Lincoln Electric SP-250 Welding System User Manual


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G-12
ELECTRICAL DIAGRAMS
G-12
G1992 CONTROL PC BOARD SCHEMATIC
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from
Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine
Operator or Technician. Improper PC board repairs could result in damage to the machine.
+5 V
3.3K
R125
D2
100V
100p
C82
100V
100p
C87
100V
100p
C81
100V
100p
C86
100V
100p
C84
P1J1
11
P1J1
14
P1J1
9
P1J1
13
P1J1
10
P1J1
16
D3
D1
D4
P1J1
12
D6
D5
D7
D0
100V
100p
C83
.33mH
L7
DISPLAY
P1J1
15
RES. NTWK.
100
.19W
R100
12
14
7
9
10
6
3
8
4
2
1
11
13
15
5
16
3.3K
R126
3.3K
R127
3.3K
R128
3.3K
R129
3.3K
R130
3.3K
R131
LCD
74HC245
B4
OUT ENDIR
B8
A7
B6
B5
A4
A3
A2
A1
A6
B7
A5
B2
B1
B3
A8
X21
191
9
2
7
6
4
3
8
5
18
17
16
15
14
13
12
11
100V
100p
C85
3.3K
R132
ELECTRICAL SYMBOLS PER E-1537
THE INTERCHANGEABILITY OF A COMPLETE BOARD.
RESISTORS = Ohms (1/4W UNLESS OTHERWISE SPECIFIED)
DIODES = 1A, 400V (UNLESS OTHERWISE SPECIFIED)
NOTES :
58
SUPPLY VOLTAGE NET
CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING
N.A. SINCE COMPONENTS OR CIRCUITRY ON A PRINTED
SCHEMATIC
SP 250
COMMON CONNECTION
EARTH GROUND CONNECTION
POWER SUPPLY SOURCE POINT
FRAME CONNECTION
LABELS
G
A COMMON CODE NUMBER.
THIS DIAGRAM MAY NOT SHOW THE EXACT
COMPONENTS OR CIRCUITRY OF CONTROLS HAVING
DR.
+5 V
10K
R97
+5 V
P6 J6
4
P5 J5
3
1N4007
D61
6.8K
R68
TRIG
DECR
INCR
+15 V
50V
2700p
C17
206
555
+
REF
-
TL431
X17
1
6
8
SUPPLY
A/D
C50
D32
320325
P5 J5
1
D
D34
1N4007
D59
C
P6 J6
2
J3
11
10K
R67
4.7
35V
C95
+15 V
1N4007
D58
1K
CW
R138
P6 J6
1
5W
1K
R84
1N4007
D62
10K
R69
330
R116
C48
C49
4.7K
R19
X13
14
8
9
10K
R77
22p
100V
C6
X13
1
6
7
33K
R80
130
4.0MHz
Y1
10K
R79
2.2K
R82
2.2K
R83
1K
R101
4.7K
R18
C31
.33mH
L6
.33mH
L4
.33mH
L3
.33mH
L5
22p
100V
C8
1/2W
100
R113
1/2W
100
R114
1/2W
100
R115
1N4007
D60
1N4007
D64
P5 J5
2
P5 J5
4
X2
98
50V
0.1
C51
CIRCUITRY
7W
.25
R40
D71
100
R108
X19
2
4
5
X19
1
6
7
X2
34
CD
C
A
-5 V
X3
12
13
11
X2
12
J4
8
J4
6
J4
4
+5 V
+15 V
J4
5
J4
1
4.7K
R109
4.7K
R20
FOR OPTION PLUG
+15 V
+5 V
J4
7
1/2W
68
R118
D75
50V
20
C55
541
PM
539
P6J6
6
CONTROL
C10
10K
R63
D70
39
10V
C15
D51
100V
.22
C29
1/2W
750
R37
X11
10
13
11
D52
X12
13
12
D41
GND
IN
OUT
X15
18
15V
C20
15K
R46
1/2W
3.9K
R22
D44
+5 V
39
20V
C21
-5 V
1W
6.2V
DZ7
common
50V
.27
C24
500mA
300V
Q13
J3
8
P3 J3
10
+15 V
C
5.6K
R74
G
D
S
18A
200V
Q11
1/2W
1.5K
R31
P4
J4
2
102K
R106
D46
1/2W
3K
R47
+5 V
D47
10K
R140
D53
100
R107
15K
R36
47K
R39
4.7K
R33
X12
5
43
X11
8
14
9
18
15V
C14
C27
D2
D1
6
C25
X13
4
2
5
270
R112
1/2W
100
R99
1W
16V
DZ5
2N4123
Q14
2N4125
Q16
50V
.27
C26
6.8K
R53
VOLTAGE AND CURRENT
SENSING CIRCUITRY
100K
R73
1/2W
3.9K
R70
C9
C44
D72
D73
P4
J4
3
10K
R49
D45
10K
R55
1/2W
1.8K
R57
P3 J3
9
OUTIN
GND
X16
D43
1/2W
56K
R56
X1
1
3
2
5W
10V
DZ3
5W
3.3K
R43
1/2W
56K
R51
TL431
X18
8
16
D48
D54
X1
7
5
6
TL431
X14
8
1
6
5W
50
R45
1400V
.0047
C94
2200
63V
C16
D39
10K
R139
_
+
B
+15 V
541A
30V
200mA
Q10
48
23
A/D
/RES
/IRQ
EXTAL
A/D
IC2
I/O
OC3
VRH
I/O
A/D
IC1
A/D
/XIRQ
XTAL
MODA
MODB
I/O
MISO
SCK
MOSI
Vss
VRL
OC4
A4/D4
A5/D5
A14
A6/D6
A11
A8
AS
A2/D2
A0/D0
R/W
A12
A1/D1
I/O
E
A10
A9
A7/D7
I/O
A15
68HC11A1
I/O
A3/D3
OC2
A13
Vdd
X6
27
44
20
9
22
17
46
39
8
25
15
13
19
7
41
3
30
45
29
43
37
4
35
36
40
2
42
38
14
24
47
21
33
28
11
12
18
6
26
5
16
1
31
10
32
34
BUZZER
J7
2
+15 V
P7
+5 V
+5 V
PIEZO
P7
PIEZO BUZZER CIRCUITRY
1/2W
27K
R121
J7
1
B
A
B
+15 V
X11
2
4
5
5.6K
R25
X11
1
7
6
3.3K
R117
1/2W
6.8K
R123
22K
R32
+5 V
10K
R8
2N4123
Q3
P2 J2
3
D28
P2 J2
5
2N4123
Q20
+5 V
X2
1312
P2 J2
9
1/2W
1.8K
R52
2N4123
Q2
533A
THERM. LD. CONN.
TO OPTIONAL
6.8K
R58
204S
+5 V
D38
P2 J2
2
P2 J2
4
+15 V
P2 J2
6
D25
207
P2 J2
8
2N4123
Q1
D31
D49
X13
13
10
11
+5 V
D
B
D30
D27
TACH
TACH CIRCUITRY
D50
6.8K
R105
6.8K
R59
2.2K
R60
10K
R111
100
R61
X1
14
12
13
H
Q
A
C
Q
Q
CLK
Q
Q
Q
B
Q
A1
A2
E
F
G
Q
R
D
74HC164
X7
6
4
2
12
13
1
10
11
8
5
3
9
CLK1
H
H
SA
CLK2
SS/PL
H
Q
F
Q
E
D
C
B
A
G
74HC165
X8
9
14
12
11
1
7
2
15
10
6
13
3
4
5
10K
R10
10K
R9
+5 V
D26
1K
R12
1K
R13
1K
R14
10K
R11
1K
R15
10K
R104
2N4123
Q4
D24
P2 J2
7
50V
0.1
C33
50V
0.1
C34
1/2W
15
R92
50V
0.1
C35
4.7
35V
C47
2.2K
R91
D65
C28
10K
R65
1/2W
10K
R62
50V
0.1
C36
1400V
.0047
C79
50V
0.1
C37
15J
50V
TP5
50V
0.1
C38
D66
50V
0.1
C77
50V
0.1
C78
NAND
X3
14
7
50V
0.1
C32
X19
14
8
9
74HC373
X5
20
10
1/2W
330
R94
74HC164
X7
14
7
1/2W
270
R89
P3J3
14
68HC11A1
X6
48
23
HEXINV
X2
14
7
74HC245
X21
20
10
LM2901
X19
3
12
P3J3
12
HEXINV
X20
14
7
1/2W
270
R90
1.0
35V
C40
D68
2N4123
Q19
10K
R93
H11C4
OCI3
21
5
6
4
5W
50
R96
1.0
35V
C39
2.2K
R95
P3 J3
5
15J
50V
TP3
P3 J3
6
P3 J3
7
1400V
.0047
C80
D67
F
X19
13
10
11
+5 V
13 12
Y
-5 V
X2
11 10
B
21
A
ACTUAL CIRCUIT
OF X10
34
C5
X20
12
X20
34
C43
LM2901
X11
3
12
C1
4066B
X12
14
7
C4
56
74HC165
X8
16
8
11 10
C
X
E
98
202
203
202
+15 V
G2
204
G1
CAPS. = ufd (.022/50V UNLESS OTHERWISE SPECIFIED)
CT. AUX.
GENERAL INFORMATION
GATE DRIVE
CIRCUITRY
203
203
204
AUX TRANSFORMER
2N4125
Q9
3.3K
R34
J9
4
Y
400V
.001
C13
D76
D35
539A
1W
18V
DZ2
1/2W
100
R30
J9
9
1/2W
2.7K
R35
5.6K
R28
22K
R119
S
G
D
200V
18A
2N4123
Q8
C56
+15 V
1W
18V
DZ1
6.8K
R38
Q21
X
541A
100V
.047
C45
2N4123
Q6
1/2W
100
R120
1/2W
750
R122
X12
6
89
X12
12
1110
+15 V
J9
5
X10
14
7
A
C
B
J9
10
300V
500mA
Q7
C7
GND
RES
IN
X9
50V
0.1
C52
+5 V
A
+5 V
1/2W
10M
R16
RESET
CRYSTAL
B
+15 V
+
+
209
209A
OUTPUT
G2
208
206
TO CIRCUIT BOARD
-
TO GROUND
204
+15 V
206A
J9
6
2W
10
R48
WELDING
1/2W
330
R87
J9
1
202
400V
.68
C23
P3 J3
4
CT. MAIN
206
209
20J
75V
TP2
1400V
.0047
C92
P3 J3
3
1400V
.0047
C93
204
2W
10
R50
14
28
D5
A7
D1
D2 A1
GND
Vpp
A13
A14
A8
A5
OE
CE
A4
A3D4
A2
A6
A12
A10
D7
A9
A11
D6
A0
D0
D3
Vcc
27C64
X4
17
16
1
13
22
7
12
20
27
10
18
9
11
23
21
26
325
2
24
5
15
6
19
8
4
533
COM
E
PULL GUN
TRIGGER
20
10
/OE
2D
5Q
6Q
0D
7Q
4Q
3Q
2Q
1Q
0Q
Vcc
GND
/LE
6D
4D
5D
1D
3D
7D
74HC373
X5
13
14
2
5
9
15
11
12
1
19
8
17
3
1618
4
6
7
KEYPAD
F
F
C
D
1922
204A
204
C-
R-
D-
LAST NO. USED
E
+15 V
95
140
D
P2 J2
1
1W
15V
DZ4
LM224
X1
4
11
5W
50
R85
LM2901
X13
3
12
10K
R88
2N4123
Q18
H11C4
OCI2
21
5
6
4
P3J3
13
C3
C2
SOLENOID
CIRCUITRY
2N4123
Q15
P1J1
6
P1J1
4
100V
100p
C88
22K
R54
1/2W
15
R86
P8J8
3
4N35
OCI1
42
1
6
5
P8J8
4
4.7
35V
C30
1/2W
470
R71
D55
D56
1K
R72
15A
60V
Q17
D57
1/2W
100
R75
CW
10K
R3
27C64
X4
28
14
+15 V
1W
18V
DZ6
3300
50V
C19
50
25V
C18
5W
1K
R44
150V
8A
Q12
541A
6.8K
R23
D42
D40
7W
.25
R136
P3 J3
1
208
P3 J3
2
20J
75V
TP1
7W
.25
R137
400V
.68
C22
J9
2
J9
3
J9
7
J9
8
G!
207
+
204S
204
+ +
208A
ZERO-CROSSING
DETECTOR LINE SENSING
POWER SUPPLIES
C
D
D
D
SOL.
P1J1
2
Vo
.39mH
L2
5W
20
R102
100V
100p
C90
P1J1
8
P6J6
3
P1J1
3
MOTOR
50V
0.1
C11
DRIVER
RS
VDD
P1J1
1
1/2W
18K
R1
3.3K
R134
3.3K
R133
1/2W
100
R6
1/2W
100
R7
D37
3.3K
R135
1.0A
30V
D20
204
D63
X1
10
8
9
330
R2
203
1/2W
100
R5
P1J1
7
R/W
VSS
-LEDB
+LEDB
E
P1J1
5
+15 V
202
204
100V
100p
C91
.39mH
L1
1/2W
1K
R66
+
t
60V
.25
R103
204
D29
+5 V
5W
20
R124
10K
R78
2.2K
R81
10K
R98
10K
R76
X20
98
D69
X2
56
X20
11 10
A
D
B
A
X3
5
4
6
+5 V
X3
10
9
8
X20
13 12
2.7K
R4
-5 V
X20
56
X3
2
1
3
A
B
A
C
J5
6
4
3
1
34
2
1
J4
J6
1
5
6
10
J9
J3,
J7,J8
1
14
7
1
4
8
58
16A
DD1
31
2
400V
10-19-90N
IDEALARC SP-250 IDEALARC SP-250
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