
C31 A/D A11 6
4.75K
R91
SPOOL GUN 22p 17 12 X11 5.62K
A/D A12 1 8 +15 V
R104
100V C
L6 4 11
OC4 A13 7 14
J5 X11
TRIG 7 3 28 Q21
+5 V RESET OC3 R/W 9
Operator or Technician. Improper PC board repairs could result in damage to the machine.
P4 .33mH C40 D51 A R106
325A 324 R105 500mA
7 IC2 E 27
300V 5.62K
2 J5 26.7K
COM 19 A/D A14 10 Q22
4 R71
11 Q23 600mA
325 41 /IRQ A15 9
J4 4.75K 600mA 40V
13 D
5 OC5 I/O 43 X11 40V Q24
68HC11A1 10 D D62
VDD
R72
1.00K 8 IC3 I/O 42 G 18A
L7 C32 750 R108
.33mH X9 RES 23 200V
0.1 Vss OC2 2 S
R107
50V S-8054HN 100
1.50K 21 VRL I/O 1 Q14 5
C33 P7
VSS 600mA B _ Q25
2
R189
2
40V X11 600mA
1K J7 PIEZO DZ4
4 B 40V
5W P7 BUZZER 6.81K 18V
R74
R92 R
1 + 1W
R109
1.50K 3.32K J7 +15 V
+15 V
A/D +15 V
R188
SUPPLY 1.50K C53
MOTOR
R77
R110
R187 22.1K
CONTROL
J6 J6 6.81K PIEZO BUZZER CIRCUITRY
15.0K 10K
R111
CIRCUITRY
6 5
14 15
R78
325A 320 8 9 3 4
R112 X12 X12
1 +
THERM. LD. CONN. +5 V A B
3.32K
1K REF TL431
+15 V 8 +5 V
X17
R79
+5 V
CW C34
+5 V 6 -
4.7 R113
9
35V D52 X19 +15 V 6.81K
10K 14 C54
10K D53 C 2.67K
.33mH L14 +5 V .001
TACH CIRCUITRY 8 12
R80
R114
R93
J5 100 16.5K 10 X12 11
515B D40 5 R116
R81
3 4.75K 15.0K
X19 D54 C41
C42 C
R115
2 10K 47.5K
A 1.50K
555 J5 .22 4.75K
11 10
R136
R96
R97
TACH 1 R82 X2 ZERO-CROSSING 4 100V
D 13
332 C36 DETECTOR LINE SENSING 11
J5 C35 X19
206B D41 2700p
2 0.1 13
50V D 1 X12 2
50V
L8 C57 10
D
207 208
.33mH +5 V
.33mH
C55 .25
207 VOLTAGE SENSING 267
J6 18 7W
R118
R119
5 L13 750
15V
R117
541A
D70 CIRCUITRY
R120
R121 J9 J9 39
2 5 10V
2 R122 100 208
1 6.81K D72
D71 X1
3 B C60
28.0K J6
R123
CURRENT SENSING 16 R140
L10 208 .25 C70 D80
CIRCUITRY
T1 7W .68 DD1
R125 R126 +5 V 16A
400V
ELECTRICAL DIAGRAMS
R124
R127 150V
.27 209 20J
.33mH 1 NULL NULL 8 D74 10 R145
50V
R144
511 7 2W
2 D82
J6 J6 INPUT V CC
Q31
X22
3 INPUT 6 3.92K
OUT R129 J6 500mA
13 11 7
4 R141
R146
5 300V
V EE NC 100 209 D83
.25 15.0K
OP27
T1 3.3K
R147
205
7W +5 V
R143
206S
28.0K 51.1K C72 5W
- + D75 TP2 X15
R131
8
R130
.0047 DZ5
+15 V SHUNT +5 V 75V
C62 1400V IN OUT
20J D85 1 6 18V
D86 X18
1W
R148 C74
G2252 CONTROL PC BOARD SCHEMATIC
C73 GND
D77 1 TL431 39
D76 6 100 3300 DZ6
C75 6.2V 20V
X14 8 50V
7
X1 R133 R134 .68 1W common
5 C 400V TL431
6.81K 10K L12 C78 6
D79 C63 6.81K
.33mH 2200 3.01K
28.0K
THERMOSTAT SENSING 63V
R149
R150
C64
CT. MAIN C79
.27 D78 CIRCUITRY
J6 J9 18
R135
50V 4 GND
4 1 15V
206 J9 206A
-5 V
T1 TP4 C80
C81 DZ7 X16
150V .0047 1K 10V
10 50 IN OUT
80J 1400V
R152
2W 5W 25V 5W
R153
J6
6
D87
NOTES : +15 V
THIS DIAGRAM MAY NOT SHOW THE EXACT C100 C101 C102
X19 X11 X13 X12 C103 X1 C104 X22 C105
OCI2
J3 5 4 H11C4 J3
1 R162 5 C106
G1 C107
LABELS 202 D90
50 R163
6
T1 5W
10K
SUPPLY VOLTAGE NET C90 1 2
33.2 26.7 D91 +5 V
.0047 562 562
R165
R164
1400V Q40
R167
R168
R166 600mA -5 V
POWER SUPPLY SOURCE POINT
TP6 40V
2.21K
LAST NO. USED 50V
C91
COMMON CONNECTION 15J GATE DRIVE
1.0
R- 191 35V CIRCUITRY
C- 117 J3 J3 20 14 14 14 28
FRAME CONNECTION 2 6
D- 93 +15 V
204A C92 204
CT. AUX. 1.0 X21
EARTH GROUND CONNECTION C108 X20 C109 X2 C110 X3 C111 X4 C112
TP7
T1 35V 0.1 0.1 0.1 0.1 0.1
50V 204 74HC245 HEXINV HEXINV NAND
50V 50V 50V 50V 27C64 50V
15J
R RED LEAD 562 562
681 681
R173
R174
26.7
203 .0047
R170
R169
OCI3
+5 V
J3 5 4 H11C4 J3
3 R175 7
GENERAL INFORMATION 203 G2
50 D93 R176
T1 6
5W
10K
1 2
ELECTRICAL SYMBOLS PER E-1537
20 48 14 16
CAPS. = ufd (.022/50V UNLESS OTHERWISE SPECIFIED) Q41
R177 600mA ACTUAL CIRCUIT
RESISTORS = Ohms (1/4W UNLESS OTHERWISE SPECIFIED)
40V OF X10
2.21K X5 C113 X6 C114 X7 C115 X8 C116
DIODES = 1A, 400V (UNLESS OTHERWISE SPECIFIED) 7
0.1 0.1 0.1 0.1
1 1 2
74HC373 50V 68HC11A1 50V 74HC164 50V 74HC165 50V A
1 X19
16
6
J1 10 23 7 8
3 B 4
5
9 1 2
1 X2
T1 SECONDARY
J2 TOP 204 +
204S
207 5 6
208 C
X Y
G1 + + +
3 4 T1 AUX.
10 + WELDING
X2
OUTPUT
1 1 4 1 3 1 6 202
2 10
206
9 8
J7 8 D
J9 J3 - X1
J4 9 8
10-9-92C
J8 X2 9
204A
SCHEMATIC
3 4 5 8 4 6 7 12 209
SP 250 CONTROL
11 10
E
G
1 7 1 8 5
G2
TO GROUND TO CIRCUIT 2
X13 203
BOARD
J5 J6 4
2251
13 12
F
8 9 16
14
IDEALARC SP-250
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from
Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine
G-13