SVM115 - Idealarc SP-255

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NOTE: This manual will cover most of the troubleshooting and repair
procedures for the code numbers listed. Some variances may exist when
troubleshooting/repairing later code numbers.
IDEALARC ® SP-255
For use with machines having Code Numbers:
10164, 10165
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SERVICE MANUAL
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SVM115-A | Issue Date 12, Apr

© Lincoln Global, Inc. All Rights Reserved.
i SAFETY i
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents The engine exhaust from this product contains chem-
are known to the State of California to cause cancer, icals known to the State of California to cause cancer,
birth defects, and other reproductive harm. birth defects, or other reproductive harm.
The Above For Diesel Engines The Above For Gasoline Engines
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 pur-
chase 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.
FOR ENGINE 1.h. To avoid scalding, do not remove the

radiator pressure cap when the engine is
powered equipment. hot.
1.a. Turn the engine off before troubleshooting and maintenance

work unless the maintenance work requires it to be running.
_____________________________________
1.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.
ELECTRIC AND
MAGNETIC FIELDS
____________________________________________________
1.c. Do not add the fuel near an open flame weld-
may be dangerous
ing arc or when the engine is running. Stop the
engine and allow it to cool before refueling to 2.a. Electric current flowing through any conductor causes
prevent spilled fuel from vaporizing on contact localized Electric and Magnetic Fields (EMF). Welding
with hot engine parts and igniting. Do not spill current creates EMF fields around welding cables and
fuel when filling tank. If fuel is spilled, wipe it welding machines

up and do not start engine until fumes have
been eliminated. 2.b. EMF fields may interfere with some pacemakers, and
____________________________________________________ welders having a pacemaker should consult their physician
1.d. Keep all equipment safety guards, covers and devices in posi- before welding.
tion and in good repair.Keep hands, hair, clothing and tools
away from V-belts, gears, fans and all other moving parts when 2.c. Exposure to EMF fields in welding may have other health
starting, operating or repairing equipment. effects which are now not known.
____________________________________________________
2.d. All welders should use the following procedures in order to
1.e. In some cases it may be necessary to remove safety guards minimize exposure to EMF fields from the welding circuit:
to perform required maintenance. Remove guards only when nec-
essary and replace them when the maintenance requiring their re- 2.d.1. Route the electrode and work cables together - Secure
moval is complete. Always use the greatest care when working near them with tape when possible.
moving parts
______________________________________ 2.d.2. Never coil the electrode lead around your body.
1.f. Do not put your hands near the engine fan. Do 2.d.3. Do not place your body between the electrode and
not attempt to override the governor or idler by work cables. If the electrode cable is on your right
pushing on the throttle control rods while the
side, the work cable should also be on your right side.
engine is running.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while 2.d.5. Do not work next to welding power source.
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
IDEALARC® SP-255
ii SAFETY ii
ELECTRIC SHOCK can kill. ARC RAYS can burn.

3.a. The electrode and work (or ground) circuits 4.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.
3.b. Insulate yourself from work and ground using dry insulation. 4.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 4.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. 5.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
3.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
3.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 within applicable OSHA PEL and
3.e. Ground the work or metal to be welded to a good electrical ACGIH TLV limits using local exhaust or mechanical ven-
(earth) ground. tilation. In confined spaces or in some circumstances,
outdoors, a respirator may be required. Additional precau-
3.f. Maintain the electrode holder, work clamp, welding cable and tions are also required when welding on galvanized steel.
welding machine in good, safe operating condition. Replace
5. b. The operation of welding fume control equipment is affected
damaged insulation.
by various factors including proper use and positioning of the
equipment, maintenance of the equipment and the specific
3.g. Never dip the electrode in water for cooling.
welding procedure and application involved. Worker expo-
sure level should be checked upon installation and periodi-

3.h. Never simultaneously touch electrically “hot” parts of
cally thereafter to be certain it is within applicable OSHA PEL
electrode holders connected to two welders because voltage
and ACGIH TLV limits.
between the two can be the total of the open circuit voltage
of both welders.
5.c. Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations. The
3.i. When working above floor level, use a safety belt to protect
heat and rays of the arc can react with solvent vapors to form
yourself from a fall should you get a shock.
phosgene, a highly toxic gas, and other irritating products.
3.j. Also see Items 6.c. and 8.
5.d. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
5.e. Read and understand the manufacturer’s instructions for this

equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.f. Also see item 1.b.

IDEALARC® SP-255
iii SAFETY iii
WELDING and CUTTING CYLINDER may explode

SPARKS can cause fire or if damaged.

explosion. 7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
6.a. Remove fire hazards from the welding area.If process used and properly operating
this is not possible, cover them to prevent the welding sparks regulators designed for the gas and
from starting a fire. Remember that welding sparks and hot pressure used. All hoses, fittings, etc. should be suitable for
materials from welding can easily go through small cracks and the application and maintained in good condition.
openings to adjcent areas. Avoid welding near hydraulic lines.
Have a fire extinguisher readily available. 7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous 7.c. Cylinders should be located:
situations. Refer to “Safety in Welding and Cutting” (ANSI • Away from areas where they may be struck or subjected to
Standard Z49.1) and the operating information for the physical damage.
equipment being used.
• A safe distance from arc welding or cutting operations and
6.c. When not welding, make certain no part of the electrode any other source of heat, sparks, or flame.
circuit is touching the work or ground. Accidental contact can
cause overheating and create a fire hazard. 7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.

6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures 7.e. Keep your head and face away from the cylinder valve outlet
will not cause flammable or toxic vapors from substances when opening the cylinder valve.
inside. They can cause an explosion even though they have
been “cleaned”. For information, purchase “Recommended 7.f. Valve protection caps should always be in place and hand
Safe Practices for the Preparation for Welding and Cutting of tight except when the cylinder is in use or connected for
Containers and Piping That Have Held Hazardous use.
Substances”, AWS F4.1 from the American Welding Society
(see address above). 7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
6.e. Vent hollow castings or containers before heating, cutting or “Precautions for Safe Handling of Compressed Gases in
welding. They may explode. Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
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.
FOR ELECTRICALLY
Always wear safety glasses with side shields when in a powered equipment.
welding area.
8.a. Turn off input power using the disconnect

6.g. Connect the work cable to the work as close to the welding
switch at the fuse box before working on
area as practical. Work cables connected to the building
the equipment.
framework or other locations away from the welding area
increase the possibility of the welding current passing through 8.b. Install equipment in accordance with the U.S. National
lifting chains, crane cables or other alternate circuits. This can Electrical Code, all local codes and the manufacturer’s
create fire hazards or overheat lifting chains or cables until recommendations.
they fail.
8.c. Ground the equipment in accordance with the U.S. National
6.h. Also see item 1.c.
6.I. Read and follow NFPA 51B “ Standard for Fire Prevention Dur-
ing Welding, Cutting and Other Hot Work”, available from
NFPA, 1 Batterymarch Park,PO box 9101, Quincy, Ma
022690-9101.
6.j. Do not use a welding power source for pipe thawing.

Refer to http://www.lincolnelectric.com/safety for additional safety information.
IDEALARC® SP-255
iv SAFETY iv
6. Eloigner les matériaux inflammables ou les recouvrir afin de

PRÉCAUTIONS DE SÛRETÉ
prévenir tout risque d’incendie dû aux étincelles.

Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce 7. Quand on ne soude pas, poser la pince à une endroit isolé de
manuel aussi bien que les précautions de sûreté générales suiv- la masse. Un court-circuit accidental peut provoquer un échauf-
antes: fement et un risque d’incendie.
Sûreté Pour Soudage A L’Arc 8. S’assurer que la masse est connectée le plus prés possible de
1. Protegez-vous contre la secousse électrique: la zone de travail qu’il est pratique de le faire. Si on place la
masse sur la charpente de la construction ou d’autres endroits
a. Les circuits à l’électrode et à la piéce sont sous tension éloignés de la zone de travail, on augmente le risque de voir
quand la machine à souder est en marche. Eviter toujours passer le courant de soudage par les chaines de levage, câbles
tout contact entre les parties sous tension et la peau nue ou de grue, ou autres circuits. Cela peut provoquer des risques
les vétements mouillés. Porter des gants secs et sans trous d’incendie ou d’echauffement des chaines et des câbles jusqu’à
pour isoler les mains. ce qu’ils se rompent.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher met- 9. Assurer une ventilation suffisante dans la zone de soudage.
allique ou des grilles metalliques, principalement dans Ceci est particuliérement important pour le soudage de tôles
les positions assis ou couché pour lesquelles une grande galvanisées plombées, ou cadmiées ou tout autre métal qui pro-
partie du corps peut être en contact avec la masse. duit des fumeés toxiques.
c. Maintenir le porte-électrode, la pince de masse, le câble de
soudage et la machine à souder en bon et sûr état defonc- 10. Ne pas souder en présence de vapeurs de chlore provenant
tionnement. d’opérations de dégraissage, nettoyage ou pistolage. La chaleur
d.Ne jamais plonger le porte-électrode dans l’eau pour le re- ou les rayons de l’arc peuvent réagir avec les vapeurs du
froidir. solvant pour produire du phosgéne (gas fortement toxique) ou
e. Ne jamais toucher simultanément les parties sous tension autres produits irritants.
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le total 11. Pour obtenir de plus amples renseignements sur la sûreté, voir
de la tension à vide des deux machines. le code “Code for safety in welding and cutting” CSA Standard
f. Si on utilise la machine à souder comme une source de W 117.2-1974.
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
2. Dans le cas de travail au dessus du niveau du sol, se protéger

PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
contre les chutes dans le cas ou on recoit un choc. Ne jamais

enrouler le câble-électrode autour de n’importe quelle partie du
corps.
TRANSFORMATEUR ET À
REDRESSEUR
3. Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:
a. Utiliser un bon masque avec un verre filtrant approprié ainsi 1. Relier à la terre le chassis du poste conformement au code de
qu’un verre blanc afin de se protéger les yeux du rayon- l’électricité et aux recommendations du fabricant. Le dispositif
nement de l’arc et des projections quand on soude ou quand de montage ou la piece à souder doit être branché à une bonne
on regarde l’arc. mise à la terre.
b. Porter des vêtements convenables afin de protéger la 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 soudage effectués par un électricien qualifié.
à l’aide d’écrans appropriés et non-inflammables.
3. Avant de faires des travaux à l’interieur de poste, la debrancher
4. Des gouttes de laitier en fusion sont émises de l’arc de 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, pantalons
4. Garder tous les couvercles et dispositifs de sûreté à leur place.

sans revers, et chaussures montantes.
5. Toujours porter des lunettes de sécurité dans la zone de

soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.
IDEALARC® SP-255
Return to Master TOC v SAFETY v
Electromagnetic Compatibility (EMC)
Conformance
Products displaying the CE mark are in conformity with European Community Council Directive of 15 Dec
2004 on the approximation of the laws of the Member States relating to electromagnetic compatibility,
2004/108/EC. It was manufactured in conformity with a national standard that implements a harmonized
standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment.
It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use.
Introduction
All electrical equipment generates small amounts of electromagnetic emission. Electrical emission may be
transmitted through power lines or radiated through space, similar to a radio transmitter. When emissions are
received by other equipment, electrical interference may result. Electrical emissions may affect many kinds of
electrical equipment; other nearby welding equipment, radio and TV reception, numerical controlled ma-
chines, telephone systems, computers, etc. Be aware that interference may result and extra precautions may
be required when a welding power source is used in a domestic establishment.
Installation and Use

The user is responsible for installing and using the welding equipment according to the manufacturer’s in-
structions. If electromagnetic disturbances are detected then it shall be the responsibility of the user of the
welding equipment to resolve the situation with the technical assistance of the manufacturer. In some cases
this remedial action may be as simple as earthing (grounding) the welding circuit, see Note. In other cases it
could involve construction of an electromagnetic screen enclosing the power source and the work complete
with associated input filters. In all cases electromagnetic disturbances must be reduced to the point where
they are no longer troublesome.
Note: The welding circuit may or may not be earthed for safety reasons according to national codes.
Changing the earthing arrangements should only be authorized by a person who is competent
to access whether the changes will increase the risk of injury, e.g., by allowing parallel welding
current return paths which may damage the earth circuits of other equipment.
Assessment of Area
Before installing welding equipment the user shall make an assessment of potential electromagnetic prob-
lems in the surrounding area. The following shall be taken into account:
a) other supply cables, control cables, signaling and telephone cables; above, below and adjacent to the
welding equipment;
b) radio and television transmitters and receivers;
c) computer and other control equipment;
d) safety critical equipment, e.g., guarding of industrial equipment;
e) the health of the people around, e.g., the use of pacemakers and hearing aids;
f) equipment used for calibration or measurement

g) the immunity of other equipment in the environment. The user shall ensure that other equipment being
used in the environment is compatible. This may require additional protection measures;
h) the time of day that welding or other activities are to be carried out.
IDEALARC® SP-255
Return to Master TOC vi SAFETY vi
Electromagnetic Compatibility (EMC)
The size of the surrounding area to be considered will depend on the structure of the building and other ac-
tivities that are taking place. The surrounding area may extend beyond the boundaries of the premises.
Methods of Reducing Emissions
Mains Supply
Welding equipment should be connected to the mains supply according to the manufacturer’s recommenda-
tions. If interference occurs, it may be necessary to take additional precautions such as filtering of the mains
supply. Consideration should be given to shielding the supply cable of permanently installed welding equip-
ment, in metallic conduit or equivalent. Shielding should be electrically continuous throughout its length. The
shielding should be connected to the welding power source so that good electrical contact is maintained be-
tween the conduit and the welding power source enclosure.
Maintenance of the Welding Equipment

The welding equipment should be routinely maintained according to the manufacturer’s recommendations.
All access and service doors and covers should be closed and properly fastened when the welding equip-
ment is in operation. The welding equipment should not be modified in any way except for those changes
and adjustments covered in the manufacturers instructions. In particular, the spark gaps of arc striking and
stabilizing devices should be adjusted and maintained according to the manufacturer’s recommendations.
Welding Cables
The welding cables should be kept as short as possible and should be positioned close together, running at
or close to floor level.
Equipotential Bonding
Bonding of all metallic components in the welding installation and adjacent to it should be considered. How-
ever, metallic components bonded to the work piece will increase the risk that the operator could receive a
shock by touching these metallic components and the electrode at the same time. The operator should be in-
sulated from all such bonded metallic components.
Earthing of the Workpiece

Where the workpiece is not bonded to earth for electrical safety, not connected to earth because of its size
and position, e.g., ships hull or building steelwork, a connection bonding the workpiece to earth may reduce
emissions in some, but not all instances. Care should be taken to prevent the earthing of the workpiece in-
creasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the connec-
tion of the workpiece to earth should be made by a direct connection to the workpiece, but in some countries
where direct connection is not permitted, the bonding should be achieved by suitable capacitance, selected
according to national regulations.
Screening and Shielding

Selective screening and shielding of other cables and equipment in the surrounding area may alleviate prob-
lems of interference. Screening of the entire welding installation may be considered for special applications. 1
_________________________
1
Portions of the preceding text are contained in EN 60974-10: “Electromagnetic Compatibility (EMC) prod-
uct standard for arc welding equipment.”
IDEALARC® SP-255
vii RETURN TO MAIN INDEX vii
TABLE OF CONTENTS
Page
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i- vi
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Select Proper Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Input Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Reconnect Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
Connect Output Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-7
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
Machine Capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4
Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4
Controls and Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5
Operating Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-10
Fan Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-15
Input Line Voltage Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-15
Wire Feed Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-16
Welding Thermal Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . .B-16
Overcurrent Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-16
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section C
Options/Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1
Making a Weld with the Spool Gun Adapter and Spool Gun Installed . . . .C-1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section D
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1
Routine and Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1
Contact Tip and Gas Nozzle Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3
Liner Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3
Liner Removal, Installation, and Trimming Instructions
for Magnum 250SP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4
Gun Handle Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-5
Magnum 250SP Gun Parts and Accessories . . . . . . . . . . . . . . . . . . . . . . .D-6
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section E
Power Supply Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-1
Thermal Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-5
SCR Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-6
Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section F
Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-14
Oscilloscope Waveforms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-29
Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-34
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section G
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P265 & P202-H.4
IDEALARC® SP-255
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
Install the Work Clamp ................................................A-7

Output Polarity Connection .........................................A-7
Gun Liner & Contact Tip .............................................A-7
Gun and Cable Connection .........................................A-7
IDEALARC® SP-255
A-1 A-1
INSTALLATION
Return to Section TOC
TECHNICAL SPECIFICATIONS - Idealarc® SP-255
INPUT - SINGLE PHASE/ 60 HERTZ ONLY
Standard Voltage Input Current at Rated Output
208/230/60 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 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-255
A-2 A-2
INSTALLATION
Read entire Installation Section before installing the 1. Before starting the installation, check with the local
Idealarc® SP-255 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-255 grounding details on reconnecting the machine to operate at
terminal (located on the side of the Case Back As- different voltages.
sembly) to a good electrical earth ground.
3. Be sure the voltage, phase, and frequency of the
• Set the Idealarc SP-255 Power switch to the OFF
® input power is as specified on the machine rating
position when connecting power cord to input plate. See Figure A.1 for the location of the ma-
power. chine’s input cord entry, Reconnect Access Door,
Reconnect Panel, and Rear Nameplate.
____________________________________
SELECT PROPER LOCATION

Place the Idealarc® SP-255 where clean air can freely
circulate in through the back and out through the front
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 nui-

sance shutdown of the machine because of excessive
operating temperatures.
STACKING
The Idealarc® SP-255 cannot be stacked.
INPUT CONNECTIONS
WARNING
FIGURE A.1 - Case Back Assembly: Input Power
All input power must be electrically dis-
Cable Entry Connections.

connected before proceeding.
____________________________________
IDEALARC® SP-255
A-3 A-3
INSTALLATION
FUSE AND WIRE SIZES super lag type fuses as shown in Figure A.2. A
green wire in the input cord connects this ter-

Protect the input circuit with the super lag fuses or delay minal to the frame of the welder. This ensures
type circuit breakers listed on the Technical Specifica- proper grounding of the welder frame when the
tions page of this manual for the machine being used. welder plug is inserted into the receptacle.
The tripping action of delay type circuit breakers de-
creases as the magnitude of the current increases. 4. Use proper wire sizes. See the Technical Specifi-
They are also called inverse time or thermal/magnetic cations table for proper wire sizes. For cable
circuit breakers. lengths over 100 feet, larger copper wires should
be used.
DO NOT use fuses or circuit breakers with a lower amp
rating than recommended. This can result in "nuisance" FIGURE A.2. - Ground Connections.
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 elec-
trical codes or see the Technical Specifications page
in this manual.
INPUT POWER CONNECTIONS AND

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 255 shipped with

a 10 ft. (3.0m) 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.
a. The center terminal in the receptacle is for the

grounding connection. See Figure A.2.
b. Fuse the two hot lines of the receptacle with
IDEALARC® SP-255
A-4 A-4
INSTALLATION
For the 230/460/575V/ 60 HZ model which is not BE SURE TO KEEP YOUR FACE AWAY FROM THE
equipped with a plug, an input cord, or a receptacle, the VALVE OUTLET WHEN OPENING THE VALVE.
input power supply leads are connected directly to the
Reconnect Panel as shown Figure A.3. Refer to the 6. Inspect the regulator for damaged threads, dirt,
specifications table at the beginning of this chapter for dust, oil or grease.
proper wiring sizes.
a. Remove dust and dirt with a clean cloth.
1. Have a qualified electrician connect the input power
leads to terminals L1 and L2 on the Reconnect NOTE: DO NOT USE THE REGULATOR IF OIL,
Panel Assembly. See Figure A.5. GREASE OR DAMAGE IS PRESENT! Have an au-
thorized repair station clean the regulator or repair any
damage.
CONNECT SHIELDING GAS
(For Gas Metal Arc Welding Processes) 7. Attach the flow regulator to the cylinder valve and
Customer must provide cylinder of appropriate type of tighten the union nut(s) securely with a wrench.
shielding gas for gas metal arc welding for the process
being used. See Figure A.4 for the location of the com- a. NOTE: If connecting the flow regulator to 100%
ponents used to connect the air supply cylinder. CO2 cylinder, insert regulator adapter provided
between regulator and cylinder valve. If
adapter is equipped with a plastic washer, be
WARNING sure it is seated properly to connect to the CO2
cylinder.
CYLINDER may explode if damaged.
Gas under pressure is explosive. Al- 8. Connect one end of the inlet gas hose to the outlet
ways keep gas cylinders in an upright fitting of the flow regulator.
position and always keep chained to
undercarriage or stationary support. 9. Connect the other end of the inlet gas hose to the
See American national Standard SP-255 rear fitting.
Z49.1, "Safety in Welding and Cutting" published by
the American welding Society. 10. Tighten both the union nuts securely with a wrench.
____________________________________
1. Set the gas cylinder on the rear platform of the SP

255.
2. Hook the chain in place to secure cylinder to rear

of welder.
3. Remove the cylinder cap.
4. Inspect the cylinder valves for damaged threads,

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

GREASE OR DAMAGE IS PRESENT! Inform your gas
supplier of this condition. Oil or grease in the presence
of high pressure oxygen is explosive.
5. Stand to one side away from the outlet and open

the cylinder valve for an instant to blow away any
dust or dirt which may have accumulated in the
valve outlet.
IDEALARC® SP-255
A-5 A-5
INSTALLATION
11. Before opening the cylinder valve, turn the regulator RECONNECT PROCEDURE
adjusting knob counter clockwise until the pressure

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 Re-
connect Panel in the Input Box Assembly is connected
a. When the cylinder pressure gage pointer stops for the proper voltage.
moving, open the valve fully.
NEVER STAND DIRECTLY IN FRONT OF OR BE- CAUTION

HIND THE FLOW REGULATOR WHEN OPENING
THE CYLINDER VALVE. ALWAYS STAND TO ONE Failure to follow these instructions can cause immediate
SIDE. 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 code 10164 208/230/1/60 machine, see Figure A.4.
For code 10165 230/460/575/1/60 machine see Figure

A.5.
FIGURE A.3 - Shielding Gas Supply Connections

IDEALARC® SP-255
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.4 - Reconnect Diagram For 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. (TORQUE TO 16 IN-LBS)

3. CONNECT A GROUNDING LEAD TO THE GROUND STUD ( ) ON THE MACHINE NEAR THE TER-
MINAL BLOCK.
FIGURE A.5 - Reconnect Diagram For 230/460/575/1/60 Machines.
IDEALARC® SP-255
A-7 A-7
INSTALLATION
CONNECT OUTPUT COMPONENTS GUN LINER & CONTACT TIP
INSTALL THE WORK CLAMP The Magnum 250 SP gun and cable provided with the
SP-255 is factory installed with a liner for a .035” or
Attach the work clamp to the cable which extends from .045” (0.9 or 1.2mm) diameter electrode and an .035
the front of the machine using the following procedure: (0.9mm) contact tip. If a .045” diameter wire size is to
be used, install the .045” contact tip (also provided).
1. Insert the lug on the end of the work cable through See Maintenance Section.
the strain relief hole in the work clamp handle. See
Figure A.6. GUN & CABLE INSTALLATION
2. Slide the work cable through the hole up to the bolt WARNING
and nut.
TURN THE WELDER POWER SWITCH OFF BEFORE
3. Fasten work cable using the bolt and nut provided. INSTALLING GUN AND CABLE.
____________________________________
1. Lay the cable out straight.
2. Make sure all pins on the gun cable connector are

aligned with the proper mating sockets on the front
panel gun connector and then 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) specifications.
See Figure A.7.
FIGURE A.6 - Installing The Work Clamp
NOTE: The thumb switch functions available on the
Magnum 250 SP gun will only be operable from the front
OUTPUT POLARITY CONNECTION panel keypad. The gun trigger switch must be capable
of switching 5 milliamps at 15 volts DC resistive.

WARNING
TURN THE WELDER POWER SWITCH OFF BEFORE
CHANGING OUTPUT CONNECTION.
____________________________________
The welder is shipped from the factory connected for

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

nection of the electrode and work cables at the output
terminals located in the wire drive compartment near
the front panel. The electrode cable, which is attached
to the wire drive, is to be connected to the negative (-)
labeled output terminal. The work cable which is at-

tached to the work clamp is to be connected to the pos-
itive (+) labeled output terminal.
FIGURE A.7 - European(FM) Style Connector
IDEALARC® SP-255
A-8 A-8
INSTALLATION
CAUTION
The gun trigger switch connected to the gun trigger
control cable must be a normally open momentary
switch. The terminals of the switch must be insu-
lated from the welding circuit. Improper operation
of or damage to the SP-255 might result if this
switch is common to an electrical circuit other than
the SP-255 trigger circuit.
____________________________________
IDEALARC® SP-255
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
Machine Capability ...........................................................B-4
Limitations ........................................................................B-4
Controls and Settings .......................................................B-5
Power Switch...............................................................B-5
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
Display Language Selection ......................................B-10
Start Mode Selections ...............................................B-10
Loading the Wire Reel ...............................................B-11
Starting the Welder ....................................................B-11
Feeding Electrode .....................................................B-12

Setting Idle Roll Pressure ..........................................B-12
Making a Weld in Auto Mode.....................................B-13
Making a Stitch Weld in Auto Mode...........................B-15
Using the Gun Thumb Switch....................................B-15
Using the Wire Drive Roll ..........................................B-15
Fan Control.....................................................................B-15
Input Line Voltage Protection .........................................B-15
Wire Feed Overload Protection ......................................B-16
Welding Thermal Overload Protection............................B-16
Overcurrent Protection ...................................................B-16
IDEALARC® SP-255
B-1 B-1
OPERATION
Read and understand this entire section before operat- ADDITIONAL SAFETY PRECAUTIONS
ing your Idealarc® SP-255.

Always operate the welder with the hinged door closed
SAFETY INSTRUCTIONS and the side panels in place as these provide maximum
protection from moving parts and insure proper cooling
air flow.
WARNING
GENERAL DESCRIPTION
ELECTRIC SHOCK can kill.
Product Description
• Do not touch electrically live parts such
as output terminals or internal wiring. The Idealarc® SP-255 is a complete semiautomatic con-
stant voltage DC arc welding machine built to meet
• Insulate yourself from the work and NEMA specifications. This unit combines a constant
ground. voltage power source, a constant speed wire feeder,
and a microcomputer-based controller to form an intel-
• Always wear dry insulating gloves. ligent welding system.
------------------------------------------------------------------------
A front panel touch key entry system with audible feed-
FUMES AND GASES back, along with a two-line, 32 character alphanumeric
can be dangerous. display, provide user friendly control of the system. The
system provides full range control from the keypad or
• Keep your head out of fumes. from the thumb switch built into the SP-255 welding
gun, which permits "on the fly" control while welding
• Use ventilation or exhaust to
remove fumes from breathing Multi language display capability allows the SP-255 to
zone. communicate with the user in any of the following five
languages: English, German, French, Spanish, or
------------------------------------------------------------------------ Japanese (Katakana).
WELDING, CUTTING and Proper welding setup is simple. You only need to select
GOUGING SPARKS the gauge size of the material to be welded and enter
can cause fire or explosion the welding process to be used. With that data, the
system
• Keep flammable material away.

• automatically computes the proper wire feed speed
• Do not weld, cut or gouge on and arc voltage relationship for the process.
containers that have held combustibles.
• selects the right procedure for optimum starting,
welding, and burnback.
------------------------------------------------------------------------
The system allows you to store up to five separate weld-
ARC RAYS ing setup procedures. You can recall them at any time
can burn. at the touch of a single key. All active setup selections,
as well as those stored in the memory locations, are au-
• Wear eye, ear and body tomatically saved when power is turned off or discon-
protection. nected. Whatever procedure was being used when
power was removed, will be recalled when power is re-
turned. The SP-255 does not require batteries to main-
------------------------------------------------------------------------ tain memory data.
Only qualified personnel should operate this equipment.

Observe all safety information throughout this manual.
IDEALARC® SP-255
B-2 B-2
OPERATION
RECOMMENDED PROCESSES AND Auto Mode - Simply set the thickness of the material
being welded and the SP-255 automatically sets the

EQUIPMENT proper wire feed speed and arc voltage for the process
being used. This eliminates the need for look-up tables,
The SP-255 is recommended for GMA welding procedure slide rules, or notebooks to find the proper
processes using 10 to 44 lb. (4.5 to 20 kg) 2" (51mm) settings. Auto Mode also provides one key control of
I.D. spools or Readi-Reel coils of the output by automatically adjusting both the wire feed
speed and arc voltage for an increase or decrease in
• .025" through .045" (0.6 - 1.2mm) solid steel using material thickness or wire feed speed. This allows the
CO2, ArCO2, or ArO2 shielding gas operator to easily increase or decrease his output with-
out having to know how much to change each parame-
• .035" (0.9mm) stainless steel using ArO2 or ter.
HeArCO2 shielding gas
Thumb Switch on Gun - Allows the operator to set or
• 3/64" (1.2mm) aluminum using Ar shielding gas change the output of the machine, the wire feed speed,
or the arc voltage from the gun, even during welding.
• .045" (1.2mm) Outershield- electrodes using CO2 This permits "on the fly" adjustment. In toggle opera-
or ArCO2 shielding gas

tion mode, the thumb switch allows the operator to tog-

gle between two procedures stored in memory.
• .035" (0.9mm) and .045 (1.2mm) Innershield self-
shielded electrodes. Memory - There are five separate memory locations
that the operator can use to save or recall a setup pro-
The SP-255 is factory equipped to feed .035 (0.9mm) cedure. This eliminates dial marking and makes recall-
and .045 (1.2mm) electrodes and includes a 200A, 60% ing a setup as simple as pushing one of the five memory
duty cycle rated, 12.5 ft. (3.8m) GMA gun and cable as- keys for instant recall. Also, when power is removed,
sembly equipped for these wire sizes. The SP-255 is these five memories as well as any current setup in use
factory equipped with an adjustable CO2 or argon blend is automatically saved. This feature does not require
flow regulator. A supply of shielding gas is required for batteries. When power is restored, the procedure in use
GMAW processes. will automatically return the unit to whatever was set up
was being used when power was removed.
OPERATIONAL FEATURES AND Trigger Interlock - Selectable four-step trigger interlock
CONTROLS allows operator to release gun trigger after weld current
is established and continue welding. Breaking the arc
Keypad - Consists of 20 membrane keys that have or re-closing and then releasing the gun trigger, stops
large touch areas. The keys are spaced far enough the welding process.
apart to provide easy selection, even if wearing welding
gloves. An audible feedback beep is provided when-
ever a key is pressed to ensure proper entry.
Display - Wide temperature range liquid crystal display

combines large 0.32" (8.1mm) high characters in a 2-
line by 16-character alphanumeric format. It has long
life LED backlighting and a non-glare cover for easy
viewing under bright or dark conditions. Multi language
display capability permits the SP-255 to communicate
in English, German, French, Spanish, or Japanese
(Katakana).
IDEALARC® SP-255
B-3 B-3
OPERATION
DESIGN FEATURES AND Output Terminals - Easily accessible in wire drive sec-
tion for quick cable connection and polarity reversal.

ADVANTAGES
Work Cable - 10 ft. (3.0m) long with work clamp.
UNIT FEATURES:
Undercarriage for Hand Mobility - Heavy duty 10" WIRE FEEDER FEATURES:
(254mm) wheels and 4" (102mm) casters are factory in-
stalled along with the handle. Handle can be used for Wire Loading - Adjustable brake spindle mounts
hanging the welding gun and work cable. Readi-Reel® Adapter, included with SP-255, or most any
2" (51mm) I.D. wire spool. Accommodating standard 12”
Gas Cylinder Platform - Factory installed on undercar- (305mm) and 8” (203mm) diameter coils, the spindle’s
riage. It permits platform mounting and support of a sin- adjustable brake provides appropriate de-reeling drag
gle gas cylinder. No full lifting of gas cylinder required to prevent wire reel overrun and loop-offs.
during loading.
Tachometer Controlled Wire Drive - Precision control
Adjustable Flow Regulator - Accommodates CO2 or of permanent magnet motor provides proper wire feed
argon blend gas. Includes a cylinder pressure gauge

acceleration and speed accuracy, independent of fluc-

and a dual seal flow gauge. tuations in line voltage and wire loading. This means
reliable arc starting and weld consistency.
Easy Accessibility - Wire feeder compartment enclo-
sure door protects wire and wire drive from dirt, dust, Selectable Run-In Speed and Volts - A user selectable
and damage, but allows easy access for wire reel load- feature allows the wire feeder to feed wire directly at the
ing, and to load or service the wire drive. A convenient select speed, as factory selected, or when the trigger is
parts bin is included above the wire drive to provide pulled the wire feeder feeds wire at slow speed regard-
storage for feeder and gun replacement parts. less of the set wire feed speed until welding current is
drawn or 2 seconds has expired. This feature enhances
POWER SOURCE FEATURES: starting and makes setting stick out a snap. The 2 sec-
ond limit permits high speed loading of the gun and
10 Ft. (3.0m) Input Power Cable - Includes plug and cable.
mating receptacle for 208/230V unit. Convenient rear While selecting fast or slow run-in speed, the run-in out-
panel reconnect allows easy access for 208V re-con- put voltage level may also be adjusted, at control panel
nection. or with gun switch, to further enhance arc starting.
Power Switch - Front panel toggle switch turns input Solid State Wire Feed Overload Protection - No cir-
power on and off. cuit breaker to reset. Simply pull the trigger to resume
welding once the overload condition has been cleared.
Thermostatically Controlled Fans - Provides cooling
of transformer and other components only when re- Unique Drive Roll and Guide Tube Design - Long life,
quired. When used intermittently or at low current pro- precisely aligned guide tubes and drive rolls. Quickly
cedures, the fan motors stay off, reducing the amount reloads by simply starting wire into ingoing guide tube.
of dust and dirt drawn into the machine. Also reduces Adjustable tension setting minimizes 'birdnesting', elim-
power consumption. inates milling through the wire, and gives positive feed-
ing. The double groove, reversible drive roll included
Electronic Overload Protection - Protects machine with the SP-255 allows use of .030 (0.8mm) through
from short circuit or high current overloading. .045 (1.2mm) diameter wire. Drive Roll kits for other
sizes and types of wire are also available.
Power Source Line Voltage Regulation - Precise
SCR phase control circuit holds the voltage setting con- Fast-Mate Gun Connector - European style gun con-
stant to maintain weld quality even when the input volt- nector provides electrode, shielding gas and gun control
age fluctuates +/-10%.

lead connections in a single connector.
Solid State Contactor - Output is turned on and off by

SCR's instead of a mechanical contactor providing extra
long life in highly repetitive welding applications.
Automatic Burnback - Provides proper burnback of
the electrode to prevent it from sticking in the weld pud-
dle at the end of a weld.
IDEALARC® SP-255
B-4 B-4
OPERATION
Gun and Cable - A 12.5 ft. (3.8) GMAW gun and cable
assembly, rated 200 amps 60% duty, is provided with

the SP-255 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 connector with addi-
tional control lead connections for the thumb activated
2 momentary position slide switch control designed into
the gun handle for use with SP-255 remote control fea-
tures.
MACHINE CAPABILITY
The Idealarc® SP-255 is rated at the following duty cy-
cles 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-255 may not operate satisfactorily if powered
with a portable or in-plant generating system.
IDEALARC® SP-255
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.
ARROW KEYS
FIGURE B.1 - SP-255 Control Panel Keys maintaining an excellent resolution. However,
when the trigger is closed, the changes will be at a
1. POWER SWITCH: Toggle switch to turn input steady, moderate rate to allow for proper “on the fly”
power ON and OFF. When the switch is in the ON control. Function of arrow keys change depending
position the red LED backlighting of the LCD dis- on PROCESS KEY being used. For function of
play lights and alphanumeric characters appear. arrow keys, refer to each process or procedure.
The welding setup in operation when the power was See Table B.1 for summary of arrow key operation.
shut off or disconnected is displayed when power
is restored. 3. PROCESS WIRE/GAS KEY: Press key to
display the Wire Type, Wire Diameter, and Welding
2. ARROW KEYS: Press keys to change the dis- Gas. Each combination of wire and gas dictates a
play selection directly above the keys. See Figure unique relationship between the wire feed speed
B.1. The left arrow keys continue to increment or and the arc voltage. The SP-255 uses this unique
decrement the selection above it at a slow, steady relationship, along with the metal thickness, to set
rate as long as the arrow key is pressed. The cen- the proper values for wire feed speed and arc volt-
ter and right sets of arrow keys increment and age. Therefore, it is very important that the wire
decrement the selections above them at a slow type, wire diameter, and welding gas displayed
rate, but the rate will gradually increase until it be- match the actual wire type, wire diameter, and weld-
comes very rapid. This allows rapid setting from a ing gas being used for the weld.
small quantity to a large quantity or vice versa while
IDEALARC® SP-255
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. Press Solid Steel .045 (1.2mm) CO2
the UP ( ) arrow key to increase the wire diameter dis- Solid Steel .045 (1.2mm) ArCO2
played. Press the DOWN ( ) arrow key to decrease
Stainless .035 (0.9mm) ArOxy
the wire diameter displayed.
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
Innershield .035 (0.9mm) None
SP-255:
Innershield .045 (1.2mm) None
IDEALARC® SP-255
B-7 B-7
OPERATION
4. AUTO KEY: Press for automatic welding set up ARROW KEY OPERATION WHEN USED WITH MAN-
of recommended Wire Speed and Arc Voltage UAL KEY:

based on Metal Thickness selected.
See Table B.1.
ARROW KEY OPERATION WHEN USED WITH AUTO
KEY: Left arrow keys: Do not function in Manual mode.
See Table B.1. Center arrow keys: Press the UP ( ) arrow key to in-
crease wire feed speed. Press the DOWN ( ) arrow
Left Arrow Keys: Press to change the metal thickness key to decrease wire feed speed.
displayed. Press the UP ( )arrow key to increase
metal thickness. Press the DOWN ( ) arrow key to Right arrow key: Press the UP ( ) arrow key to in-
decrease the metal thickness. Increasing or decreasing crease arc voltage. Press the DOWN ( ) arrow key to
metal thickness automatically increases or decreases decrease arc voltage.
both wire feed speed (IPM) and arc voltage (VOLTS) si-
multaneously. See gauge chart on the instruction label NOTE: If the spot or stitch timers are ON, it will be in-
on the inside of SP-255 door for available sizes. dicated in the bottom left corner of the display. See Fig-
ure B.2.
NOTE: If the spot or stitch timers are on, metal thick-
ness is not displayed and, therefore, the left arrow keys
will not function. Also, the left arrow keys do not function
when trigger is closed.
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 FIGURE B.2 - Display when Stitch or Spot Weld
setting. Timers are ON.
Right Arrow Keys: Press to change arc voltage setting. 6. SAVE KEY: Press to save the current set up.
Press the UP ( ) arrow key to increase the arc voltage The process, procedure, and timer functions (if
setting displayed. Press the DOWN ( ) arrow key to used) are saved to one of five memory locations by
decrease arc voltage setting displayed. An up arrow in- pressing one of the five memory keys. When the
dicator appears below the V in VOLTS if the arc voltage Save key is pressed, a prompting message instruct-
has been set higher than the recommended value. A ing the operator to "PRESS MEMORY 1-5 TO
down arrow indicator appears below the V in VOLTS if SAVE SETUP" is displayed. See Figure B. 3 for
the arc voltage is below the recommended value. No sample SAVE sequence. This message remains
arrow indicates that you are set to the recommended displayed until a memory number key is selected or
value. one of the other keys, such as Auto, Manual, or
Process, is pressed. If a memory number key is se-
Pressing the AUTO key again resets the wire feed lected, a message will be displayed for 2.5 seconds
speed and arc voltage settings to the recommended that confirms that the setup was saved to that mem-
values for the metal thickness displayed. (NOTE: If the ory number.
spot or stitch timers are on, metal thickness is not dis-
played and, therefore, the reset function does not work.) The six arrow keys perform no function when saving a
setup.
5. MANUAL KEY: Press to set wire feed speed
and arc voltage for manual procedure setup. The NOTE: When a setup is saved to a memory location,
manual screen displays wire feed speed, arc volt- the previous contents of that memory is lost because it
age, and a cursor that indicates when the wire feed is replaced by the present setup. Removing input
speed or arc voltage is being controlled by the power does not effect the setup in memory.
thumb switch on the SP-255 gun.
IDEALARC® SP-255
B-8 B-8
OPERATION
7. MEMORY KEYS: Press memory key location Center arrow keys: Press UP ( ) arrow key to in-
number in which you want to save a procedure or crease Stitch time ON from 0.20 seconds to 2.50 sec-
from which you want to recall a procedure from onds. Press the DOWN ( ) arrow key to decrease
memory. See SAVE Key. 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 bottom left
corner of the Auto and Manual mode display disap-
pears.
The six arrow keys do not function with this key.

FIGURE B.3 - Sample SAVE Sequence.

11. GUN SWITCH CONTROL IPM VOLTS
8. SPOT KEY: Press to turn ON the Spot Weld KEY: Press to engage the gun thumb switch to
Timer and display the spot weld ON time. Pressing control IPM or VOLTS. Pushing the gun thumb
the SPOT KEY a second time returns the screen to switch forward (toward the tip) increases IPM or
the previous display without turning off the spot VOLTS . Pulling gun thumb switch back decreases
timer. Anytime the Spot weld timer is on and the IPM or VOLTS. The underlining cursor always in-
display is in the Auto or Manual mode, the word dicates the selection being controlled by the gun
SPOT will appear in the bottom left corner of the thumb switch. See Figure B.4.
display. See Figure B.2.
If the cursor is not present, the gun thumb switch does
ARROW KEY OPERATION WHEN USED WITH SPOT not function. This prevents any inadvertent actuations.
KEY: 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 in- NOTE: In Auto Mode, changing IPM changes arc volt-
crease Spot Weld ON time from 0.20 seconds to 2.5 age. This can result in a change in metal thickness set-
seconds. Press DOWN ( ) arrow key to decrease ting 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. Any-
time the Stitch weld timers are on and the display is in
the Auto or Manual mode, the abbreviation STCH will ap-
pear 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.
Left arrow keys: Do not function.
IDEALARC® SP-255
B-9 B-9
OPERATION
12. TOGGLE KEY: When first pressed, this key
turns ON the TOGGLE MODE and recalls the weld Center arrow keys: Press the UP ( ) arrow key to in-
setup in memory 4. Pressing the key again crease wire feed speed. Press DOWN ( ) arrow key
switches to the weld setup in memory location 5. to decrease wire feed speed setting. If in Auto Mode,
Each time the key is pressed, it alternates between increasing or decreasing wire feed speed simultane-
the two memory locations. When the TOGGLE key ously causes an increase or decrease in the arc voltage
is pressed, the LED screen displays the memory and can change the metal thickness setting.
number the current setup was recalled from, indi-
cates automatic (AUTO:) or manual (MAN:) mode, Right arrow keys: Press the UP ( ) arrow key to in-
displays wire gauge (Auto Mode), wire feed speed, creases arc voltage setting. Press the DOWN ( )
and arc voltage. The cursor underlines the memory arrow key to decrease the arc voltage setting. When in
number currently selected. the Auto Mode, an up arrow indicator appears below the
V in VOLTS if the arc voltage has been set higher than
If in AUTO mode, an up or down arrow shows the recommended value. A down arrow indicator ap-
whether the arc voltage has been adjusted above pears below the V in VOLTS if the arc voltage is below
or below the recommended level. Spot or Stitch the recommended value. No arrow indicates that you
timer status is displayed in the lower left-hand cor- are set to the recommended value.
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, MANUAL,

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
after the toggle (5 or 4). FIGURE B.5 - Using the TOGGLE Function.
When power is returned, the machine will not be in the 4-STEP TRIGGER INTERLOCK KEYS
toggle mode. However, the weld setting placed in mem-
ory when power was removed will return so you may
continue to weld right where you left off. Press the Pressing and
TOGGLE key to return to toggle mode.
ARROW KEY OPERATION WHEN USED WITH THE Controls whether 4-step trigger interlock is activated or
TOGGLE KEY deactivated. (See “Using 4-step Trigger Interlock Func-
tion” section.
See Table B.1.

NOTE: 4-Step Trigger is automatically deactivated if ei-
Left arrow keys: If metal thickness is displayed, Press ther the spot or stitch timer mode is being used.
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 func-
tion in any other mode.
IDEALARC® SP-255
B-10 B-10
OPERATION
OPERATING STEPS 1. Run-In Speed
The SP-255 is factory set for FAST run-in (Figure

Before operating the machine, be sure you have all the B.6) where the wire feed will accelerate directly to
materials needed to perform the work. Be sure you are the preset speed. SLOW run-in will initially feed at
familiar with and have taken all possible safety precau- 50 IPM until welding current is sensed, or for 2 sec-
tions before starting the work. It is important that you onds if feeding without welding (loading wire).
follow these operating steps each time you use the ma-
chine. SLOW run-in may be selected using the left arrow
keys which will toggle the starting screen display to
DISPLAY LANGUAGE SELECTION SLOW (Figure B.7) or back to FAST (Figure B.6)
The SP-255 has multilingual display capability permit- RUN IN

START
ting the SP-255 prompts, messages, and other display = SLOW
information to be in any of five languages: English, Ger- FIGURE B.7
man, French, Spanish, and Japanese (Katakana). The
user may select the chosen language by simultaneously
2. Start Voltage
pressing the PROCESS Key and the appropriate Num-

ber Key per the instructions given in the appropriate lan- The START voltage setting (FIGURES B.6 and B.7)
guage on the Keypad Instruction Decal inside the may be offset from the factory programmed level
SP-255 door, also shown below: (00%) by up to ±30% above or below programmed
level using the right arrow keys, or from the gun
For ENGLISH display press both PROCESS
and 1 thumbswitch by positioning the screen cursor be-
keys at the same time. WIRE/GAS neath the START display using the IPM-VOLTS key.
(See “Gun Switch Keys” In this section.
Für die optische Anzeige auf PROCESS und 2
DEUTSCH sind beide Tasten WIRE/GAS

3. Spool Gun Start Mode
gleichzeitig zu drüken. If using optional spool gun mode (see “Making a
PROCESS 3 Weld with the Spool Gun” in Accessories section),
Pour l’affichage en FRANCAIS et
appuyez les deux touches en WIRE/GAS the RUN-IN portion of the starting screen is not
même temps. functional and will not be displayed. The START
voltage is adjusted as described above. The start-
4
Para monstrar en ESPAÑOL pulsar PROCESS
y ing screen is exited by pressing any key on the key-
las dos teclas a la vez. WIRE/GAS
pad except TIMERS OFF, IPM-VOLTS or any arrow
key. Closing Gun Trigger will also not clear the

PROCESS 5 starting screen.
WIRE/GAS
NOTE: It is not necessary to repeat the above proce-

dure each time the unit is powered up. That is, the unit
START MODE SELECTIONS will remember the start mode settings from the previous
power down and return you to that same state upon
The SP-255 permits selection of Fast/Slow Run-in wire your next power up. Thus, you need only perform the
feed speed as well as adjustment of the start striking above procedure when you want to change the start
voltage, to optimize arc starting, using the starting mode settings.
screen display.
PROCESS
When saving to Memory locations 1-5, the start mode
The starting screen (see Figures B.6 and B.7) at the time of saving will be saved into the memory lo-
WIRE/GAS
is displayed by pressing and holding both the cation as well. Thus, the operator should be aware that
TIMERS PROCESS key and the TIMERS OFF key at when recalling a memorized procedure, he is also re-
OFF
the same time. calling particular start mode which will override any
present start mode setting and remain in effect until ei-

ther the mode is changed using the above procedure

RUN IN
START containing another start mode is recalled.
= FAST
FIGURE B.6
IDEALARC® SP-255
B-11 B-11
OPERATION
LOADING THE WIRE REEL NOTE: The retaining spring side of the adapter should
be facing the center (inner) panel of the SP-255.

To mount a 22-30 lb. (10-14 kg) Readi-Reel package
using the Readi-Reel adapter provided: 7. To remove the Readi-Reel from Adapter, depress
retaining spring tab with thumb while pulling the
1. Remove the locking collar from the 2” (51 mm) O.D. Readi-Reel cage from the molded adapter with both
spindle and mount the K363P Adapter so the spin- hands. Do not remove adapter from spindle.
dle pin engages the hole provided in the Adapter.
Replace and tighten the locking collar. To mount 10 to 44 lb. (4.5 to 20 kg) spools: 8"
(200mm) [use K468 Adapter] and 12" (300 mm) di-
2. Rotate the spindle and adapter so the retaining ameter:
spring is at the 12 o'clock position.
1. Remove the locking collar and the Readi-Reel
3. Position the Readi-Reel so that it will rotate in a adapter (if installed) on the 2 inch (51 mm) diameter
clockwise direction when wire is dereeled from the spindle.
top of the coil. See Figure B. 8.
2. If using an 8” (200 mm) spool, place the K468
adapter on the spindle first. The hole in the adapter

arm is to engage the pin on the spindle.
MOULDED ADAPTER
RETAINING SPRING 3. Place the spool on the spindle, making certain the
brake driving pin enters one of the holes in the back
WIRE DEREELING side of the spool. Be certain the wire comes off the
DIRECTION reel in a clockwise direction when dereeled from the
top of the coil.
2" (51 mm) 4. Replace and tighten the locking collar for several
O.D. SPINDLE seconds.
LOCKING COLLAR
BRAKE TENSION
ADJUSTING SCREW
STARTING THE WELDER
READI-REEL
INSIDE CAGE WIRES Turn the "Power" switch to "ON". This lights the red
LED back lighting of the LCD display and a readable
screen should be visible on the display. Operate the

gun trigger for welder output and to energize the wire
FIGURE B. 8 - Wire Reel Loading. feed motor.
4. Set one of the Readi-Reel inside cage wires on the

slot in the retaining spring tab.
5. Lower the Readi-Reel to depress the retaining

spring and align the other inside cage wires with the
grooves in the molded adapter.
6. Slide the cage all the way onto the adapter until the
retaining spring "pops up" fully.
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-255
B-12 B-12
OPERATION
FEEDING ELECTRODE 1. Press end of gun against a solid object that is elec-
trically isolated from the welder output and press

WARNING the gun trigger for several seconds.
When inching, the electrode and drive mechanism are 2. If the wire "birdnests", jams, or breaks at the drive
always “hot” to work and ground. The electrode re- roll, the idle roll pressure is too great. Back the
mains “hot” several seconds after the gun trigger is re- thumb screw out 1/2 turn and run new wire through
leased. the gun. Repeat above step.
____________________________________
3. If the drive roll slips, loosen the gun cable Fast-Mate
NOTE: Check that the proper drive rolls and gun parts connection nut from the front of the SP-255. Pull
are used for the wire size and wire type being used. the gun cable forward about 6" (152 mm). There
should be a slight waviness in the exposed wire. If
1. Turn the Readi-Reel or spool until the free end of there is no waviness, the pressure is too low.
the electrode is accessible. Tighten the thumb screw 1/4 turn and lock the gun
cable in place. Repeat the above procedure.
2. While tightly holding the electrode, cut off the bent
end and straighten the first six inches (152 mm).

Cut off the first inch (25 mm). (If the electrode is
not properly straightened, it may not feed properly
into the outgoing guide tube or welding gun causing
a "birdnest".)
3. Turn off weld timers by pressing the timers off key.
4. 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.
5. Inch the electrode through the gun.

NOTE: If using the low speed starting feature of the SP-

255, the wire will feed at low speed for 2 seconds while
inching, then come up to the set speed.
6. 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 21/2 turns from full pressure. This is an ap-
proximate setting. The optimum idle roll pressure varies
with type of wire, wire diameter, surface condition, lu-
brication, and hardness. As a general rule, hard wires
may require greater pressure, and soft, or aluminum

wire, may require less pressure than the factory setting.
The optimum idle roll setting can be determined as fol-
lows:
IDEALARC® SP-255
B-13 B-13
OPERATION
MAKING A WELD IN AUTO MODE 14. If welding gas is to be used, turn on the gas supply
and set the required flow rate (typically 25-35

1. Check that the polarity is correct for the process CFH/12-16.5 l/min.).
being used.
NOTE: When using an Innershield electrode, the gas
2. Turn the ON/OFF POWER SWITCH to ON. nozzle may be removed from the insulation on the end
of the gun. This will give improved visibility and elimi-
3. Press PROCESS key. nate the possibility of the gas nozzle overheating.
4. Press LEFT UP or DOWN ARROW Keys to select 15. Connect work clamp to metal to be welded. Work
wire type being used. clamp must make good electrical contact to the
work. The work must be grounded.
5. Press CENTER UP or DOWN ARROW Keys to se-
lect wire diameter being used.
WARNING
6. Press RIGHT UP or DOWN ARROW Keys to select
welding gas type being used. WHEN USING AN OPEN ARC PROCESS, IT IS NEC-
ESSARY TO USE CORRECT EYE, HEAD, AND BODY

7. Press AUTO key. When the AUTO key is pressed, PROTECTION.
an alarm will beep three times. The following mes- ____________________________________
sage is displayed for 2.5 seconds: PROCESS
MUST MATCH WIRE & GAS. 16. Position electrode over joint. End of electrode may
be lightly touching the work.
8. Press UP or DOWN ARROW Keys to select metal
thickness. 17. Lower welding helmet, close gun trigger, and begin
welding. Hold the gun so the contact tip to work dis-
9. If SPOT or STITCH timing modes are NOT re- tance is about 3/8 inch (9.5 mm) (3/4" 19 mm for
quired, go to Step 12. Outershield).
10. If SPOT timing mode required: 18. To stop welding, release the gun trigger and then
pull the gun away from the work after the arc goes
a. Press SPOT key. out.
b. Press CENTER UP or DOWN ARROW keys to 19. When no more welding is to be done, close valve
select SPOT ON TIME required. on gas cylinder (if used). Momentarily operate gun
c. Press SPOT key to return to previous display. trigger to release gas pressure.
d. Go to Step 12.
20. Turn the ON/OFF POWER SWITCH to OFF.
11. If STITCH timing mode required:
a. Press STITCH key.

b. Press CENTER UP and DOWN ARROW keys
to select STITCH ON time required.
c. Press RIGHT UP or DOWN ARROW keys to
select STITCH OFF time required.
d. Press STITCH key to return to previous display.
e. Go to Step 12.
12. Inch the electrode through the gun and cable.
13. Cut the electrode within approximately 3/8" (9.5

mm) of the end of the contact tip (3/4" 19mm for

Outershield).
IDEALARC® SP-255
B-14 B-14
OPERATION
USING THE 4-STEP INTERLOCK FUNCTION IN 7. Press spot weld nozzle against the top sheet so the
AUTO MODE top and bottom sheets are tight together. If a spot
weld nozzle is not used, smoother welds will result
When the 4-Step Interlock function is not activated, the by moving the welding wire in a small circle while
trigger functions in the normal mode so that welding making the weld.
happens only when the trigger is closed.
8. Close the trigger and hold it closed until the arc
When the 4-Step Interlock function is activated, it goes out.
functions as follows:
When the arc is struck, the gun trigger may be released.

The welding continues until welding is stopped by either
of these two methods:
1) The arc is extinguished by manually jerking the gun

away from the work.
2) The gun trigger is closed and then released at the

end of the weld. This action returns the trigger func-
tion to the normal mode so the weld stops when the
trigger is released. Releasing the trigger reinstates
the trigger interlock function for the next weld. This
is the preferred Interlock mode because it provides
better control at the end of the weld and allows au-
tomatic burnback to prevent excessive wire feed
speed overrun.
The 4-step trigger feature does not function when using

SPOT or STITCH timed welding modes.
MAKING A SPOT WELD IN AUTO MODE
Arc spot plug welds are used when continuous welds

are not needed or to hold thin sheet metal together prior
to stitch welding or continuous welding. Arc spot plug

welds are made by using a punch to make a 3/16 inch
(5 mm) diameter hole in the top sheet and arc welding
through the hole into the back sheet.
To make an arc spot plug weld
1. Punch 3/16” (5 mm) hole in top sheet.
2. Set the procedure for the metal thickness to be

welded.
3. Press the SPOT key. SPOT : ON is displayed.

4. Press the CENTER UP & DOWN ARROW keys to
set the required Spot On time. Suggested initial
setting is 1.2 seconds.
5. Press the SPOT key. Display returns to Auto

screen. Spot timer status is shown in bottom left
corner of screen.
6. Install spot weld nozzle (if available) on gun.
IDEALARC® SP-255
B-15 B-15
OPERATION
MAKING A STITCH WELD IN AUTO MODE USING THE GUN THUMB SWITCH (MAG-
NUM 250SP GUN ONLY)

A stitch weld is used to weld thin material because
warpage and burnthrough are a problem. Properly ad- The Gun Thumb switch is used to control wire feed
justing the ON and OFF times and arc travel speed, per- speed, arc voltage, or to switch, or toggle, between
mits welding thin sheet metal using small welds that memory locations 4 and 5. See IPM VOLTS key and
result in minimum distortion and no burnthrough. TOGGLE key for control details. The Thumb switch is
used to increase or decrease IPM or VOLTS.
To make a stitch weld
1. Set the procedure for the metal thickness to be THE WIRE DRIVE ROLL
welded.
The drive roll provided with the SP-255 has two
2. Press STITCH key. Stitch screen is displayed. grooves, one for .030”-.035” (0.8-0.9mm) solid steel
electrode, and the other for .045” (1.2mm) solid steel
3. Press CENTER ARROW keys to set Stitch ON electrode. The welder is shipped with the drive roll in-
time. Start with a Stitch ON time setting of 0.5 sec- stalled in the .030”-.035” (0.8-0.9mm) position as indi-
onds. Increase the Time ON setting to increase cated by the stenciling on the exposed side of the drive
penetration and weld size. Decrease the Time ON roll. If .045” (1.2mm) electrode is to be used or one of
setting to reduce burnthrough and distortion. the optional drive rolls is required, then the drive roll
must be reversed or changed per the instructions pro-
4. Press the RIGHT ARROW keys to set the Stitch vided on the instruction decal inside the SP-255 Drive
OFF time. Start with a Time OFF setting of 0.5 Roll Access door.
seconds. Increase the Time OFF setting to reduce
burnthrough. Decrease the Time OFF setting to
produce a flatter and smoother weld.
FAN CONTROL
5. Press STITCH key. Auto screen is displayed. Stitch
timer status is display in lower left portion of screen. The fan motor is thermostatically controlled to provide
cooling for the transformer and other components only
6. Close the gun trigger and hold it closed for the when required. Even though the power switch is on,
length of seam. Hold gun in one place during ON the fan motor will not run when the machine does not
time and move gun just beyond edge of molten require fan cooling, such as when first turned on, or
metal during OFF time. For smoothest welds on when welding at low current of duty cycle procedures.
thinner metal, point gun slightly towards the direc-

tion of travel.
INPUT LINE VOLTAGE
PROTECTION
USING THE GUN TRIGGER SWITCH
HIGH LINE VOLTAGE -- If the line voltage exceeds
The Gun Trigger Switch turns on arc voltage, wire 121% of rated input voltage, the output will be reduced
feeder, and gas solenoid (except with Innershield) when to the lower level to protect voltage rating of the capac-
the Gun Trigger Switch is closed. When closed, the itor bank. A HIGH LINE message will be displayed if
LED screen displays the Auto or Manual screens, de- the output has been reduced (see Section on Explana-
pending on which mode is being used. When the Gun tion of Prompting and Error Messages in Trou-
Trigger Switch is released, or opened, arc voltage, wire bleshooting Section.)
feeder, and gas solenoid are turned off.
LOW LINE VOLTAGE -- You may not be able to get
NOTE: When the trigger is pulled, the wire feeder maximum output from the machine if the line voltage is
feeds wire at low speed regardless of the set wire feed
less than rated input. If the output you want is not ob-
speed until the welding arc starts or 2 seconds has tainable because of insufficient line voltage, a LOW
elapsed. This feature enhances starting and makes it LINE message will be displayed (see Section on Expla-
easier to set the stick out. The 2 second limit permits nation of Prompting and Error Messages in Trou-
high speed loading of the gun and cable. bleshooting Section.) The unit will continue to weld, but
the output will be less than what is set.
IDEALARC® SP-255
B-16 B-16
OPERATION
WIRE FEED OVERLOAD
PROTECTION
The SP-255 has solid state overload protection of the
wire drive motor. If the motor becomes overloaded, the
protection circuitry turns off the arc voltage, wire feed
speed and gas solenoid and then causes the alarm to
beep 3 times. The screen displays a message for 2.5
seconds stating that the motor is being overloaded and
the gun and wire drive should be checked. 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.
WELDING THERMAL OVERLOAD

PROTECTION
The SP-255 has built-in protective thermostats that re-
spond to excessive temperature. They open the wire
feed and welder output circuits if the machine exceeds
the maximum safe operating temperature because of a
frequent overload, or high ambient temperature plus
overload. The thermostats automatically reset when the
temperature reaches a safe operating level.
OVERCURRENT PROTECTION
The machine will automatically reduce the output if the
load on the machine exceeds 260 to 280 amperes. This
protects the welding power SCR’s from excessive short

circuit currents and from exceeding their temperature
rating before the thermostats can react. A CURRENT
OVERLOAD message is displayed when the overcur-
rent protection is active (see Section on Explanation
of Prompting and Error Messages in Troubleshooting
Section).
IDEALARC® SP-255
ACCESSORIES
TABLE OF CONTENTS
- ACCESSORIES SECTION -
ACCESSORIES SECTION ....................................... Section C

Options/Accessories ........................................................C-1
Making a Weld with the Spool Gun Adapter
and Spool Gun Installed...................................................C-1
Spot Key......................................................................C-2
Stitch Key ....................................................................C-3
Toggle Key...................................................................C-3
Disabling Spool Gun....................................................C-3
IDEALARC® SP-255
C-1 C-1
ACCESSORIES
DRIVE ROLL KITS (OPTIONAL K672-1)
The K672-1 Spool Gun Adapter Kit provides recessed

Drive Rolls available to feed different sizes and types of panel “up front” direct connection for use of the recom-
electrode: mended K487 Spool Gun (with remote speed control),
or the optional K469 Spool Gun (requires K518 Con-
nection Adapter).
Drive Rolls Drive Roll
Part No. It also provides single switch transfer of Trigger and
Steel Wire Sizes: Wire Speed Controls between the 250 SP gun or the
.025-.035” (0.6-0.9 mm) KP674-035S spool gun for same polarity welding with different wire
.030-.045” (0.8-1.2 mm) KP674-045S and gas processes.
.045” Cored (1.2 mm) KP674-045C
The kit includes a spool gun adapter module assembly
Aluminum Wire Sizes: with plug for front installation and connects to the ma-
3/64” (1.2 mm) KP674-3/64A chine. Also includes a rear gas inlet fitting with hose, a
gun and cable holder, mounting hardware, and installa-
tion and operation instructions. (L-9696).
3/64” (1.2 mm) ALUMINUM FEEDING

For spool gun installation refer to L9696 instructions in-
KIT (K673-1) cluded with spool gun adapter kit (K672-1).
The kit provides gun and wire drive conversion parts to

weld with 3/64” (1.2 mm) aluminum wire. 5356 alloy
aluminum wire is recommended for best push feeding
CAUTION
performance. The spool gun module is intended for use with Lin-
coln Electric® Magnum™ Spool Guns only. Use
Kit includes drive roll and incoming guide tube for the with other units may cause damage to the equip-
wire drive, and a 450 gun tube, liner and two contact ment. For Spool Gun operation, refer to the instruc-
tips for the gun. Install per the S21529 Installation In- tion manual provided with the Magnum™ Spool
structions provided with the kit. Gun.
____________________________________
8” SPOOL ADAPTER (K468)
MAKING A WELD WITH THE SPOOL
Permits use of 8” (200 mm) spools on the SP-255 spin-

dle.
GUN ADAPTER AND SPOOL GUN IN-
STALLED
DUAL CYLINDER MOUNTING KIT
The toggle switch on the front of the spool gun adapter
(K671-1) box permits quick transfer between the use of the SP-
255 with its feeder gun and the connected spool gun for
Permits stable side-by-side mounting of two full size [9” same polarity electrodes.
(225 mm) dia. x 5’ (1.6 m) high] gas cylinders, with “no
lift” loading. Simple installation with installation kick
stand and easy instructions. Includes upper and lower CAUTION
cylinder supports, wheel axles and mounting hardware. In either transfer switch position, closing the gun
trigger will cause the electrode of both guns to be
SPOOL GUN DESCRIPTION electrically “HOT”. Be sure unused gun is posi-
tioned so that electrode or tip will not contact metal
The optional Magnum SG Spool Gun is a lightweight, case or other metal common to work.
well-balanced, hand held semi-automatic wire feeder. It ____________________________________

is available in two models, the K469-25 and the K487-
25 with remote wire speed control.
SPOOL GUN ADAPTER KIT
IDEALARC® SP-255
C-2 C-2
ACCESSORIES
1 Transfer switch in FEEDER position: crease (down arrow) arc voltage.
a. Disables spool gun trigger, wire feed and gas d. Procedure settings may be stored in memory
output. for later recall. (See Memory Keys in Opera-
tion Section.)
b. Closing feeder gun trigger starts feeder gun
welding and makes both electrodes electrically 4. The following procedure settings can be used as
“HOT”. initial settings for making test welds to determine
final settings:
2. Transfer switch in SPOOL position:
a. Disables feeder gun wire feed and gas output. Wire Diameter Arc Voltage
However, closing feeder gun trigger will make In. (mm) WFS Setting Setting
both electrodes electrically “HOT” and activate
spool gun gas output. .030 (0.8) 42% 15V
.035 *(0.9) 39% 16V
b. Closing spool gun trigger starts spool gun weld- 3/64 (1.2) 32% 21V
ing and makes both electrodes electrically

“HOT”. Spot Weld Timer On
SPOT SPOT: ON
3. Operation with SP-255: SET
2.50s
DISPLAY
a. Turn the input power ON. With the transfer

Selected On Time
switch in SPOOL gun position, the display will
flash the messages: SPOT KEY
Anytime the Spot weld timer is on and the display is in
SPOOL GUN HAS PRESS MANUAL TO Spool Mode, the word SPOT will appear in the bottom
BEEN CONNECTED ENTER SETTINGS left corner of the display.
b. Pressing the Manual key will change the dis-

TYPICAL SPOT KEY PRESS SEQUENCE
play to the spool screen.
Spool screen is displayed prior to pressing Spot key.
Spot key is pressed, Spot On timer is activated and the
MANUAL SPOOL: WFS VOLTS Arc display changes to Spot screen. Spot On timer can now
50% 18.0 Voltage be adjusted using the center arrow keys. Once the
timer has been set, pressing the Spot key again returns
Percentage of Wire Feed Speed the display to the original Spool screen with the Spot
timer status indicated in the bottom left corner.
c. Pressing the up or down arrow keys under volts
on the display will increase or decrease your
welding voltage.
Press Set Timer
The 1-99% on the display represents a percent-
SPOOL: WFS VOLTS SPOT SPOT: ON
age of wire feed speed. This is the set speed 50% 18.0 SET
2.50s
DISPLAY
for the K469 spool gun and the maximum set
speed for the K487 spool gun (with the remote
Press
control in gun handle at maximum). The remote
control turned to minimum will give you approx- SPOT SPOOL: WFS VOLTS
SET SPOT 50% 18.0
imately 50% of the maximum set WFS. DISPLAY
Left arrow keys -- do not function.
Center arrow keys -- Increase (up arrow) or de-

crease (down arrow) percent of wire feed
speed.
Right arrow keys -- Increase (up arrow) or de-
IDEALARC® SP-255
C-3 C-3
ACCESSORIES
STITCH KEY TYPICAL TOGGLE KEY PRESS SEQUENCE
Anytime the Stitch weld timers are on and the display is

in Spool Mode, the abbreviation STCH will appear in the Spool screen is displayed prior to pressing Toggle key.
bottom left corner of the display. Toggle key is pressed, memory 4 is recalled and ap-
pears on the display. The unit is now in toggle mode.
Pressing the Toggle key again “toggles” the unit, and
SPOT STITCH: ON - - - OFF
SET memory 4 is recalled and appears on the display. This
1.90s 1.25s
DISPLAY whole cycle is repeatable as long as the unit remains in
Toggle mode.
Stitch On Time Stitch Off Time
Press
SPOOL: WFS VOLTS TOGGLE
TYPICAL STITCH KEY PRESS SEQUENCE 50% 18.0 4 5
Spool screen is displayed prior to pressing Stitch key.

Press
Stitch timers are activated and the display changes to
Stitch screen. Stitch ON and OFF timers can now be 4 SPOL: WFS VOLTS TOGGLE 5 SPOL: WFS VOLTS
SPOT 50% 18.0 STCH 50% 18.0
adjusted using the center and right arrow keys. Once 4 5
the timers have been set, pressing the Stitch key again
returns the display to the original Spool screen with the Press
Stitch timer status indicated in the bottom left corner. TOGGLE
4 5
Press Set Timers

SPOOL: WFS VOLTS STITCH STITCH: ON - - - OFF
50% 18.0 SET
1.90s 1.25s
DISABLING SPOOL GUN
DISPLAY
Press
When the Spool Gun Adapter box transfer switch is set
STITCH
SET
SPOOL: WFS VOLTS to FEEDER Gun position, the display will flash between
STCH 50% 18.0
DISPLAY
these two messages:
SPOOL GUN HAS PRESS PROCESS TO

TOGGLE KEY BEEN REMOVED ENTER SETTINGS
Memory Currently Active
TOGGLE 4 SPOL: WFS VOLTS 5 SPOL: WFS VOLTS Pressing the Process key will return you to the last
4 5 SPOT 50% 18.0 STCH 50% 18.0 process entered before the Spool gun was attached.
The first time this key is pressed it turns on toggle mode

and recalls the setup in memory 4. This mode allows
ENTER SOLID STEEL GAS
PROCESS
you to toggle between the setups in memory 4 and WIRE/GAS
WIRE .035 ArCO2
memory 5. Each time the key is pressed, it alternates
between the two memories. The toggle screen displays
the memory number the current setup was recalled
from, indicates spool (SPOL:) mode, displays percent-
age of wire feed speed, and set arc voltage. The cursor
underlines the memory number currently selected.
IDEALARC® SP-255
MAINTENANCE
TABLE OF CONTENTS
- MAINTENANCE SECTION -
MAINTENANCE SECTION ....................................... Section D

Safety Precautions ...........................................................D-1
Routine and Periodic Maintenance ..................................D-1
Contact Tip and Gas Nozzle Installation ..........................D-3
Liner Removal and Replacement.....................................D-3
Liner Removal, Installation, and Trimming Instructions
for Magnum 250SP ..........................................................D-4
Gun Handle Disassembly.................................................D-5
Magnum 250SP Gun Parts and Accessories ...................D-6
IDEALARC® SP-255
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 sizes
• Disconnect input power at main input supply they will feed. If a wire size other than that stamped on
prior to working inside machine. the roll is used, the drive roll must be changed.
____________________________________
Read the Safety Precautions in the front of this manual Cable Cleaning
before working on this machine.
Clean cable liner after using approximately 300 pounds
(136 kg) of electrode. Remove the cable from the wire
ROUTINE AND PERIODIC feeder and lay it out straight on the floor. Remove the
MAINTENANCE contact tip from the gun. Using an air hose and only
partial pressure, gently blow out the cable liner from the
gas diffuser end.
Disconnect input AC power supply lines to the machine
before performing periodic maintenance, tightening,
cleaning, or replacing parts. See Figure D.1. CAUTION
Excessive pressure at the start may cause dirt to
Perform the following daily: form a plug.
____________________________________
1. Check that no combustible materials are in the
welding area or around the machine. Flex the cable over its entire length and again blow out
the cable. Repeat this procedure until no further dirt
2. Remove any debris, dust, dirt, or materials that comes out.
could block the air flow to the machine for cooling.
3. Inspect the electrode cables for any slits, punctures Gun Tubes and Nozzles
in the cable jacket, or any condition that would af-

fect the proper operation of the machine. 1. Replace worn contact tips as required.
2. Remove spatter from inside of gas nozzle and from

Perform Periodically: tip after each 10 minutes of arc time or as required.
Clean the inside of the machine with low pressure air

stream. Clean the following parts. Refer to Figure D.1.
Main transformer and choke.

Electrode and work cable connections.
SCR rectifier bridge and heat sink fins.
Control board.
Fan Assembly.
NOTE: The fan motor has sealed bearings which re-

quire no maintenance.
IDEALARC® SP-255
D-2 D-2
MAINTENANCE
7 2
4
6
5
1 Control Board 4 Choke 7 Wire Drive Unit
2 Fan Assembly 5 Main Transformer

3 SCR Rectifier 6 Capacitor Bank
Figure D.1 - Component Locations

IDEALARC® SP-255
D-3 D-3
MAINTENANCE
CONTACT TIP AND GAS NOZZLE
INSTALLATION
1. Choose the correct size contact tip for the elec-
trodes being used (wire size is stenciled on the side
of the contact tip) and screw it snugly into the gas
diffuser.
2. Screw the appropriate fixed gas nozzle fully onto

the diffuser. Either the standard .50" (12.7 mm)
flush nozzle or other optional flush or recessed
(spray arc) nozzle sizes may be used. (See table
at the end of this section.)
3. Be sure the nozzle insulator is fully screwed onto

the gun tube and does not block the gas holes in
the diffuser.
4. If using an optional adjustable slip on nozzle, slip

the appropriate gas nozzle onto the insulator. Ei-
ther a standard .40" (12.7 mm) or optional .62"
(15.9 mm) I.D. slip-on gas nozzle may be used and
should be selected based on the welding applica-
tion.
5. Adjust the gas nozzle as appropriate for the GMAW

process to be used. Typically, the contact tip end
should be flush to .12" (3.2 mm) extended for the
short-circuiting transfer process and .12" (3.2 mm)
recessed for spray transfer.
LINER REMOVAL AND

REPLACEMENT
NOTE: Changing the liner for a different wire size re-
quires replacement of the gas diffuser per the table
below to properly secure the different liner.
Fixed Nozzle Gas Adjustable Nozzle

Diameter of Replacement Liner Size Stencilled on
Diffuser Part No. Gas Diffuser Part No.
Electrodes Used Part Number End of Liner Bushing
(and Stencil) (and Stencil)
.025-.030” Steel KP1934-2 KP2026-3 KP2026-2

.030” (0.8 mm)
(0.6-0.8 mm) (M16087-2) (S19418-3) (S19418-2)
.035-.045” Steel KP1934-1 KP2026-3 KP2026-1

.045” (1.2 mm)
(0.9-1.2 mm) (M16087-1) (S19418-3) (S19418-1)
3/64” Aluminum KP1936-1 KP2026-3 KP2026-1

(Plastic Liner)
(1.2 mm) (M16107-1) (S19418-3) (S19418-1)
IDEALARC® SP-255
D-4 D-4
MAINTENANCE
LINER REMOVAL, INSTALLATION,
AND TRIMMING INSTRUCTIONS

FOR MAGNUM 250SP
NOTICE: The variation in cable lengths prevents the in-
terchange ability of liners between guns. Once a liner
has been cut for a particular gun, it should not be in-
stalled in another gun unless it can meet the liner cutoff
length requirement. Liners are shipped with the jacket
of the liner extended the proper amount.
1. Remove the gas nozzle (and nozzle insulator, if

used) to locate the set screw in the gas diffuser
which is used to hold the old liner in place. Loosen
the set screw with a 5/64" (2.0 mm) Allen wrench.
2. Remove the gas diffuser from the gun tube.
3. Lay the gun and cable out straight on a flat surface.

Remove the liner nut from the Fast-MateTM connec-
tor end of the cable and pull the liner out of the
cable.
4. Insert a new untrimmed liner into the connector end

of the cable. Be sure the liner busing is stenciled
appropriately for the wire size being used.
5. Fully seat the liner bushing into the connector. Fin-

ger tighten the liner nut onto the cable connector.
The gas diffuser, at this time, should not be installed
onto the end of the gun tube.
6. With the gas diffuser still removed from the gun

tube, be sure the cable is straight, and then trim the

liner to the length shown in Figure D.2. Remove
any burrs from the end of the liner.
7. Screw the diffuser onto the end of the gun tube and
securely tighten. Be sure the gas diffuser is correct
for the liner being used. (See table and diffuser
stencil.)
8. Tighten the set screw in the side of the gas diffuser

against the cable liner using a 5/64" (2.0 mm) Allen
wrench.
CAUTION
This screw should only be gently tightened. Over

tightening will split or collapse the liner and cause
poor wire feeding.
____________________________________
IDEALARC® SP-255
D-5 D-5
MAINTENANCE
LINER ASSEMBLY (LINER BUSHING

TO BE TIGHTLY SEATED) 1-1/4"
FEEDER END FAST-MATE
TM (31.8MM)
CONNECTOR ASSEMBLY LINER TRIM
LENGTH
SET SCREW
LINER NUT GAS DIFFUSER
NOZZLE INSULATOR (IF USED)
GAS NOZZLE
Figure D.2 - Liner Trim Length for the 250SP Gun.
GUN HANDLE DISASSEMBLY

The internal parts of the gun handle may be inspected
or serviced if necessary.
The gun handle consists of two halves that are held to-
COUNTER-
CLOCKWISE
gether with a collar on each end. To open up the han-

dle, turn the collars approximately 60 degrees
counterclockwise (the same direction as removing a
right hand thread) until the collar reaches a stop. Then
pull the collar off the gun handle. If the collars are diffi-
cult to turn, position the gun handle against a corner,
place a screwdriver against the tab on the collar and
give the screwdriver a sharp blow to turn the collar past
an internal locking rib. See Figure D.3.
Figure D.3 - Gun Handle Disassembly.

IDEALARC® SP-255
D-6 D-6
MAINTENANCE
MAGNUM 250SP GUN PARTS AND
ACCESSORIES
Description Part Number English Size Metric Size
CABLE LINER
For 15’ (4.5 m) KP1934-1 .025 - .030” 0.6 - 0.8 mm
or shorter Cable KP1934-1* .035-.045” 0.9 - 1.2 mm
KP1955-1** 3/64” 1.2 mm
(Alum. wire) (Alum. wire)
CONTACT TIPS
Standard Duty KP2020-6B1 .025” 0.6 mm
KP2020-7B1 .030” 0.8 mm
KP2020-1B1* .035” 0.9 mm
KP2020-2B1* .045” 1.2 mm
Heavy Duty KP2021-1B1 .035” 0.9 mm

KP2021-2B1 .045” 1.2 mm
Tapered KP2022-5B1 .025” 0.6 mm
KP2022-6B1 .030” 0.8 mm
KP2022-1B1 .035” 0.9 mm
KP2022-2B1 .045” 1.2 mm
Tab (For Aluminum) KP2010-5B1** 3/64” (Alum. wire) 1.2 mm
GAS NOZZLES
Fixed (Flush) KP1931-1 3/8” 9.5 mm
KP1931-2* 1/2” 12.7 mm
KP1931-3 5/8” 15.9 mm
Fixed (Recessed) KP1930-1 3/8” 9.5 mm
KP1930-2 1/2” 12.7 mm
KP1930-3 5/8” 15.9 mm
Requires:
Gas Diffuser As’bly KP2026-3 .025-.045 0.6-1.2 mm
Adjustable Slip-On KP1935-2 1/2” 12.7 mm
Requires:
Nozzle Insulator As'bly KP2025-1
Requires:
Gas Diffuser As'bly KP2026-2 .025-.030” 0.6-0.8 mm
KP2026-1 .035-.045” 0.9-1.2 mm
Gasless Nozzle KP1947-1***
(For Innershield)
GUN TUBE
ASSEMBLIES
Standard (600) KP2015-1*
450 KP2041-1***
* Included with Idealarc® SP-255.

** Included with K673-1 3/64" (1.2 mm) Aluminum
Feeding kit.
5356 Alloy aluminum wire is recommended to alle-
viate potential soft wire feeding problems with push-
type wire feeding.

*** Requires KP2026-1 Gas Diffuser Assembly.
IDEALARC® SP-255
THEORY OF OPERATION
TABLE OF CONTENTS
- THEORY OF OPERATION SECTION -
THEORY OF OPERATION SECTION ...................... Section E

Power Supply Operation .................................................E-1
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-255
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-255 through a line switch located on the front
panel.
A reconnect panel allows the user to configure the ma-

chine for the desired input voltage. This AC input volt-
age is applied to the primary of the main transformer
and to the thermostatically controlled fan motors. The
transformer changes the high voltage, low current input
power to a low voltage, high current output. In addition,
the main transformer also has an isolated center tapped
30VAC auxiliary winding that supplies power to the Con-
trol Board for SCR gate drive and gas solenoid opera-
tion. The weld power windings connect to the Control

Board as well as to the main SCR Rectifier.

IDEALARC® SP-255
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 controls 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-255
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 assem-

bly is filtered by the capacitor bank and the output
choke, which is in series with the gun and welding load,
resulting in a constant voltage output at the output ter-
minals of the machine.

IDEALARC® SP-255
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 con-
trolled which in turn regulates the electrode wire feed
speed through the gun.

IDEALARC® SP-255
E-5 E-5
THEORY OF OPERATION
THERMAL PROTECTION
A thermostat protects the machine from excessive op-

erating temperatures.. Excessive operating tempera-
tures may be caused by a lack of cooling air or
operating the machine beyond the duty cycle and output
rating. There are three thermostats within the SP-255
machine. One of the thermostats, located on the output
choke, energizes the cooling fan motors when required.
The other choke thermostat "opens" the trigger circuit,
preventing machine weld output and wire feed, if exces-
sive operating temperatures are detected. 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 op-
erating 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 ob-
structed, then the input power must be removed and the
fan problem or air obstruction be corrected.
IDEALARC® SP-255
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 de- This gate pulse must be more positive than the cathode
vice used to control rather large currents to a load. An voltage. Since there is a standard PN junction between
SCR acts very much like a switch. When a gate signal gate and cathode, the voltage between these terminals
is applied to the SCR it is turned ON and there is current must be slightly greater than 0.6V. Once the SCR has
flow from anode to cathode. In the ON state the SCR fired it is not necessary to continue the flow of gate cur-
acts like a closed switch. When the SCR is turned OFF rent. As long as current continues to flow from anode to
there is no current flow from anode to cathode thus the cathode the SCR will remain on. When the anode to
device acts like an open switch. As the name suggests, cathode current drops below a minimum value, called
the SCR is a rectifier, so it passes current only during holding current, the SCR will shut off. This normally oc-
positive half cycles of the AC supply. The positive half curs as the AC supply voltage passes through zero into
cycle is the portion of the sine wave in which the anode the negative portion of the sine wave. If the SCR is
of the SCR is more positive than the cathode. turned on early in the positive half cycle, the conduction
time is longer resulting in greater SCR output. If the gate
When an AC supply voltage is applied to the SCR, the firing occurs later in the cycle the conduction time is less
device spends a certain portion of the AC cycle time in 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.
An SCR is fired by a short burst of current into the gate.
IDEALARC® SP-255
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
Explanation of Prompting Error Messages .....................F-11
Test Procedures
SP-255 Main Transformer Test .......................................F-14
Static SCR Rectifier Assembly Test ................................F-17
Active SCR Rectifier Assembly Test ...............................F-20
SP-255 Keypad Resistance Test ....................................F-23
Wire Drive Motor and Tach Feedback Test.....................F-26
Oscilloscope Waveforms.....................................................F-29
Replacement Procedures
Control PC Board Removal and Replacement ...............F-34
Keypad Removal and Replacement ...............................F-36
Wire Drive Assembly Removal and Replacement ..........F-38
SCR Output Rectifier Removal and Replacement..........F-41
Capacitor Bank Removal and Replacement...................F-43
Main Transformer Removal and Replacement ...............F-45
Fan Motor and Fan Removal and Replacement.............F-47
Retest After Repair .........................................................F-50
IDEALARC® SP-255
F-1 F-1
HOW TO USE TROUBLESHOOTING GUIDE
WARNING
Service and repair should be performed by only 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 help you Step 3. PERFORM COMPONENT TESTS. The
locate and repair possible machine malfunctions. last column, labeled “Recommended Course of
Simply follow the three-step procedure listed Action” lists the most likely components that may
below. have failed in your machine. It also specifies the

appropriate test procedure to verify that the subject
component is either good or bad. If there are a
Step 1. LOCATE PROBLEM (SYMPTOM). Look number of possible components, check the com-
under the column labeled “PROBLEM” (SYMP- ponents in the order listed to eliminate one possi-
TOMS). This column describes possible symp- bility at a time until you locate the cause of your
toms that the machine may exhibit. Find the listing problem.
that best describes the symptom that the machine
is exhibiting. Symptoms are grouped into four
main categories: Output Problems, Engine Prob- All of the referenced test procedures referred to in
lems Function Problems, and Welding Problems. the Troubleshooting Guide are described in detail
at the end of this section. Refer to the Trou-
bleshooting and Repair Table of Contents to locate
Step 2. PERFORM EXTERNAL TESTS. The each specific Test Procedure. All of the referred to
second column, labeled “POSSIBLE AREAS OF test points, components, terminal strips, etc., can
MISADJUSTMENT(S)”, lists the obvious external be found on the referenced electrical wiring dia-
possibilities that may contribute to the machine grams and schematics. Refer to the Electrical Di-
symptom. Perform these tests/checks in the order agrams Section Table of Contents to locate the
listed. In general, these tests can be conducted appropriate diagram.
without removing the case cover.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs
safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before
you proceed. Call 1-888-935-3877.
IDEALARC® SP-255
F-2 F-2
PC BOARD TROUBLESHOOTING PROCEDURES
- Remove the PC board from the static-shielding bag

WARNING and place it directly into the equipment. Don’t set the
ELECTRIC SHOCK PC board on or near paper, plastic or cloth which could
can kill. have a static charge. If the PC board can’t be installed
immediately, put it back in the static-shielding bag.
• Have an electrician install and
- If the PC board uses protective shorting jumpers, don’t
service this equipment. Turn the
remove them until installation is complete.
input power OFF at the fuse box
before working on equipment. Do - If you return a PC board to The Lincoln Electric Com-
not touch electrically hot parts. pany for credit, it must be in the static-shielding bag.
This will prevent further damage and allow proper fail-
ure analysis.
CAUTION
4. Test the machine to determine if the failure
Sometimes machine failures appear to be due to PC symptom has been corrected by the
board failures. These problems can sometimes be replacement PC board.
traced to poor electrical connections. To avoid problems

when troubleshooting and replacing PC boards, please NOTE: It is desirable to have a spare (known good)
use the following procedure: PC board available for PC board troubleshooting.
1. Determine to the best of your technical ability NOTE: Allow the machine to heat up so that all
that the PC board is the most likely component electrical components can reach their operating
causing the failure symptom. temperature.
2. Check for loose connections at the PC board to 5. Remove the replacement PC board and
assure that the PC board is properly connected. substitute it with the original PC board to
recreate the original problem.
3. If the problem persists, replace the suspect PC
a. If the original problem does not reappear by
board using standard practices to avoid static
substituting the original board, then the PC
electrical damage and electrical shock. Read
board was not the problem. Continue to look
the warning inside the static resistant bag and
for bad connections in the control wiring
perform the following procedures:
harness, junction blocks, and terminal strips.
PC board can be damaged by static electricity.

b. If the original problem is recreated by the

- Remove your body’s static substitution of the original board, then the PC
charge before opening the static- board was the problem. Reinstall the
shielding bag. Wear an anti-static replacement PC board and test the machine.
wrist strap. For safety, use a 1 6. Always indicate that this procedure was
Meg ohm resistive cord connected followed when warranty reports are to be
to a grounded part of the submitted.
ATTENTION equipment frame.
NOTE: Following this procedure and writing on the war-
Static-Sensitive - If you don’t have a wrist strap, ranty report, “INSTALLED AND SWITCHED PC
Devices touch an un-painted, grounded, BOARDS TO VERIFY PROBLEM,” will help avoid de-
Handle only at part of the equipment frame. Keep nial of legitimate PC board warranty claims.
Static-Safe touching the frame to prevent
Workstations static build-up. Be sure not to
touch any electrically live parts at
the same time.
- Tools which come in contact with the PC board must

be either conductive, anti-static or static-dissipative.
IDEALARC® SP-255
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 Elec- 1. Contact The Lincoln Electric
is Evident tric Authorized Field Service Fa- Service Dept. 1-888-935-3877.
cility.
Machine is dead - No Open Circuit 1. Make certain that the input power 1. Check input power switch (S1). It
Voltage output and No Wire Feed switch is in the "ON" position. may be faulty.
when gun trigger is pulled. No Dis-
play. 2. Check the input voltage at the 2. Check for loose or broken wires
machine. Input voltage must at the reconnect panel.
match the rating plate and the re-
connect panel. 3. Perform Main Transformer Test.
3. Blown or missing fuses in the

input line.
1. Check the input voltage at the

No Open Circuit Voltage output but machine. Input voltage must 1. Check for loose or broken con-
wire feeds normally when gun trigger match the rating plate and the re- nections at the output terminals,
is pulled. - Display lights properly. connect panel - High or Low Line the choke, the capacitor bank
message may be displayed. and all heavy current carrying
leads.
2. The gun may be faulty. Check or
replace. 2. Make sure that the transformer
secondary leads are securely
connected to the SCR Rectifier
Assembly.
3. Perform the SCR Rectifier As-

sembly 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, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877.
IDEALARC® SP-255
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 prop- machine operates normally after connections. See Wiring Dia-
erly. a cooling off period then check gram.
for proper fan operation and ven-
tilation for both fans. Make cer- 2. Perform The Main Transformer
tain that the machine's duty cycle Test.
is not 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 connec-
causing wire to "stub". on the display then proceed to tions of the heavy current carry-
Welds are "cold". Machine cannot Explanation of Prompting and ing 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. Re-
3. Check gun and work cable for place if necessary.
loose or faulty connections. WARNING: The liquid elec-
trolyte in these capacitors is
toxic. Avoid contact with any
portion of your body.

sembly Test.
4. Perform the Main Transformer

Test.

Replace.
CAUTION
IDEALARC® SP-255
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 trig-
present continuously or pulsing when is resolved the gun trigger circuit ger leads for grounds or shorts.
gun trigger is NOT activated. is faulty. Repair or replace. 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. Per-
2. If the problem persists after gun form 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 and match the rating plate and the re- 2. Perform the Main Transformer
the display do not function properly. connect panel - High or Low Line Test.
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.- Re-
place. 4. The LCD display may be faulty. -

Replace.
CAUTION
IDEALARC® SP-255
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 pres-
ent then the audio 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.- Re-
play does NOT change. place. 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 trigger selected that requires gas flow. connecting it from Plug J21 and
is pulled. Wire feeds and weld volt- applying a 12VDC external sup-
age is present. The display functions 2. Check gas source and hoses for ply to the gas solenoid. If the so-
properly. leaks or kinks. lenoid does NOT activate then
it may be faulty. - Replace.
2. Check wiring to Plugs J20 and

J21 (see wiring diagram). Make
sure Jumper Plug is in place
3. The control board may be faulty.-

Replace.
No readable message on the display. 1. Check the input voltage at the 1. The display board may be faulty.
Backlight is lit indicating there is machine. The input voltage must Replace.
power to the machine. match the rating plate and the re-
connect panel. 2. The control board may be faulty.
Replace.
2. Turn the line switch (S1) off. Wait
a minute and turn power on. If
problem is not resolved contact
your local Lincoln Electric Author-
ized Field Service Facility.
CAUTION
IDEALARC® SP-255
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 while 1. Check for mechanical restrictions 1. Check the motor armature cur-
welding and the MOTOR OVER- in the wire feeding path. The gun rent. Normal armature current is
LOAD message appears on the dis- cable may be clogged. 1.5 - 2.5 amps.
play. 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.
“CURRENT OVERLOAD” message 1. Check procedures. 1. Max current is 250 Amps.

appears while welding
2. Check line volts. 2. Must be ±10% of rated line volts.
3. Check shunt. 3. Shunt rating is 50mv @ 300

Amps.
4. Check output capacitors.

CAUTION
IDEALARC® SP-255
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 re- and Tach Feedback Test.
place.
- 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 restriction and Tach Feedback Test.
voltage is present. in the wire feed path, or improper
drive roll pressure. 2. The control board may be faulty.
- Replace.
2. The gun liner may be clogged.

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

when the gun trigger is pulled
then contact your local Lincoln
Electric Authorized Field Service
Facility.
CAUTION
IDEALARC® SP-255
F-9 F-9

WELDING PROBLEMS
The arc is unstable and or "hunting". 1. Check for worn or melted contact 1. Check for loose connections at
tip. the output terminals, the choke,
the capacitor bank and all heavy
2. Check for loose or faulty connec- current carrying leads.
tions on the work and electrode
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. Re-
gas are correct for process being place if necessary.
used. WARNING: The liquid elec-
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 stubbing and electrode polarity is correct be faulty. Check for loose con-
into plate. for the process being used. nections at the capacitors. Also
check for leaky capacitors. Re-
2. Make sure shielding gas is cor- place if necessary.

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

sembly Test.

Replace.
CAUTION
IDEALARC® SP-255
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 temper-

ature antisieze lubricant (such as
Lincoln E2607 Graphite Grease)
may be applied to the contact tip
threads.
CAUTION
IDEALARC® SP-255
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-255 rating can be accommo-
dated 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-255 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 memory
CONTAINS SETUP number is determined by the memory number key that was pressed following
Save.
MEMORY 2 An attempt was made to recall a setup from a memory that does not contain
IS EMPTY one. The actual memory number is determined by the memory number 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 mem-
ory 4 to find out what process is required. The memory number indicates
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-255
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-255 will recall the
setup and reset the improper data to within machine limits. However, all set-
tings 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 solenoid.
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 In-
NEG. POLARITY nershield wire type is selected.
LOW LINE: CHECK Indicates to operator that the input line voltage is too low to obtain the output
RECONNECT PANEL 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 ma-
PRESS ANY KEY chine is not obtainable at that line voltage and load current. The operator
TO STOP MESSAGE 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 (ap-
proximately 1.3 sec.) allowing the operator to view the increase or decrease
in that setting.
IDEALARC® SP-255
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 op-
RECONNECT PANEL erator 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 weld-
TO STOP MESSAGE ing 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 oper-
ator to view the increase or decrease in that setting.
CURRENT OVERLOAD Indicates to operator that too much current is being drawn from the machine,
REDUCE OUTPUT 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 WFS will reduce
PRESS ANY KEY the output requirement and allow operation within the machine rating. Press-
TO STOP MESSAGE ing any key or gun switch when the operator is not welding will stop the mes-
sage 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 seconds) allowing the operator to view the in-
crease or decrease in that setting.
SXXXXX -X Only displayed at power-up. Displays the part number of the ROM ASSEM-
ROM ASSEMBLY BLY 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 switched in and connected and the
BEEN CONNECTED Manual key must be pressed to enter any Spool gun welding procedures.
PRESS MANUAL
TO ENTER SETTINGS
SPOOL GUN HAS Reminder that the Spool gun has been switched out or removed and the
BEEN REMOVED Process key must be pressed to enter SP-255 weld settings. This message
may also be displayed if there is an open lead in the spool gun 6-pin plug
PRESS PROCESS TO assembly.
TO ENTER SETTINGS
IDEALARC® SP-255
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 precau-
tions 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 1-888-935-3877.
_____________________________________________________________
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” (8 mm) Nut Driver
Volt-Ohm Meter
IDEALARC® SP-255
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 Pan-

els with a 5/16” nut driver.
3. Locate Plug J3 and Plug J6 on the

G2801 Control PC Board.
See Figure F.1.
NOTE: The location of Plugs may vary

depending on the machine code.
SP-255 CONTROL
G2801
J2
J8
J7
J3
J4
J9
#206
#203 #204A #202
(4J6)
(3J3) (2J3) (1J3)
#209
(7J6)
J5 J6
#208
(16J6)
FIGURE F.1 - G2801 Control PC Board Main Transformer Test Points.
IDEALARC® SP-255
F-16 F-16
4. Locate the following leads on Plug J3 a. Turn the machine OFF between
on the Control Board. each test.
G2801:
b. Carefully insert the meter probes
LEAD PLUG
into the back of each Molex Plug
LOCATION
pin cavity to perform the test.
#202 1J3 G2801:
#203 3J3 c. If any of the voltages tested are
#204 A 2J3
FROM TO EXPECTED
5. Connect main input power to the ma- LEAD LEAD VOLTAGE
chine.
#208 #209 60 VAC
6. Turn the Idealarc® SP-255 ON/OFF (16J6) (7J6)
POWER SWITCH to ON. #208 #206 30 VAC
(16J6) (4J6)
7. Make the following voltage tests at

Plug J3. #209 #206 30 VAC
(7J6) (4J6)
a. Turn the machine OFF between
each test. incorrect, check for loose or bro-
ken leads between the test
b. Carefully insert the meter probes points and the main transformer.
into the back of each Molex Plug
pin cavity to perform the test. d. If ALL the voltages tested are in-
G2801: correct or missing, go to Step 12.
8. Turn OFF the machine
FROM TO EXPECTED 12. Test for correct nameplate input volt-
LEAD LEAD VOLTAGE age between the H1 lead at the
ON/OFF POWER SWITCH to H2 or
#202 #203 30 VAC H3 at the reconnect panel. Voltage
(1J3) (3J3) tested will vary depending on Input
Voltage Connection. See wiring dia-

#202 #204 A 15 VAC
gram for test point locations.
(1J3) (2J3)
#203 #204 A 15 VAC a. If the voltage test is incorrect,

(3J3) (2J3)
- check for loose or broken
leads between the reconnect
9. Locate the following leads on Plug J6 panel and the ON/OFF POWER
on the G2801 Control PC Board. SWITCH.
See Figure F.1.
G2801: - test the ON/OFF POWER
SWITCH for proper operation.
LEAD PLUG
LOCATION b. If the correct nameplate voltage
is being applied to the main
#206 4J6 transformer and one or more of
the secondary voltages are

#208 16J6
#209 7J6 missing or are incorrect, the
main transformer may faulty.
10. Turn ON the machine. Replace.
11. Make the following voltage tests at

Plug J6 on the G2801 Control PC
Board.
IDEALARC® SP-255
F-17 F-17
STATIC SCR RECTIFIER ASSEMBLY TEST
WARNING

Call 1-888-935-3877.
_____________________________________________________________
TEST DESCRIPTION
The Static SCR Test is used to quickly determine if an SCR is shorted or "leaky." See the Wave-
form Section in this manual for normal and abnormal SCR waveforms.
MATERIALS NEEDED
Analog Ohmmeter (Multimeter)
Idealarc® SP-255 wiring diagrams (See Electrical Diagrams Section of this Manual).
5/16” Nut Driver
1/2" open end or socket wrench
IDEALARC® SP-255
F-18 F-18
TEST PROCEDURE
1. Disconnect main AC input power to
the machine.
2. Disconnect Plugs J3 and J6 from the

G2801 Control Board. This electri-
cally isolates the SCR bridge assem-
bly. See Figures F.2.
SP-255 CONTROL
LEADS
G2801
X2 AND X3
J2
NEGATIVE
J8 CAPACITOR
BANK
BUSS BAR
J7
FIGURE F.3 - Location of Leads X2

J4 and X3.
5. Separate leads X2 and X3 from the

J9 J3
negative capacitor bank buss bar.
Be sure there is no electrical contact.
See Figure F.3.
J5 J6
FIGURE F.2 - Remove Plugs J3 and J6

to Perform Static SCR Rectifier As-
sembly Test.
3. Test with an Analog Volt-Ohm meter

that capacitors have completely dis-
charged.
4. Disconnect leads X2 and X3 from the

negative capacitor bank using a 1/2"
open end wrench. See Figure F.3.
IDEALARC® SP-255
F-19 F-19
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 ana-
log 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 problem

or to further test the SCR, go to the
Active SCR Test.
IDEALARC® SP-255
F-20 F-20
ACTIVE SCR RECTIFIER ASSEMBLY TEST
WARNING

Call 1-888-935-3877.
_____________________________________________________________
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-255 wiring diagrams (See Electrical Diagrams Section of this Manual).
SCR Heat Sink Assembly Drawings
IDEALARC® SP-255
F-21 F-21
TEST PROCEDURE
1. Disconnect main AC input power to
the machine.
2. Disconnect Molex Plugs J3 and J6

from the G2801 Control Board.
See Figure F.5.
LEADS
X2 AND X3
SP-255 CONTROL
G2801 NEGATIVE
J2 CAPACITOR
BANK
J8
BUSS BAR
FIGURE F.6 - Location of Leads X2

J7 and X3.
J4 5. Separate leads X2 and X3 from the

negative capacitor bank buss bar.
J9 J3 Be sure there is no electrical contact.
See Figure F6.
NOTE: DO NOT DISASSEMBLE THE

J5
SCR RECTIFIER HEAT SINK ASSEM-
J6
BLY.
FIGURE F.5 - Control Board Molex
Plug Locations for G2801 PC Control 6. Construct the circuit shown in Figure
Board. F.8. One 6-volt lantern battery can
be used. R1 and R2 resistor values

3. Test with an Analog Volt-Ohm meter are ±10%. Set voltmeter scale low,
that capacitors have completely dis- at approximately 0-5 volts or 5-10
charged. volts.
4. Disconnect leads X2 and X3 from the a. Test the voltage level of the bat-
negative capacitor bank using a 1/2" tery. Short leads (A) and (C).
open end wrench. Close switch SW-1. Battery volt-
See Figure F. 6. age should be 4.5 volts or
higher. If lower, replace the bat-
tery.
IDEALARC® SP-255
F-22 F-22
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 func-
a. Connect Tester lead (A) to the tioning.
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 de-
c. Connect Tester lead (G) to the fective.
gate.
NOTE: Be sure battery is functioning
properly. A low battery can affect the re-
sults 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.8.
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 zero,
SCR connections. 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-255
F-23 F-23
SP-255 KEYPAD RESISTANCE TEST
WARNING

Call 1-888-935-3877.
_____________________________________________________________
TEST DESCRIPTION
This test will determine if any key is not functioning properly.
MATERIALS NEEDED
5/16” Nut Driver

Analog volt-ohmmeter
IDEALARC® SP-255
F-24 F-24
TEST PROCEDURE
1. Disconnect main input power to the
machine.

els using the 5/16” nut driver.
3. Locate and disconnect Plug J2 con-

nected to the Control PC Board. See
Figure F.8.
SP-255 CONTROL
G2801
J2
J8
FIGURE F.9 - Plug J2 Test Points.

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

G2801 PC Control Board.
4. Measure the resistance of each key

at Plug J2 using an analog volt-ohm
meter as described in Table F.1.
a. The resistance measurements

are taken from the pin locations
on Plug J2. See Figure F.9 for
each pin location.
b. If any of the resistance tests are

not correct, the keypad may be

faulty. Replace.
IDEALARC® SP-255
F-25 F-25
TABLE F.1 - SP-255 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-255
F-26 F-26
WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST
WARNING

Call 1-888-935-3877.
_____________________________________________________________
TEST DESCRIPTION
This test will determine if the wire drive motor and voltage feedback circuit are functioning prop-
erly.
MATERIALS NEEDED
5/16” Nut Driver

Volt-Ohmmeter
IDEALARC® SP-255
F-27 F-27
TEST PROCEDURE
NOTE: POLARITY MUST BE OB-
SERVED FOR THESE TESTS.
Test for Correct Wire Drive Motor Arma-

ture Voltage

machine.

els using a 5/16” nut driver.
3. Locate Plug J5 on the G2801 Control

Board. See Figure F.10.
SP-255 CONTROL
G2801
J2
J8
J7
J4 #541(w)
(13J5)
J5 J9 J3
#515B
(3J5)
#206B
(2J5) J6
#555 #539(B)
(1J5) (12J5)
FIGURE F.10 - Plug J5 Location on

G2801 PC Control Board.
IDEALARC® SP-255
F-28 F-28
4. Test for 2-25 VDC between lead being received from the Control
#539(B) (positive) and lead #541(W) Board. Go to Feedback Test.
(negative) to determine if the correct
armature voltage is being supplied. c. If the 15 VDC is not present and
See Figure F.10. the leads are okay, check Plug
J15. The Control Board may be
a. Insert probes into the Molex pin faulty. Replace.
cavities.
Test for Feedback Voltage to the Con-
5. Pull the gun trigger. trol Board
6. Read meter. Normal DC volts is from 1. Test for 1.5 - 3.5 VDC between lead
2 - 25 VDC. VDC varies depending #555 (positive) and lead #206B (neg-
on wire feed speed. ative). See Figure F.10 for pin loca-
tions.
a. If voltage to the wire drive motor

armature is zero, check the wires a. Insert probes into Molex pin cav-
between Plug J5 and the wire ities.
drive motor. (Check J11, J12 and
J15) See wiring diagram. 2. Pull gun trigger.
b. If the wires and plugs are okay 3. Read meter for 1.5 - 3.5 VDC.
and voltage to the drive motor
armature is zero, the Control a. If the 1.5 - 3.5 VDC is present,
Board may be faulty. Replace. the tach circuit is sending the
correct feedback signal to the
c. If the correct DC armature volt- Control Board.
age is present at the wire drive
motor, the motor or motor NOTE: IF THE MOTOR IS NOT RUN-
brushes may be faulty. Test NING, THE FEEDBACK VOLTAGE MAY
and/or replace. BE FROM 0 TO 5 VDC.
d. If the motor is running at high b. If the 1.5 - 3.5 VDC is not pres-
speed and the armature voltage ent or not correct, the Control
is high and uncontrollable, pro- Board is not receiving the proper
ceed with the tachometer test. feedback voltage from the tach
circuit. Check the leads from the
Test for Supply Voltage to Tachometer tach circuit to the Control Board
for loose or broken connections.
1. Test for 15 VDC between lead #515B (Plug J15).
(positive) and lead #206B (negative).
See Figure F.10 for pin locations. c. If the leads are okay, the tach cir-
cuit may be faulty. Replace.
a. Insert probes into Molex pin cav-
ities.
2. Pull gun trigger.

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 voltage is
IDEALARC® SP-255
F-29 F-29
NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM

SCOPE SETTINGS
This is a typical DC output voltage waveform

generated from a properly operating ma- Volts/Div . . . . . . . . . . . . . . . . . .20 V/Div.
chine. Note that each vertical division repre-
sents 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-255
F-30 F-30
TYPICAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED

MACHINE LOADED TO 250 AMPS AT 26 VDC

SCOPE SETTINGS
This is a typical DC output voltage waveform

generated from a properly operating ma- Volts/Div . . . . . . . . . . . . . . . . . .20 V/Div.
chine. Note that each vertical division repre-
sents 20 volts and that each horizontal Horizontal Sweep . . . . . . . . . .5 ms/Div.
division represents 5 milliseconds in time.
The machine was loaded with a resistance Coupling . . . . . . . . . . . . . . . . . . . . . .DC.
grid bank.
Trigger . . . . . . . . . . . . . . . . . . . .Internal.
output terminals: (+) probe to electrode, (-)
probe to work.
IDEALARC® SP-255
F-31 F-31
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 each Coupling . . . . . . . . . . . . . . . . . . . . . .DC.
horizontal division represents 5 milliseconds
in time. The machine was loaded with a re- Trigger . . . . . . . . . . . . . . . . . . . .Internal.
sistance grid bank.

probe to work.
IDEALARC® SP-255
F-32 F-32
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 bank Horizontal Sweep . . . . . . . . . .5 ms/Div.
was disconnected. Each vertical division
represents 20 volts and each horizontal divi- Coupling . . . . . . . . . . . . . . . . . . . . . .DC.
sion represents 5 milliseconds in time.
Trigger . . . . . . . . . . . . . . . . . . . .Internal.
probe to work.
IDEALARC® SP-255
F-33 F-33
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 Horizontal Sweep . . . . . . . . . .5 ms/Div.
represents 2 volts and each horizontal divi-
sion represents 5 milliseconds in time. Coupling . . . . . . . . . . . . . . . . . . . . . .DC.
Note: Scope probes connected at Plug J3 on Trigger . . . . . . . . . . . . . . . . . . . .Internal.

the control board. The (+) probe to lead G2,
and the (-) probe to lead 204.
IDEALARC® SP-255
F-34 F-34
CONTROL PC BOARD REMOVAL AND REPLACEMENT
CAUTION
Printed Circuit Boards can be dam-
aged by static electricity. Follow
static handling guidelines detailed in
“PC Board Troubleshooting Proce-
dures” at the beginning of this chap-
ter.
_____________________________
REMOVAL AND REPLACEMENT

PROCEDURE
MATERIALS NEEDED
5/16” Nut Driver

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

machine.
2. Remove the Case Top and Side

Panels using 5/16” nut driver.
3. Disconnect all wiring harness

plugs and Molex Plugs connected
to the Control Board. See Figure
F.11.
SP-255 CONTROL
G2801
J2
J8
J7
J3
J4
J9
J5 J6
FIGURE F.11 - Wiring Harness and Molex Plug Locations.
IDEALARC® SP-255
F-35 F-35
CONTROL PC BOARD REMOVAL AND REPLACEMENT
4. Carefully remove P.C. Board from

mounting standoffs. See Figure
F.12.
FIGURE F.12 - Control Board

Mounting Locations may vary with
different Code Machines.
5. Lift the Control Board straight up

and out from the machine.
6. When re-installing the Control

Board carefully secure Board to
mounting standoffs.
IDEALARC® SP-255
F-36 F-36
KEYPAD REMOVAL AND REPLACEMENT
WARNING

Call 1-888-935-3877.
_____________________________________________________________
MATERIALS NEEDED
5/16” Nut Driver

1/4" Nut Driver
IDEALARC® SP-255
F-37 F-37
KEYPAD REMOVAL AND REPLACEMENT
PROCEDURE
NOTE: BEFORE REMOVING THE KEY-
PAD, PERFORM THE KEYPAD RE-
SISTANCE TEST TO BE SURE THE
KEYPAD IS FAULTY.

machine.

els 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 ad-

hesive 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-255
F-38 F-38
WIRE DRIVE ASSEMBLY REMOVAL AND REPLACEMENT
WARNING

Call 1-888-935-3877.
_____________________________________________________________
MATERIALS NEEDED
Large slot head screwdriver

5/16” Nut Driver
Small slot head screwdriver
IDEALARC® SP-255
F-39
F-39 TROUBLESHOOTING & REPAIR
PROCEDURE
machine.

els.
3. Remove the drive roll. See Figure

F.13.
a. Remove the thumb screw, drive

hub, and the spacer.
FIGURE F.13 - Wire Drive Assembly

Removal
4. Remove the three screws from the

gear box housing using a 5/16” nut-
driver.
IDEALARC® SP-255
F-40 F-40
5. Remove the screw holding the gun

connector assembly to the Case
Front Panel. See Figure F.14.
FIGURE F.14 - Location of Screw Hold-

ing the Gun Connector Assembly to
the Case Front Panel.
6. Slide the entire wire drive assembly b. Wiggle the drive motor and drive
carefully toward the Case Back and assembly gently back and forth
approximately 2” (51 mm) away from until the two parts separate.
the center baffle to gain access to

the drive motor and wiring. 9. Disconnect molex plugs J15, J12,
and J11. See wiring diagram.
a. The gas hose and gun connector
leads will limit the travel dis- 10. Remove the drive roll assembly.
tance.
a. Remove the two screws mount-
7. Disconnect the drive motor from the ing the drive roll assembly to the
drive roll assembly. insulator board using a 5/16” nut
driver.
a. Remove the three large phillips
head screws on the outboard b. Loosen the set screw using a
side of the drive roll assembly slot head screwdriver that holds
face plate using a phillips head the outgoing guide tube into the
screw driver. drive roll assembly.
8. Separate the drive roll assembly c. Remove the drive assembly by

from the drive motor. sliding it off the out going guide
tube and towards the Case Back
a. Grip the drive motor in one hand at the rear of the machine.
and the drive assembly in the
other hand.
IDEALARC® SP-255
F-41 F-41
SCR OUTPUT RECTIFIER REMOVAL
WARNING

Call 1-888-935-3877.
_____________________________________________________________
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-255
F-42 F-42
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 Trans- gram) using wire cutters.
former Lead X1 from the heat sink on
the left side of the machine (facing a. The easiest access to these
the front) using a 1/2” socket wrench. leads is from the right side of the
See Figure F.15. 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 ma-
chine 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.17.
FIGURE F.15 - 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. 16.
3. Remove the diode lead from the neg- FIGURE F.17 - Heat Sink Lead Discon-
ative capacitor band buss bar on the nection
right side of the machine using a slot
head screwdriver and 3/8" open end 7. Remove lead #209 and Transformer
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.16 - Heat Sink lead discon-

nection.
IDEALARC® SP-255
F-43 F-43
CAPACITOR BANK REMOVAL AND REPLACEMENT
WARNING

Call 1-888-935-3877.
_____________________________________________________________
WARNING
WARNING
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-255
F-44 F-44
CAPACITOR BANK REMOVAL AND REPLACEMENT
PROCEDURE
See Figure F.18 for location of Capacitor
Bank Removal and Replacement compo-
nents.
FIGURE F.18 - Location of Capacitor

Bank Removal and Replacement
Components
1. Disconnect main input power to the 6. Remove the #204 lead from the pos-
machine. itive buss bar.
2. Test that the capacitors are dis- 7. Remove the shunt from the negative
charged using a volt ohmmeter. Po- capacitor bank buss bar using a 1/2”
larity must be observed. socket wrench with a universal tool
adapter.
3. Remove the two transformer second-
ary leads (X2 and X3) for the nega- a. Two people may be required to
tive capacitor bank buss bar using remove the shunt. One person
two 1/2” open end wrenches. may have to reach through from
the left side of the machine to
4. Remove the output choke lead and keep the bolt in position while
the heavy lead extending from the the other person loosens the nut.
SCR Rectifier Assembly to the posi-
tive capacitor bank buss bar using a 8. Remove the two screws holding the
capacitor bank to the floor of the ma-

1/2” (13 mm) open end wrench.

5. Remove lead #206 and the D1 diode
lead from the negative capacitor 9. Clear the leads and carefully remove
bank buss bar using a slot head the capacitor bank assembly from
screwdriver and 3/8” open end the machine.
wrench.
IDEALARC® SP-255
F-45 F-45
MAIN TRANSFORMER REMOVAL AND REPLACEMENT
WARNING

Call 1-888-935-3877.
_____________________________________________________________
MATERIALS NEEDED
5/16” Nut Driver
3/8" Open end wrench
1/2” Socket wrench, extender, universal adapter
Wire cutters
IDEALARC® SP-255
F-46 F-46
MAIN TRANSFORMER REMOVAL AND REPLACEMENT
PROCEDURE
1. Disconnect main input power to the 12. Carefully remove the main trans-
machine. former.
2. Remove the Case Top and Side Pan- a. Be sure all leads are clear.
els.
3. Perform the Capacitor Bank Re-

moval Procedure.
4. Remove lead X1 from the left side

SCR heat sink assembly using a 1/2”
socket wrench, extender and univer-
sal adapter.
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 re-
moval using wire cutters and screw-

driver.
11. Remove the four screws mounting

the transformer to the floor of the ma-
IDEALARC® SP-255
F-47 F-47
FAN MOTOR AND FAN REMOVAL AND REPLACEMENT
WARNING

Call 1-888-935-3877.
_____________________________________________________________
MATERIALS NEEDED
1/2” Socket wrench with extension
Phillips head screwdriver
IDEALARC® SP-255
F-48 F-48
PROCEDURE
See Figure F.19 for fan motor and fan re-
moval components.
FIGURE F.19 - Fan Motor and Fan Re-

moval Components the machine using a 5/16” socket
wrench with extension.
1. Remove the Case Back screws.
5. Loosen the two screws holding the
2. Remove the gas solenoid using a reconnect panel in place and slide
3/4” open end wrench. the reconnect panel from the frame.
3. Using a 5/16” wrench, remove the 5 6. Remove the fan blade. Note fan
screws holding the fan motor mount- blade position on motor shaft for ref-
ing bracket to the case back. erence for replacing fan.
4. With a 7/16” wrench remove the bolt a. Pry the fan blade off the motor.
holding the Case Back to the vertical
baffle. Tilt the Case Back away from b. Slide the fan blade off the motor
the machine and remove the screws shaft.
holding the Case Back to the floor of
IDEALARC® SP-255
F-49 F-49
7. Remove the fan motor.
a. Loosen and remove the two

screws from the motor mounting
bracket using a phillips head
screw driver.
b. When the motor is free from the

mounting bracket, place it care-
fully on the bottom of the ma-
chine.
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-255
F-50 F-50
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-255
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-51
NOTES
IDEALARC® SP-255
F-51
ELECTRICAL DIAGRAMS
TABLE OF CONTENTS
- ELECTRICAL DIAGRAMS SECTION -
ELECTRICAL DIAGRAMS SECTION ....................... Section G

WIRING DIAGRAM (Code 10164) (L9688) ...................G - 2
WIRING DIAGRAM (Code 10165) (L9689) ...................G - 3
SCHEMATIC CONTROL PC BOARD (G2799) ............G - 4
IDEALARC® SP-255
G-2 ElEcTrical DiaGramS G-2
WiriNG DiaGram - (cODE 10164) (l9688)
SP - 255 (DUAL VOLTAGE)
GENERAL INFORMATION
1
1 (J7)
* CONTROL BOARD 2 ELECTRICAL SYMBOLS PER E1537
(J8)
*
* 3 392
2
2 LINE X 16 CHAR. (J4)
390 COLOR CODE:
3 4
ALPHA-NUMERI C 4 B - BLACK
1 2 3 4
W - WHIT E
*
5 (J9)
1 2 3 4 5 6 7 8 R - RE D
LCD DISPLAY 6
R
U - BLUE
7
8
(J1)
* B
* INDICATES CONNECTOR CAVITY NO.
541A
324A
325A
206A
515
495
542
543
1 2 3 4 5 6
9
10 R.F.
AUTO MANUAL 11 CHOKE
12
AS'BLY.
13
J21
*
*
14 1
202 1
15 1 555 2
204A 2 1
PROCESS SAVE 16 2 206B 3
203 3 2
WIRE/ 3 515B 206 4
4 392B 3
5
4 325 207 5
GAS 390A 4
3 G1 5
5 GND 6
204
*
1 6
6 326 209 7 (J3)
(J2) G2 7
MEMORY 7 * (J5)
7 324 8
*
5 9 8
1 2 3 4
*
J20
*
*
8 9
9 GAS
6 (J6)
9
10
8 10 SOLENOID
10 205 SPOOL GUN ADAPTER
11
2 11 HARNESS
IPM VOLTS 11 12
SPOT STITCH TOGGLE 12
4
TIMERS SET SET 4 5 12 B 206S 13 515 1
13 W 325A 14 325A 2
OFF DISPLAY DISPLAY
324A
TO
14 327 320 15 3
208 16 206A 4
KEYPAD MATRIX
541A 5 SPOOL GUN
N.F.
OPTION
495 6
542 7
GND
J15
*
*
543 8
*
*
J14 515B 1 515B
392 9
390 10
326 1 326 555 2 555 392B
B R 11
2 B 3 B
J11
*
*
325 325 390A 12
327 3 327 206B 4 206B 13

B 1 JUMPER USED WITHOUT
14
324 4 324 5 SPOOL GUN OPTION
PIEZO
W 6 W W 2
ALARM
TO
R.F. R.F.
NOTES
WORK
N.A. N.C. CHOKE CHOKE N.A. WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE
W CURRENT AND DUTY CYCLE OF IMMEDIATE AND
AS'BLY. AS'BLY.
MOTOR/ FUTURE APPLICATIONS.
T R 515B
327 GEARBOX P.M. A
U 555 N.B. THIS DIAGRAM SHOWS THE "ELECTRODE" POLARITY
C J12
*
*
"POSITIVE". TO CHANGE POLARITY, TURN THE UNIT
N.J. 324 H B 206B 326 1
325 2 OFF AND REVERSE LEAD CONNECTIONS AT CABLE

B 1
325 CONDUCTOR STRAP AND WORK STUD.
206 207
327 3
326 B W 2
324 4 N.C. CONNECTOR SHOWN GEARBOX SIDE VIEW.
THUMB
SWITCH J13
*
*
320 328 325A N.E. THERMOSTATS MOUNTED ON CHOKE COIL .
327 N.E.
N.G.
S2 MOUNTED CLOSEST TO FAN; S3 MOUNTED CLOSEST TO
TO SINGLE PHASE
R.F. FILTER POWER TRANSFORMER.
SUPPLY LINE
INC. DEC. THERMOSTAT THERMOSTAT
N.B. S3 S4 L1 N.F. KEYPAD MATRIX SHOWN FRONT VIEW.
N.G. THERMOSTAT S4 MOUNTED ON FAN SENSOR BRACKET

326
324 L2 N.H. RESISTOR R2 MOUNTED ON FAN SENSOR BRACKET.
X5
202
N.J. CONNECTOR SHOWN PIN SIDE VIEW.
TRIGGER X6 W
H4 P2
204A GND
325 H2 H3
TO GROUND PER
X7 208 L1
203 LOW V.
NATIONAL ELECTRICAL
X1 G1 HIGH V.
CODE
H1 SCR 1 B JUMPER
250V
204 470A
L2
L1 L2 X2 SCR HEATSINK
ASBLY
GND. RECONNECT PANEL
H2 X3 SCR 2
*
*
250V
470A
G CAVITY
H3
X4
G2 N.E. CAVITY NUMBERING SEQUENCE NUMBERING SEQUENCE
H1 H4
209 (COMPONENT SIDE OF P.C. BOARD) (NON-LEAD SIDE OF CONNECTOR)
SHUNT POWER TRANSFORMER D1 P2
300V T1 T2
T1 P1 P2 TOP
+ 85A 1 2 1 2 1 3
16 1 9 J13
H1 - J11
FAN J1 J2 J14 J15
LINE 206 S2 J12
MOTORS J21
SWITCH THERMOSTAT 3 4
1 4 6
S1 205
1 6 1 4
15 OHMS
J3 J4 1 7
R1
100 W
C1 THRU C4
206S C1 C2 C3 C4 R2
30,000 MFD 7 12
J20
5 8
2.5K
+ 50V
+ + + 204
OUTPUT N.H. 10W 8 14

CHOKE
1 7 1 8
207
J5 J6
8 14 9 16
1 2 1 3
J7
J9
J8
3 4 4 6
3-24-95
L9688
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
iDEalarc® SP-255
WiriNG DiaGram - (cODE 10165) (l9689)
SP-255 (230 / 460 / 575V)
1 (J7)
* CONTROL BOARD 2 GENERAL INFORMATION
(J8)
*
* 3 392
2
2 LINE X 16 CHAR. (J4)
390
ELECTRICAL SYMBOLS PER E1537
3 4
ALPHA-NUMERI C 4 COLOR CODE:
1 2 3 4 *
5 (J9)
B - BLACK
LCD DISPLAY 1 2 3 4 5 6 7 8
6 W - WHIT E
R
7 R - RE D
(J1) B
8 * U - BLUE
541A
324A
325A
206A
515
495
542
543
1 2 3 4 5 6
9
10 R.F.
* INDICATES CONNECTOR CAVITY NO.
AUTO MANUAL 11 CHOKE

12
AS'BLY.
13
J21
*
*
14 1
202 1
15 1 555 2
204A 2 1
PROCESS SAVE 16 2 206B 3
203 3 2
WIRE/ 3 515B 206 4
4 392B 3
5
4 325 207 5
GAS 390A 4
3 G1 5
5 GND 6
204
*
1 6
6 326 209 7 (J3)
(J2) G2 7
MEMORY 7 * (J5)
7 324 8
*
5 9 8
1 2 3 4
*
8
J20
*
*
9 GAS
6 9
9 (J6)
10 SOLENOID
8 10 SPOOL GUN ADAPTER
10 205 11
2 11 HARNESS
IPM VOLTS 11 12
SPOT STITCH TOGGLE 12
4
12 B 206S 13 515 1
TIMERS SET SET 4 5
13 W 325A 325A 2
OFF DISPLAY DISPLAY 14
324A
TO
14 327 320 15 3
208 206A 4
16
KEYPAD MATRIX
541A 5 SPOOL GUN
N.F.
OPTION
495 6
542 7
543 8
** 392 9
GND
** J15 390 10
392B
B R J14
11
515B 1 515B
390A 12
326 1 326 555 2 555 13

JUMPER USED WITHOUT
**
B 14
325 2 325 3 B J11 SPOOL GUN OPTION
PIEZO
327 3 327 206B 4 206B
ALARM B 1
324 4 324 5
W 6 W W 2
TO
WORK
N.A.
NOTES
N.C.
R.F. R.F.
W
CHOKE CHOKE N.A. WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE
327 MOTOR/
T R 515B AS'BLY. AS'BLY. CURRENT AND DUTY CYCLE OF IMMEDIATE AND
GEARBOX
**
P.M. A J12 FUTURE APPLICATIONS.
N.J. 324 U 555
C
N.B. THIS DIAGRAM SHOWS THE "ELECTRODE" POLARITY
325 H B 206B
B 1 "POSITIVE". TO CHANGE POLARITY, TURN THE UNIT
1
206 207 326
OFF AND REVERSE LEAD CONNECTIONS AT CABLE
326 B W 2 2
325
THUMB CONDUCTOR STRAP AND WORK STUD.

327 3
N.C. CONNECTOR SHOWN GEARBOX SIDE VIEW.
SWITCH 327
320 328 325A
324 4
N.E. N.E. THERMOSTATS MOUNTED ON CHOKE COIL
N.G. **
R.F. FILTER J13
S2 MOUNTED CLOSEST TO FAN; S3 MOUNTED CLOSEST TO
INC. DEC. THERMOSTAT THERMOSTAT TO SINGLE PHASE
POWER TRANSFORMER.
N.B. S3 S4 SUPPLY LINE
L1 N.F. KEYPAD MATRIX SHOWN FRONT VIEW.
326 N.G. THERMOSTAT S4 MOUNTED ON FAN SENSOR BRACKET.

324 L2
X5 N.H. RESISTOR R2 MOUNTED ON FAN SENSOR BRACKET.
202
5 N.J. CONNECTOR SHOWN PIN SIDE VIEW.
TRIGGER X6
H5 GND
204A
325 L1 L2
TO GROUND PER
X7 208
T1 203 NATIONAL ELECTRICAL
X1 G1 4 2 H2
CODE
H1 SCR 1 H2 13/32 ffeA3j3 7/32 33: 63/64 –
P2 250V
204 470A
H2 H4
1 3
L1 L2 H5 X2 SCR HEATSINK
ASBLY H3
H3
X3 SCR 2
*
*
CAVITY
H1
250V
RECONNECT PANEL (SHOWN CONNECTED
CAVITY NUMBERING SEQUENCE NUMBERING SEQUENCE
470A GND.
X4 FOR 230 VOLT.)
G2
H1 H4
H4 209
G (COMPONENT SIDE OF P.C. BOARD) (NON-LEAD SIDE OF CONNECTOR)
SHUNT POWER TRANSFORMER D1
300V N.E. TOP
1 2 1 2 1 3
+ 85A 16 1 9 J13
J11
H1 - P2 J1 J2 J14 J15
J12
LINE 206 T1 T2 J21
P1 P2 1 3 4 4 6
SWITCH
1 6 1 4
S1 205 FAN
15 OHMS S2 J3 J4 1 7
MOTORS
R1
100 W THERMOSTAT
C1 THRU C4 J20
206S C1 C2 C3 C4 7 12
30,000 MFD 5 8
+ + + + 50V 204 8 14
OUTPUT
CHOKE R2 1 7 1 8
207 2.5K
J5 J6
N.H. 10W
8 14 9 16
1 2 1 3
J7
J9
J8
3 4 4 6
3-24-95
L9689
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
iDEalarc® SP-255
SchEmaTic - cOmPlETE machiNE (G2799)
CHANGE DETAIL: SCR1 AND SCR2 , REVISED AMPS

G2799 ENGINEERING CONTROLLED
MANUFACTURER: No
12A
12A
PROPRIETARY & CONFIDENTIAL: THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
UNLESS OTHERWISE SPECIFIED TOLERANCE
MANUFACTURING TOLERANCE PER E2056 DESIGN INFORMATION REFERENCE:
EQUIPMENT TYPE: SP 255 CONTROL 1
1 OF ___
PAGE ___
SOLID EDGE
ON 2 PLACE DECIMALS IS ± .02
ON 3 PLACE DECIMALS IS ± .002 DRAWN BY: FEI - DOCUMENT DOCUMENT
ON ALL ANGLES IS ± .5 OF A DEGREE
MATERIAL TOLERANCE (" t ") TO AGREE ENGINEER: SCALE:
SUBJECT: SCHEMATIC NUMBER: REVISION:
EN-170
WITH PUBLISHED STANDARDS.

DO NOT SCALE THIS DRAWING APPROVED: NONE
MATERIAL
DISPOSITION:
UF APPROVAL
DATE:
01/25/2007 PROJECT
NUMBER:
CRM37912 G2799 A
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
iDEalarc® SP-255

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View Safety Info

SVM115-A | Issue D­ate 12, Apr

CALIFORNIA PROPOSITION 65 WARNINGS

FOR ENGINE 1.h. To avoid scalding, do not remove the

1.a. Turn the engine off before troubleshooting and maintenance

fuel when filling tank. If fuel is spilled, wipe it welding machines

ELECTRIC SHOCK can kill. ARC RAYS can burn.

• DC Manual (Stick) Welder. hazardous to health. Avoid breathing these

sure level should be checked upon installation and periodi-

5.e. Read and understand the manufacturer’s instructions for this

5.f. Also see item 1.b.

WELDING and CUTTING CYLINDER may explode

SPARKS can cause fire or if damaged.

electrically “hot” parts to touch a cylinder.

8.a. Turn off input power using the disconnect

6.j. Do not use a welding power source for pipe thawing.

Refer to http://www.lincolnelectric.com/safety for additional safety information.

6. Eloigner les matériaux inflammables ou les recouvrir afin de

prévenir tout risque d’incendie dû aux étincelles.

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

4. Garder tous les couvercles et dispositifs de sûreté à leur place.

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

Electromagnetic Compatibility (EMC)

Installation and Use

b) radio and television transmitters and receivers;

c) computer and other control equipment;

d) safety critical equipment, e.g., guarding of industrial equipment;

f) equipment used for calibration or measurement

Electromagnetic Compatibility (EMC)

Methods of Reducing Emissions

Maintenance of the Welding Equipment

Earthing of the Workpiece

Screening and Shielding

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

Install the Work Clamp ................................................A-7

TECHNICAL SPECIFICATIONS - Idealarc® SP-255

INPUT - SINGLE PHASE/ 60 HERTZ ONLY

Standard Voltage Input Current at Rated Output

208/230/60 53/49 Amps

230/460/575 50/25/20 Amps

100% 145 amps 26

60% 200 amps 28

35% 250 amps 26

30A - 250A 40V 50 - 600 IPM

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

28.2” 18.8” 40.1” 222 lbs.

Idealarc® SP-255 power company to determine if there is any ques-

Also see the Reconnect Section of this manual for

SELECT PROPER LOCATION

Not following these precautions can result in the nui-

The Idealarc® SP-255 cannot be stacked.

Cable Entry Connections.

green wire in the input cord connects this ter-

INPUT POWER CONNECTIONS AND

Have a qualified electrician connect the receptacle or

1. Follow the Input Supply Connection Diagram on the

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

SVM115-A | Issue Date 12, Apr