Lincoln SP-100 Service Manual
SP-100
SERVICE MANUAL
SVM102-A
March, 1999
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However, your
overall safety can be increased by
proper installation ... and thoughtful operation on your part. DO
NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT READING THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and be careful.
For use with machines
having Code Numbers
9284-10050
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• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
World's Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors
i
SAFETY
SP-100
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN
AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040,
Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the
Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
ARC RAYS can burn.
2.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.
2.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
2.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
ELECTRIC SHOCK can
kill.
1.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.
1.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.
In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or Iying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
1.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
1.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.
1.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
1.f.
Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
1.g. Never dip the electrode in water for cooling.
1.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.
1.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
1.j. Also see Items 4.c. and 6.
WARNING
ARC WELDING can be hazardous.
FUMES AND GASES
can be dangerous.
3.a.Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases.When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.
3.b.
Do not weld in locations near chlorinated hydrocarbon
vapors
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
to
form phosgene, a highly toxic gas, and other irritating
products.
3.c. 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.
3.d. 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.
3.e. Also see item 7b.
Apr. ‘93
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ii
SP-100
SAFETY
FOR ELECTRICALLY
powered equipment.
6.a.Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
6.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.
6.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
CYLINDER may explode
if damaged.
5.a. Use only compressed gas cylinders
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
5.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
5.c. Cylinders should be located:
•Away from areas where they may be struck or subjected to
physical damage.
• A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
5.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
5.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
5.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
5.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
Mar. ‘93
WELDING SPARKS can
cause fire or explosion.
4.a.
Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
the welding sparks from starting a fire.
Remember that welding sparks and hot
materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.
4.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.
4.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact
can cause overheating and create a fire hazard.
4.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even
though
they have
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Preparation
for Welding and Cutting of
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
4.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
4.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.
Always wear safety glasses with side shields when in a
welding area.
4.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate circuits. This can create fire hazards or overheat lifting chains
or cables until they fail.
4.h. Also see item 7c.
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iii
SAFETY
SP-100
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Mar. ‘93
ELECTRIC AND MAGNETIC
FIELDS
may be dangerous
8.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines
8.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
8.c. Exposure to EMF fields in welding may have other health
effects which are now not known.
8d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
8.d.1.
Route the electrode and work cables together - Secure
them with tape when possible.
8.d.2. Never coil the electrode lead around your body.
8.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.
8.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
8.d.5. Do not work next to welding power source.
FOR ENGINE
powered equipment.
7.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
7.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.
____________________________________________________
7.c. Do not add the fuel near an open flame
welding arc or when the engine is running.
Stop the engine and allow it to cool before
refueling to prevent spilled fuel from
vaporizing on contact with hot engine parts
and igniting. Do not spill fuel when filling
tank. If fuel is spilled, wipe it up and do not
start engine until fumes have been
eliminated.
____________________________________________________
7.d. Keep all equipment safety guards, covers
and devices in position and in good repair.
Keep hands, hair, clothing and tools away
from V-belts, gears, fans and all other
moving parts when starting, operating or
repairing equipment.
____________________________________________________
7.e. In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.
7.f. Do not put your hands near the engine fan. Do not
attempt to override the governor or idler by pushing on
the throttle control rods while the engine is running.
7.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
___________________________________________________
7.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
iv
SAFETY
SP-100
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PRÉCAUTIONS DE SÛRETÉ
Pour
votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent
dans ce manuel aussi bien que les précautions de sûreté
générales suivantes:
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une
grande partie du corps peut être en contact avec la
masse.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état
defonctionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
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 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.
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 qu’un verre blanc afin de se protéger les yeux du
rayonnement de l’arc et des projections quand on soude
ou quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
l‘arc.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection
libres de l’huile, tels que les gants en cuir, chemise épaisse,
pantalons 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.
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
8. S’assurer que la masse est connectée le plus prés possible
de 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 éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de levage, câbles de grue, ou autres circuits. Cela peut provoquer
des risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les
vapeurs du solvant pour produire du phosgéne (gas fortement toxique) ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code
de l’électricité et aux recommendations du fabricant. Le dispositif de montage ou la piece à souder doit être branché à
une bonne mise à la terre.
2. Autant que possible, I’installation et l’entretien du poste
seront effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la
debrancher à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
Mar. ‘93
MASTER TABLE OF CONTENTS FOR ALL SECTIONS
Page
Installation.......................................................................................................Section A
Technical Specifications........................................................................................A-1
Identify and Locate Components...........................................................................A-2
Select Suitable Location........................................................................................A-3
Output Connections...............................................................................................A-3
Input Connections..................................................................................................A-5
Code Requirements ..............................................................................................A-6
Operation.........................................................................................................Section B
Safety Precautions ................................................................................................B-1
General Description...............................................................................................B-2
Design Features and Advantages...................................................................B-2
Welding Capability ..........................................................................................B-2
Limitations.......................................................................................................B-2
Controls and Settings......................................................................................B-2
Welding Operations...............................................................................................B-3
Overload Protection...............................................................................................B-6
Accessories.....................................................................................................Section C
Accessories...........................................................................................................C-1
Replacement Parts................................................................................................C-1
Maintenance ....................................................................................................Section D
Safety Precautions ................................................................................................D-1
Items Requiring No Maintenance..........................................................................D-1
Routine and Periodic Maintenance........................................................................D-1
Component Replacement Procedures ..................................................................D-2
Location of Components........................................................................................D-4
Theory of Operation........................................................................................Section E
Input Line Voltage, Fan Motor and Main Transformer...........................................E-1
Output Control, Rectification and Voltage Feedback.............................................E-2
Trigger, Gas Solenoid and Wire Drive...................................................................E-3
SCR Operation ......................................................................................................E-4
Thermal Protection ................................................................................................E-5
Troubleshooting and Repair...........................................................................Section F
How To Use Troubleshooting Guide......................................................................F-1
PC Board Troubleshooting Procedures.................................................................F-2
Troubleshooting Guide...........................................................................................F-3
Oscilloscope Waveforms .......................................................................................F-9
Replacement Procedures ....................................................................................F-12
Retest After Repair ..............................................................................................F-14
Electrical Diagrams.........................................................................................Section G
SP-100 Parts Manual .............................................................................................P-180
v
SP-100
RETURN TO MAIN INDEX
Installation ......................................................................................................Section A
Technical Specifications........................................................................................A-1
Input and Output Specifications......................................................................A-1
Cable and Fuse Sizes.....................................................................................A-1
Physical Dimensions.......................................................................................A-1
Identify and Locate Components...........................................................................A-2
Select Suitable Location........................................................................................A-3
Stacking ..........................................................................................................A-3
Tilting...............................................................................................................A-3
Output Connections ..............................................................................................A-3
Work Clamp Installation .................................................................................A-3
Work Cable Installation ..................................................................................A-3
Gun Installation...............................................................................................A-4
Connecting Gun Cable to the SP-100 ............................................................A-4
Gas Connection ..............................................................................................A-4
Input Connections..................................................................................................A-5
Code Requirements For Input Connections....................................................A-6
Requirements For Rated Output...............................................................A-6
Requirements For Maximum Output ........................................................A-6
Requirements For CSA Rated Output .....................................................A-6
Extension Cord Usage ...................................................................................A-6
Section A
TABLE OF CONTENTS
– INSTALLATION SECTION –
SP-100
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A-1
INSTALLATION
SP-100
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Fuse or
Output Mode Input Voltage Breaker Size Input Amps Power Cord Extension Cord
RATED 115V/60Hz 20 Amp 20 15 Amp, 125V, Three Conductor
Three Prong Plug #14 AWG
(NEMA Type 5-15P) (2.1 mm2) or Larger
For lengths up to
MAXIMUM 115V/60Hz 25 Amp 25 25 Amp, 125V, 25 Ft. (7.5 m)
Three Prong Plug
(NEMA Type 5-20P) Three Conductor
#12 AWG
CSA 115V/60Hz 15 Amp 12 15 Amp, 125V, (3.3 mm2)
Three Prong Plug For lengths up to
(NEMA Type 5-15P) 50 Ft. (15 m)
TECHNICAL SPECIFICATIONS – SP-100
INPUT – SINGLE PHASE ONLY
RATED OUTPUT
OUTPUT
RECOMMENDED INPUT CABLE AND FUSE SIZES
Height Width Depth Weight
12.0 in 9.75 in 16.5 in 54 Ibs
305 mm 248 mm 419 mm 24.3 kg
PHYSICAL DIMENSIONS
Standard Voltage/Frequency Input Current
115V/60Hz 20 Amps - Rated Output
115V/60Hz 25 Amps - Maximum Output
115V/60Hz 12 Amps - CSA Rated output
Duty Cycle Amps Volts at Rated Amperes
20% Duty Cycle 90 18
30% Duty Cycle 100 17
20% Duty Cycle - CSA Rated Output 63 20
Welding Current Range (Continuous) Maximum Open Circuit Voltage Auxiliary Power
Rated DC Output: 0 - 90 amps 28 N/A
Maximum DC Output: 0 - 100 amps
CSA Rated DC Output: 0 - 63 amps
A-2
INSTALLATION
SP-100
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Read entire installation section before starting
installation.
SAFETY PRECAUTIONS
IDENTIFY AND LOCATE
COMPONENTS
If you have not already done so, unpack the SP-100
from its carton and remove all packing material
around the SP-100. Remove the following loose items
from the carton (see Figure A.1):
1. SP-100
2. Gun and cable assembly
(1)
3. Literature envelope which contains:
a) This operating manual
b) A contact tip for .030” (0,8 mm) diameter wire.
4. 10 ft (3,0 m) work cable.
5. Work clamp.
(1)
Gun is ready to feed .025" (0.6 mm) diameter wire
(also .023 and .024 diameter wire).
ELECTRIC SHOCK can kill.
• Only qualified personnel should perform
this installation.
• Only personnel that have read and understood the SP-100 Operating Manual should
install and operate this equipment.
• Machine must be plugged into a receptacle
which is grounded per any national, local
or other applicable electrical codes.
• The SP-100 power switch is to be in the
OFF (“O”) position when installing work
cable and gun and when connecting power
cord to input power.
WARNING
FIGURE A.1
1
2
3a
3b
4
5
A-3
INSTALLATION
SP-100
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SELECT SUITABLE LOCATION
Locate the welder in a dry location where there is free
circulation of clean air into the louvers in the back and
out the front of the unit. A location that minimizes the
amount of smoke and dirt drawn into the rear louvers
reduces the chance of dirt accumulation that can block
air passages and cause overheating.
STACKING
SP-100’s cannot be stacked.
TILTING
Each machine must be placed on a secure, level surface, either directly or on a recommended undercarriage. The machine may topple over if this procedure
is not followed.
OUTPUT CONNECTIONS
Refer to Figure A.2.
1. Work Cable Access Hole.
2. Gun Cable and Control Lead Access Hole.
3. Connector Block.
4. Gun Trigger Lead Connectors.
5. Positive (+) and negative (–) output terminals.
WORK CLAMP INSTALLATION
Attach the work clamp per the following:
1. Unplug the machine or turn the power switch to the
“OFF” position.
2. Insert the work cable terminal lug with the larger
hole through the strain relief hole in the work clamp
as shown in Figure A-3.
3. Fasten securely with the bolt and nut provided.
FIGURE A.3
WORK CABLE INSTALLATION
Refer to Figure A.2.
1. Open the wire feed section door on the right side of
the SP-100.
2. Pass the end of the work cable that has the terminal lug with the smaller hole through the Work
Cable Access Hole (1) in the case front.
Strain Relief Hole
Nut & Bolt
Work Clamp
Work Cable
FIGURE A.2
2
1
3
4
5
6
7
8
A-4
INSTALLATION
SP-100
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3. Route the cable under and around the back of the
Wire Feed Gearbox (6).
4. For GMAW Only: Refer to Figure A.2. As deliv-
ered, the SP-100 is wired for positive polarity. This
is the appropriate configuration for the Gas Metal
Arc Welding (GMAW) process. To complete installation, use the provided wing nut to connect the
work cable’s terminal lug to the negative (–) output
terminal (5) located above the Wire Feed Gearbox
(6). Make sure that both wing nuts are tight.
5. For Innershield Only: Refer to Figure A.4. To wire
for negative polarity, connect the short cable
attached to the connector block (1) to the negative
(–) output terminal (2) and the work cable (3) to the
positive (+) terminal (4).
FIGURE A.4
3. Insert the connector on the gun conductor cable
into the Gun Cable Access Hole (2) in the SP-100
case front. Make sure the connector is all the way
in the metal connector block to obtain proper gas
flow. Rotate the connector so control leads are on
the underside and tighten the Thumbscrew (8) in
the connector block.
4. Connect the gun trigger control lead terminals to
the two insulated 1/4" (6,4 mm) tab connector
bushings located above the “Gun Trigger
Connection” decal in the wire feed section (4).
Either lead can go to either connector. Form the
leads so that they are as close as possible to the
inside panel.
If the gun trigger switch being used is other than
that supplied with the SP-100, the switch must be
a normally open, momentary switch. The terminals
of the switch must be insulated from the welding
circuit. Malfunction of the SP-100 may result if this
switch shorts to the SP-100 welding output circuit
or is common to any electrical circuit other than
the SP-100 trigger circuit.
GAS CONNECTION
Refer to Figure A.5
When using the GMAW process, a cylinder of carbon
dioxide (CO2) or argon-carbon dioxide mixed shielding
gas, flow regulator, and an inlet gas hose must be
obtained. For more information about selecting gas
cylinders for use with the SP-100, refer to the ACCESSORIES section.
CYLINDER may explode if damaged. Keep cylinder upright and
chained to support
• Keep cylinder away from areas
where it may be damaged.
• Never lift welder with cylinder
attached.
• Never allow welding electrode to
touch cylinder.
• Keep cylinder away from welding
or other live electrical circuits.
GUN INSTALLATION
As shipped from the factory, the SP-100 gun is ready
to feed 0.023 - 0.025” (0,6 mm) wire. If 0.030” (0,8
mm) wire is to be used install the 0.030” (0.8 mm)
contact tip. Refer to the MAINTENANCE section for
contact tip installation details.
CONNECTING GUN CABLE TO THE SP-100
1. Refer to Figure A.2. Unplug the machine or turn
power switch to the off “O” position.
2. Pass the insulated terminals of the gun trigger control leads, one at a time, through the Gun Cable
and Control Lead Access Slot (2) in the case front.
The leads are to be routed under the Wire Feed
Gearbox (6) and through the Cable Hanger (7) on
the inner panel.
CAUTION
WARNING
1
2
3
4
3. Attach the flow regulator to the cylinder valve and
tighten the union nut securely with a wrench. The
flow regulator for carbon dioxide must have a plastic washer seated in the fitting that attaches to the
cylinder to prevent leakage.
4. Refer to Figure A.6. Attach one end of inlet gas
hose to the outlet fitting of the flow regulator and
tighten the union nut securely with a wrench.
Connect the other end to the SP-100 Gas Solenoid
Inlet Fitting (5/8-18 female threads — for CGA —
032 fitting). Make certain the gas hose is not
kinked or twisted.
INPUT CONNECTIONS
Refer to Figure A.6.
The SP-100 has two input connections, the power
input cable, and the Gas Solenoid Inlet Fitting. Both
connections are located on the rear of the machine.
FIGURE A.6
BUILDUP OF SHIELDING GAS may
harm health or kill.
• Shut off shielding gas supply
when not in use.
• SEE AMERICAN NATIONAL
STANDARD Z-49.1, “SAFETY IN
WELDING AND CUTTING” PUBLISHED BY THE AMERICAN
WELDING SOCIETY.
1. Chain the cylinder to a wall or other stationary support to prevent the cylinder from falling over.
Insulate the cylinder from the work circuit and earth
ground.
FIGURE A.5
2. With the cylinder securely installed, remove the
cylinder cap. Stand to one side away from the outlet and open the cylinder valve very slightly for an
instant. This blows away any dust or dirt which may
have accumulated in the valve outlet.
BE SURE TO KEEP YOUR FACE AWAY FROM THE
VALVE OUTLET WHEN “CRACKING” THE VALVE.
Never stand directly in front of or behind the flow
regulator when opening the cylinder valve. Always
stand to one side.
A-5
INSTALLATION
SP-100
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WARNING
WARNING
Cylinder Valve
Gas Hose
Flow Regulator
Gas Solenoid
Inlet Fitting
Power
Input
Cable
A-6
INSTALLATION
SP-100
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CODE REQUIREMENTS FOR INPUT
CONNECTIONS
This welding machine must be connected to
power source in accordance with applicable electrical codes.
The United States National Electrical Code (Article
630-B, 1990 Edition) provides standards for amperage
handling capability of supply conductors based on
duty cycle of the welding source.
If there is any question about the installation meeting
applicable electrical code requirements, consult a
qualified electrician.
Do not connect the SP-100 to an input power supply with a rated voltage that is greater than 125
volts.
Do not remove the power cord ground prong.
REQUIREMENTS FOR RATED OUTPUT
A power cord with a 15 amp, 125 volt, three prong
plug (NEMA Type 5-15P) is factory installed on the
SP-100. Connect this plug to a mating grounded
receptacle which is connected to a 20 amp branch circuit with a nominal voltage rating of 115 to 125 volts,
60 Hertz, AC only.
The rated output with this installation is 90 amps, 18
Volts, 20% duty cycle (2 minutes of every 10 minutes
used for welding).
REQUIREMENTS FOR MAXIMUM OUTPUT
An optional power cord (K467 Input Line Cord) is
available to permit the SP-100 to be connected to a
25 amp branch circuit with a nominal voltage rating of
115 to 125 volts, 60 Hertz, AC only. With this installation the SP-100 can be used at an output of 100
amps, 17 volts, 30% duty cycle.
Refer to the ACCESSORIES section for specific information about the K467 Input Line Cord
REQUIREMENTS FOR CSA RATED OUTPUT
A line cord with a 15 amp, 125 volt, three-prong plug
(NEMA Type 5-15P) is factory installed. Connect this
plug to a mating grounded receptacle which is connected to a 15 amp branch circuit with a nominal voltage rating of 115 volts to 125 volts, 60 hertz, AC only.
With this installation, the SP-100 can be used at an
output of 63 amps, 20 volts, 20% duty cycle.
EXTENTION CORD USAGE
If an extension cord is required, use one that is rated
for the application and is 3 conductor #14 AWG (2.1
mm2) or larger. The recommended maximum lengths
are 25 ft (7.5 m) if #14 AWG (2.1 mm2) is used and
50 ft (15 m) if #12 AWG* (3.3 mm2) is used.
WARNING
CAUTION
A7
NOTES
SP-100
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SP-100
TABLE OF CONTENTS
– OPERATION SECTION –
Operation ...........................................................................................................Section B
Safety Precautions ......................................................................................................B-1
General Description ....................................................................................................B-2
Recommended Processes.....................................................................................B-2
Operational Features and Controls........................................................................B-2
Design Features and Advantages .........................................................................B-2
Welding Capability ................................................................................................B-2
Limitations .............................................................................................................B-2
Controls and Settings...................................................................................................B-2
Welding Operations......................................................................................................B-3
Process Guidelines................................................................................................B-3
Sequence of Operations........................................................................................B-3
Wire Loading..........................................................................................................B-3
Friction Brake Adjustments....................................................................................B-4
Wire Threading......................................................................................................B-4
Shielding Gas .......................................................................................................B-5
Making a Weld ......................................................................................................B-5
Cleaning Tip and Nozzle........................................................................................B-6
Changing Machine Over To Feed Other Wire Sizes .............................................B-6
Welding With Innershield.......................................................................................B-6
Overload Protection .....................................................................................................B-6
Output Overload ....................................................................................................B-6
Thermal Protection ................................................................................................B-6
Wire Feed Overload Protection ............................................................................B-6
Section B
B-1
SP-100
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OPERATION
Read entire operation section before
operating the SP-100.
ELECTRIC SHOCK can kill.
• Do not touch electrically live
parts or electrode with skin or
wet clothing. Insulate yourself
from work and ground.
• Always wear dry insulating
gloves.
FUMES AND GASES can be
dangerous.
• Keep your head out of fumes.
• Use ventilation or exhaust to
remove fumes from breathing
zone.
WELDING SPARKS can
cause fire or explosion.
• Keep flammable material away.
• Do not weld on closed containers.
ARC RAYS can burn eyes
and skin.
• Wear eye, ear and body protection.
Observe all safety information throughout
this manual.
WARNING
B-2
SP-100
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OPERATION
GENERAL DESCRIPTION
The SP-100, Type K462, is a complete semiautomatic
constant voltage DC arc welding machine. Included is
a solid state controlled, single phase constant voltage
transformer/ rectifier power source and a wire feeder
for feeding solid steel electrode and cored electrode.
The SP-100 is ideally suited for individuals having
access to 115 volt AC input power, and wanting the
ease of use, quality and dependability of both gas
metal arc welding or GMAW (also known as MIG
welding) and the Innershield electrode process (self
shielded flux cored or FCAW). The SP-100 is a
rugged and reliable machine that has been designed
for dependable service and long life.
RECOMMENDED PROCESSES
The SP-100 can be used for welding mild steel using
the GMAW, single pass, process which requires a
supply of shielding gas or it can be used for the self
shielded, Innershield electrode process (FCAW). The
SP-100 is configured for use with the GMAW (MIG)
process as delivered from the factory.
OPERATIONAL FEATURES AND
CONTROLS
The SP-100 has the following controls as standard:
Power ON/OFF Switch, Voltage Control, Wire Speed
Control, and a Circuit Breaker.
DESIGN FEATURES AND
ADVANTAGES
● Operates on 115 volt input — no special wiring
required.
● Solid state output control.
● “Cold electrode” until gun trigger is pressed for an
added measure of safety.
● Overload protection — incorporates both a thermo-
stat and a circuit breaker.
● Quality wire drive with electronic overload protec-
tion.
● Easy-to-set continuous range controls for precise
setting of arc voltage and wire speed.
● Continuous voltage control.
● “Quick Release” idle roll pressure arm is easily
adjusted.
● Reversible, dual groove drive roll. Drive roll will
feed .023-.025” (0,6- 0,9 mm) diameter wire.
● Accommodates both 8” (200 mm) diameter and 4”
(100 mm) diameter spools of wire.
● No external shielding gas is required when used
with Lincoln Innershield .035” (0,9 mm) NR®-211MP electrode.
● Easy to change polarity.
WELDING CAPABILITY
The SP-100 is rated at 90 amps, 18 volts, at 20% duty
cycle on a ten minute basis. It is capable of higher
duty cycles at lower output currents.
LIMITATIONS
Arc Gouging cannot be performed with the SP-100.
The SP-100 is not recommended for pipe thawing.
CONTROLS AND SETTINGS
Refer to Figure B.1a.
1. Power ON/OFF Switch —
When the power is on the
fan motor will run and air will
be exhausted out the louvers
in the front of the machine.
The welding output and wire
feeder remain off until the
gun trigger is pressed.
2. Voltage Control — A continuous control that gives full
range adjustment of power
source output voltage.
Voltage can be adjusted
while welding.
3. Wire Speed Control —
Controls the wire feed speed
from 50 – 400 in /min (1.3 –
10 m/min). The control can
be preset on the dial to the
setting specified on the SP100 Application Guide located on the inside of the wire
feed section door. Wire
speed is not affected when
changes are made in the
voltage control.
I
On
O
Off
V
Arc Volts
o|o
Wire Speed
B-3
SP-100
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OPERATION
FIGURE B.1a
Refer to Figure B-1b.
4. Circuit Breaker - Protects machine from damage if
maximum output is exceeded. Button will extend
out when tripped (Manual reset).
FIGURE B.1b
WELDING OPERATIONS
PROCESS GUIDELINES
The SP-100 can be used for welding mild steel using
the GMAW, single pass, process which requires a
supply of shielding gas or it can be used for the self
shielded, Innershield electrode process.
The recommended gas and electrode for GMAW is
welding grade CO2gas and 0.025” (0 6 mm) diameter
Lincoln L-56 mild-steel welding wire [supplied on
121/2 Ib (6 kg) spools]. For 14 gauge (2,0 mm) and
thinner, CO2gas is recommended because it gives
equal or better performance than a blended gas at a
lower cost. A mixed gas consisting of 75 to 80% Argon
and 20 to 25% CO2is recommended for welding on
heavier gauge [12 gauge (2,5 mm) for example] steel.
The recommended electrode for the self-shielded
process is 0.035” (0,9 mm) diameter Lincoln
Innershield NR-211-MP on 10 Ib (4,5 kg) spools. This
electrode can be used for all position welding of 20
gauge through 5/16” (1 0 – 8,0 mm) thick steel [multiple passes are required for 1/4” and 5/16” (6,0 and 8,0
mm)].
SEQUENCE OF OPERATION
WIRE LOADING
Refer to Figure B.2. and B.3.
The machine power switch should be turned to the
OFF (“O”) position before working inside the wire feed
enclosure.
The machine is shipped from the factory ready to
feed 8” (200 mm) diameter spools [2.2” (56 mm)
max. width]. These spools fit on a 2” (50 mm) diame-
ter spindle that has a built-in adjustable* friction brake
to prevent overrun of the spool and excess slack in
the wire. The thumb screw at the end of the shaft is
not intended to be loosened. It should be tightened full
clockwise. NOTE: If full tightening of the spindle
thumbscrew causes too much tension in the wire
spool, the thumb screw stop point should be
adjusted.
*Earlier spindle shafts did not include a set screw to
adjust brake friction. If a set screw is desired, order
Lincoln part number T12932-2.
Load an 8” (200 mm) diameter spool on the wire spool
spindle shown in Figure B.2.
To use 4” (100 mm) diameter spools, the 2” (50
mm) diameter spindle must be removed (See Figure
B.3). Remove the thumb screw at the end of the shaft
and remove the spindle. The spindle can be stored in
the wire feed compartment. A 4’ (100 mm) diameter
spool is mounted directly on the 5/8” (16 mm) diameter shaft and held in place with the previously removed
thumb screw. Make certain that the thumbscrew is
3
2
1
4
B-4
SP-100
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OPERATION
tightened fully clockwise. Also make certain the start
end of the wire, which may protrude through the side
of the spool does not contact any metallic case parts.
FIGURE B.3
FRICTION BRAKE ADJUSTMENTS
1. Remove the Wire Spool thumbscrew.
2. Using a 3/16” (4,8 mm) hex wrench, turn the set
screw, located inside the tapped hole in the spindle
shaft, one or two turns counter-clockwise.
3. Fully reinstall the thumbscrew and check for proper
brake force to prevent spool overrun, but still allow
smooth and easy wire feeding. Readjust, if necessary.
WIRE THREADING
Refer to Figure B-4
1. Release the Spring Loaded Pressure Arm (1)
rotate the Idle Roll Arm (2) away from. the Wire
Feed Drive Roll (3). Ensure that the visible, .stenciled size on the drive roll matches the wire size
being used.
2. Carefully detach the end of the wire from the
spool. To prevent the spool from unwinding, do
not release the wire until after step 5.
3. Cut the bent portion of wire off and straighten the
first 4” (100 mm).
4. Thread the wire through the In-going guide tube
(4), over the drive roll (3), and into the out-going
guide tube (5).
5. Close the idle roll arm and latch the spring loaded
pressure arm (2) in place (now you may release
the welding wire).
6. The idle roll pressure adjustment wing nut is normally set for mid-position on the pressure arm
threads. If feeding problems occur because the
wire is flattened excessively, turn the pressure
adjustment counter-clockwise to reduce distortion
of the wire. Slightly less pressure may be required
when using 0.023 – 0.025” (0,6 mm) wire. If the
drive roll slips while feeding wire, the pressure
should be increased until the wire feeds properly.
FIGURE B.4
The Wire Drive Feed Roll can
accommodate two wire sizes by
flipping the wire drive feed roll
over. The sizes are stenciled on
the drive roll.
1
2
3
4
5
Wire Spindle Shaft
4" Wire Spool
Thumb Screw
To Wire Drive
Wire Spool must be pushed all the way on the spindle so that the
spindle’s tab will hold it in place. The Wire Spool will rotate clockwise when wire is dereeled.
8” Wire Spool
Wire Spool Spindle
Be sure that this stud engages
the hole in the wire spool.
To Wire Drive
FIGURE B.2
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