Lincoln Electric SP-250 инструкция обслуживания

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Хорошее руководство по эксплуатации

Законодательство обязывает продавца передать покупателю, вместе с товаром, руководство по эксплуатации Lincoln Electric SP-250. Отсутствие инструкции либо неправильная информация, переданная потребителю, составляют основание для рекламации в связи с несоответствием устройства с договором. В законодательстве допускается предоставлении руководства в другой, чем бумажная форме, что, в последнее время, часто используется, предоставляя графическую или электронную форму инструкции Lincoln Electric SP-250 или обучающее видео для пользователей. Условием остается четкая и понятная форма.

Что такое руководство?

Слово происходит от латинского "instructio", тоесть привести в порядок. Следовательно в инструкции Lincoln Electric SP-250 можно найти описание этапов поведения. Цель инструкции заключается в облегчении запуска, использования оборудования либо выполнения определенной деятельности. Инструкция является набором информации о предмете/услуге, подсказкой.

К сожалению немного пользователей находит время для чтения инструкций Lincoln Electric SP-250, и хорошая инструкция позволяет не только узнать ряд дополнительных функций приобретенного устройства, но и позволяет избежать возникновения большинства поломок.

Из чего должно состоять идеальное руководство по эксплуатации?

Прежде всего в инструкции Lincoln Electric SP-250 должна находится:
- информация относительно технических данных устройства Lincoln Electric SP-250
- название производителя и год производства оборудования Lincoln Electric SP-250
- правила обслуживания, настройки и ухода за оборудованием Lincoln Electric SP-250
- знаки безопасности и сертификаты, подтверждающие соответствие стандартам

Почему мы не читаем инструкций?

Как правило из-за нехватки времени и уверенности в отдельных функциональностях приобретенных устройств. К сожалению само подсоединение и запуск Lincoln Electric SP-250 это слишком мало. Инструкция заключает ряд отдельных указаний, касающихся функциональности, принципов безопасности, способов ухода (даже то, какие средства стоит использовать), возможных поломок Lincoln Electric SP-250 и способов решения проблем, возникающих во время использования. И наконец то, в инструкции можно найти адресные данные сайта Lincoln Electric, в случае отсутствия эффективности предлагаемых решений. Сейчас очень большой популярностью пользуются инструкции в форме интересных анимаций или видео материалов, которое лучше, чем брошюра воспринимаются пользователем. Такой вид инструкции позволяет пользователю просмотреть весь фильм, не пропуская спецификацию и сложные технические описания Lincoln Electric SP-250, как это часто бывает в случае бумажной версии.

Почему стоит читать инструкции?

Прежде всего здесь мы найдем ответы касательно конструкции, возможностей устройства Lincoln Electric SP-250, использования отдельных аксессуаров и ряд информации, позволяющей вполне использовать все функции и упрощения.

После удачной покупки оборудования/устройства стоит посвятить несколько минут для ознакомления с каждой частью инструкции Lincoln Electric SP-250. Сейчас их старательно готовят или переводят, чтобы они были не только понятными для пользователя, но и чтобы выполняли свою основную информационно-поддерживающую функцию.

Содержание руководства

  • Страница 1

    IDEALARC SP-250 SER VICE MANUAL Sales and Service through Subsidiaries and Distributors Worldwide 22801 St. Clair A ve. Cleveland, Ohio 441 17-1 199 U.S.A. T el. (216) 481-8100 World's Leader in W elding and Cutting Products Premier Manufacturer of Industrial Motors SVM 1 1 1-A January , 1996 Safety Depends on Y ou Lincoln arc welding and cutt[...]

  • Страница 2

    i SAFETY i IDEALARC SP-250 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJUR Y OR DEA TH. KEEP CHILDREN A W A Y . P ACEMAKER WEARERS SHOULD CONSUL T WITH THEIR DOCTOR BEFORE OPERA TING. Read and understand the following safety highlights. For additional safety[...]

  • Страница 3

    FOR ELECTRICALL Y powered equipment. 6.a. T urn off input power using the disconnect switch at the fuse box before working on the equipment. 6.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer ’ s recommendations. 6.c. Ground the equipment in accordance with the U.S. National Electrica[...]

  • Страница 4

    iii SAFETY iii IDEALARC SP-250 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Mar . ‘93 ELECTRIC AND MAG- NETIC FIELDS may be dangerous 8.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). W elding current creates EMF fields around welding cables and welding [...]

  • Страница 5

    iv SAFETY iv IDEALARC SP-250 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes[...]

  • Страница 6

    Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i - v Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A T echnical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 Safety Precautions .[...]

  • Страница 7

    INST ALLA TION IDEALARC SP-250 INST ALLA TION SECTION ........................................ Section A T echnical Specifications ...................................................A-1 Safety Precautions ...........................................................A-2 Select Proper Location .....................................................A-2 St[...]

  • Страница 8

    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 Duty Cycle Amps V olts at Rated Amps 100% 145 amps 26 60% 200 amps 28 35% 250 amps 26 Current Range Maximum Open Circuit V oltage Wire Speed Range 30A - 250A 10V - 40V 50 - 600 I[...]

  • Страница 9

    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 Read entire Installation Section before installing the IDEALARC SP-250 SAFETY PRECAUTIONS ELECTRIC SHOCK CAN KILL. • Only qualified personnel should install this machine. • T[...]

  • Страница 10

    A-3 INST ALLA TION IDEALARC SP-250 A-3 FUSE AND WIRE SIZES Protect the input circuit with the super lag fuses or delay type circuit breakers listed on the Specifications page of this manual for the machine being used. The tripping action of delay type circuit breakers decreases as the magnitude of the current increases. They are also called inverse[...]

  • Страница 11

    A-4 INST ALLA TION IDEALARC SP-250 A-4 For the 230/460/575V/ 60 HZ model which is not equipped with a plug, an input cord, or a receptacle, the input power supply leads are connected directly to the Reconnect Panel as shown Figure A.3. Refer to the specifications table at the beginning of this chapter for proper wiring sizes. 1. Connect the input p[...]

  • Страница 12

    A-5 INST ALLA TION IDEALARC SP-250 A-5 1 1. Before opening the cylinder valve, turn the regula- tor adjusting knob counter clockwise until the pres- sure is released from the adjusting spring. 12. Open the cylinder valve slowly a fraction of a turn. a. When the cylinder pressure gage pointer stops moving, open the valve fully . NEVER ST AND DIRECTL[...]

  • Страница 13

    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 A-6 INST ALLA TION IDEALARC SP-250 A-6 FIGURE A.5 - Reconnect Diagram For Codes 9402, 9723, and 10001 208/230/1/60 Machines. FIGURE A.6 - Reconnect Diagram For Codes 9546 & 1[...]

  • Страница 14

    A-7 INST ALLA TION IDEALARC SP-250 A-7 CONNECT OUTPUT COMPONENTS INST ALL THE WORK CLAMP Attach the work clamp to the cable which extends from the front of the machine using the following procedure: 1. Insert the lug on the end of the work cable through the strain relief hole in the work clamp handle. See Figure A.7. 2. Slide the work cable through[...]

  • Страница 15

    A-8 INST ALLA TION IDEALARC SP-250 A-8 GUN & CABLE INST ALLA TION W ARNING: TURN THE WELDER POWER SWITCH OFF BEFORE INST ALLING GUN AND CABLE. ____________________________________ 1. Lay the cable out straight. 2. Make sure all pins on the gun cable connector are aligned with the proper mating sockets on the front panel gun connector and then j[...]

  • Страница 16

    OPERA TION IDEALARC SP-250 OPERA TION SECTION ............................................ Section B Safety Instructions ............................................................B-1 General Description..........................................................B-1 Recommended Processes and Equipment ......................B-2 Operational Features a[...]

  • Страница 17

    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 B-1 OPERA TION B-1 Read and understand this entire section before operat- ing your Idealarc SP-250. SAFETY INSTRUCTIONS ELECTRIC SHOCK can kill. • Do not touch electrically liv[...]

  • Страница 18

    B-2 OPERA TION B-2 The system includes the following features: • 2-step or 4-step selectable trigger function (above code 9500 only). • both timed spot and stitch welding selections. • drop-in 2" (51mm) O.D. wire reel spindle with a 22- 30 lb. (10 - 13.6 kg) Readi-Reel- adapter . • integral gas cylinder mounting undercarriage. • 12.5[...]

  • Страница 19

    B-3 OPERA TION B-3 DESIGN FEA TURES AND ADV ANT AGES UNIT FEA TURES: Undercarriage for Hand Mobility - Heavy duty 10" (254mm) wheels and 4" (102mm) casters are factory installed along with the handle. Handle can be used for hanging the welding gun and work cable. Gas Cylinder Platform - Factory installed on under- carriage. It permits pla[...]

  • Страница 20

    B-4 OPERA TION B-4 Gun and Cable (K524-1) - A 12.5 ft. (3.8) GMAW gun and cable assembly , rated 200 amps 60% duty , is pro- vided with the SP-250 and includes a liner , diffuser , and contact tips for .035 (0.9mm) and .045 (1.2mm) electrodes. The gun is equipped with a Fast-Mate con- nector with additional control lead connections for the thumb ac[...]

  • Страница 21

    B-5 OPERA TION B-5 CONTROLS AND SETTINGS All operator controls are located on the Front Panel Keypad/Nameplate. See Figure B.1 for the location of each control. FIGURE B.1 - SP-250 Control Panel Keys 1. POWER SWITCH: T oggle switch to turn input power ON and OFF . When the switch is in the ON position the red LED backlighting of the LCD dis- play l[...]

  • Страница 22

    B-6 OPERA TION B-6 ARROW KEY OPERA TION WHEN USED WITH PROCESS WIRE/GAS KEY : See T able B.1. Left Arrow Keys: Press to set Wire T ype. Pressing the UP and DOWN arrow keys changes the Wire T ype dis- played. Center Arrow Keys : Press to set Wire Diameter . Press the UP ( ) arrow key to increase the wire diam- eter displayed. Press the DOWN ( ) arro[...]

  • Страница 23

    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 ARROW KEY OPERA TION WHEN USED WITH MANUAL KEY : See T able B.1. Left arrow keys: Do not function in Manual mode. Center arrow keys: Press the UP ( ) arrow key to increase wire f[...]

  • Страница 24

    B-8 OPERA TION B-8 7. MEMOR Y KEYS: Press memory key location number in which you want to save a procedure or from which you want to recall a procedure from memory . See SA VE Key . FIGURE B.3 - Sample SA VE Sequence. 8. SPOT KEY : Press to turn ON the Spot Weld T imer and display the spot weld ON time. Pressing the SPOT KEY a second time returns t[...]

  • Страница 25

    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 12. TOGGLE KEY : When first pressed, this key turns ON the T OGGLE MODE and recalls the weld setup in memory 4. Pressing the key again switch- es to the weld setup in memory loca[...]

  • Страница 26

    B-10 OPERA TION B-10 OPERA TING STEPS Before operating the machine, be sure you have all the materials needed to perform the work. Be sure you are familiar with and have taken all possible safety pre- cautions before starting the work. It is important that you follow these operating steps each time you use the machine. RUN-IN MODE The IDEALARC SP-2[...]

  • Страница 27

    B-1 1 OPERA TION B-1 1 10. If SPOT timing mode required. a. Press SPOT key . b. Press CENTER UP or DOWN ARROW keys to select SPOT ON TIME required. c. Press SPOT key to return to previous display . d. Go to Step 12. 1 1. If STITCH timing mode required. a. Press STITCH key . b. Press CENTER UP and DOWN ARROW keys to select STITCH ON time required. c[...]

  • Страница 28

    B-12 OPERA TION B-12 4. Press the CENTER UP & DOWN ARROW keys to set the required Spot On time. Suggested initial setting is 1.2 seconds. 5. Press the SPOT key . Display returns to Auto screen. Spot timer status is shown in bottom left corner of screen. 6. Install spot weld nozzle (if available) on gun. 7. Press spot weld nozzle against the top[...]

  • Страница 29

    B-13 OPERA TION B-13 LOADING THE WIRE REEL T o mount a 22-30 lb. (10-14 kg) Readi-Reel- package using the Readi-Reel adapter provided: 1. Pull the Readi-Reel adapter and spindle up out of the SP-250 spindle mounting clips (V -brackets). 2. Rotate the spindle and adapter so the retaining spring is at the 12 o'clock position. 3. Position the Rea[...]

  • Страница 30

    B-14 OPERA TION B-14 FEEDING ELECTRODE When inching, the electrode and drive mechanism are always “hot” to work and ground. The electrode remains “hot” several seconds after the gun trigger is released. ____________________________________ NOTE: Check that the proper drive rolls and gun parts are used for the wire size and wire type being u[...]

  • Страница 31

    ACCESSORIES IDEALARC SP-250 ACCESSORIES SECTION ....................................... Section C Options/Accessories ........................................................C-1 Replacement Magnum 250-SP Gun and Cable Assemblies ........................................................C-1 Spool Gun Adapter Kit Installation Spool Gun Module Board Ins[...]

  • Страница 32

    C-1 ACCESSORIES C-1 OPTIONS / ACCESSORIES Replacement Magnum 250-SP Gun and Cable Assemblies The following GMA W gun and cable assemblies are available for use with the SP-250. Each is rated at 200 amps at 60% duty cycle. Each is equipped with a Fast- Mate connector and additional control lead connec- tions for the thumb activated 2 momentary posit[...]

  • Страница 33

    C-2 ACCESSORIES C-2 Figure C.2 - Spool Gun Module Board Installation. 1. Remove input power to the machine before start- ing. 2. Remove the six screws that hold the Case Side Panels. 3. Locate the four snap-mount fasteners mounted to the side panel of the control Board. 4. Position the spool gun module board over the snap-mount fasteners, making su[...]

  • Страница 34

    C-3 ACCESSORIES C-3 SPOOL GUN CONNECTION BOX INST ALLA TION NOTE: Model codes below 9900 require the addition of three holes to the front of the machine's base as shown in Fig C.3. Figure C.3 - Spool Gun Connection Box Installation Mounting Holes 1. Remove the plug button, if present, from the cen- ter hole in the front of the machine's b[...]

  • Страница 35

    C-4 ACCESSORIES C-4 SPOOL GUN CONNECTION CAUTION: The spool gun module is intended for use with Lincoln Electric Magnum Spool Guns only . Use with other units may cause damage to the equipment. For Spool Gun operation, refer to the instruction man- ual provided with the Magnum Spool Gun. 1. Connect the spool gun control cable 6-pin plug to mating r[...]

  • Страница 36

    C-5 ACCESSORIES C-5 SPOOL GUN INST ALLA TION TO OLD K531 KIT . 1. Slide the spool gun cable assembly through the opening in the louvers provided for the work lead. See Figure C.6. 2. Remove the SP-250 gas line from the gas line con- nector . 3. Screw the spool gun 6-pin plug into the new con- nector just below the gas line connector . 4. Attach the[...]

  • Страница 37

    MAINTENANCE IDEALARC SP-250 MAINTENANCE SECTION ...................................... Section D Safety Precautions ...........................................................D-1 Routine and Periodic Maintenance ..................................D-1 Component Locations ......................................................D-2 T ABLE OF CONTENTS - M[...]

  • Страница 38

    D-1 MAINTENANCE D-1 SAFETY PRECAUTIONS •Have a qualified technician do the maintenance and troubleshooting work. •Disconnect input power at main input supply prior to working inside machine. ____________________________________ Read the Safety Precautions in the front of this manu- al before working on this machine. ROUTINE AND PERIODIC MAINTEN[...]

  • Страница 39

    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 D-2 MAINTENANCE D-2 Figure D.1 - Component Locations IDEALARC SP-250 2 1 3 4 5  5 4 3 1  2 Control Board Fan Assembly SCR Rectifier Choke Main Transformer[...]

  • Страница 40

    THEOR Y OF OPERA TION IDEALARC SP-250 Figure E.1 -Block Logic Diagram NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion THEORY OF OPERA TION SECTION ...................... Section E Power Supply Operation ........................................E-1 - E-3 Input Line V oltage and Main T ransformer ...................E-1 Output[...]

  • Страница 41

    E-1 THEOR Y OF OPERA TION E-1 IDEALARC SP-250 INPUT LINE VOL T AGE AND MAIN TRANS- FORMER The desired single phase input power is connected to the SP-250 through a line switch located on the front panel. A reconnect panel allows the user to configure the machine for the desired input voltage. This AC input voltage is applied to the primary of the m[...]

  • Страница 42

    E-2 THEOR Y OF OPERA TION E-2 IDEALARC SP-250 OUTPUT RECTIFICA TION AND FEED- BACK CONTROL The AC output from the main transformer secondary weld winding is rectified and controlled through the SCR rectifier assembly . Output voltage and current are sensed at the shunt and output terminals and fed back to the control board. The control board compar[...]

  • Страница 43

    E-3 THEOR Y OF OPERA TION E-3 IDEALARC SP-250 CONST ANT VOL T AGE OUTPUT The controlled DC output from the SCR rectifier assembly is filtered by the capacitor bank and the out- put choke, which is in series with the gun and welding load, resulting in a constant voltage output at the out- put terminals of the machine. Figure E.4 - Constant V oltage [...]

  • Страница 44

    E-4 THEOR Y OF OPERA TION E-4 IDEALARC SP-250 WIRE DRIVE MOTOR AND FEEDBACK The wire drive motor is controlled by the control board. A motor speed feedback signal is generated at the motor tach and sent to the control board. The control board compares this feedback signal with the com- mands set forth by the keypad (or the gun thumb switch) and sen[...]

  • Страница 45

    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 E-5 THEOR Y OF OPERA TION E-5 IDEALARC SP-250 A thermostat protects the machine from excessive operating temperatures.. Excessive operating temper- atures may be caused by a lack[...]

  • Страница 46

    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 E-6 THEOR Y OF OPERA TION E-6 IDEALARC SP-250 A silicon controlled rectifier (SCR) is a three terminal device used to control rather large currents to a load. An SCR acts very mu[...]

  • Страница 47

    TROUBLESHOOTING & REP AIR IDEALARC SP-250 TROUBLESHOOTING & REP AIR SECTION ........... Section F How to use T roubleshooting Guide ..................................F-1 PC Board T roubleshooting Procedures ............................F-2 T roubleshooting Guide ............................................F-3 - F10 Explanation of Prompting E[...]

  • Страница 48

    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 F-1 TROUBLESHOOTING & REP AIR F-1 IDEALARC SP-250 This T roubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three[...]

  • Страница 49

    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 F-2 TROUBLESHOOTING & REP AIR F-2 IDEALARC SP-250 CAUTION: Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor el[...]

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    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 F-3 TROUBLESHOOTING & REP AIR F-3 IDEALARC SP-250 TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understan[...]

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    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 F-4 TROUBLESHOOTING & REP AIR F-4 IDEALARC SP-250 TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual OUTPUT PROBLEMS PROBLEMS (SYMPTOMS) PO[...]

  • Страница 52

    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 F-5 TROUBLESHOOTING & REP AIR F-5 IDEALARC SP-250 TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual OUTPUT PROBLEMS PROBLEMS (SYMPTOMS) PO[...]

  • Страница 53

    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 F-6 TROUBLESHOOTING & REP AIR F-6 IDEALARC SP-250 TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual FUNCTION PROBLEMS PROBLEMS (SYMPTOMS) [...]

  • Страница 54

    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 F-7 TROUBLESHOOTING & REP AIR F-7 IDEALARC SP-250 TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual FUNCTION PROBLEMS PROBLEMS (SYMPTOMS) [...]

  • Страница 55

    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 F-8 TROUBLESHOOTING & REP AIR F-8 IDEALARC SP-250 TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual WIRE FEEDING PROBLEMS PROBLEMS (SYMPTO[...]

  • Страница 56

    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 F-9 TROUBLESHOOTING & REP AIR F-9 IDEALARC SP-250 TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual WELDING PROBLEMS PROBLEMS (SYMPTOMS) P[...]

  • Страница 57

    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 F-10 TROUBLESHOOTING & REP AIR F-10 IDEALARC SP-250 TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual WELDING PROBLEMS PROBLEMS (SYMPTOMS)[...]

  • Страница 58

    F-1 1 TROUBLESHOOTING & REP AIR F-1 1 IDEALARC SP-250 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 EXPLANA TION OF PROMPTING AND ERROR MESSAGES ON SCREEN ERROR MESSAGE PROCESS MUST MA TCH WIRE & GAS ONL Y SET UP FOR[...]

  • Страница 59

    F-12 TROUBLESHOOTING & REP AIR F-12 IDEALARC SP-250 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 EXPLANA TION OF PROMPTING AND ERROR MESSAGES (CONT’D) ON SCREEN ERROR MESSAGE DA T A ***ERROR*** CHECK SETTINGS PRESS PR[...]

  • Страница 60

    F-13 TROUBLESHOOTING & REP AIR F-13 IDEALARC SP-250 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 EXPLANA TION OF PROMPTING AND ERROR MESSAGES (CONT’D) ON SCREEN ERROR MESSAGE HIGH LINE: CHECK RECONNECT P ANEL PRESS AN[...]

  • Страница 61

    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 F-14 TROUBLESHOOTING & REP AIR F-14 IDEALARC SP-250 TEST DESCRIPTION This test will determine if the correct voltages are being a. applied to the primary windings of the Main[...]

  • Страница 62

    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 F-15 TROUBLESHOOTING & REP AIR F-15 IDEALARC SP-250 TEST PROCEDURE The ON/OFF POWER SWITCH will be "hot" during these tests. __________________________ NOTE: Second[...]

  • Страница 63

    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 F-16 TROUBLESHOOTING & REP AIR F-16 IDEALARC SP-250 G1992 (code 9402 only): 5. Connect main input power to the machine. 6. T urn the IDEALARC SP-250 ON/OFF POWER SWITCH to ON[...]

  • Страница 64

    F-17 TROUBLESHOOTING & REP AIR F-17 IDEALARC SP-250 G1992 (Code 9402 only): 8. T urn OFF the machine 9. Locate the following leads on Plug J6 on the G2252 Control PC Board or Plug J3 on the G1992 Control PC Board. See Figures F .1A & F1.B. G2252: G1992 (Code 9402 only): 10. T urn ON the machine. 1 1. Make the following voltage tests at Plug[...]

  • Страница 65

    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 F-18 TROUBLESHOOTING & REP AIR F-18 IDEALARC SP-250 MAIN TRANSFORMER TEST b. If the correct nameplate voltage is being applied to the main transformer and one or more of the [...]

  • Страница 66

    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 F-19 TROUBLESHOOTING & REP AIR F-19 IDEALARC SP-250 TEST DESCRIPTION The Static SCR T est is used to quickly determine if an SCR is shorted or "leaky ." See the W a[...]

  • Страница 67

    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 FIGURE F .2B - Remove Plug J3 to Perform Static SCR Rectifier Assembly T est. TEST PROCEDURE 1. Disconnect main AC input power to the machine. 2. Disconnect Plugs J3 and J6 from [...]

  • Страница 68

    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 F-21 TROUBLESHOOTING & REP AIR F-21 IDEALARC SP-250 NOTE: DO NOT DISASSEMBLE THE SCR RECTIFIER HEA T SINK ASSEM- BL Y . 6. T est for high or infinite resistance from the anod[...]

  • Страница 69

    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 F-22 TROUBLESHOOTING & REP AIR F-22 IDEALARC SP-250 TEST DESCRIPTION The Active SCR T est will determine if the device is able to be gated ON and conduct current from anode t[...]

  • Страница 70

    F-23 TROUBLESHOOTING & REP AIR F-23 IDEALARC SP-250 TEST PROCEDURE 1. Disconnect main AC input power to the machine. 2. Disconnect Molex Plugs J3 and J6 from the G2252 Control Board or remove Plug J3 from G1992 Control Board (Code 9402 only) See Figures F .5A and F .5B. FIGURE F .5A - Control Board Molex Plug Locations for G2252 PC Control Boar[...]

  • Страница 71

    F-24 TROUBLESHOOTING & REP AIR F-24 IDEALARC SP-250 7. Connect the T ester to the SCR 1 as shown in Figure F .7. a. Connect T ester lead (A) to the anode. b. Connect T ester lead (C) to the cathode. c. Connect T ester lead (G) to the gate. FIGURE F .7 - SCR T ester Circuit and SCR connections. 8. Close switch SW-1. NOTE: Switch SW-2 should be o[...]

  • Страница 72

    F-25 TROUBLESHOOTING & REP AIR F-25 IDEALARC SP-250 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 TEST DESCRIPTION This test will determine if any key is not functioning properly . MA TERIALS NEEDED 5/16" Nut Driver[...]

  • Страница 73

    F-26 TROUBLESHOOTING & REP AIR F-26 IDEALARC SP-250 TEST PROCEDURE 1. Disconnect main input power to the machine. 2. Remove the Case T op and Side Panels using the 5/16" nut driver . 3. Locate and disconnect Plug J2 con- nected to the Control PC Board. See Figures F .8A and F8B. FIGURE F .8A - Plug J2 Location on G2252 PC Control Board. FI[...]

  • Страница 74

    F-27 TROUBLESHOOTING & REP AIR F-27 IDEALARC SP-250 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 TEST POINTS KEY PRESSED MAXIMUM ALLOW ABLE RESIST ANCE (TYPICAL RESIST ANCE) FROM PIN T O PIN 1J2 6J2 CENTER UP ARROW 100 [...]

  • Страница 75

    F-28 TROUBLESHOOTING & REP AIR F-28 IDEALARC SP-250 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 TEST DESCRIPTION This test will determine if the wire drive motor and voltage feedback circuit are functioning properly . [...]

  • Страница 76

    F-29 TROUBLESHOOTING & REP AIR F-29 IDEALARC SP-250 TEST PROCEDURE NOTE: POLARITY MUST BE OBSERVED FOR THESE TESTS. T est for Correct Wire Drive Motor Armature V oltage 1. Disconnect main input power to the machine. 2. Remove the Case T op and Side Panels using a 5/16" nut driver . 3. Locate Plug J5 on the G2252 Control Board, or Plug J6 o[...]

  • Страница 77

    F-30 TROUBLESHOOTING & REP AIR F-30 IDEALARC SP-250 FIGURE F .10B - Plug J6 Location on G1992 PC Control Board (Code 9402 only .) NOTE: Plugs J5 and J6 are on the inboard non-component side of the Control Board. 4. T est for 2-25 VDC between lead #539 (positive) and lead #541 (neg- ative) to determine if the correct armature voltage is being su[...]

  • Страница 78

    F-31 TROUBLESHOOTING & REP AIR F-31 IDEALARC SP-250 T est for Supply V oltage to T achometer 1. T est for 15 VDC between lead #515B (positive) and lead #206B (negative). See Figure F . 10 for pin locations. a. Insert probes into Molex pin cavities. 2. Pull gun trigger . 3. Read meter for 15 VDC. a. If the 15 VDC is present, check the leads to t[...]

  • Страница 79

    F-32 TROUBLESHOOTING & REP AIR F-32 IDEALARC SP-250 This is a typical DC output voltage wave- form generated from a properly operating machine. Note that each vertical division represents 20 volts and that each horizontal division represents 2 milliseconds in time. Note: Scope probes connected at machine output terminals: (+) probe to electrode[...]

  • Страница 80

    F-33 TROUBLESHOOTING & REP AIR F-33 IDEALARC SP-250 This is a typical DC output voltage wave- form generated from a properly operating machine. Note that each vertical division represents 20 volts and that each horizontal division represents 5 milliseconds in time. The machine was loaded with a resistance grid bank. Note: Scope probes connected[...]

  • Страница 81

    F-34 TROUBLESHOOTING & REP AIR F-34 IDEALARC SP-250 This is NOT a typical DC output voltage waveform. One output SCR is not function- ing. Note the increased ripple content. One SCR gate was disconnected to simulate an open or non-functioning output SCR. Each vertical division represents 20 volts and each horizontal division represents 5 mil- l[...]

  • Страница 82

    F-35 TROUBLESHOOTING & REP AIR F-35 IDEALARC SP-250 This is NOT the typical DC output voltage waveform. The output capacitors are not functioning. Note the lack of “filtering” in the output waveform. The output capacitor bank was disconnected. Each vertical divi- sion represents 20 volts and each horizontal division represents 5 millisecond[...]

  • Страница 83

    F-36 TROUBLESHOOTING & REP AIR F-36 IDEALARC SP-250 This is a typical SCR gate pulse voltage waveform. The machine was in an open cir- cuit condition (no load) and operating prop- erly . Note that each vertical division repre- sents 2 volts and each horizontal division represents 5 milliseconds in time. Note: Scope probes connected at Plug J3 o[...]

  • Страница 84

    F-37 TROUBLESHOOTING & REP AIR F-37 IDEALARC SP-250 Printed Circuit Boards can be dam- aged by static electricity . Follow sta- tic handling guidelines detailed in “PC Board T roubleshooting Procedures” at the beginning of this chapter . _____________________________ REMOV AL AND REPLACEMENT PROCEDURE MA TERIALS NEEDED 5/16" Nut Driver[...]

  • Страница 85

    F-38 TROUBLESHOOTING & REP AIR F-38 IDEALARC SP-250 4. Remove the eight Phillips Head mounting screws using a Phillips Head screwdriver . See Figure F .12. FIGURE F .12 - Control Board Mounting Screw Locations may vary with different Code Machines. 5. Lift the Control Board straight up and out from the machine. 6. Replace all mounting screws an[...]

  • Страница 86

    F-39 TROUBLESHOOTING & REP AIR F-39 IDEALARC SP-250 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 MA TERIALS NEEDED 5/16" Nut Driver 1/4" Nut Driver KEYP AD REMOV AL AND REPLACEMENT Service and repair should be[...]

  • Страница 87

    F-40 TROUBLESHOOTING & REP AIR F-40 IDEALARC SP-250 PROCEDURE NOTE: BEFORE REMOVING THE KEYP AD, PERFORM THE KEYP AD RESIST ANCE TEST TO BE SURE THE KEYP AD IS F AUL TY . 1. Disconnect main input power to the machine. 2. Remove the Case T op and Side Panels with 5/16" nut driver . 3. Disconnect Keypad Plug J2 from the Control Panel. 4. Rem[...]

  • Страница 88

    F-41 TROUBLESHOOTING & REP AIR F-41 IDEALARC SP-250 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 MA TERIALS NEEDED Large slot head screwdriver 5/16" Nut Driver Small slot head screwdriver WIRE DRIVE ASSEMBL Y REMOV[...]

  • Страница 89

    F-42 TROUBLESHOOTING & REP AIR F-42 IDEALARC SP-250 PROCEDURE 1. Disconnect main input power to the machine. 2. Remove the Case T op and Side Panels. 3. Remove the large mounting screw with a large slot head screwdriver located in front of the drive roll. See Figure F .13. a. Note the placement of the insu- lators and washers for replace- ment.[...]

  • Страница 90

    F-43 TROUBLESHOOTING & REP AIR F-43 IDEALARC SP-250 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 MA TERIALS NEEDED 5/16" Nut Driver 1/2" Open End Wrench 1/2" Socket wrench, universal tool, and extension 3[...]

  • Страница 91

    F-44 TROUBLESHOOTING & REP AIR F-44 IDEALARC SP-250 PROCEDURE 1. Disconnect lead #208 and T ransformer Lead X1 from the heat sink on the left side of the machine (facing the front) using a 1/2" socket wrench. See Figure F .14. a. Thin lead is always on the out- board side of the connection. FIGURE F .14 - Heat Sink lead discon- nection. 2.[...]

  • Страница 92

    F-45 TROUBLESHOOTING & REP AIR F-45 IDEALARC SP-250 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 THE LIQUID ELECTROL YTE IN THE CAP ACITORS IS TOXIC. DO NOT TOUCH THE CAP ACITORS WITH ANY P ART OF YOUR BODY . MA TERIALS[...]

  • Страница 93

    F-46 TROUBLESHOOTING & REP AIR F-46 IDEALARC SP-250 PROCEDURE See Figure F .17 for location of Capacitor Bank Removal and Replacement com- ponents. FIGURE F .17 - Location of Capacitor Bank Removal and Replacement Components 1. Disconnect main input power to the machine. 2. T est that the capacitors are dis- charged using a volt ohmmeter . Pola[...]

  • Страница 94

    F-47 TROUBLESHOOTING & REP AIR F-47 IDEALARC SP-250 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 MA TERIALS NEEDED 5/16" Nut Driver 1/2" Open end wrench 3/8" Open end wrench 1/2" Socket wrench, exten[...]

  • Страница 95

    F-48 TROUBLESHOOTING & REP AIR F-48 IDEALARC SP-250 PROCEDURE 1. Disconnect main input power to the machine. 2. Remove the Case T op and Side Panels. 3. Perform the Capacitor Bank Removal Procedure. 4. Remove lead X1 from the left side SCR heat sink assembly using a 1/2" socket wrench, extender and universal adapter . 5. Remove lead X4 fro[...]

  • Страница 96

    F-49 TROUBLESHOOTING & REP AIR F-49 IDEALARC SP-250 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 MA TERIALS NEEDED 3/4" Open end wrench 1/2" Socket wrench with extension Phillips head screwdriver F AN MOTOR AN[...]

  • Страница 97

    F-50 TROUBLESHOOTING & REP AIR F-50 IDEALARC SP-250 PROCEDURE See Figure F .18 for fan motor and fan removal components. FIGURE F .18 - Fan Motor and Fan Removal Components 1. Remove the Case Back screws. 2. Remove the gas solenoid using a 3/4" open end wrench. 3. Using a 5/16” wrench, remove the 5 screws holding the fan motor mount- ing[...]

  • Страница 98

    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 F-51 TROUBLESHOOTING & REP AIR F-51 IDEALARC SP-250 7. Remove the fan motor . a. Loosen and remove the two screws from the motor mounting bracket using a slot head screw driv[...]

  • Страница 99

    F-52 TROUBLESHOOTING & REP AIR F-52 IDEALARC SP-250 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 INPUT IDLE AMPS AND W A TTS WIRE SPEED RANGE OPEN CIRCUIT VOL T AGE RETEST AFTER REP AIR Maximum Idle W atts Maximum Idle [...]

  • Страница 100

    T ABLE OF CONTENTS - ELECTRICAL DIAGRAMS - Section G IDEALARC SP-250 ELECTRICAL DIAGRAMS SECTION ...................... Section G G1992 CONTROL PC BOARD LA YOUT .....................G - 1 G2252 CONTROL PC BOARD LA YOUT ......................G - 5 WIRING DIAGRAM (Code 9402) ..................................G - 9 WIRING DIAGRAM (Code 9546 & 1000[...]

  • Страница 101

    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 J5 J6 J3 J4 C16 C18 X14 R47 C19 DZ3 R40 R89 R90 R48 R50 C23 C22 D24 D25 D26 D27 D28 D29 D30 D31 X8 R56 R51 C21 D44 D42 X18 R45 R22 Q12 D41 R43 D39 D40 R44 D43 D63 D55 D56 R66 C30[...]

  • Страница 102

    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-2 ELECTRICAL DIAGRAMS G1992 CONTROL PC BOARD G-2 IDEALARC SP-250 NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshoot- ing.[...]

  • Страница 103

    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 R16 . . . . . . . . . . . . . . . . . . .RESISTOR-CC,1/2W ,10M,5% R32,R54,R1 19 . . . . . . . . . . . . . .RESISTOR-MF 22K 1/4W R60,R81,R82,R83,R91,R95 . . .RESISTOR-MF 2.2K 1/4W[...]

  • Страница 104

    G-4 NOTES G-4 IDEALARC SP-250 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[...]

  • Страница 105

    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 SP 250 CONTROL G2252- 2 1 9 1 16 G-5 ELECTRICAL DIAGRAMS G2252 CONTROL PC BOARD G-5 IDEALARC SP-250 NOTE: Lincoln Electric assumes no responsibility for liablilities resulting fr[...]

  • Страница 106

    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-6 ELECTRICAL DIAGRAMS G2252 CONTROL PC BOARD G-6 IDEALARC SP-250 Item Identification Item Identification C61,C64 . . . . . . . . . . . . . CAP ACITOR-PCF ,0.27,50V ,20% C73 . .[...]

  • Страница 107

    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 Item Identification Item Identification G-7 ELECTRICAL DIAGRAMS G2252 CONTROL PC BOARD G-7 IDEALARC SP-250 Q1,Q2,Q3,Q4,Q5, TRANSISTOR-N,T226,0.5A,40V ,2N4401 Q10,Q12,Q14,Q22,Q23,[...]

  • Страница 108

    G-8 NOTES G-8 IDEALARC SP-250 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[...]

  • Страница 109

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC G-9 G-9 IDEALARC SP-250 IDEALARC SP-250 ELECTRICAL DIAGRAMS WIRING DIAGRAM FOR CODE 9402 NOTE: This diagram is for reference only. It may not be accurate for all machines covered[...]

  • Страница 110

    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-10 G-10 IDEALARC SP-250 IDEALARC SP-250 ELECTRICAL DIAGRAMS WIRING DIAGRAM FOR CODE 9546 & 10002 NOTE: This diagram is for reference only. It may not be accurate for all ma[...]

  • Страница 111

    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-11 G-11 IDEALARC SP-250 IDEALARC SP-250 ELECTRICAL DIAGRAMS WIRING DIAGRAM FOR CODE 9723 & 10001 NOTE: This diagram is for reference only. It may not be accurate for all ma[...]

  • Страница 112

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC G-12 ELECTRICAL DIAGRAMS G-12 G1992 CONTROL PC BOARD SCHEMA TIC NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC B[...]

  • Страница 113

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC G-13 ELECTRICAL DIAGRAMS G-13 G2252 CONTROL PC BOARD SCHEMA TIC NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC B[...]