Idealarc SP-250

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SVM 111-A
Return to Master TOC
IDEALARC SP-250 January, 1996

View Safety Info
For use with machines having Code Numbers: 9402

9546
9723
10001
10002
Safety Depends on You

Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However,
your overall safety can be
increased by proper installation

View Safety Info
... and thoughtful operation on

your part. DO NOT INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT READ-
ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON-
TAINED THROUGHOUT. And,
most importantly, think before you
act and be careful.
View Safety Info
SERVICE MANUAL
View Safety Info
World's Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors
Sales and Service through Subsidiaries and Distributors Worldwide
22801 St. Clair Ave. Cleveland, Ohio 44117-1199 U.S.A. Tel. (216) 481-8100
More user manuals on ManualsBase.com
i i
Return to Master TOC SAFETY
WARNING ARC WELDING can be hazardous.
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN
AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American 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.
ELECTRIC SHOCK can kill. ARC RAYS can burn.

1.a. The electrode and work (or ground) circuits 2.a. Use a shield with the proper filter and cover
are electrically “hot” when the welder is on. plates to protect your eyes from sparks and
Do not touch these “hot” parts with your bare the rays of the arc when welding or observing
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
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.
especially in confined areas, to insure breathing air is safe.

1.i. When working above floor level, use a safety belt to protect
3.d. Read and understand the manufacturer’s instructions for this
yourself from a fall should you get a shock.
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
1.j. Also see Items 4.c. and 6.
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
3.e. Also see item 7b.

Apr. ‘93
IDEALARC SP-250

ii ii
WELDING SPARKS can CYLINDER may explode
cause fire or explosion. if damaged.
4.a. Remove fire hazards from the welding area.
If this is not possible, cover them to prevent 5.a. Use only compressed gas cylinders
the welding sparks from starting a fire. containing the correct shielding gas for the
Remember that welding sparks and hot process used and properly operating
materials from welding can easily go through small cracks regulators designed for the gas and
and openings to adjacent areas. Avoid welding near pressure used. All hoses, fittings, etc. should be suitable for
hydraulic lines. Have a fire extinguisher readily available. the application and maintained in good condition.
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.
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
6.a. Turn off input power using the disconnect

area as practical. Work cables connected to the building
switch at the fuse box before working on
framework or other locations away from the welding area
the equipment.
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate circuits.
6.b. Install equipment in accordance with the U.S. National
This can create fire hazards or overheat lifting chains or
Electrical Code, all local codes and the manufacturer’s
cables until they fail.
recommendations.
4.h. Also see item 7c.
6.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Feb. ‘95
IDEALARC SP-250

iii iii
FOR ENGINE ELECTRIC AND MAG-
powered equipment. NETIC FIELDS
7.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
may be dangerous
____________________________________________________
8.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
7.b. Operate engines in open, well-ventilated current creates EMF fields around welding cables and
areas or vent the engine exhaust fumes welding machines
outdoors.
8.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
____________________________________________________ before welding.
8.c. Exposure to EMF fields in welding may have other health

7.c. Do not add the fuel near an open flame effects which are now not known.
welding arc or when the engine is run-
ning. Stop the engine and allow it to cool 8d. All welders should use the following procedures in order to
before refueling to prevent spilled fuel minimize exposure to EMF fields from the welding circuit:
from vaporizing on contact with hot

engine parts and igniting. Do not spill 8.d.1. Route the electrode and work cables together - Secure
fuel when filling tank. If fuel is spilled, them with tape when possible.
wipe it up and do not start engine until
fumes have been eliminated. 8.d.2. Never coil the electrode lead around your body.
____________________________________________________ 8.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right
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
guards only when necessary and replace them when the

maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.
7.f. Do not put your hands near the engine fan. Do not
attempt to override the governor or idler by pushing on
the throttle control rods while the engine is running.
7.g. To prevent accidentally starting gasoline engines while

turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
___________________________________________________
7.h. To avoid scalding, do not remove the

radiator pressure cap when the engine is
hot.
IDEALARC SP-250

iv iv
zones où l’on pique le laitier.
PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les instructions 6. Eloigner les matériaux inflammables ou les recouvrir afin de
et les précautions de sûreté specifiques qui parraissent dans ce prévenir tout risque d’incendie dû aux étincelles.
manuel aussi bien que les précautions de sûreté générales suiv-
antes: 7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
Sûreté Pour Soudage A L’Arc échauffement et un risque d’incendie.
1. Protegez-vous contre la secousse électrique:
8. S’assurer que la masse est connectée le plus prés possible de
a. Les circuits à l’électrode et à la piéce sont sous tension la zone de travail qu’il est pratique de le faire. Si on place la
quand la machine à souder est en marche. Eviter toujours masse sur la charpente de la construction ou d’autres endroits
tout contact entre les parties sous tension et la peau nue éloignés de la zone de travail, on augmente le risque de voir
ou les vétements mouillés. Porter des gants secs et sans passer le courant de soudage par les chaines de levage,
trous pour isoler les mains. câbles de grue, ou autres circuits. Cela peut provoquer des
b. Faire trés attention de bien s’isoler de la masse quand on risques d’incendie ou d’echauffement des chaines et des
soude dans des endroits humides, ou sur un plancher met- câbles jusqu’à ce qu’ils se rompent.
allique ou des grilles metalliques, principalement dans

les positions assis ou couché pour lesquelles une grande 9. Assurer une ventilation suffisante dans la zone de soudage.
partie du corps peut être en contact avec la masse. Ceci est particuliérement important pour le soudage de tôles
c. Maintenir le porte-électrode, la pince de masse, le câble de galvanisées plombées, ou cadmiées ou tout autre métal qui
soudage et la machine à souder en bon et sûr état defonc- produit des fumeés toxiques.
tionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le 10. Ne pas souder en présence de vapeurs de chlore provenant
refroidir. d’opérations de dégraissage, nettoyage ou pistolage. La
e. Ne jamais toucher simultanément les parties sous tension chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
des porte-électrodes connectés à deux machines à soud- du solvant pour produire du phosgéne (gas fortement toxique)
er parce que la tension entre les deux pinces peut être le ou autres produits irritants.
total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de 11. Pour obtenir de plus amples renseignements sur la sûreté, voir
courant pour soudage semi-automatique, ces precautions le code “Code for safety in welding and cutting” CSA Standard
pour le porte-électrode s’applicuent aussi au pistolet de W 117.2-1974.
soudage.
2. Dans le cas de travail au dessus du niveau du sol, se protéger

contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie
PRÉCAUTIONS DE SÛRETÉ POUR
du corps. LES MACHINES À SOUDER À
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
TRANSFORMATEUR ET À
donc: REDRESSEUR
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du ray- 1. Relier à la terre le chassis du poste conformement au code de
onnement de l’arc et des projections quand on soude ou l’électricité et aux recommendations du fabricant. Le dispositif
quand on regarde l’arc. de montage ou la piece à souder doit être branché à une
b. Porter des vêtements convenables afin de protéger la bonne mise à la terre.
peau de soudeur et des aides contre le rayonnement de
l‘arc. 2. Autant que possible, I’installation et l’entretien du poste seront
c. Protéger l’autre personnel travaillant à proximité au effectués par un électricien qualifié.
soudage à l’aide d’écrans appropriés et non-inflammables.
3. Avant de faires des travaux à l’interieur de poste, la debranch-

4. Des gouttes de laitier en fusion sont émises de l’arc de er à l’interrupteur à la boite de fusibles.
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan- 4. Garder tous les couvercles et dispositifs de sûreté à leur
talons sans revers, et chaussures montantes. place.
5. Toujours porter des lunettes de sécurité dans la zone de

soudage. Utiliser des lunettes avec écrans lateraux dans les
Mar. ‘93
IDEALARC SP-250

v v
RETURN TO MAIN INDEX
TABLE OF CONTENTS
Page
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i - v
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Select Proper Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Input Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Reconnect Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
Connect Output Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-7 - A-9
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section B
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
Recommended Processes and Equipment . . . . . . . . . . . . . . . . . . . . . . .B-2
Operational Features and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
Design Features and Advantages . . . . . . . . . . . . . . . . . . . . . . . . . .B-3 - B-4
Machine Capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4
Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4 - B-9
Controls and Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5 - B-9
Operating Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-10 - B-14
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section C
Options/Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section D
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1
Routine and Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section E

Power Supply Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-1 - E-4
Thermal Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-5
SCR Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-6
Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section F

How to use Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-1
PC Board Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . .F-2
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-3 - F-53
Error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-11 - F-13
Retest after Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-52
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section G
Parts Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-201
IDEALARC SP-250

INSTALLATION
TABLE OF CONTENTS
- INSTALLATION SECTION -
INSTALLATION SECTION ........................................ Section A

Technical Specifications ...................................................A-1
Safety Precautions ...........................................................A-2
Select Proper Location.....................................................A-2
Stacking.......................................................................A-2
Input Electrical Connections.............................................A-2
Fuse and Wire Sizes ...................................................A-3
Input Power Connections and Ground Connections...A-3
Connect Shielding Gas................................................A-4
Reconnect Procedure.......................................................A-5
Connect Output Components..................................A-7 - A-9

Install the Work Clamp ................................................A-7
Output Polarity Connection .........................................A-7
Gun Liner & Contact Tip Installation ...........................A-7
Gun and Cable Connection.........................................A-8
IDEALARC SP-250

A-1 A-1
INSTALLATION
Return to Section TOC
TECHNICAL SPECIFICATIONS - Idealarc SP-250
INPUT - SINGLE PHASE/ 60 HERTZ ONLY
Standard Voltage Input Current at Rated Output
208/230/1/60 53/49 Amps
230/460/575 50/25/20 Amps

RATED OUTPUT
Duty Cycle Amps Volts at Rated Amps
100% 145 amps 26

60% 200 amps 28
35% 250 amps 26

OUTPUT
Current Range Maximum Open Circuit Voltage Wire Speed Range
30A - 250A 10V - 40V 50 - 600 IPM

(1.27-15.2 m./minute)
RECOMMENDED INPUT WIRE & FUSE SIZE
Input Voltage/ Fuse (Superlag) Type 750C wire in Type 750C Copper
Frequency or Breaker Size Copper conduit AWG Ground Wire in Conduit
(IEC Sizes)
Runs to Runs over
100ft. (30m.) 100ft.(30m.)
208/60 60 8 (10mm2) 6 (16mm2) 10 (6mm2)

230/60 60 10 (6mm2) 8 (10mm2) 10 (6mm2)
460/60 30 14 (2.5mm2) 12 (4mm2) 10 (6mm2)
575/60 25 14 (2.5mm2) 12 (4mm2) 10 (6mm2)
PHYSICAL DIMENSIONS
HEIGHT Width DEPTH WEIGHT
(W/GUN)
28.2” 18.8” 40.1” 222 lbs.

(719mm) (480mm) (1019mm) (101 Kg.)
OPERATING TEMPERATURE
STORAGE OPERATING
± 400C -200C to 400C
IDEALARC SP-250

A-2 A-2
INSTALLATION
Read entire Installation Section before installing 1. Before starting the installation, check with the local
the IDEALARC SP-250 power company to determine if there is any ques-

tion about whether your power supply is adequate
SAFETY PRECAUTIONS for the voltage, amperes, phase, and frequency
ELECTRIC SHOCK CAN KILL. specified on the welder nameplate. Also be sure
the planned installation will meet the U.S. National
Electrical Code and local code requirements. This
WARNING welder may be operated from a single-phase line
or from one phase of a three-phase line.
• Only qualified personnel should install
this machine. 2. Models that have multiple input voltages specified
on the nameplate (e.g., 208/230) are shipped con-
• Turn the input power OFF at the dis- nected for the highest voltage. If the welder is to
connect switch or fuse box before be operated at a lower voltage, it must be recon-
working on the equipment. nected according to the instructions on the inside
of the removable panel (Reconnect Access Door)
• Do not touch electrically hot parts. near the top left side of the Case Back Assembly.
Also see the Reconnect Section of this manual for

• Always connect the IDEALARC SP-250 grounding details on reconnecting the machine to operate at
terminal (located on the side of the Case Back different voltages.
Assembly) to a good electrical earth ground.
3. Be sure the voltage, phase, and frequency of the
• Set the IDEALARC SP-250 Power switch to the input power is as specified on the machine rating
OFF position when connecting power cord to input plate. See Figure A.1 for the location of the
power. machine’s input cord entry, Reconnect Access
Door, Reconnect Panel, and Rear Nameplate.
____________________________________
SELECT PROPER LOCATION

Place the IDEALARC SP-250 where clean air can
freely circulate in through the front intake and out
through the rear louvers. Dirt, dust, or any foreign
material that can be drawn into the machine should be
kept at a minimum. Not following these precautions

can result in the nuisance shutdown of the machine
because of excessive operating temperatures.
STACKING
The IDEALARC SP-250 cannot be stacked.
INPUT CONNECTIONS
WARNING
FIGURE A.1 - Case Back Assembly: Input Power
All input power must be electrically

Cable Entry Connections.

disconnected before proceeding.
____________________________________
IDEALARC SP-250

A-3 A-3
INSTALLATION
FUSE AND WIRE SIZES proper grounding of the welder frame when the
welder plug is inserted into the receptacle.

Protect the input circuit with the super lag fuses or
delay type circuit breakers listed on the Specifications 4. Use proper wire sizes. See the Specification table
page of this manual for the machine being used. The for proper wire sizes. For cable lengths over 100
tripping action of delay type circuit breakers decreases feet, larger copper wires should be used.
as the magnitude of the current increases. They are
also called inverse time or thermal/magnetic circuit
breakers.
DO NOT use fuses or circuit breakers with a lower amp

rating than recommended. This can result in "nui-
sance" tripping caused by inrush current even when
machine is not being used for welding at high output
currents.
Use input and grounding wire sizes that meet local

electrical codes or see the Specifications page in this

manual.
INPUT POWER CONNECTIONS AND

FIGURE A.2. - Ground Connections.
GROUND CONNECTIONS
Have a qualified electrician connect the receptacle or

cable to the input power lines and the system ground
according to the U.S. National Electrical Code and any
applicable local codes.
1. Follow the Input Supply Connection Diagram on

the inside of the Reconnect Panel Access Door.
2. Use a single-phase line or one phase of a 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 matching receptacle supplied with the
machine.
1. Mount the receptacle in a suitable location using

the screws provided.
2. Locate the receptacle within reach of the 10 ft.

input cord attached to the welder.
3. Mount the receptacle with the grounding terminal

at the top. This allows the power cable to hang
down without bending. See Figure A.2.
a. The center terminal in the receptacle is for the

grounding connection.
b. Fuse the two hot lines of the receptacle with

super lag type fuses as shown in Figure A.2. A
green wire in the input cord connects this ter-
minal to the frame of the welder. This ensures
IDEALARC SP-250

A-4 A-4
INSTALLATION
For the 230/460/575V/ 60 HZ model which is not 1. Set the gas cylinder on the rear platform of the SP
equipped with a plug, an input cord, or a receptacle, 250.

the input power supply leads are connected directly to
the Reconnect Panel as shown Figure A.3. Refer to the 2. Hook the chain in place to secure cylinder to rear
specifications table at the beginning of this chapter for of welder.
proper wiring sizes.
3. Remove the cylinder cap.
1. Connect the input power leads to terminals L1 and
L2 on the Reconnect Panel Assembly. 4. Inspect the cylinder valves for damaged threads,
dirt, dust, oil or grease.
a. For input power supply leads of 10 AWG or
smaller, connect leads to Reconnect Panel a. Remove dust and dirt with a clean cloth.
using the ferrules (S19117-1) provided.
NOTE: DO NOT ATTACH THE REGULATOR IF OIL,
b. Strip fi" (13mm) of insulation from the input GREASE OR DAMAGE IS PRESENT! Inform your
power supply leads. gas supplier of this condition. Oil or grease in the pres-
ence of high pressure oxygen is explosive.
c. Place ferrule over wire.

5. Stand to one side away from the outlet and open
e. Torque the terminal screws to 16 in.-lbs. the cylinder valve for an instant to blow away any
(1.8nm). dust or dirt which may have accumulated in the
valve outlet.
BE SURE TO KEEP YOUR FACE AWAY FROM THE

VALVE OUTLET WHEN OPENING THE VALVE.
6. Inspect the regulator for damaged threads, dirt,

dust, oil or grease.
a. Remove dust and dirt with a clean cloth.
NOTE: DO NOT USE THE REGULATOR IF OIL,

GREASE OR DAMAGE IS PRESENT! Have an
authorized repair station clean the regulator or repair
any damage.
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.
CONNECT SHIELDING GAS a. NOTE: If connecting the flow regulator to

100% CO2 cylinder, insert regulator adapter
Customer must provide cylinder of appropriate type of provided between regulator and cylinder valve.
shielding gas for gas metal arc welding for the process If adapter is equipped with a plastic washer, be
being used. See Figure A.4 for the location of the com- sure it is seated properly to connect to the
ponents used to connect the air supply cylinder. CO2 cylinder.
8. Connect one end of the inlet gas hose to the outlet

WARNING fitting of the flow regulator.
GAS UNDER PRESSURE IS EXPLO- 9. Connect the other end of the inlet gas hose to the
SIVE. ALWAYS KEEP GAS CYLIN- SP-250 rear fitting.

DERS IN AN UPRIGHT POSITION AND
ALWAYS KEEP CHAINED TO UNDER- 10. Tighten both the union nuts securely with a
CARRIAGE OR STATIONARY SUP- wrench.
PORT.
____________________________________
IDEALARC SP-250

A-5 A-5
INSTALLATION
11. Before opening the cylinder valve, turn the regula- RECONNECT PROCEDURE
tor adjusting knob counter clockwise until the pres-

sure is released from the adjusting spring. Multiple voltage machines are shipped connected to
the highest input voltage listed on the machine's rating
12. Open the cylinder valve slowly a fraction of a turn. plate. Before installing the machine, check that the
Reconnect Panel in the Input Box Assembly is con-
a. When the cylinder pressure gage pointer stops nected for the proper voltage.
moving, open the valve fully.
NEVER STAND DIRECTLY IN FRONT OF OR CAUTION

BEHIND THE FLOW REGULATOR WHEN OPENING
THE CYLINDER VALVE. ALWAYS STAND TO ONE Failure to follow these instructions can cause immedi-
SIDE. ate failure of components within the machine.
13. Adjust the flow regulator for the flow rate recom-
mended for the procedure and process being used
____________________________________
before making the weld.
To reconnect a dual or triple voltage machine to a dif-

ferent voltage, change the position of the leads or links

on the Reconnect Panel based on the type of machine.
Follow The Input Supply Connection Diagram located
on the inside of the Case Back Reconnect Panel
Access Door.
For codes 9402, 9723, and 10001 208/230/1/60

machines, see Figure A.5.
For codes 9546 and 10002 230/460/575/1/60

machines, see Figure A.6.
FIGURE A.4 - Shielding Gas Supply Connections

IDEALARC SP-250

A-6 A-6
INSTALLATION
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.)
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.
2. CONNECT THE INPUT POWER TO THE INPUT TERMINAL BLOCK, L1 AND L2 AT THE UPPER COR-
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.
FIGURE A.6 - Reconnect Diagram For Codes 9546 & 10002 230/460/575/1/60 Machine.
IDEALARC SP-250

A-7 A-7
INSTALLATION
CONNECT OUTPUT COMPONENTS GUN LINER & CONTACT TIP
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
the side of the contact tip) and screw it snugly

into the gas diffuser.
b. Be sure the nozzle insulator is fully screwed

onto the gun tube and does not block the gas
holes in the diffuser.
c. Slip the appropriate gas nozzle onto the noz-

zle insulator. Either a standard .50" (12.7mm)
or optional .62” (15.9mm) I.D. slip on gas noz-
zle may be used and should be selected
based on the welding application.
FIGURE A.7 - Installing The Work Clamp
d. Adjust the gas nozzle for the GMAW process
to be used.
OUTPUT POLARITY CONNECTION
For the short-circuiting transfer process, the contact

WARNING tip end should be flush to extended to .12" (3.2mm)
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).
____________________________________
The welder is shipped from the factory connected for

electrode positive (+) polarity. This is the normal polar-
ity for GMA welding.
If negative (-) polarity is required, interchange the con-

nection of the two cables located in the wire drive com-
partment near the front panel. The negative lead is the
lead closest to the front panel (where the leads come
out of the floor of the compartment) and should be
reconnected to the brass conductor tube of the gun

connector. The positive lead is stamped (+) on its ter-
minal and should be reconnected to the work lead ter-
minal.
FIGURE A.8 - Contact Tip and Electrode

Connections
IDEALARC SP-250

A-8 A-8
INSTALLATION
GUN & CABLE INSTALLATION
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.
NOTE: If a gun and cable other than the Magnum 250

SP is to be used, it must conform to standard

European style connector (Magnum Fast Mate) speci-
fications. See Figure A.9.
NOTE: The thumb switch functions available on the

Magnum 250 SP gun will only be operable from the
front panel keypad. The gun trigger switch must be
capable of switching 5 milliamps at 15 volts DC resis-
tive.
FIGURE A.9 - European Style Connector

IDEALARC SP-250

OPERATION
TABLE OF CONTENTS
- OPERATION SECTION -
OPERATION SECTION ............................................ Section B

Safety Instructions............................................................B-1
General Description..........................................................B-1
Recommended Processes and Equipment......................B-2
Operational Features and Controls ..................................B-2
Design Features and Advantages ...........................B-3 - B-4
Machine Capability ...........................................................B-4
Limitations ...............................................................B-4 - B-9
Controls and Settings..............................................B-5 - B-9
Power Switch...............................................................B-5
Set Up Arrow Keys ......................................................B-5

Process Wire/Gas Key ................................................B-5
Auto Key......................................................................B-7
Manual Key .................................................................B-7
Save Key .....................................................................B-7
Memory Keys ..............................................................B-8
Spot Key......................................................................B-8
Stitch Key ....................................................................B-8
Timers Off Key.............................................................B-8
Gun Switch Control IPM Volts Key..............................B-8
Toggle Key...................................................................B-9
Operating Steps ..................................................B-10 - B-14
IDEALARC SP-250

B-1 B-1
OPERATION
Read and understand this entire section before operat- Proper welding setup is simple. You only need to
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
• automatically computes the proper wire feed

WARNING speed and arc voltage relationship for the process.
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
------------------------------------------------------------------------ when power was removed, will be recalled when power

Only qualified personnel should operate this equip- is returned. The SP-250 does not require batteries to
ment. maintain memory data.
ADDITIONAL SAFETY PRECAUTIONS
Always operate the welder with the hinged door closed

and the side panels in place as these provide maxi-
mum protection from moving parts and insure proper
cooling air flow.
GENERAL DESCRIPTION
Product Description
The IDEALARC SP-250 is a complete semiautomatic

constant voltage DC arc welding machine built to meet
NEMA specifications. This unit combines a constant
voltage power source, a constant speed wire feeder,
and a microcomputer-based controller to form an intel-
ligent welding system.
A front panel touch 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
or from the thumb switch built into the SP-250 welding
gun, which permits "on the fly" control while welding
Multi language display capability allows the SP-250 to

communicate with the user in any of the following five
languages: English, German, French, Spanish, or

Japanese (Katakana).
IDEALARC SP-250

B-2 B-2
OPERATION
The system includes the following features: OPERATIONAL FEATURES AND
• 2-step or 4-step selectable trigger function (above CONTROLS

code 9500 only).
Keypad - Consists of 20 membrane keys that have
• both timed spot and stitch welding selections. large touch areas. The keys are spaced far enough
apart to provide easy selection, even if wearing weld-
• drop-in 2" (51mm) O.D. wire reel spindle with a 22- ing gloves. An audible feedback beep is provided
30 lb. (10 - 13.6 kg) Readi-Reel- adapter. whenever a key is pressed to ensure proper entry.
• 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
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,
I.D. spools or Readi-Reel coils of

or the arc voltage from the gun, even during welding.

• .025" through .045" (0.61.2mm) solid steel using This permits "on the fly" adjustment. In toggle opera-
CO2, ArCO2, or ArO2 shielding gas tion mode, the thumb switch allows the operator to
toggle between two procedures stored in memory.
• .035" (0.9mm) stainless steel using ArO2 or
Memory - There are five separate memory locations
HeArCO2 shielding gas that the operator can use to save or recall a setup pro-
cedure. This eliminates dial marking and makes recall-
• 3/64" (1.2mm) aluminum using Ar shielding gas ing a setup as simple as pushing one of the five mem-
ory keys for instant recall. Also, when power is
• .045" (1.2mm) Outershield- electrodes using CO2 removed, these five memories as well as any current
or ArCO2 shielding gas setup in use is automatically saved. This feature does
not require batteries. When power is restored, the pro-
cedure in use will automatically return the unit to what-
• .035" (0.9mm) and .045 (1.2mm) Innershield self- ever was set up was being used when power was
shielded electrodes. removed.
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

B-3 B-3
OPERATION
DESIGN FEATURES AND Automatic Burnback - Provides proper burnback of
the electrode to prevent it from sticking in the weld pud-

ADVANTAGES dle at the end of a weld.
Output Terminals - Easily accessible in wire drive
section for quick cable connection and polarity rever-
UNIT FEATURES: sal.
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”
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
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
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

B-4 B-4
OPERATION
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 activated 2 momentary position slide switch
control designed into 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 6 minutes on and 4 minutes off).
DUTY AMPS VOLTS

CYCLE
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.
IDEALARC SP-250

B-5 B-5
OPERATION
CONTROLS AND SETTINGS
All operator controls are located on the Front Panel

Keypad/Nameplate. See Figure B.1 for the location of
each control.
FIGURE B.1 - SP-250 Control Panel Keys
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
2. SET UP ARROW KEYS: Press keys to type, wire diameter, and welding gas displayed
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

B-6 B-6
OPERATION
TABLE B.1 - Arrow Key Functions.
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
Stainless 035 (0.9mm) HeArCo2

Right Arrow Keys: Press to select Welding Gas.
Aluminum (5356) 3/64 (1.2mm) Argon
Pressing the UP and DOWN arrow keys changes the
Welding Gas displayed. Outershield .045 (1.2mm) CO2
Outershield .045 (1.2mm) ArCO2
The following 16 processes are programmed into the
SP-250: Innershield .035 (0.9mm) None
Innershield .045 (1.2mm) None
IDEALARC SP-250

B-7 B-7
OPERATION
4. AUTO KEY: Press for automatic welding set up
of recommended Wire Speed and Arc Voltage ARROW KEY OPERATION WHEN USED WITH
based on Metal Thickness selected. MANUAL KEY:
ARROW KEY OPERATION WHEN USED WITH See Table B.1.

AUTO KEY:
Left arrow keys: Do not function in Manual mode.
See Table B.1.
Center arrow keys: Press the UP ( ) arrow key to
Left Arrow Keys: Press to change the metal thickness increase wire feed speed. Press the DOWN ( ) arrow
displayed. Press the UP ( )arrow key to increase key to decrease wire feed speed.
metal thickness. Press the DOWN ( ) arrow key to
decrease the metal thickness. Increasing or decreas- Right arrow key: Press the UP ( ) arrow key to
ing metal thickness automatically increases or increase arc voltage. Press the DOWN ( ) arrow key
decreases both wire feed speed (IPM) and arc voltage to decrease arc voltage.
(VOLTS) simultaneously. See gauge chart on the
instruction label on the inside of SP-250 door for avail- NOTE: If the spot or stitch timers are ON, it will be indi-
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.
Right Arrow Keys: Press to change arc voltage set-

ting. Press the UP ( ) arrow key to increase the arc FIGURE B.2 - Display when Stitch or Spot Weld
voltage setting displayed. Press the DOWN ( ) arrow Timers are ON.
key to decrease arc voltage setting displayed. An up
arrow indicator appears below the V in VOLTS if the 6. SAVE KEY: Press to save the current set up. The
process, procedure, and timer functions (if used)
arc voltage has been set higher than the recommend-

ed value. A down arrow indicator appears below the V are saved to one of five memory locations by
in VOLTS if the arc voltage is below the recommended pressing one of the five memory keys. When the
value. No arrow indicates that you are set to the rec- Save key is pressed, a prompting message
ommended value. instructing the operator to "PRESS MEMORY 1-5
TO SAVE SETUP" is displayed. See Figure B. 3
Pressing the AUTO key again resets the wire feed for sample SAVE sequence. This message
speed and arc voltage settings to the recommended remains displayed until a memory number key is
values for the metal thickness displayed. (NOTE: If selected or one of the other keys, such as Auto,
the spot or stitch timers are on, metal thickness is not Manual, or Process, is pressed. If a memory num-
displayed and, therefore, the reset function does not ber key is selected, a message will be displayed
work.) for 2.5 seconds that confirms that the setup was
saved to that memory number.
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-
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

B-8 B-8
OPERATION
7. MEMORY KEYS: Press memory key location Left arrow keys: Do not function.
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.
Right arrow keys: Press UP ( ) arrow key to increase

Stitch OFF time from 0.20 seconds to 2.50 seconds.
Press DOWN ( ) arrow key to decrease Stitch OFF
time from 2.50 seconds to 0.20 seconds.
10. TIMERS OFF KEY: Press to turn OFF both

Spot and Stitch timers. When the TIMERS OFF
key is pressed the indicating letters from the bot-
tom left corner of the Auto and Manual mode dis-
play disappears.
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
Left arrow keys: Do not function. pressed.
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.
Right arrow keys: - Do not function.
9. STITCH KEY: Press to turn Stitch Weld timers

ON and display the Stitch Weld ON and OFF
times. Pressing the STITCH key a second time
returns the screen to the previous display without
turning off the stitch timers. Anytime the Stitch
weld timers are on and the display is in the Auto or
Manual mode, the abbreviation STITCH will
appear in the bottom left corner of the display. See

Figure B.2.
ARROW KEY OPERATION WHEN USED WITH

STITCH KEY:
FIGURE B.4 - Using the IPM VOLTS key.
See Table B.1.
IDEALARC SP-250

B-9 B-9
OPERATION
12. TOGGLE KEY: When first pressed, this key Center arrow keys: Press the UP ( ) arrow key to
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-
ner if either timer is active.
The gun thumb switch functions as a Toggle key in

Toggle mode. Pushing the gun thumb switch for-
ward (toward the tip) selects the setup in memory
5. Pulling gun thumb switch back selects the setup
in memory 4. The gun thumb switch also functions
with the trigger closed for "on the fly" changes dur-
ing a weld. See Figure B.5.
To turn the toggle mode off, press the AUTO, MANU-

AL, or any MEMORY Number key.
NOTE: Any changes made to settings in toggle mode

are not automatically saved when power is removed,
or if toggle mode is turned off. To save these changes
Press the SAVE key

Press the MEMORY number key that is currently dis-
played on the screen (4 or 5)
Press the SAVE key
Press other MEMORY Number key that was displayed FIGURE B.5 - Using the TOGGLE Function.
after the toggle (5 or 4).
4-STEP TRIGGER INTERLOCK KEYS
When power is returned, the machine will not be in the PROCESS TOGGLE
toggle mode. However, the weld setting placed in Pressing and
WIRE/GAS 4 5
memory when power was removed will return so you
may continue to weld right where you left off. Press the Controls whether 4-step trigger interlock is activated or
TOGGLE key to return to toggle mode. deactivated. (See “Using 4-Step Trigger Interlock
Function” section)
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.
Left arrow keys: If metal thickness is displayed, Press

the UP ( ) arrow key to increase metal thickness. Press
the DOWN ( ) arrow key to decrease metal thickness.
The Left arrow keys do not perform any function in any
other mode.
1/96
IDEALARC SP-250

B-10 B-10
OPERATION
OPERATING STEPS b. If run-in mode displayed is not the required
mode, repeat Step 1. By repeating Step 1, the

Before operating the machine, be sure you have all the run-in mode changes. Pressing the TIMERS
materials needed to perform the work. Be sure you are OFF key and the PROCESS key allows you to
familiar with and have taken all possible safety pre- switch back and forth between the two run-in
cautions before starting the work. It is important that modes.
you follow these operating steps each time you use the
machine. You need only perform the above procedure when you
want to change the run-in mode. It is not necessary to
repeat the above procedure each time the unit is pow-
ered up. The unit will remember the run-in mode from
RUN-IN MODE the previous power down and return you to that same
state on your next power up. When saving to Memory
The IDEALARC SP-250 can operate in either a slow or locations 1-5, the run-in mode is saved at the same
fast run-in mode. It is factory set to operate in the slow time. All operators should be aware that when recalling
run-in mode. In the slow run-in mode, the SP-250 ini- a procedure from a memory location, the run-in mode
tially feeds wire at the rate of 50 IPM until output cur- in memory overrides any present run-in mode setting.
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.
When the SP-250 is in the fast run-in mode, the wire

feed speed immediately accelerates to the preset wire MAKING A WELD IN AUTO MODE
feed speed - (available on later codes only.)
1. Check that the polarity is correct for the process
being used.
CHANGING RUN-IN MODE (CODES 10001
AND ABOVE) 2. Turn the ON/OFF POWER SWITCH to ON.
NOTE: Arc starting characteristics may be affected 3. Press (PROCESS) key.

when using the fast run-in mode because normal start-
ing processes are overridden. 4. Press LEFT UP or DOWN ARROW Keys to select
wire type being used.

1. Turn the ON/OFF POWER SWITCH to ON.
5. Press CENTER UP or DOWN ARROW Keys to
2. Press and hold both the TIMERS OFF key and the select wire diameter being used.
PROCESS key.
6. Press RIGHT UP or DOWN ARROW Keys to
NOTE: The order in which the TIMERS OFF key and select welding gas type being used.
the PROCESS key are pressed does not matter.
7. Press AUTO key. When the AUTO key is pressed,
3. Read the SP-250 LED display. One of two mes- an alarm will beep three times. The following mes-
sages appear: sage is displayed for 2.5 seconds: PROCESS
FAST INCH ENABLED = (Fast run-in mode) MUST MATCH WIRE & GAS.
FAST INCH DISABLED = (Slow run-in mode)
8. Press UP or DOWN ARROW Keys to select metal
NOTE: The run-in message appears on the display for thickness.
2 seconds. Pressing the PROCESS key causes the
message to disappear immediately. 9. If SPOT or STITCH timing modes NOT required,
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

B-11 B-11
OPERATION
10. If SPOT timing mode required. distance is about 3/8 inch (3/4" for Outershield).
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
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:
When the arc is struck, the gun trigger may be

NOTE: When the trigger is pulled, the wire feeder released. The welding continues until welding is
feeds wire at low speed regardless of the set wire feed stopped by either of these two methods:
speed until the welding arc starts or 2 seconds has 1) The arc is extinguished by manually jerking the
elapsed. This feature enhances starting and makes it gun away from the work.
easier to set the stick out. The two-second limit per-
mits high speed loading of the gun and cable. To 2) The gun trigger is closed and then released at the
change Run-In Mode, see changing Run-In Mode sec- end of the weld. This action returns the trigger
tion. function to the normal mode so the weld stops
when the trigger is released. Releasing the trigger
14. If welding gas is to be used, turn on the gas supply reinstates the trigger interlock function for the next
and set the required flow rate (typically 25-35 weld. This is the preferred Interlock mode
CFH/12-16 l/min.). because it provides better control at the end of the

weld and allows automatic burnback to prevent
NOTE: When using an Innershield electrode, the gas excessive wire feed speed overrun.
nozzle may be removed from the insulation on the end
of the gun. This will give improved visibility and elimi- The 4-step trigger feature does not function when
nate the possibility of the gas nozzle overheating. using SPOT or STITCH timed welding modes.
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.
____________________________________ To make an arc spot plug weld
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

B-12 B-12
OPERATION
4. Press the CENTER UP & DOWN ARROW keys to USING THE GUN TRIGGER SWITCH
set the required Spot On time. Suggested initial

setting is 1.2 seconds. The Gun Trigger Switch turns on arc voltage, wire
feeder, and gas solenoid (except with Innershield)
5. Press the SPOT key. Display returns to Auto when the Gun Trigger Switch is closed. When closed,
screen. Spot timer status is shown in bottom left the LED screen displays the Auto or Manual screens,
corner of screen. depending on which mode is being used. When the
Gun Trigger Switch is released, or opened, arc voltage,
6. Install spot weld nozzle (if available) on gun. wire feeder, and gas solenoid are turned off.
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
goes out. USING THE GUN THUMB SWITCH

(MAGNUM SP-250 ONLY)
MAKING A STITCH WELD IN AUTO MODE
The Gun Thumb switch is used to control wire feed
A stitch weld is used to weld thin material because speed, arc voltage, or to switch, or toggle, between
warpage and burnthrough are a problem. Properly memory locations 4 and 5. See IPM VOLTS key and
adjusting the ON and OFF times and arc travel speed, TOGGLE key for control details. The Thumb switch is
permits welding thin sheet metal using small welds that used to increase or decrease IPM or VOLTS.
result in minimum distortion and no burnthrough.
To make a stitch weld

USING THE WIRE DRIVE ROLL
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
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.
5. Press STITCH key. Auto screen is displayed.

Stitch timer status is display in lower left portion of
screen.
6. Close the gun trigger and hold it closed for the

length of seam. Hold gun in one place during ON
time and move gun just beyond edge of molten
metal during OFF time. For smoothest welds on
thinner metal, point gun slightly towards the direc-
tion of travel.
IDEALARC SP-250

B-13 B-13
OPERATION
LOADING THE WIRE REEL 7. Check that the mating surfaces of the spindle hubs
and spindle mounting clips (V-brackets) are clear

To mount a 22-30 lb. (10-14 kg) Readi-Reel- package of dirt and debris and that the adapter is fully
using the Readi-Reel adapter provided: engaged onto the spindle.
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.
To mount 10 to 30 lb. spools: (8" and 12" diameter):
1. Remove the Readi-Reel adapter shipped on the 2

inch diameter spindle.
2. Be sure that the mating surfaces of the spindle

hubs and spindle mounting clips (V-brackets) are
clear of dirt and debris.
3. Place the spool on the spindle. Make certain the

brake driving pin enters one of the holes in the
back side of the spool.
4. Lower the loaded spindle into the spindle mounting

clips (V brackets) so the wire dereels from the top
of the reel toward the wire drive.
FIGURE B. 6 - Wire Reel Loading

NOTE: The SP-250 Spindle was designed to mount
4. Set one of the Readi-Reel inside cage wires on the 12"- (300mm) and 8"- (200mm) diameter spools meet-
slot in the retaining spring tab. ing international spool size specifications. If the spool
being used is too narrow to keep the brake driving pin*
5. Lower the Readi-Reel to depress the retaining engaged with the spool pin hole, a 2" (51mm) I D shim
spring and align the other inside cage wires with washer could be used between the spool and the spin-
the grooves in the molded adapter. dle retaining clip to take up the space.
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
WARNING: Check to be sure the the retaining spring

has fully returned to the locking position and has

securely locked the readi-reel cage in place. Retaining
spring must rest on the cage, not the welding elec-
trode.
____________________________________
IDEALARC SP-250

B-14 B-14
OPERATION
FEEDING ELECTRODE 2. If the wire "birdnests", jams, or breaks at the drive
roll, the idle roll pressure is too great. Back the

WARNING wing screw out fi turn and run new wire through the
gun. Repeat above step.
When inching, the electrode and drive mechanism are
always “hot” to work and ground. The electrode 3. If the drive roll slips, loosen the gun cable Fast-
remains “hot” several seconds after the gun trigger is Mate connection nut from the front of the SP-250.
released. Pull the gun cable forward about 6". There should
____________________________________ be a slight waviness in the exposed wire. If there
is no waviness, the pressure is too low. Tighten the
NOTE: Check that the proper drive rolls and gun parts wing screw 1/4 turn and lock the gun cable in
are used for the wire size and wire type being used. place. Repeat the above procedure.
1. Turn the Readi-Reel or spool until the free end of

the electrode is accessible.
2. While tightly holding the electrode, cut off the bent

end and straighten the first six inches. Cut off the
first inch. (If the electrode is not properly straight-
ened, it may not feed properly into the outgoing
guide tube or welding gun causing a "birdnest".)
3. Push the wire through the ingoing guide tube, then

press the gun trigger and push the electrode into
the drive roll. If the electrode fails to thread itself
into the outgoing guide tube of the wire drive, open
the quick release idle roll arm, thread the electrode
manually, and reclose the arm.
4. Inch the electrode through the gun.
NOTE: Due to the low speed starting feature of the

SP-250, the wire will feed at low speed for 2 seconds
while inching, then come up to the set speed.
5. Check that the welding process is set for the wire

type, diameter, and gas per instructions on 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 is an
approximate setting. The optimum idle roll pressure
varies with type of wire, wire diameter, surface condi-
tion, lubrication, and hardness. As a general rule, hard
wires may require greater pressure, and soft, or alu-
minum wire, may require less pressure than the facto-
ry setting. The optimum idle roll setting can be deter-

mined as follows:
1. Press end of gun against a solid object that is elec-

trically isolated from the welder output and press
the gun trigger for several seconds.
IDEALARC SP-250

ACCESSORIES
TABLE OF CONTENTS
- ACCESSORIES SECTION -
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 Installation ...................C-1
Spool Gun Connection Box Installation ................C-3
Spool Gun Connection ..........................................C-4
Spool Gun Installation to Old K531 ............................C-5
IDEALARC SP-250

C-1 C-1
ACCESSORIES
OPTIONS / ACCESSORIES The connection box mounts to the front of the
machine's base and provides for inlet connection of the

Replacement Magnum 250-SP Gun and Cable spool gun gas supply hose. It provides up-front easy
Assemblies connection of the spool gun gas line, control plug, and
electrode lead (using the Twist-Mate plug provided with
The following GMAW gun and cable assemblies are the kit). Installation and Operation Accessory Manual
available for use with the SP-250. Each is rated at 200 (AM-105) is included with the kit.
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 position SPOOL GUN MODULE BOARD
slide switch control designed into the gun handle to INSTALLATION
use with the SP-250 remote control features:
NOTE: The K607-1 Spool Gun Adapter Kit is designed
K524-1 Gun and Cable -A 12.5 ft. (3.8m) GMAW gun for use with SP-250, SP 250-I and Wire-matic 250
and cable assembly; includes a liner, diffuser, and con- model codes above code 9900. Model Codes below
tact tips for .035 (0.9mm) and .045 (1.2mm) elec- 9900 may be used with the addition of holes to the
trodes. case as described in the installation instructions below.
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.
____________________________________
K607-1 Spool Gun adapter Kit See Figures C-1 and C-2.
The K607-1 Spool Gun Adapter Kit provides "up front"

direct connection with the SP-250. It is used with the
K487 Spool Gun (with remote speed control) or the
K469 Spool Gun (requiring K518 Connection Adapter).
It also provides single switch transfer between the
machine's feeder gun or the spool gun for same polar-
ity welding with different wire and gas processes. 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

INSTALLATION
(Option K607-1)
The spool gun module mounts inside the control sec-

tion of the machine and provides control and inter-con-
nection between the machine's control board and the
spool gun kit connection box. Figure C.1 - Spool Gun Installation.
IDEALARC SP-250

C-2 C-2
ACCESSORIES
CAUTION
CAUTION: Collect metal filings with a rag to protect
against possible metal contamination of the control
board or other internal electrical components.
____________________________________
9. Fasten the panel receptacle to the case with the

three #6-32 x 3/8" self tapping screws provided.
Insert screws from wire drive side, through the
sheet metal, and into the receptacle mounting
plate holes.
10. Plug the 10-pin, 8-pin, and 6-pin connector plugs

from the other end of the receptacle lead harness
into the 10-, 8-and 6-pin connectors (J12, J11 and

J13) at the top of the spool gun module board.
Figure C.2 - Spool Gun Module Board Installation. Plug in the 8-pin connector at the opposite end of
this harness into the unused 8-pin connector on
1. Remove input power to the machine before start- the SP-250 control board (J4).
ing.
11. Disconnect the 4-pin gas solenoid plug from the
2. Remove the six screws that hold the Case Side receptacle (J8) on the upper right corner of the
Panels. Control Board. See Figure C.2. Reconnect this
plug into the 4-pin receptacle (J14) on the top of
3. Locate the four snap-mount fasteners mounted to the Module Board.
the side panel of the control Board.
12. Plug the 4-pin connector plug, included with the
4. Position the spool gun module board over the panel receptacle harness connected in step 10
snap-mount fasteners, making sure that the lead above, into the Control Board receptacle (J8), dis-
plug connectors are placed at the top. connected in step 11 above.
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.
7. Slide the metal cover out from behind the motor

bracket. Flip the cover over so that the screw hole
is in the top right corner, then reinstall as a spacer
plate with the hex head screw. See Figure C-1.
8. Find the panel receptacle lead harness included in

the kit. See Figure C-2. Insert the panel recepta-
cle into the hole from the control board side of the
panel, making sure that the panel receptacle
mounting plate is positioned so that the grounding

screw is in the lower left corner of the plate.
NOTE: For model codes below 9900, small notches

may need to be filed at top and bottom of panel hole to
clear the plastic mounting ears of the receptacle.
IDEALARC SP-250

C-3 C-3
ACCESSORIES
SPOOL GUN CONNECTION BOX the machine connected for electrode positive,
INSTALLATION (refer to instruction manual), remove the positive

electrode lead from its connection on the wire
NOTE: Model codes below 9900 require the addition drive. Then reconnect with the connection box
of three holes to the front of the machine's base as electrode lead on the bolt under the positive elec-
shown in Fig C.3. trode lead so the connection box electrode lead is
sandwiched between the positive electrode lead
terminal and the wire drive contact surface.
Tighten snugly, being careful not to strip the
threads.
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 base and par- Figure C.4 - Spool Gun Connection Box
tially thread the two #10 thread forming screws, Installation.
provided with kit, into the two small holes on both

sides of the center hole.
2. Route a user-provided gas supply hose, from the

flow regulator of the spool gun gas cylinder, over
the rear axle of the machine, and out to the front
through the center hole in the front of the base.
3. Connect the gas hose to the 5/8-18 female inert

gas fitting on the back of the connection box.
4. Slip the connection box mounting keyholes over

the screw heads (installed in Step 1 above) and
pivot the box clockwise 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 drive, and
connect the plug to the kit receptacle installed in
the previous section A. See Figure C.4.
6. Route the electrode lead of the connection box up

through the same opening in the front louver. With
IDEALARC SP-250

C-4 C-4
ACCESSORIES
SPOOL GUN CONNECTION
CAUTION
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 receptacle on the front of the spool gun
adapter connection box.
NOTE: If using a 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 gas line to the gas outlet fit-
ting on the front of the connection box.
4. Refer to the Instruction Manual included with the

K487 or K469 Spool Gun for more detail in Spool
Gun set-up and operation.
Figure C.5 - Spool Gun Connect.

IDEALARC SP-250

C-5 C-5
ACCESSORIES
SPOOL GUN INSTALLATION TO OLD K531 KIT. c. Press the MANUAL key for spool gun welding
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.
4. Attach the spool gun gas hose to the gas connec-

tor.
5. Tighten the gas hose tightly, being careful not to

strip the brass threads.
NOTE: If using a K469 Spool Gun with a 4-pin plug,

use the K518 adapter.
6. Thread the removed SP-250 gas line between the

new gas hose and spool gun cable. See Figure
C.6.
7. Pull the SP-250 gas hose up and through until it

wedges between the cable connector and gas con-
nector.
a. Make sure the SP-250 gas hose connector

does not touch the wire drive unit.
FIGURE C.6 - Spool Gun Connection.
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 the SP-250 electrode lead on the terminal.

The spool gun electrode lead should be on the
inboard side.
11. Tighten the hex nut, being careful not to strip the
threads.
12. Confirm the spool gun has been connected prop-

erly.
a. Toggle the POWER SWITCH to the “ON” posi-

tion.
b. If the spool gun cable has been installed prop-

erly, the following display appears
SPOOL GUN HAS BEEN CONNECTED
PRESS MANUAL TO ENTER SETTINGS.
IDEALARC SP-250

MAINTENANCE
TABLE OF CONTENTS
- MAINTENANCE SECTION -
MAINTENANCE SECTION ...................................... Section D

Safety Precautions ...........................................................D-1
Routine and Periodic Maintenance ..................................D-1
Component Locations ......................................................D-2
IDEALARC SP-250

D-1 D-1
MAINTENANCE
SAFETY PRECAUTIONS Drive Rolls and Guide Tubes
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 .
Read the Safety Precautions in the front of this manu-

al before working on this machine. Drop-In Reel Spindle and Clips
Before loading a coil of wire into the SP-250 drop-in

ROUTINE AND PERIODIC spindle, inspect the mating surfaces of the spindle
MAINTENANCE hubs and the spindle mounting clips (V-brackets) and,
if necessary, wipe or blow out any dirt and debris which

may have deposited on these surfaces .
Disconnect input AC power supply lines to the machine
before performing periodic maintenance, tightening, Cable Cleaning
cleaning, or replacing parts. See Figure D.1.
Clean cable liner after using approximately 300
pounds (136 kg) of electrode. Remove the cable from
Perform the following daily: the wire feeder and lay it out straight on the floor.
Remove the contact tip from the gun. Using an air hose
1. Check that no combustible materials are in the and only partial pressure, gently blow out the cable
welding or cutting area or around the machine. liner from the gas diffuser end.
2. Remove any debris, dust, dirt, or materials that

could block the air flow to the machine for cooling. CAUTION
3. Inspect the electrode cables for any slits, punc- Excessive pressure at the start may cause dirt to form
tures in the cable jacket, or any condition that a plug.

would affect the proper operation of the machine. ____________________________________
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.
IDEALARC SP-250

D-2 D-2
MAINTENANCE
3
5
1 Control Board 4 Choke

2 Fan Assembly 5 Main Transformer
3 SCR Rectifier
Figure D.1 - Component Locations

IDEALARC SP-250

THEORY OF OPERATION
TABLE OF CONTENTS
- THEORY OF OPERATION SECTION -
THEORY OF OPERATION SECTION ...................... Section E

Power Supply Operation ........................................E-1 - E-3
Input Line Voltage and Main Transformer ...................E-1
Output Rectification and Feedback Control ................E-2
Constant Voltage Output .............................................E-3
Wire Drive Motor and Feedback .................................E-4
Thermal Protection ...........................................................E-5
SCR Operation ............................................................... E-6
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
SCR I B
RECTIFIER T A
O C
R K
FAN S NEGATIVE
MOTORS TERMINAL
SHUNT
Figure E.1 -Block Logic Diagram

NOTE: Unshaded areas of Block Logic

Diagram are the subject of discussion
IDEALARC SP-250

E-1 E-1
THEORY OF OPERATION
POWER SUPPLY OPERATION
PIEZO GAS
LCD ALARM SOLENOID
DISPLAY
WIRE
DRIVE
MOTOR
KEYPAD
CONTROL BOARD
TACH
G
A
T
LINE MAIN
TRANSFORMER S
SWITCH I
G FEEDBACK
N
A
L
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
Figure E.2 - Input Line Voltage and Main Transformer

INPUT LINE VOLTAGE 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 main trans-
former and to the thermostatically controlled fan
motors. The transformer changes the high voltage, low
current input power to a low voltage, high current out-
put. In addition, the main transformer also has an iso-
lated center tapped 30VAC auxiliary 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.

IDEALARC SP-250

E-2 E-2
THEORY OF OPERATION
POWER SUPPLY OPERATION (CONTINUED)
PIEZO GAS
LCD ALARM SOLENOID
DISPLAY
WIRE
DRIVE
MOTOR
KEYPAD
CONTROL BOARD
TACH
G
A
T
LINE MAIN
TRANSFORMER S
SWITCH I
G FEEDBACK
N
A
L
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
Figure E.3 - Output Rectification and Feedback Control

OUTPUT RECTIFICATION 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 compares
the commands of the keypad (or gun thumb switch)
with the feedback signals. The appropriate gate firing
pulses are generated by the control board and applied
to the SCR rectifier assembly. The control board con-
trols the firing of the SCRs, thus controlling 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.

IDEALARC SP-250

E-3 E-3
THEORY OF OPERATION
PIEZO GAS
LCD ALARM SOLENOID
DISPLAY
WIRE
DRIVE
MOTOR
KEYPAD
CONTROL BOARD
TACH
G
A
T
LINE MAIN
TRANSFORMER S
SWITCH I
G FEEDBACK
N
A
L
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
Figure E.4 - Constant Voltage Output

CONSTANT VOLTAGE 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.

IDEALARC SP-250

E-4 E-4
THEORY OF OPERATION
PIEZO GAS
LCD ALARM SOLENOID
DISPLAY
WIRE
DRIVE
MOTOR
KEYPAD
CONTROL BOARD
TACH
G
A
T
LINE MAIN
TRANSFORMER S
SWITCH I
G FEEDBACK
N
A
L
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
Figure E.5 - Wire Drive Motor and Feedback

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 sends the appropriate armature voltage to
the wire drive motor. The drive motor speed is thus
controlled which in turn regulates the electrode wire
feed speed through the gun.

IDEALARC SP-250

E-5 E-5
THEORY OF OPERATION
THERMAL PROTECTION
A thermostat protects the machine from excessive

operating temperatures.. Excessive operating temper-
atures may be caused by a lack of cooling air or oper-
ating the machine beyond the duty cycle and output
rating. There are three thermostats within the SP-250
machine. One of the thermostats, located on the out-
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 detect-
ed. The third thermostat insures that the fan motors
are operating when required.
The thermostats are self-resetting once the machine

cools sufficiently. It the thermostat shutdown is caused
by excessive output or duty cycle and the fans are
operating normally, the power switch may be left on
and the reset should occur within a 15 minute period.
If the fans are not turning or the air intake louvers are
obstructed, then the input power must be removed and
the fan problem or air obstruction be corrected.
IDEALARC SP-250

E-6 E-6
THEORY OF OPERATION
SCR OPERATION
INPUT
CATHODE
OUTPUT
NOTE: AS THE GATE
PULSE IS APPLIED
ANODE LATER IN THE CYCLE
THE SCR OUTPUT
IS DECREASED.
GATE
Figure E.6 - SCR Operation

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.
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.
IDEALARC SP-250

TROUBLESHOOTING & REPAIR
TABLE OF CONTENTS
- TROUBLESHOOTING & REPAIR SECTION -
TROUBLESHOOTING & REPAIR SECTION ........... Section F

How to use Troubleshooting Guide ..................................F-1
PC Board Troubleshooting Procedures............................F-2
Troubleshooting Guide............................................F-3 - F10
Explanation of Prompting Error Messages ............F11 -F-13
Test Procedures
SP-250 Main Transformer Test............................F-14 - F-18
Static SCR Rectifier Test .....................................F-19 - F-21
Active SCR Rectifier Test.....................................F-22 - F-24
SP-250 Keypad 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-39 - F-40
Wire Drive Assembly Remove/Replace...............F-41 - F-42
SCR Output Rectifier Remove/Replace ..............F-43 - F-44
Capacitor Bank Remove/Replace .......................F-45 - F-46
Main Transformer Remove/Replace....................F-47 - F-48
Fan Motor Remove/Replace................................F-49 - F-51
Retest After Repair .........................................................F-52
IDEALARC SP-250

F-1 F-1
HOW TO USE TROUBLESHOOTING GUIDE

WARNING
Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician and
machine operator and will invalidate your factory warranty. For your safety and to avoid
Electrical Shock, please observe all safety notes and precautions detailed throughout this
manual.
__________________________________________________________________________
This Troubleshooting Guide is provided to Step 3. RECOMMENDED COURSE OF
help you locate and repair possible machine ACTION
malfunctions. Simply follow the three-step

procedure listed below. The last column labeled “Recommended
Course of Action” lists the most likely com-
Step 1. LOCATE PROBLEM (SYMPTOM). ponents that may have failed in your
Look under the column labeled “PROBLEM machine. It also specifies the appropriate
(SYMPTOMS)”. This column describes pos- test procedure to verify that the subject com-
sible symptoms that the machine may exhib- ponent is either good or bad. If there are a
it. Find the listing that best describes the number of possible components, check the
symptom that the machine is exhibiting. components in the order listed to eliminate
Symptoms are grouped into the following one possibility at a time until you locate the
categories: output problems, function prob- cause of your problem.
lems, wire feeding problems, and welding
problems. All of the referenced test procedures
referred to in the Troubleshooting Guide are
Step 2. PERFORM EXTERNAL TESTS. described in detail at the end of this chapter.
The second column labeled “POSSIBLE Refer to the Troubleshooting and Repair
AREAS OF MISADJUSTMENT(S)” lists the Table of Contents to locate each specific

obvious external possibilities that may con- Test Procedure. All of the specified test
tribute to the machine symptom. Perform points, components, terminal strips, etc. can
these tests/checks in the order listed. In be found on the referenced electrical wiring
general, these tests can be conducted with- diagrams and schematics. Refer to the
out removing the case wrap-around cover. Electrical Diagrams Section Table of
Contents to locate the appropriate diagram.
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.
_____________________________________________________________
IDEALARC SP-250

F-2 F-2
PC BOARD TROUBLESHOOTING PROCEDURES
- Remove the P.C. Board from the static-

WARNING shielding bag and place it directly into the
equipment. Don’t set the P.C. Board on or near
ELECTRIC SHOCK can paper, plastic or cloth which could have a sta-
kill. tic charge. If the P.C. Board can’t be installed
Have an electrician install and
service this equipment. Turn the
immediately, put it back in the static-shielding
input power OFF at the fuse box bag.
before working on equipment. Do
not touch electrically hot parts. - If the P.C. Board uses protective shorting
jumpers, don’t remove them until installation is
complete.
CAUTION: Sometimes machine failures
appear to be due to PC board failures. These - If you return a P.C. Board to The Lincoln
problems can sometimes be traced to poor Electric Company for credit, it must be in the
electrical connections. To avoid problems when static-shielding bag. This will prevent further
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.
cedures:
P.C. Board can be dam-

aged by static electricity. a. If the original problem does not reappear
by substituting the original board, then
- Remove your body’s stat- the PC board was not the problem.
ic charge before opening Continue to look for bad connections in
the static-shielding bag. the control wiring harness, junction
ATTENTION Wear an anti-static wrist blocks, and terminal strips.
Static-Sensitive strap. For safety, use a 1
Devices Meg ohm resistive cord b. If the original problem is recreated by the
Handle only at connected to a grounded substitution of the original board, then
Static-Safe part of the equipment the PC board was the problem. Reinstall
Workstations frame. the replacement PC board and test the
machine.
Reusable - If you don’t have a wrist
Container strap, touch an unpainted, 6. Always indicate that this procedure was fol-
Do Not Destroy grounded, part of the equip- lowed when warranty reports are to be sub-
ment frame. Keep touching the frame to pre- mitted.

vent static build-up. Be sure not to touch any
electrically live parts at the same time. NOTE: Following this procedure and writing
on the warranty report, “INSTALLED AND
- Tools which come in contact with the P.C. SWITCHED PC BOARDS TO VERIFY PROB-
Board must be either conductive, anti-static or LEM,” will help avoid denial of legitimate PC
static-dissipative. board warranty claims.
IDEALARC SP-250

F-3 F-3
TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE AREAS OF RECOMMENDED

(SYMPTOMS) MISADJUSTMENTS(S) COURSE OF ACTION
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.
reconnect panel.
3. Blown or missing fuses in the

input line.
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.
3. Perform the SCR Rectifier

Assembly Test.
4. 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

F-4 F-4

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
continuity ( zero ohms) when the

gun trigger is pulled. If not then
the gun may be faulty - replace.
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
body.

Assembly Test.
4. Perform the Main Transformer

Test.

Replace.
CAUTION
383-2531 or 1-800-833-9353
IDEALARC SP-250

F-5 F-5

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.
2. If the problem is not resolved 2. The control board may be faulty.

then contact your Local Lincoln Replace.
Electric Authorized Field Service
Facility.
Output settings (voltage and/or wire 1. Remove the gun. If the problem 1. Check leads #326 and #327 for
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.-
Replace. 4. The LCD display may be faulty. -

Replace.
CAUTION
383-2531 or 1-800-833-9353
IDEALARC SP-250

F-6 F-6

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
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.
3. The LCD Display may be faulty.-

Replace.
1. Make certain that a process is 1. Check the gas solenoid by dis-

There is no gas flow when gun trig- selected that requires gas flow. connecting it from the control
ger is pulled. Wire feeds and weld board (Plug J8) and applying a
voltage is present. The display func- 2. Check gas source and hoses for 12VDC external supply to the
tions properly. leaks or kinks. gas solenoid. If the solenoid
does NOT activate then it may
be faulty. - Replace.

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
Facility.
CAUTION
383-2531 or 1-800-833-9353
IDEALARC SP-250

F-7 F-7

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.
2. If the 12VDC is not present at

pins 1J1 to 2J1 then perform the
Main Transformer Test.

Replace.
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.
2. If the motor armature current is

high (over 3 amps) and there are
NO restrictions in the wire feed-
ing path then the motor or gear
box may be defective.-Replace.
CAUTION
383-2531 or 1-800-833-9353
IDEALARC SP-250

F-8 F-8

WIRE FEEDING PROBLEMS

No control of wire feed speed. 1. The thumb switch circuit in the 1. Perform the Wire Drive Motor
Other machine functions are normal. gun may be faulty. Check or and Tach Feedback test.
replace.
Replace.
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 gun liner may be clogged. - Replace.

Check or replace.
3. If the drive rolls are NOT turning

when the gun trigger is pulled
then contact your local Lincoln
Facility.
CAUTION
383-2531 or 1-800-833-9353
IDEALARC SP-250

F-9 F-9

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
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.

Replace.
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.
2. Make sure shielding gas is cor- Replace if necessary.

rect and flow is proper. WARNING: The liquid elec-
trolyte in these capacitors is
3. Make sure the weld joint is not toxic. Avoid contact with any
"contaminated". portion of your body.

Assembly Test.

Replace.
CAUTION
383-2531 or 1-800-833-9353
IDEALARC SP-250

F-10 F-10

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.
2. A light application of high tem-

perature antisieze lubricant
(such as Lincoln E2607 Graphite
Grease) may be applied to the
contact tip threads.
CAUTION
383-2531 or 1-800-833-9353
IDEALARC SP-250

F-11 F-11
EXPLANATION OF PROMPTING AND ERROR MESSAGES
ON SCREEN ERROR MESSAGE MESSAGE EXPLANATION
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.
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-
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
IDEALARC SP-250

F-12 F-12
EXPLANATION OF PROMPTING AND ERROR MESSAGES (CONT’D)
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
impede the wire feeding. To resume welding, simply pull the trigger.
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
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
VOLTS and/or IPM can eliminate the message. Pressing any key or gun
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

F-13 F-13
EXPLANATION OF PROMPTING AND ERROR MESSAGES (CONT’D)
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.
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.
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
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

F-14 F-14
MAIN TRANSFORMER TEST
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
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
a. applied to the primary windings of the Main Transformer.

b. induced on the weld winding and auxiliary windings.
MATERIALS NEEDED
5/16" Nut Driver
Volt-Ohm Meter
IDEALARC SP-250

F-15 F-15
TEST PROCEDURE
WARNING
The ON/OFF POWER SWITCH will be
"hot" during these tests.
__________________________
NOTE: Secondary voltages will vary pro-

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

G2252 Control PC Board or Plug J3
on the G1992 (Code 9402 only)
Control PC Board. See Figures
F.1A and F.1B.
NOTE: The location of Plugs may vary

depending on the machine code.
SP-250 CONTROL
G2252
J2
J8
J7
J3
J4
J9
#206
#203 #204A #202
(4J6)
(3J3) (2J3) (1J3)
#209
(7J6)
J5 J6
#208
(16J6)
FIGURE F.1A - G2252 Control PC Board Main Transformer Test Points.
IDEALARC SP-250

F-16 F-16
SP-250 CONTROL
G1992
J2
J8
J7
J4
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:
G1992 (code 9402 only):

5. Connect main input power to the

LEAD PLUG machine.
LOCATION
6. Turn the IDEALARC SP-250
#202 1J3 ON/OFF POWER SWITCH to ON.
#203 3J3
#204 A 2J3 7. Make the following voltage tests at
Plug J3.
G2252:
LEAD PLUG
FROM TO EXPECTED
LOCATION
LEAD LEAD VOLTAGE
#202 6J3
#202 #203 30 VAC
#203 7J3
(1J3) (3J3)
#204 A 5J3
#202 #204 A 15 VAC

(1J3) (2J3)
#203 #204 A 15 VAC

(3J3) (2J3)
IDEALARC SP-250

F-17 F-17
G1992 (Code 9402 only): G2252:
FROM TO EXPECTED FROM TO EXPECTED

LEAD LEAD VOLTAGE LEAD LEAD VOLTAGE
#202 #203 30 VAC #208 #209 60 VAC

(6J3) (7J3) (16J6) (7J6)
#202 #204 A 15 VAC #208 #206 30 VAC

(6J3) (5J3) (16J6) (4J6)
#203 #204 A 15 VAC #209 #206 30 VAC

(7J3) (5J3) (7J6) (4J6)
8. Turn OFF the machine G1992 (Code 9402 only):
9. Locate the following leads on Plug FROM TO EXPECTED

J6 on the G2252 Control PC Board LEAD LEAD VOLTAGE
or Plug J3 on the G1992 Control PC
Board. See Figures F.1A & F1.B. #208 #209 60 VAC
G2252: (1J3) (2J3)
#208 #206 30 VAC

LEAD PLUG (1J3) (3J3)
LOCATION
#209 #206 30 VAC
#206 4J6 (2J3) (3J3)
#208 16J6
#209 7J6
c. If any of the voltages tested are
G1992 (Code 9402 only): incorrect, check for loose or bro-
ken leads between the test
points and the main transformer.

LEAD PLUG
LOCATION d. If ALL the voltages tested are
incorrect or missing, go to Step
#206 3J3 12.
#208 1J3
#209 2J3 12. Test for correct nameplate input volt-
10. age between the H1 lead at the
Turn ON the machine. ON/OFF POWER SWITCH to H2 or
H3 at the reconnect panel. Voltage
11. Make the following voltage tests at tested will vary depending on Input
Plug J6 on the G2252 Control PC Voltage Connection. See wiring dia-
Board, or at Plug J3 on the G1992 gram for test point locations.
Control PC Board (Code 9402 only.)
a. If the voltage test is incorrect,
a. Turn the machine OFF between
each test. - check for loose or broken

leads between the reconnect
b. Carefully insert the meter panel and the ON/OFF POWER
probes into the back of each SWITCH.
Molex Plug pin cavity to perform
the test. - test the ON/OFF POWER
SWITCH for proper operation.
IDEALARC SP-250

F-18 F-18
b. If the correct nameplate voltage

is being applied to the main
transformer and one or more of
the secondary voltages are
missing or are incorrect, the
main transformer may faulty.
Replace.
IDEALARC SP-250

F-19 F-19
STATIC SCR RECTIFIER ASSEMBLY TEST
WARNING
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.
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
IDEALARC SP-250

F-20 F-20
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
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.
J6 to Perform Static SCR Rectifier

Assembly Test. 5. Separate leads X2 and X3 from the
negative capacitor bank buss bar.
Be sure there is no electrical con-
tact. See Figure F.3.
SP-250 CONTROL
G1992
J2
J8
J7
J4
J9
J5
J3 J6
FIGURE F.2B - Remove Plug J3 to

Perform Static SCR Rectifier
Assembly Test.
IDEALARC SP-250

F-21 F-21
NOTE: DO NOT DISASSEMBLE THE

SCR RECTIFIER HEAT SINK ASSEM-
BLY.
6. Test for high or infinite resistance

from the anode to the cathode of
SCR 1. See Figure F.4. Use an
analog 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 resistance is

indicated for both tests 6 and 7,
the SCR 1 is not “shorted”.
b. If a low resistance is indicated in

either tests 6 or 7, the SCR is
faulty. Replace SCR Assembly.
8. Repeat Steps #7 to test SCR 2.
9. Reconnect leads X2 and X3.

10. Reconnect Plugs J3 and J6.
11. If this test did not identify the prob-

lem or to further test the SCR, go to
the Active SCR Test.
IDEALARC SP-250

F-22 F-22
ACTIVE SCR RECTIFIER ASSEMBLY TEST
WARNING
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.
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
IDEALARC SP-250

F-23 F-23
TEST PROCEDURE 3. Test with an Analog Volt-Ohm meter

that capacitors have completely dis-
1. Disconnect main AC input power to charged.
the machine.
4. Disconnect leads X2 and X3 from
2. Disconnect Molex Plugs J3 and J6 the negative capacitor bank using a
from the G2252 Control Board or fi" open end wrench.
remove Plug J3 from G1992 Control See Figure F. 6.
Board (Code 9402 only)
See Figures F.5A and F.5B.
SP-250 CONTROL
G2252
J2
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.
Board.
Be sure there is no electrical con-

tact. See Figure F6.
SP-250 CONTROL
G1992
NOTE: DO NOT DISASSEMBLE THE
J2
SCR RECTIFIER HEAT SINK ASSEM-
BLY.
J8
J7 6. Construct the circuit shown in Figure

F.8. One 6-volt lantern battery can
J4
be used. R1 and R2 resistor values
are ±10%. Set voltmeter scale low,
J9
J5 at approximately 0-5 volts or 5-10
volts.
J3 J6 a. Test the voltage level of the bat-

tery. Short leads (A) and (C).
Close switch SW-1. Battery

voltage should be 4.5 volts or
FIGURE F.5B - Control Board Molex higher. If lower, replace the bat-
Plug Locations for G1992 PC Control tery.
Board (Code 9402 only.)
IDEALARC SP-250

F-24 F-24
7. Connect the Tester to the SCR 1 as a. If the voltage is 3 - 6 volts while

shown in Figure F.7. the switch is closed and after
the switch is open, the SCR is
a. Connect Tester lead (A) to the functioning.
anode.
b. If the voltages is 3-6 volts only
b. Connect Tester lead (C) to the when the switch is closed or
cathode. there is no voltage when the
switch is closed, the SCR is
c. Connect Tester lead (G) to the defective.
gate.
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. Reconnect the Tester leads. See

Figure F.7.
a. Connect Tester lead (A) to the

cathode.
b. Connect Tester lead (C) to the

anode.
c. Disconnect Test lead (G) from

the gate.
14. Close switch SW-1.

15. Read meter for zero voltage.
a. If the voltage is zero, the SCR is

functioning.
FIGURE F.7 - SCR Tester Circuit and b. If the voltage is higher than
SCR connections. zero, the SCR is shorted.
8. Close switch SW-1.

16. Perform the Active Test Procedure
NOTE: Switch SW-2 should be open. outlined in Steps 5-13 for SCR 2.
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
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.
11. Close switch SW-2 for 2 seconds

and release and read meter.
IDEALARC SP-250

F-25 F-25
SP-250 KEYPAD RESISTANCE TEST
WARNING
Call (216) 383-2531 or (800) 833-9353 (WELD).
TEST DESCRIPTION
This test will determine if any key is not functioning properly.
MATERIALS NEEDED
5/16" Nut Driver

Analog volt-ohmmeter
IDEALARC SP-250

F-26 F-26
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.
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.
G2252
J2
J8
J7
J4
J9 J3
J5 J6
FIGURE F.8A - Plug J2 Location on

G2252 PC Control Board.
SP-250 CONTROL
G1992
FIGURE F.9 - Plug J2 Test Points.

J2
J8
J7
J4
J9
J5
J3 J6
FIGURE F.8B - Plug J2 Location on

G1992 PC Control Board (Code 9402
only).
IDEALARC SP-250

F-27 F-27
TABLE F.1 - SP-250 KEYPAD RESISTANCE TESTS
NOTE: THERE SHOULD NOT BE CONTINUITY BETWEEN PINS UNTIL A KEY IS PRESSED ON THE KEYPAD.
TEST POINTS KEY PRESSED MAXIMUM ALLOWABLE

RESISTANCE
(TYPICAL RESISTANCE)
FROM PIN TO PIN
1J2 6J2 CENTER UP ARROW 100 OHMS (30 TYPICAL)

1J2 8J2 CENTER DOWN ARROW 100 OHMS (30 TYPICAL)
1J2 2J2 MEMORY 3 100 OHMS (30 TYPICAL)
1J2 4J2 SWITCH SET DISPLAY 100 OHMS (30 TYPICAL)
3J2 6J2 LEFT UP ARROW 100 OHMS (30 TYPICAL)
3J2 8J2 LEFT DOWN ARROW 100 OHMS (30 TYPICAL)
3J2 4J2 SPOT 100 OHMS (30 TYPICAL)
4J2 9J2 TOGGLE 100 OHMS (30 TYPICAL)

4J2 7J2 IMP VOLTS 100 OHMS (30 TYPICAL)
4J2 5J2 TIMERS OFF 100 OHMS (30 TYPICAL)
5J2 6J2 AUTO 100 OHMS (30 TYPICAL)
5J2 8J2 PROCESS WIRE/GAS 100 OHMS (30 TYPICAL)
6J2 9J2 MANUAL 100 OHMS (30 TYPICAL)
6J2 7J2 RIGHT UP ARROW 100 OHMS (30 TYPICAL)
7J2 8J2 RIGHT DOWN ARROW 100 OHMS (30 TYPICAL)
8J2 9J2 SAVE 100 OHMS (30 TYPICAL)
IDEALARC SP-250

F-28 F-28
WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST
WARNING
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
5/16" Nut Driver

Volt-Ohmmeter
IDEALARC SP-250

F-29 F-29
TEST PROCEDURE
NOTE: POLARITY MUST BE
OBSERVED FOR THESE TESTS.
Test for Correct Wire Drive Motor

Armature Voltage
1. Disconnect main input power to the

machine.

Panels using a 5/16" nut driver.
3. Locate Plug J5 on the G2252

Control Board, or Plug J6 on the
G1992 Control Board (Code 9402
only).. See Figures F.10A and
F.10B.
SP-250 CONTROL
G2252
J2
J8
J7
J4
J5 J9 J3
#515B
(3J5)
#206B
(2J5) J6
#555 #539 #541

(1J5) (8J5) (9J5)
FIGURE F.10A - Plug J5 Location on

G2252 PC Control Board.
IDEALARC SP-250

F-30 F-30
J2
J8
J7
J4
#206B
(4J6) #515B
(1J6)
J5
J9
#555
(2J6)
J6 J3
#541
(6J6)
#539
(3J6)
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.
6. Read meter. Normal DC volts is d. If the motor is running at high

from 2 - 25 VDC. VDC varies speed and the armature voltage

depending on wire feed speed. is high and uncontrollable, pro-
ceed with the tachometer test.
a. If voltage to the wire drive motor
armature is zero, check the
wires between Plug J5 (J6 on
Code 9402) and the wire drive
motor.
IDEALARC SP-250

F-31 F-31
Test for Supply Voltage to

Tachometer b. If the 1.5 - 3.5 VDC is not pre-
sent or not correct, the Control
1. Test for 15 VDC between lead Board is not receiving the prop-
#515B (positive) and lead #206B er feedback voltage from the
(negative). See Figure F. 10 for pin tach circuit. Check the leads
locations. from the tach circuit to the
Control Board for loose or bro-
a. Insert probes into Molex pin ken connections.
cavities.
c. If the leads are okay, the Control
2. Pull gun trigger. Board may be faulty. Replace.
3. Read meter for 15 VDC.

a. If the 15 VDC is present, check

the leads to the tach circuit.
b. If the leads are okay and 15

VDC is present, the correct volt-
age is being received from the
Control Board. Go to Feedback
Test.
c. If the 15 VDC is not present and

the leads are okay, the Control
Board may be faulty. Replace.
Test for Feedback Voltage to the

Control Board
1. Test for 1.5 - 3.5 VDC between lead

#555 (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 1.5 - 3.5 VDC.
a. If the 1.5 - 3.5 VDC is present,

the tach circuit is sending the
correct feedback signal to the
Control Board.
NOTE: IF THE MOTOR IS NOT RUN-

NING, THE FEEDBACK VOLTAGE MAY
BE FROM 0 TO 5 VDC.
IDEALARC SP-250

F-32 F-32
NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM

SCOPE SETTINGS
This is a typical DC output voltage wave-

form generated from a properly operating Volts/Div . . . . . . . . . . . . . . . . .20 V/Div.
machine. Note that each vertical division
represents 20 volts and that each horizontal Horizontal Sweep . . . . . . . . . .2 ms/Div.
division represents 2 milliseconds in time.
Coupling . . . . . . . . . . . . . . . . . . . . .DC.
Note: Scope probes connected at machine
output terminals: (+) probe to electrode, (-) Trigger . . . . . . . . . . . . . . . . . . .Internal.
probe to work.
IDEALARC SP-250

F-33 F-33
TYPICAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED

MACHINE LOADED TO 250 AMPS AT 26 VDC

SCOPE SETTINGS
This is a typical DC output voltage wave-

form generated from a properly operating Volts/Div . . . . . . . . . . . . . . . . .20 V/Div.
machine. Note that each vertical division
represents 20 volts and that each horizontal Horizontal Sweep . . . . . . . . . .5 ms/Div.
The machine was loaded with a resistance Coupling . . . . . . . . . . . . . . . . . . . . .DC.
grid bank.
Trigger . . . . . . . . . . . . . . . . . . .Internal.
output terminals: (+) probe to electrode, (-)
probe to work.
IDEALARC SP-250

F-34 F-34
ABNORMAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED

ONE OUTPUT SCR NOT FUNCTIONING
MACHINE LOADED TO 220 AMPS AT 22 VDC

SCOPE SETTINGS
This is NOT a typical DC output voltage

waveform. One output SCR is not function- Volts/Div . . . . . . . . . . . . . . . . .20 V/Div.
ing. Note the increased ripple content. One
SCR gate was disconnected to simulate an Horizontal Sweep . . . . . . . . . .5 ms/Div.
open or non-functioning output SCR. Each
vertical division represents 20 volts and Coupling . . . . . . . . . . . . . . . . . . . . .DC.
each horizontal division represents 5 mil-
liseconds in time. The machine was loaded Trigger . . . . . . . . . . . . . . . . . . .Internal.
with a resistance grid bank.

probe to work.
IDEALARC SP-250

F-35 F-35
ABNORMAL OPEN CIRCUIT VOLTAGE

OUTPUT CAPACITOR BANK NOT FUNCTIONING
SCOPE SETTINGS
This is NOT the typical DC output voltage

waveform. The output capacitors are not Volts/Div . . . . . . . . . . . . . . . . .20 V/Div.
functioning. Note the lack of “filtering” in the
output waveform. The output capacitor Horizontal Sweep . . . . . . . . . .5 ms/Div.
bank was disconnected. Each vertical divi-
sion represents 20 volts and each horizontal Coupling . . . . . . . . . . . . . . . . . . . . .DC.
Trigger . . . . . . . . . . . . . . . . . . .Internal.
probe to work.
IDEALARC SP-250

F-36 F-36
TYPICAL SCR GATE VOLTAGE WAVEFORM

SCOPE SETTINGS
This is a typical SCR gate pulse voltage

waveform. The machine was in an open cir- Volts/Div . . . . . . . . . . . . . . . . . .2 V/Div.
cuit condition (no load) and operating prop-
erly. Note that each vertical division repre- Horizontal Sweep . . . . . . . . . .5 ms/Div.
sents 2 volts and each horizontal division
represents 5 milliseconds in time. Coupling . . . . . . . . . . . . . . . . . . . . .DC.
Note: Scope probes connected at Plug J3 Trigger . . . . . . . . . . . . . . . . . . .Internal.

on the control board. The (+) probe to lead
G2, and the (-) probe to lead 204.
IDEALARC SP-250

F-37 F-37
CONTROL PC BOARD REMOVAL AND REPLACEMENT
CAUTION SP-250 CONTROL

G2252
Printed Circuit Boards can be dam-
J2
aged by static electricity. Follow sta-
tic handling guidelines detailed in
“PC Board Troubleshooting J8
Procedures” at the beginning of this
chapter.
_____________________________ J7
REMOVAL AND REPLACEMENT

J3
PROCEDURE J4
J9
MATERIALS NEEDED
5/16" Nut Driver

Phillips Head Screwdriver J5
Static Electricity Grounding Strap J6
1. Disconnect main input power the

machine. SP-250 CONTROL
G1992
Panels using 5/16" nut driver. J2
J8
3. Disconnect all wiring harness
plugs and Molex Plugs connect- J7
ed to the Control Board. See
Figure F.11.
J4
J6 J9
J5
J3
FIGURE F.11 - Wiring Harness and

Molex Plug Locations.
IDEALARC SP-250

F-38 F-38
CONTROL PC BOARD REMOVAL AND REPLACEMENT
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 and

wiring connections when
installing the Control Board.
IDEALARC SP-250

F-39 F-39
KEYPAD REMOVAL AND REPLACEMENT
WARNING
Call (216) 383-2531 or (800) 833-9353 (WELD).
MATERIALS NEEDED
5/16" Nut Driver

1/4" Nut Driver
IDEALARC SP-250

F-40 F-40
KEYPAD REMOVAL AND REPLACEMENT
PROCEDURE
NOTE: BEFORE REMOVING THE
KEYPAD, PERFORM THE KEYPAD
RESISTANCE TEST TO BE SURE THE
KEYPAD IS FAULTY.

machine.

Panels with 5/16" nut driver.
3. Disconnect Keypad Plug J2 from the

Control Panel.
4. Remove the two screws holding the

POWER SWITCH and bezel using a
1/4" nut driver.
5. Grasp the upper 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 backing from

the new Keypad to uncover the
adhesive backing.
b. Install the new Keypad by care-

fully pressing the Keypad to the
Front Panel. Be sure to smooth
out any air bubbles that become
trapped under the Keypad.
IDEALARC SP-250

F-41 F-41
WIRE DRIVE ASSEMBLY REMOVAL AND REPLACEMENT
WARNING
Call (216) 383-2531 or (800) 833-9353 (WELD).
MATERIALS NEEDED
Large slot head screwdriver

5/16" Nut Driver
Small slot head screwdriver
IDEALARC SP-250

F-42 F-42
WIRE DRIVE ASSEMBLY REMOVAL AND REPLACEMENT
PROCEDURE
machine.

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.
FIGURE F.13 - Wire Drive Assembly

Removal
4. Using a small slot head screw driver, a. The six pin plug contains the
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.
5. Disconnect the six pin plug from the

vertical baffle connector.
IDEALARC SP-250

F-43 F-43
SCR OUTPUT RECTIFIER REMOVAL
WARNING
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
Slot head screwdriver

Wire cutters
IDEALARC SP-250

F-44 F-44
SCR OUTPUT RECTIFIER REMOVAL
PROCEDURE 4. Cut the SCR gate leads G1 and G2

(see wire markers and wiring dia-
1. Disconnect lead #208 and gram) using wire cutters.
Transformer Lead X1 from the heat
sink on the left side of the machine a. The easiest access to these
(facing the front) using a 1/2" socket leads is from the right side of the
wrench. See Figure F.14. machine.
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.
6. Pivot the SCR Assembly counter-

clockwise to provide access to the
right side heat sink.
See Figure F.16.
FIGURE F.14 - Heat Sink lead discon-

nection.
2. Disconnect lead #204 and heavy

lead from the middle heat sink with a
1/2" socket wrench and 1/2" open

end wrench. See Figure F. 15.
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.
8. Clear the leads and carefully

remove the SCR Rectifier Assembly.
NOTE: When installing the SCR

Rectifier Assembly, apply a thin coating
of Dow Corning #340 Compound to the
electrical connections.
FIGURE F.15 - Heat Sink lead discon-

nection.
IDEALARC SP-250

F-45 F-45
CAPACITOR BANK REMOVAL AND REPLACEMENT
WARNING
Call (216) 383-2531 or (800) 833-9353 (WELD).
WARNING
THE LIQUID ELECTROLYTE IN THE CAPACITORS IS TOXIC. DO NOT TOUCH THE
CAPACITORS WITH ANY PART OF YOUR BODY.
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
IDEALARC SP-250

F-46 F-46
CAPACITOR BANK REMOVAL AND REPLACEMENT
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 6. Remove the #204 lead from the pos-
itive buss bar.

machine. 7. Remove the shunt from the negative
capacitor bank buss bar using a 1/2"
2. Test that the capacitors are dis- socket wrench with a universal tool
charged using a volt ohmmeter. adapter.
Polarity must be observed.
a. Two people may be required to
3. Remove the two transformer sec- remove the shunt. One person
ondary leads (X2 and X3) for the may have to reach through from
negative capacitor bank buss bar the left side of the machine to
using two fi" open end wrenches. keep the bolt in position while
the other person loosens the
4. Remove the output choke lead and nut.
the heavy lead extending from the
SCR Rectifier Assembly to the posi- b. There is no shunt on machine
tive capacitor bank buss bar using a code 9402.
fi" open end wrench.

8. Remove the two screws holding the
5. Remove lead #206 and the D1 capacitor bank to the floor of the
diode lead from the negative capac- machine using a 5/16" nut driver.
itor bank buss bar using a slot head
screwdriver and 3/8" open end 9. Clear the leads and carefully
wrench. remove the capacitor bank assem-
bly from the machine.
IDEALARC SP-250

F-47 F-47
MAIN TRANSFORMER REMOVAL AND REPLACEMENT
WARNING
Call (216) 383-2531 or (800) 833-9353 (WELD).
MATERIALS NEEDED
5/16" Nut Driver
1/2" Socket wrench, extender, universal adapter
Wire cutters
IDEALARC SP-250

F-48 F-48
MAIN TRANSFORMER REMOVAL AND REPLACEMENT
PROCEDURE 12. Disconnect the positive output lead

at the wire drive motor.
machine. 13. Remove the strain relief grommet
through which the positive output
2. Remove the Case Top and Side lead passes through the horizontal
Panels. baffle of the machine.
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.
universal adapter. a. Be sure all leads are clear.
5. Remove lead X4 from the right side

heat sink assembly using a 1/2"
socket wrench, extender and univer-
sal adapter.
6. Disconnect all leads from the recon-

nect panel using a 3/8" open end
wrench.
7. Disconnect all leads from the

POWER SWITCH.
8. Remove the POWER SWITCH.

9. Label and cut leads #202, #203,

#204A.
a. Cut lead #204A at a point just in

front of the transformer.
b. These leads must be re-spliced

during reassembly.
c. An 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 during transformer
removal using wire cutters and

screwdriver.
11. Remove the four screws mounting

the transformer to the floor of the
machine using a 5/16" nut driver.
IDEALARC SP-250

F-49 F-49
FAN MOTOR AND FAN REMOVAL AND REPLACEMENT
WARNING
Call (216) 383-2531 or (800) 833-9353 (WELD).
MATERIALS NEEDED
1/2" Socket wrench with extension
Phillips head screwdriver
IDEALARC SP-250

F-50 F-50
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. 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.
ing bracket to the case back.

a. Pry the fan blade off the motor.
4. Tilt the Case Back away from the
machine and remove the screws b. Slide the fan blade off the motor
holding the Case Back to the floor of shaft.
the machine using a 1/2" socket
wrench with extension.
IDEALARC SP-250

F-51 F-51
7. Remove the fan motor.
a. Loosen and remove the two

screws from the motor mounting
bracket using a slot head screw
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

motor.
8. Install the replacement motor in the

reverse order of removal.
9. Install the fan blade. When

installing the fan blade, the blade is
flush with the end of the motor shaft.
a. Spin the fan to be sure it is free

to rotate.
10. Reassemble the remaining compo-

nents in reverse order of removal.
IDEALARC SP-250

F-52 F-52
RETEST AFTER REPAIR
INPUT IDLE AMPS AND WATTS
Input Volts/Hertz Maximum Idle Amps Maximum Idle Watts
230/60 6.4 375
OPEN CIRCUIT VOLTAGE

10 to 40 VDC 35-40 VDC Strike Voltage
WIRE SPEED RANGE
50 - 600 IPM (1.27 - 15.2 m/minute)

IDEALARC SP-250

TABLE OF CONTENTS Section G
- ELECTRICAL DIAGRAMS -
ELECTRICAL DIAGRAMS SECTION ...................... Section G
G1992 CONTROL 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 CONTROL PC BOARD SCHEMATIC ............G - 13
IDEALARC SP-250

G-1 ELECTRICAL DIAGRAMS G-1
G1992 CONTROL PC BOARD

SP-250 CONTROL
R132
R130
R129
C11
R131
C88
C87
C86
C85
X21
G1992-2
R100
X17
R138
C95
C77 R98 R69
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
C10 D49 R59

R33 R63
D
R2 R60
R105
Q14
R104 R70
R57
R95
Q20
Q18
X7 R91
C33
C32
X20 X2 X3
R8
C17
R11
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
D52 R62 D42

C18 R45
C1
R119
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
R120
X19 R34 DD1

R99
DZ1
D64
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
Q8 C45 OCI3 OCI2 OCI1

C51
J9 R93 R88
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
C94 C93 C92

C23 C22
Q17
R136
R137
R84 J3
DZ5
R124 R96 R85

R66
R75
D63
C79
C80
L1
R48 R50
R90
R103
D55
D56
R89
R102
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


Item Identification Item Identification
C45 . . . . . . . . . . . . . . .CAPACITOR-PEMF,.047,100V,10% C79,C80,C92, . . .CAPACITOR-CD,.0047/.005,1400V,20%

C21 . . . . . . . . . . . . . . . . .CAPACITOR-TAEL,39,20V,10% C93,C94
C16 . . . . . . . . . . . .CAPACITOR-ALEL,2200,63V,+30/-10%
C30,C47,C95 . . . . . . . . . .CAPACITOR-TAEL,4.7,35V,10% D1,D2,D24,D25,D26,D27, . . . . . .DIODE-AXLDS,1A,400V
C15 . . . . . . . . . . . . . . . . .CAPACITOR-TAEL,39,10V,10% D28,D29,D30,D31,D32,D34,D35,D37,D38,D39,D40,D41,
C14,C20 . . . . . . . . . . . . . .CAPACITOR-TAEL,18,15V,10% D42,D43,D44,D45,D46,D47,D48,D49,D50,D51,D52,D53,
C39,C40 . . . . . . . . . . . . .CAPACITOR-TAEL,1.0,35V,10% D54,D55,D56,D57,D63,D65,D66,D67,D68,D69,D70,D71,
C25 . . . . . . . . . . . . .CAPACITOR-ALEL,6,150V,+50/-10% D72,D73,D75,D76
C55 . . . . . . . . . . . . .CAPACITOR-ALEL,20,50V,+75/-10%
C13 . . . . . . . . . . . . . . . .CAPACITOR-PEF,.001,400V,10% D58,D59,D60,D61,D62,D64 . . . .DIODE-AXLDS,1A,1000V
C18 . . . . . . . . . . . . .CAPACITOR-ALEL,50,25V,+75/-10% L3,L4,L5,L6,L7 . . . .CHOKE-330UH,10%,110MA,MOLDED
C24,C26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27/50 L1,L2 . . . . . . . .CHOKE-390UH,5%,225MA,CONFORMAL
R40 . . . . . . . . . . . . . . . . . . .RESISTOR-WW,7W,0.25,1%
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
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
IDEALARC SP-250

2/95
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
R34,R117,R125,R126,R127, . . .RESISTOR-MF 3.3K 1/4W

R128,R129,R130,R131,R132,R133,R134,R135
R18,R19,R20,R33,R109 . . . . . .RESISTOR-MF 4.7K 1/4W

R25,R28,R74 . . . . . . . . . . . . . .RESISTOR-MF 5.6K 1/4W
R23,R38,R53,R58,R59,R68, . . .RESISTOR-MF 6.8K 1/4W

R105
R8,R9,R10,R11,R63,R65, . . . . .RESISTOR-MF 10K 1/4W

R76,R77,R78,R79,R88,R93,R97,R98,R104,R111,R140
R80 . . . . . . . . . . . . . . . . . . . . . .RESISTOR-MF 33K 1/4W

R73 . . . . . . . . . . . . . . . . . . . . .RESISTOR-MF 100K 1/4W
R4 . . . . . . . . . . . . . . . . . . . . . .RESISTOR-MF 2.7K 1/4W
R39 . . . . . . . . . . . . . . . . . . . . . .RESISTOR-MF 47K 1/4W
R36,R46 . . . . . . . . . . . . . . . . . .RESISTOR-MF 15K 1/4W
R12,R13,R14,R15,R72,R101 . . . .RESISTOR-MF 1K 1/4W
R44,R84 . . . . . . . . . . . . . .RESISTOR-WW,5W,1K,5%,SQ
R45,R85,R96 . . . . . . . . . . .RESISTOR-WW,5W,50,5%,SQ
R102,R124 . . . . . . . . . . . .RESISTOR-WW,5W,20,5%,SQ
R136,R137 . . . . . . . . . . . . . .RESISTOR-WW,7W,0.25,5%
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
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
IDEALARC SP-250

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Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC G-4

NOTES
IDEALARC SP-250
G-4

SP 250 CONTROL
G2252- 2
16
1
9
1
IDEALARC SP-250


W1 . . . . . . . . . . . . . . . .20 AWG UNINSULATED JUMPER C61,C64 . . . . . . . . . . . . . CAPACITOR-PCF,0.27,50V,20%

C81 . . . . . . . . . . . . . CAPACITOR-ALEL,50,25V,+75/-10% C73 . . . . . . . . . . . CAPACITOR-ALEL,3300,50V,+30/-10%
X10 . . . . . . . . IC-CMOS,INVERTER,SCHMITT,HEX,4584 X14,X17,X18 . . . . . . IC-VOLT REF,ADJ,PRECISION,431I
X16 . . . . . . . . . . . . . . . . . . . . . . .VOLTAGE REGULATOR X22 . . . . . . . . IC-OP-AMP,SINGLE,PRECISION,OP-27GZ
R48 . . . . . . . . . . . . TRIMMER-MT,1/2W,10K,10%,LINEAR
C30,C31 . . . . . . . . . . . CAPACITOR-CEMO,22P,100V,5% C20,C35,C108, . . . . . .CAPACITOR-CEMO, 0.1, 50V, 10%
C109,C110,C111,C112,C113,C114,C115,C116
C10,C11,C12, . . . . . . CAPACITOR-CEMO,100P,100V,5%
C13,C14,C15,C16,C17,C18,C19 J3 . . . . . . . . . . . CONNECTOR,MOLEX,MINI,PCB,12-PIN
J5 . . . . . . . . . . . CONNECTOR,MOLEX,MINI,PCB,14-PIN
C36 . . . . . . . . . . . . . . CAPACITOR-CEMO,2700P,50V,5% J6 . . . . . . . . . . . CONNECTOR,MOLEX,MINI,PCB,16-PIN
J1 . . . . . . . . . CONNECTOR,PCB,WW,VERTICAL,16-PIN
R79 . . . . . . . . . . . . . TRIMMER-ST,1/2W,1K,10%,LINEAR
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
J2 . . . . . . . . . . . . CONNECTOR,PCB,WW,MALE,DIL,1X9 C71,C72,C80, . . . CAPACITOR-CD,.0047/.005,1400V,20%

Q30 . . . . . . . . . . . . . . . . . . . . . . . . . . HEAT SINK ASBLY C90,C93
DD1 . . . . . . . . . . . . . . . . . . DIODE & HEAT SINK ASBLY
J7,J8 . . . . . . . . . . CONNECTOR,MOLEX,MINI,PCB,4-PIN R119 . . . . . . . . . . . . . . . . . . RESISTOR-WW,7W,0.25,1%
J9 . . . . . . . . . . . . CONNECTOR,MOLEX,MINI,PCB,6-PIN DZ2 . . . . . . . . . . . . ZENER DIODE-1W,16V,5%,1N4745A
J4 . . . . . . . . . . . . CONNECTOR,MOLEX,MINI,PCB,8-PIN DZ1 . . . . . . . . . . . . ZENER DIODE-1W,15V,5%,1N4744A
R61 . . . . . . . . THERMISTOR-PTC,.02-0.47 OHMS,0.90A DZ7 . . . . . . . . . . . . ZENER DIODE-5W,10V,5%,1N5347B
X15 . . . . . . . . POS VOLTAGE REG & HEAT SINK ASBLY DZ6 . . . . . . . . . . . . ZENER DIODE-1W,6.2V,5%,1N4735A
Q24 . . . . . . . . . . . . . TRANSISTOR & HEAT SINK ASBLY DZ3,DZ4,DZ5 . . . . . ZENER DIODE-1W,18V,5%,1N4746A
Q20 . . . . . . . . . . . . . . TRANSISTOR & HEATSINK ASBLY Q11 . . . . . . . . TRANSISTOR-NMF,T220,15A,60V,15N06E
D20 . . . . . . . . . . . . . . DIODE-AXLDS,1A,30V,SCHOTTKY
D1,D2,D3,D4,D5,D6,D7,D8, . . . . DIODE-AXLDS,1A,400V R144,R152 . . . . . . . . . . . . . . . RESISTOR-CC,2W,10,10%
D21,D22,D23,D24,D33,D34,D40,D41,D50,D51,D52,D53, TP5 . . . . . . . . . . . . . . . . . . . . MOV-130VRMS,38J,14MM
D54,D60,D61,D62,D70,D71,D72,D73,D74,D75,D76,D77, TP6,TP7 . . . . . . . . . . . . . . . . . . MOV-50VRMS,15J,14MM
D78,D79,D80,D82,D83,D85,D86,D87,D90,D91,D92,D93 TP4 . . . . . . . . . . . . . . . . . . . . MOV-150VRMS,80J,20MM
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%
IDEALARC SP-250


R97,R110,R160,R161, . . . RESISTOR-MF,1/4W,1.50K,1% Q1,Q2,Q3,Q4,Q5, TRANSISTOR-N,T226,0.5A,40V,2N4401

R171,R172,R188,R189 Q10,Q12,Q14,Q22,Q23,Q40,Q41
R23,R115,R147,R187 . . . . RESISTOR-MF,1/4W,15.0K,1% Q13,Q25 . . . . . . . TRANSISTOR-P,T226,0.5A,40V,2N4403

R95 . . . . . . . . . . . . . . . . . RESISTOR-MF,1/4W,16.5K,1% R191 . . . . . . . . . . . . . . . . . RESISTOR-MF,1/4W,475K,1%
R11,R15,R18,R166,R177 . RESISTOR-MF,1/4W,2.21K,1% Y1 . . . . . . . . . . . . . . . . . . CRYSTAL-QUARTZ,4.000MHZ
R46,R47,R102,R111 . . . . . RESISTOR-MF,1/4W,22.1K,1% OCI2,OCI3 . . . . . . . . . . .OPTOCOUPLER TRIAC DRIVER
R118 . . . . . . . . . . . . . . . . . . RESISTOR-MF,1/4W,267,1% SCR1,SCR2 . . . . . . . . . . . . . . . . . . .4 A. 400 VOLT. SCR
R114 . . . . . . . . . . . . . . . . RESISTOR-MF,1/4W,2.67K,1%
R105 . . . . . . . . . . . . . . . . RESISTOR-MF,1/4W,26.7K,1%
R165,R170 . . . . . . . . . . . . . RESISTOR-MF,1/4W,26.7,1%
R120,R123,R130,R135 . . . RESISTOR-MF,1/4W,28.0K,1%
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%
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
IDEALARC SP-250

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NOTES
IDEALARC SP-250
G-8
G-9
ELECTRICAL DIAGRAMS G-9
WIRING DIAGRAM FOR CODE 9402

SP-250 (DUAL VOLTAGE) - WIRING DIAGRAM
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
AUTO MANUAL 11 3 324B
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
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
SUPPLY LINE N.D. CONNECTORS MOUNTED ON NON-COMPONENT SIDE

THERMOSTAT THERMOSTAT
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
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.
IDEALARC SP-250 IDEALARC SP-250

G-10
WIRING DIAGRAM FOR CODE 9546 & 10002

SP-250 (230/460/575V) - WIRING DIAGRAM
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
1 204
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
OFF DISPLAY DISPLAY 13 325A 14

14 327 320 15
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
326 1 326 555 2 555
325 2 325 539 3 539

PIEZO
327 3 327 206B 4 206B
ALARM
324 4 324 5
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
N.J. 324 H B 206B
N.C. CONNECTOR SHOWN GEARBOX SIDE VIEW.

325 B 539
206 N.E. THERMOSTATS MOUNTED ON CHOKE COIL
326 207 N.B. S2 MOUNTED CLOSEST TO FAN; S3 MOUNTED CLOSEST TO
THUMB POWER TRANSFORMER.
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
205
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

G-11
WIRING DIAGRAM FOR CODE 9723 & 10001

SP-250 (DUAL VOLTAGE) - WIRING DIAGRAM
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
1 6
*
6 326 209 7 (J3) 10

(J2)
* G2 7
MEMORY 7 (J5)
*
7 324 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
OFF DISPLAY DISPLAY 13 325A 14

14 327 320 15
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
326 1 326 555 2 555
325 2 325 539 3 539

PIEZO
327 3 327 206B 4 206B
ALARM
324 4 324 5
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

325 B 539
206 207 N.C. CONNECTOR SHOWN GEARBOX SIDE VIEW.
326 N.B.
THUMB N.E. THERMOSTATS MOUNTED ON CHOKE COIL .
SWITCH 327
320 328 325A S2 MOUNTED CLOSEST TO FAN; S3 MOUNTED CLOSEST TO
N.E. POWER TRANSFORMER.
N.G. TO SINGLE PHASE
R.F. FILTER SUPPLY LINE N.F. KEYPAD MATRIX SHOWN FRONT VIEW.
INC. DEC. THERMOSTAT THERMOSTAT
S3 S4 L1
N.G. THERMOSTAT S4 MOUNTED ON FAN SENSOR BRACKET
326 N.H. RESISTOR R2 MOUNTED ON FAN SENSOR BRACKET.

324 L2
X5 N.J. CONNECTOR SHOWN PIN SIDE VIEW.
202
H4
TRIGGER X6 W
P2
204A GND
325 H2 H3
TO GROUND PER
X7 208 L1
X1
203
G1 LOW V. HIGH V.
NATIONAL ELECTRICAL CAVITY NUMBERING SEQUENCE
CODE
H1 SCR 1 B JUMPER (COMPONENT SIDE OF P.C. BOARD)
250V J1 TOP
470A 1 16
204 1 9
L2
L1 L2 X2 SCR HEATSINK J2
ASBLY
GND. RECONNECT PANEL
H2 X3 SCR 2 J3
250V G 1 6 1 5 1 4
470A
X4 J4
H3 G2 N.E. J12
H1 H4
209
J11
SHUNT POWER TRANSFORMER D1 P2
7 12 6 10 5 8
300V T1 T2
T1 85A P1 P2
+
H1 - 1 2 1 3
FAN
LINE 206 S2 J7
MOTORS J9
SWITCH THERMOSTAT
J8
S1 205
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

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
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 15 D6

R104 74HC164
KEYPAD 2N4123 18 74HC245 2 16 1 J1 P1
B8 A8
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 D7 A6 4 X20 X20 1/2W
R81
R78
+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
MOSI Vdd
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
100 102K 10K 1/2W 15V

R63
R37
TACH CIRCUITRY D70

R107 R106 R140
5
X13 10K C15
207 R108 2 D C29 D2
1/2W C27 C25 D1 39
10 +15 V D52
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
C26 1.8K X1 R60 1 R136 3 7 5W 8A

10K 208 R45
.27 D48 1/2W 12 D 208A
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
CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING 204

208 204S
207
THE INTERCHANGEABILITY OF A COMPLETE BOARD. +
G!
+ + + + WELDING
THIS DIAGRAM MAY NOT SHOW THE EXACT OUTPUT
COMPONENTS OR CIRCUITRY OF CONTROLS HAVING -

206
A COMMON CODE NUMBER.
TO GROUND TO CIRCUIT BOARD

+15 V
209
204
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
LM2901 LM2901 LM2901 4066B LM224

1400V 1/2W
R89
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
1/2W ACTUAL CIRCUIT

R94
COMMON CONNECTION C80 15

D67
.0047 1/2W OF X10
R92
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 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
SCK A7/D7 33.2 D60
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
R94 R95 400V

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
28.0K +15 V C56

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
D73 .33mH C71 Q30

L11 TP1 400V 50 POWER SUPPLIES
511 51.1K .0047 +15 V
10K 8A 5W
C61 75V
1400V
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
N.A. SINCE COMPONENTS OR CIRCUITRY ON A PRINTED 204 207
CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING TP5

130V 3 3 3 14 4 7
THE INTERCHANGEABILITY OF A COMPLETE BOARD. +15 V 38J
THIS DIAGRAM MAY NOT SHOW THE EXACT C100 C101 C102
X19 X11 X13 X12 C103 X1 C104 X22 C105
COMPONENTS OR CIRCUITRY OF CONTROLS HAVING

LM2901 LM2901 LM2901 4066B LM224 OP27
681 681
202
R160
R161
A COMMON CODE NUMBER.

12 12 12 7 11 4
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
1400V 33.2 D92 10 7 7 7 14

R171
R172
26.7
203 .0047
R170
R169
B BLACK LEAD C93
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

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Idealarc SP-250

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RETURN TO MAIN INDEX

IDEALARC SP-250 January, 1996

For use with machines having Code Numbers: 9402

Safety Depends on You

increased by proper installation

... and thoughtful operation on

ELECTRIC SHOCK can kill. ARC RAYS can burn.

especially in confined areas, to insure breathing air is safe.

3.e. Also see item 7b.

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6.a. Turn off input power using the disconnect

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8.c. Exposure to EMF fields in welding may have other health

from vaporizing on contact with hot

guards only when necessary and replace them when the

7.g. To prevent accidentally starting gasoline engines while

7.h. To avoid scalding, do not remove the

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allique ou des grilles metalliques, principalement dans

2. Dans le cas de travail au dessus du niveau du sol, se protéger

3. Avant de faires des travaux à l’interieur de poste, la debranch-

5. Toujours porter des lunettes de sécurité dans la zone de

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Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section E

Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section F

Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section G

Parts Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-201

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INSTALLATION SECTION ........................................ Section A

Connect Output Components..................................A-7 - A-9

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TECHNICAL SPECIFICATIONS - Idealarc SP-250

INPUT - SINGLE PHASE/ 60 HERTZ ONLY

Standard Voltage Input Current at Rated Output

208/230/1/60 53/49 Amps

230/460/575 50/25/20 Amps

100% 145 amps 26

60% 200 amps 28

35% 250 amps 26

30A - 250A 10V - 40V 50 - 600 IPM

208/60 60 8 (10mm2) 6 (16mm2) 10 (6mm2)

28.2” 18.8” 40.1” 222 lbs.

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the IDEALARC SP-250 power company to determine if there is any ques-

Also see the Reconnect Section of this manual for

SELECT PROPER LOCATION

kept at a minimum. Not following these precautions

The IDEALARC SP-250 cannot be stacked.

All input power must be electrically

Cable Entry Connections.

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welder plug is inserted into the receptacle.

DO NOT use fuses or circuit breakers with a lower amp

Use input and grounding wire sizes that meet local

electrical codes or see the Specifications page in this

INPUT POWER CONNECTIONS AND

Have a qualified electrician connect the receptacle or

1. Follow the Input Supply Connection Diagram on

2. Use a single-phase line or one phase of a three-

For the 208V/230V/ 60 HZ model SP 250 shipped with

1. Mount the receptacle in a suitable location using

2. Locate the receptacle within reach of the 10 ft.

3. Mount the receptacle with the grounding terminal