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G-12

ELECTRICAL DIAGRAMS

G-12

G1992 CONTROL PC BOARD SCHEMATIC

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
Operator or Technician. Improper PC board repairs could result in damage to the machine.

+5 V

3.3K

R125

100V

100p

C82

100V

100p

C87

100V

100p

C81

100V

100p

C86

100V

100p

C84

100V

100p

C83

.33mH

DISPLAY

RES. NTWK.

100

.19W

R100

3.3K

R126

3.3K

R127

3.3K

R128

3.3K

R129

3.3K

R130

3.3K

R131

LCD

74HC245

OUT EN

DIR

X21

100V

100p

C85

3.3K

R132

ELECTRICAL SYMBOLS PER E-1537

THE INTERCHANGEABILITY OF A COMPLETE BOARD.

RESISTORS = Ohms (1/4W UNLESS OTHERWISE SPECIFIED)

DIODES = 1A, 400V (UNLESS OTHERWISE SPECIFIED)

NOTES :

SUPPLY

VOLTAGE NET

CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING

N.A. SINCE COMPONENTS OR CIRCUITRY ON A PRINTED

SCHEMATIC

SP 250

COMMON CONNECTION

EARTH GROUND CONNECTION

POWER SUPPLY SOURCE POINT

FRAME CONNECTION

LABELS

A COMMON CODE NUMBER.

THIS DIAGRAM MAY NOT SHOW THE EXACT

COMPONENTS OR CIRCUITRY OF CONTROLS HAVING

DR.

+5 V

10K

R97

+5 V

1N4007

D61

6.8K

R68

TRIG

DECR

INCR

+15 V

50V

2700p

C17

206

555

REF

TL431

X17

SUPPLY

A/D

C50

D32

320

325

D34

1N4007

D59

10K

R67

4.7

35V

C95

+15 V

1N4007

D58

R138

R84

1N4007

D62

10K

R69

330

R116

C48

C49

4.7K

R19

X13

10K

R77

22p

100V

X13

33K

R80

130

4.0MHz

10K

R79

2.2K

R82

2.2K

R83

R101

4.7K

R18

C31

.33mH

22p

100V

1/2W

100

R113

1/2W

100

R114

1/2W

100

R115

1N4007

D60

1N4007

D64

50V

0.1

C51

CIRCUITRY

.25

R40

D71

100

R108

X19

-5 V

+5 V

+15 V

4.7K

R109

4.7K

R20

FOR OPTION PLUG

+15 V

+5 V

1/2W

R118

D75

50V

C55

541

539

CONTROL

C10

10K

R63

D70

10V

C15

D51

100V

.22

C29

1/2W

750

R37

X11

D52

X12

D41

GND

OUT

X15

15V

C20

15K

R46

1/2W

3.9K

R22

D44

+5 V

20V

C21

-5 V

6.2V

DZ7

common

50V

.27

C24

500mA

300V

Q13

+15 V

5.6K

R74

18A

200V

Q11

1/2W

1.5K

R31

102K

R106

D46

1/2W

R47

+5 V

D47

10K

R140

D53

100

R107

15K

R36

47K

R39

4.7K

R33

X12

X11

15V

C14

C27

C25

X13

270

R112

1/2W

100

R99

16V

DZ5

2N4123

Q14

2N4125

Q16

50V

.27

C26

6.8K

R53

VOLTAGE AND CURRENT

SENSING CIRCUITRY

100K

R73

1/2W

3.9K

R70

C44

D72

D73

10K

R49

D45

10K

R55

1/2W

1.8K

R57

OUT

GND

X16

D43

1/2W

56K

R56

10V

DZ3

3.3K

R43

1/2W

56K

R51

TL431

X18

D48

D54

TL431

X14

R45

1400V

.0047

C94

2200

63V

C16

D39

10K

R139

+15 V

541A

30V

200mA

Q10

A/D

/RES

/IRQ

EXTAL

A/D

IC2

I/O

OC3

VRH

I/O

A/D

IC1

A/D

/XIRQ

XTAL

MODA

MODB

I/O

MISO

SCK

MOSI

Vss

VRL

OC4

A4/D4

A5/D5

A14

A6/D6

A11

A2/D2

A0/D0

R/W

A12

A1/D1

I/O

A10

A7/D7

I/O

A15

68HC11A1

I/O

A3/D3

OC2

A13

Vdd

BUZZER

+15 V

+5 V

PIEZO

PIEZO BUZZER CIRCUITRY

1/2W

27K

R121

+15 V

X11

5.6K

R25

X11

3.3K

R117

1/2W

6.8K

R123

22K

R32

+5 V

10K

2N4123

D28

2N4123

Q20

+5 V

1/2W

1.8K

R52

2N4123

533A

THERM. LD. CONN.

TO OPTIONAL

6.8K

R58

204S

+5 V

D38

+15 V

D25

207

2N4123

D31

D49

X13

+5 V

D30

D27

TACH

TACH CIRCUITRY

D50

6.8K

R105

6.8K

R59

2.2K

R60

10K

R111

100 R61

CLK

74HC164

CLK1

CLK2

SS/PL

H
Q

74HC165

10K

R10

10K

+5 V

D26

R12

R13

R14

10K

R11

R15

10K

R104

2N4123

D24

50V

0.1

C33

50V

0.1

C34

1/2W

R92

50V

0.1

C35

4.7

35V

C47

2.2K

R91

D65

C28

10K

R65

1/2W

10K

R62

50V

0.1

C36

1400V

.0047

C79

50V

0.1

C37

15J

50V

TP5

50V

0.1

C38

D66

50V

0.1

C77

50V

0.1

C78

NAND

50V

0.1

C32

X19

74HC373

1/2W

330

R94

74HC164

1/2W

270

R89

68HC11A1

HEXINV

74HC245

X21

LM2901

X19

HEXINV

X20

1/2W

270

R90

1.0 35V

C40

D68

2N4123

Q19

10K

R93

H11C4

OCI3

R96

1.0

35V

C39

2.2K

R95

15J

50V

TP3

1400V

.0047

C80

D67

X19

+5 V

-5 V

ACTUAL CIRCUIT

OF X10

X20

C43

LM2901

X11

4066B

X12

74HC165

202

203

202

+15 V

204

CAPS. = ufd (.022/50V UNLESS OTHERWISE SPECIFIED)

CT. AUX.

GENERAL INFORMATION

GATE DRIVE

CIRCUITRY

203

204

AUX TRANSFORMER

2N4125

3.3K

R34

400V

.001

C13

D76

D35

539A

18V

DZ2

1/2W

100

R30

1/2W

2.7K

R35

5.6K

R28

22K

R119

200V

18A

2N4123

C56

+15 V

18V

DZ1

6.8K

R38

Q21

541A

100V

.047

C45

2N4123

1/2W

100

R120

1/2W

750

R122

X12

+15 V

X10

300V

500mA

GND

RES

50V

0.1

C52

+5 V

1/2W

10M

R16

RESET

CRYSTAL

+15 V

209

209A

OUTPUT

208

206

TO CIRCUIT BOARD

TO GROUND

204

+15 V

206A

R48

WELDING

1/2W

330

R87

202

400V

.68

C23

CT. MAIN

206

209

20J

75V

TP2

1400V

.0047

C92

1400V

.0047

C93

204

R50

GND

Vpp

A13

A14

A12

A10

A11

Vcc

27C64

533

COM

PULL GUN

TRIGGER

/OE

Vcc

GND

/LE

74HC373

KEYPAD

1922

204A

204

C-

R-

D-

LAST NO. USED

+15 V

140

15V

DZ4

LM224

R85

LM2901

X13

10K

R88

2N4123

Q18

H11C4

OCI2

SOLENOID

CIRCUITRY

2N4123

Q15

100V

100p

C88

22K

R54

1/2W

R86

4N35

OCI1

4.7

35V

C30

1/2W

470

R71

D55

D56

R72

15A

60V

Q17

D57

1/2W

100

R75

10K

27C64

+15 V

18V

DZ6

3300

50V

C19

25V

C18

R44

150V

Q12

541A

6.8K

R23

D42

D40

.25

R136

208

20J

75V

TP1

.25

R137

400V

.68

C22

207

204S

204

208A

ZERO-CROSSING

DETECTOR

LINE SENSING

POWER SUPPLIES

SOL.

.39mH

R102

100V

100p

C90

MOTOR

50V

0.1

C11

DRIVER

VDD

1/2W

18K

3.3K

R134

3.3K

R133

1/2W

100

1/2W

100

D37

3.3K

R135

1.0A

30V

D20

204

D63

330

203

1/2W

100

R/W

VSS

-LEDB

+LEDB

+15 V

202

204

100V

100p

C91

.39mH

1/2W

R66

60V

.25

R103

204

D29

+5 V

R124

10K

R78

2.2K

R81

10K R98

10K

R76

X20

D69

X20

+5 V

X20

2.7K

-5 V

X20

J7,J8

16A

DD1

400V

10-19-90N

IDEALARC SP-250

Содержание IDEALARC SP-250

Страница 1: ...built with safety in mind However your overall safety can be increased by proper installation and thoughtful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READ ING THI...

Страница 2: ...ol 1 c In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot 1 d Always be sure the work cable makes a good...

Страница 3: ...ing area If this is not possible cover them to prevent the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openin...

Страница 4: ...ell ventilated areas or vent the engine exhaust fumes outdoors ____________________________________________________ 7 c Do not add the fuel near an open flame welding arc or when the engine is run nin...

Страница 5: ...availlant proximit au soudage l aide d crans appropri s et non inflammables 4 Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l h...

Страница 6: ...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 Locat...

Страница 7: ...re Sizes A 3 Input Power Connections and Ground Connections A 3 Connect Shielding Gas A 4 Reconnect Procedure A 5 Connect Output Components A 7 A 9 Install the Work Clamp A 7 Output Polarity Connectio...

Страница 8: ...Copper conduit AWG Ground Wire in Conduit IEC Sizes Runs to Runs over 100ft 30m 100ft 30m 208 60 60 8 10mm2 6 16mm2 10 6mm2 230 60 60 10 6mm2 8 10mm2 10 6mm2 460 60 30 14 2 5mm2 12 4mm2 10 6mm2 575 60...

Страница 9: ...UT CONNECTIONS All input power must be electrically disconnected before proceeding ____________________________________ A 2 INSTALLATION IDEALARC SP 250 A 2 1 Before starting the installation check wi...

Страница 10: ...ct Panel Access Door 2 Use a single phase line or one phase of a three phase line For the 208V 230V 60 HZ model SP 250 shipped with a 10 ft input cord and plug connected to the welder mount the matchi...

Страница 11: ...the cylinder valves for damaged threads dirt dust oil or grease a Remove dust and dirt with a clean cloth NOTE DO NOT ATTACH THE REGULATOR IF OIL GREASE OR DAMAGE IS PRESENT Inform your gas supplier o...

Страница 12: ...voltage listed on the machine s rating plate Before installing the machine check that the Reconnect Panel in the Input Box Assembly is con nected for the proper voltage Failure to follow these instruc...

Страница 13: ...AL 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 TH...

Страница 14: ...l GUN LINER CONTACT TIP INSTALLATION The Magnum 250 SP gun and cable provided with the SP 250 is factory installed with a liner for a 035 or 045 0 9 or 1 2mm diameter electrode and an 035 0 9mm contac...

Страница 15: ...umb switch functions available on the Magnum 250 SP gun will only be operable from the front panel keypad The gun trigger switch must be capable of switching 5 milliamps at 15 volts DC resis tive FIGU...

Страница 16: ...pability B 4 Limitations B 4 B 9 Controls and Settings B 5 B 9 Power Switch B 5 Set Up Arrow Keys B 5 Process Wire Gas Key B 5 Auto Key B 7 Manual Key B 7 Save Key B 7 Memory Keys B 8 Spot Key B 8 Sti...

Страница 17: ...ch key entry system with audible feed back along with a two line 32 character alphanumer ic display provide user friendly control of the system The system provides full range control from the keypad o...

Страница 18: ...non glare cover for easy viewing under bright or dark conditions Multi lan guage display capability permits the SP 250 to com municate in English German French Spanish or Japanese Katakana Auto Mode S...

Страница 19: ...ty rever sal Work Cable 10 ft 3 0m long with work clamp WIRE FEEDER FEATURES Drop in Wire Loading Wire spindle snaps into Readi Reel Adapter included with SP 250 or most any 2 51mm I D wire spool The...

Страница 20: ...nto the gun handle for use with SP 250 remote control features 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...

Страница 21: ...g 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 3 PROCESS WIRE GAS KEY Press key to display the Wire Type Wir...

Страница 22: ...rogrammed into the SP 250 Wire Type Wire Diameter Welding Gas Solid Steel 025 0 6mm CO2 Solid Steel 025 0 6mm ArCO2 Solid Steel 030 0 8mm CO2 Solid Steel 030 0 8mm ArCO2 Solid Steel 035 0 9mm CO2 Soli...

Страница 23: ...ed on Metal Thickness selected ARROW KEY OPERATION WHEN USED WITH AUTO KEY See Table B 1 Left Arrow Keys Press to change the metal thickness displayed Press the UP arrow key to increase metal thicknes...

Страница 24: ...r arrow keys Press UP arrow key to increase Stitch time ON from 0 20 seconds to 2 50 seconds Press the DOWN arrow key to decrease Stitch ON time from 2 50 seconds to 0 20 seconds Right arrow keys Pres...

Страница 25: ...ed on the screen 4 or 5 Press the SAVE key Press other MEMORY Number key that was displayed after the toggle 5 or 4 When power is returned the machine will not be in the toggle mode However the weld s...

Страница 26: ...ue with weld process b If run in mode displayed is not the required mode repeat Step 1 By repeating Step 1 the run in mode changes Pressing the TIMERS OFF key and the PROCESS key allows you to switch...

Страница 27: ...s about 3 8 inch 3 4 for Outershield 18 To stop welding release the gun trigger and then pull the gun away from the work after the arc goes out 19 When no more welding is to be done close valve on gas...

Страница 28: ...move gun just beyond edge of molten metal during OFF time For smoothest welds on thinner metal point gun slightly towards the direc tion of travel USING THE GUN TRIGGER SWITCH The Gun Trigger Switch...

Страница 29: ...ips V brackets so wire dereels from top of coil toward wire drive NOTE The retaining spring side of the adapter should be facing the center inner panel of the SP 250 9 To remove the Readi Reel from Ad...

Страница 30: ...s set for the wire type diameter and gas per instructions on name plate SETTING IDLE ROLL PRESSURE The idle roll pressure wing screw is set at the factory backed out 2fi turns from full pressure This...

Страница 31: ...e Assemblies C 1 Spool Gun Adapter Kit Installation Spool Gun Module Board Installation C 1 Spool Gun Connection Box Installation C 3 Spool Gun Connection C 4 Spool Gun Installation to Old K531 C 5 TA...

Страница 32: ...ocesses The kit includes a spool gun module board a connection box assembly with connecting plug and lead harness es mounting hardware and installation and operation instructions SPOOL GUN ADAPTER KIT...

Страница 33: ...cle CAUTION Collect metal filings with a rag to protect against possible metal contamination of the control board or other internal electrical components ____________________________________ 9 Fasten...

Страница 34: ...ckwise to engage and level the box then tighten the screws 5 Route the control cable of the connection box up through the opening in the front louver provided for the work lead then up behind the wire...

Страница 35: ...K469 spool gun with 4 pin plug use the K518 adapter 2 Insert the Twist Mate plug into the mating recepta cle on the front of the connection box and twist to lock the connection 3 Attach the spool gun...

Страница 36: ...e drive unit 8 With the SP 250 connected electrode positive remove the positive electrode lead from the termi nal on the wire drive 9 Position the spool gun electrode lead on the termi nal 10 Place th...

Страница 37: ...TENANCE SECTION Section D Safety Precautions D 1 Routine and Periodic Maintenance D 1 Component Locations D 2 TABLE OF CONTENTS MAINTENANCE SECTION Return to Master TOC Return to Master TOC Return to...

Страница 38: ...as necessary by blowing with low pres sure compressed air Do not use solvents for cleaning the idle roll because it may wash the lubricant out of the bearing All drive rolls are stamped with the wire...

Страница 39: ...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 Co...

Страница 40: ...oltage Output E 3 Wire Drive Motor and Feedback E 4 Thermal Protection E 5 SCR Operation E 6 TABLE OF CONTENTS THEORY OF OPERATION SECTION LINE SWITCH MAIN TRANSFORMER RECONNECT FAN MOTORS SCR RECTIFI...

Страница 41: ...ary winding that sup plies power to the Control Board for SCR gate drive and gas solenoid operation The weld power windings connect to the Control Board as well as to the main SCR Rectifier Figure E 2...

Страница 42: ...ling the output of the machine See SCR Operation The control board also powers and commands the keypad the LCD Display the piezo alarm the gas solenoid and the wire drive motor Figure E 3 Output Recti...

Страница 43: ...LY OPERATION CONTINUED LINE SWITCH MAIN TRANSFORMER RECONNECT FAN MOTORS SCR RECTIFIER C A P A C I T O R S SHUNT CHOKE WIRE DRIVE MOTOR TACH POSITIVE TERMINAL NEGATIVE TERMINAL GAS SOLENOID PIEZO ALAR...

Страница 44: ...egulates the electrode wire feed speed through the gun Figure E 5 Wire Drive Motor and Feedback POWER SUPPLY OPERATION CONTINUED LINE SWITCH MAIN TRANSFORMER RECONNECT FAN MOTORS SCR RECTIFIER C A P A...

Страница 45: ...put choke energizes the cooling fan motors when required The other choke thermostat opens the trig ger circuit preventing machine weld output and wire feed if excessive operating temperatures are dete...

Страница 46: ...he AC cycle time in the off state and the remainder of the time in the on state The amount of time spent in the ON state is con trolled by the gate An SCR is fired by a short burst of current into the...

Страница 47: ...pad Resistance Test F 25 F 27 Wire Drive Motor and Tach Feedback Test F 28 F 31 Oscilloscope Waveforms F 32 F 36 Replacement Procedures Control Board Remove Replace F 37 F 38 Keypad Remove Replace F 3...

Страница 48: ...t com ponent is either good or bad If there are a number of possible components check the components in the order listed to eliminate one possibility at a time until you locate the cause of your probl...

Страница 49: ...o not touch electrically hot parts Remove the P C Board from the static shielding bag and place it directly into the equipment Don t set the P C Board on or near paper plastic or cloth which could hav...

Страница 50: ...gun trigger is pulled Display lights properly 1 Contact The Lincoln Electric Service Dept 216 383 2531 or 1 800 833 9353 WELD 1 Check input power switch S1 It may be faulty 2 Check for loose or broken...

Страница 51: ...pacitors Also check for leaky capacitors Replace if necessary WARN ING The liquid electrolyte in these capacitors is toxic Avoid contact with any portion of your body 3 Perform the SCR Rectifier Assem...

Страница 52: ...Wiring Diagram 2 The Keypad may be faulty Perform the Keypad Test 3 The control board may be faulty Replace 1 Perform the Keypad Test 2 Perform the Main Transformer Test 3 The control board may be fau...

Страница 53: ...essed then the control board may be defective Replace 1 Perform the Keypad Test 2 The control board may be faulty Replace 3 The LCD Display may be faulty Replace 1 Check the gas solenoid by dis connec...

Страница 54: ...iring Diagram 2 If the 12VDC is not present at pins 1J1 to 2J1 then perform the Main Transformer Test 3 The control board may be faulty Replace 1 Check the motor armature cur rent Normal armature curr...

Страница 55: ...Motor and Tach Feedback test 2 The control board may be faulty Replace 1 Perform the Wire Drive Motor and Tach Feedback Test 2 The control board may be faulty Replace 1 The thumb switch circuit in the...

Страница 56: ...ct with any portion of your body 4 The control board may be faulty Replace 1 The output capacitor bank may be faulty Check for loose con nections at the capacitors Also check for leaky capacitors Repl...

Страница 57: ...S RECOMMENDED COURSE OF ACTION The contact tip seizes in the gas dif fuser 1 The tip is being over heated due to excessive high current and or high duty cycle welding 2 A light application of high tem...

Страница 58: ...by using the manual mode Unit is only programmed for 045 1 1mm diameter in Outershield elec trode wire Other wire diameters within the SP 250 rating can be accom modated by using the Manual mode Inner...

Страница 59: ...d due to excessive electrical interference 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 contin...

Страница 60: ...se or decrease in that setting Indicates to operator that too much current is being drawn from the machine and the output has been reduced to prevent the current from exceeding safe levels This will t...

Страница 61: ...IN TRANSFORMER TEST 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...

Страница 62: ...portionably with the primary input volt age 1 Disconnect the main input power supply to the machine 2 Remove the Case Top and Side Panels with a 5 16 nut driver 3 Locate Plug J3 and Plug J6 on the G22...

Страница 63: ...following voltage tests at Plug J3 MAIN TRANSFORMER TEST 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 Contr...

Страница 64: ...rect nameplate input volt age between the H1 lead at the ON OFF POWER SWITCH to H2 or H3 at the reconnect panel Voltage tested will vary depending on Input Voltage Connection See wiring dia gram for t...

Страница 65: ...to Master TOC Return to Master TOC Return to Master TOC F 18 TROUBLESHOOTING REPAIR F 18 IDEALARC SP 250 MAIN TRANSFORMER TEST b If the correct nameplate voltage is being applied to the main transfor...

Страница 66: ...5 16 Nut Driver fi open end or socket wrench STATIC SCR RECTIFIER ASSEMBLY TEST Service and repair should be performed only by Lincoln Electric factory trained per sonnel Unauthorized repairs performe...

Страница 67: ...See Figures F 2A and F 2B FIGURE F 2A Remove Plugs J3 and J6 to Perform Static SCR Rectifier Assembly Test 3 Test with an Analog Volt Ohm meter that capacitors have completely dis charged 4 Disconnec...

Страница 68: ...g ohmmeter Multimeter FIGURE F 4 SCR 1 Test Points 7 Test for high or infinite resistance from the cathode to the anode of SCR 1 by reversing the meter leads See Figure F 4 a If a high or infinite res...

Страница 69: ...at Sink Assembly Drawings ACTIVE SCR RECTIFIER ASSEMBLY TEST Service and repair should be performed only by Lincoln Electric factory trained per sonnel Unauthorized repairs performed on this equipment...

Страница 70: ...leads X2 and X3 from the negative capacitor bank buss bar Be sure there is no electrical con tact See Figure F6 NOTE DO NOT DISASSEMBLE THE SCR RECTIFIER HEAT SINK ASSEM BLY 6 Construct the circuit s...

Страница 71: ...closed the SCR is defective NOTE Be sure battery is functioning properly A low battery can affect the results of the test Repeat Battery Test Procedure in Step 6 if needed 12 Open switch SW 1 13 Recon...

Страница 72: ...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 y...

Страница 73: ...esistance of each key at Plug J2 using an analog volt ohm meter as described in Table F 1 a The resistance measurements are taken from the pin locations on Plug J2 See Figure F 9 for each pin location...

Страница 74: ...2 MEMORY 4 100 OHMS 30 TYPICAL 2J2 3J2 MEMORY 2 100 OHMS 30 TYPICAL 2J2 5J2 MEMORY 1 100 OHMS 30 TYPICAL 3J2 6J2 LEFT UP ARROW 100 OHMS 30 TYPICAL 3J2 8J2 LEFT DOWN ARROW 100 OHMS 30 TYPICAL 3J2 4J2 S...

Страница 75: ...rvice 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 operat...

Страница 76: ...J5 on the G2252 Control Board or Plug J6 on the G1992 Control Board Code 9402 only See Figures F 10A and F 10B FIGURE F 10A Plug J5 Location on G2252 PC Control Board WIRE DRIVE MOTOR AND TACHOMETER...

Страница 77: ...armature is zero check the wires between Plug J5 J6 on Code 9402 and the wire drive motor b If the wires are okay and voltage to the drive motor armature is zero the Control Board may be faulty Repla...

Страница 78: ...tive and lead 206B negative See Figure F 10 for pin locations a Insert probes into Molex pin cavities 2 Pull gun trigger 3 Read meter for 1 5 3 5 VDC a If the 1 5 3 5 VDC is present the tach circuit i...

Страница 79: ...on represents 2 milliseconds in time Note Scope probes connected at machine output terminals probe to electrode probe to work Volts Div 20 V Div Horizontal Sweep 2 ms Div Coupling DC Trigger Internal...

Страница 80: ...was loaded with a resistance grid bank Note Scope probes connected at machine output terminals probe to electrode probe to work Volts Div 20 V Div Horizontal Sweep 5 ms Div Coupling DC Trigger Interna...

Страница 81: ...liseconds in time The machine was loaded with a resistance grid bank Note Scope probes connected at machine output terminals probe to electrode probe to work Volts Div 20 V Div Horizontal Sweep 5 ms...

Страница 82: ...nd each horizontal division represents 5 milliseconds in time Note Scope probes connected at machine output terminals probe to electrode probe to work Volts Div 20 V Div Horizontal Sweep 5 ms Div Coup...

Страница 83: ...al division represents 5 milliseconds in time Note Scope probes connected at Plug J3 on the control board The probe to lead G2 and the probe to lead 204 Volts Div 2 V Div Horizontal Sweep 5 ms Div Cou...

Страница 84: ...ng Strap 1 Disconnect main input power the machine 2 Remove the Case Top and Side Panels using 5 16 nut driver 3 Disconnect all wiring harness plugs and Molex Plugs connect ed to the Control Board See...

Страница 85: ...may vary with different Code Machines 5 Lift the Control Board straight up and out from the machine 6 Replace all mounting screws and wiring connections when installing the Control Board CONTROL PC BO...

Страница 86: ...ry 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...

Страница 87: ...right hand corner of the Keyboard and peel it off the front panel a The back of the Keypad is an adhesive material that bonds the Keypad to the Front Panel 6 Install a new Keypad a Remove the paper ba...

Страница 88: ...y 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 warr...

Страница 89: ...al 4 Using a small slot head screw driver loosen the set screw holding the out going guide tube into the drive roll assembly Carefully slide out the wire drive assembly 5 Disconnect the six pin plug f...

Страница 90: ...r 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 inv...

Страница 91: ...ing dia gram using wire cutters a The easiest access to these leads is from the right side of the machine b Cut any necessary cable ties 5 Remove the four screws holding the SCR Assembly to the floor...

Страница 92: ...APACITOR BANK REMOVAL AND REPLACEMENT Service and repair should be performed only by Lincoln Electric factory trained per sonnel Unauthorized repairs performed on this equipment could result in danger...

Страница 93: ...he negative capac itor bank buss bar using a slot head screwdriver and 3 8 open end wrench 6 Remove the 204 lead from the pos itive buss bar 7 Remove the shunt from the negative capacitor bank buss ba...

Страница 94: ...ld 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 invalidat...

Страница 95: ...alternative to cutting these leads is to remove them from Molex Plug J3 and pull them free of any wire bundles 10 Remove all cable ties wire mounts and any harness tape that could get in the way durin...

Страница 96: ...nly 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 wa...

Страница 97: ...ove the screws holding the Case Back to the floor of the machine using a 1 2 socket wrench with extension 5 Loosen the two screws holding the reconnect panel in place and a slide the reconnect panel f...

Страница 98: ...rew driver b When the motor is free from the mounting bracket place it care fully on the bottom of the machine c Cut any necessary wire wraps bundling the motor leads d Remove the leads from the fan m...

Страница 99: ...to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC INPUT IDLE AMPS AND WATTS WIRE SPEED RANGE OPEN CIRCUIT VOLTAGE RETEST AFTER REPAIR Maximum Idle Wat...

Страница 100: ...PC BOARD LAYOUT G 1 G2252 CONTROL PC BOARD LAYOUT G 5 WIRING DIAGRAM Code 9402 G 9 WIRING DIAGRAM Code 9546 10002 G 10 WIRING DIAGRAM Code 9723 10001 G 11 G1992 CONTROL PC BOARD SCHEMATIC G 12 G2252...

Страница 101: ...48 D47 C26 D70 D71 C27 R57 D49 D50 D38 C47 R52 D46 C24 D53 D54 C28 R16 C6 C8 C7 D32 D34 C17 D57 R70 R6 C10 C5 C4 D69 R1 R5 D45 D20 C32 C33 C34 C36 C37 C52 R3 C35 J8 SP 250 CONTROL R123 C77 C78 Y1 C81...

Страница 102: ...13 R114 R115 R120 R37 R122 RESISTOR MF 1 2W 750 2 R52 R57 RESISTOR MF 1 2W 1 8K 2 R118 RESISTOR MF 1 2W 68 2 R89 R90 RESISTOR MF 1 2W 270 2 R31 RESISTOR MF 1 2W 1 5K 2 R62 RESISTOR MF 1 2W 10K 2 R1 RE...

Страница 103: ...OS 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 Y1 CRYSTAL QUARTZ 4 000MHZ X3 IC CMOS GATE NAND 2 INPUT QUAD H...

Страница 104: ...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: ...sponsibility 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 Linc...

Страница 106: ...ER C81 CAPACITOR ALEL 50 25V 75 10 X10 IC CMOS INVERTER SCHMITT HEX 4584 X16 VOLTAGE REGULATOR R48 TRIMMER MT 1 2W 10K 10 LINEAR C30 C31 CAPACITOR CEMO 22P 100V 5 C10 C11 C12 CAPACITOR CEMO 100P 100V...

Страница 107: ...71 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 R...

Страница 108: ...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: ...IMMEDIATE AND FUTURE APPLICATIONS N B THIS DIAGRAM SHOWS THE ELECTRODE POLARITY N C CONNECTOR SHOWN GEARBOX SIDE VIEW N D CONNECTORS MOUNTED ON NON COMPONENT SIDE OF BOARD COMPONENT SIDE OF P C BOARD...

Страница 110: ...ATRIX SHOWN FRONT VIEW R RED U BLUE 2 5K 10W G X3 X4 X5 X6 X7 N H RESISTOR R2 MOUNTED ON FAN SENSOR BRACKET N J CONNECTOR SHOWN PIN SIDE VIEW N H N G 15 OHMS 100 W R1 PROCESS WIRE GAS AUTO MEMORY 1 TI...

Страница 111: ...LOSEST TO POWER TRANSFORMER N F KEYPAD MATRIX SHOWN FRONT VIEW R RED U BLUE 2 5K 10W G B W X3 X4 X5 X6 X7 N G THERMOSTAT S4 MOUNTED ON FAN SENSOR BRACKET N H RESISTOR R2 MOUNTED ON FAN SENSOR BRACKET...

Страница 112: ...35 36 40 2 42 38 14 24 47 21 33 28 11 12 18 6 26 5 16 1 31 10 32 34 BUZZER J7 2 15 V P7 5 V 5 V PIEZO P7 PIEZO BUZZER CIRCUITRY 1 2W 27K R121 J7 1 B A B 15 V X11 2 4 5 5 6K R25 X11 1 7 6 3 3K R117 1 2...

Страница 113: ...2 67K R114 15 0K R115 D54 100 R94 C41 X19 4 2 5 100V 22 C42 X11 13 10 11 40V 600mA Q22 40V 600mA Q23 10K R93 1 00K R7 74HC245 B4 OUT EN DIR B8 A7 B6 B5 A4 A3 A2 A1 A6 B7 A5 B2 B1 B3 A8 X21 19 1 9 2 7...

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