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

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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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.

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

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

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

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

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

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

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.

Off

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

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.

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

B-5

SP-100

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OPERATION

When inching the welding wire, the drive rolls, the gun connector block and the gun contact tip are always energized relative to work and ground and remain energized several seconds after the gun trigger is released.

7. Refer to Figure B.5. Remove gas nozzle and contact tip from end of gun.

8. Turn the SP-100 ON (“I”).

9. Straighten the gun cable assembly.

10. Depress the gun trigger switch and feed welding wire through the gun and cable. (Point gun away from yourself and others while feeding wire.) Release gun trigger after wire appears at end of gun.

11. Replace contact tip and gas nozzle.

12. Refer to Figure B-6. Cut the wire off 1/4” – 3/8” (6 – 10 mm) from the end of the tip. The SP-100 is now ready to weld.

SHIELDING GAS

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. Refer to the ACCESSORIES section for more information about selecting gas cylinders for use with the SP-100.

1. For CO2, open the cylinder very slowly. For argonmixed gas, open cylinder valve slowly a fraction of a turn. When the cylinder pressure gauge pointer stops moving, open the valve fully.

FIGURE B.6FIGURE B.5

Gun Handle

Gas Diffuser/ Contact Tip

Gas Nozzle

WARNING

2. If using a regulator with an adjustable flow meter, close the gun trigger and adjust the flow to give 15 – 20 cubic ft per hour (CFH) (7 – 10 I/min) [use 20

-– 25 CFH (10 – 12 I/min) when welding out of position or in a drafty location for CO2]. For argon mixed gas, trigger to release gas pressure, and turn off the adjust the flow to give 25 – 30 CFH (12 – 14 I/min).

3. Keep the cylinder valve closed, except when using the SP-100. When finished welding:

a) Close the cylinder valve to stop gas flow. b) Depress the gun trigger briefly to release the

pressure in the gas hose.

c) Turn off the SP-100.

MAKING A WELD

1. See Recommended Processes And Equipment section for selection of welding wire and shielding gas and for range of metal thicknesses that can be welded.

2. See the Application Guide on the inside of wire feed section door for information on setting the SP-100 controls.

3. Set the Voltage (“V”) and Wire Speed (“olo’”) controls to the settings suggested for the welding wire and base metal thickness being used.

4. Check that the polarity is correct for the welding wire being used and that the gas supply, if required, is turned on.

5. When using Innershield electrode, remove the gas nozzle and install the gasless nozzle. This will improve visibility of the arc and protect the gas diffuser from weld spatter. Refer to the MAINTENANCE section for details on nozzle replacement.

3/8" – 1/2" Electrical Stickout

Contact Tip

Wire Electrode

B-6

SP-100

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OPERATION

6. Refer to Figure B.7. Connect work clamp to metal to be welded. Work clamp must make good electrical contact to the workpiece. The workpiece must also be grounded as stated in “Arc Welding Safety Precautions” in the beginning of this manual.

7. Position gun over joint. End of wire may be lightly touching the work.

8. Lower welding helmet, close gun trigger, and begin welding Hold the gun so the contact tip to work distance is about 3/8 inch (10 mm).

9. To stop welding, release the gun trigger and then pull the gun away from the work after the arc goes out

10. When no more welding is to be done, close valve on gas cylinder (if used), momentarily operate gun trigger to release gas pressure, and turn off the SP-100.

CLEANING TIP AND NOZZLE

Clean the contact tip and nozzle to avoid arc bridging between the nozzle and contact tip which can result in a shorted nozzle, poor welds and an overheated gun. Hint: Anti-stick spray or gel, available from a welding supply distributor, may reduce buildup and aid in spatter removal.

CHANGING MACHINE OVER TO FEED OTHER WIRE SIZES

The SP-100 is shipped from the factory ready to feed

0.023-0.025” (0,6 mm) diameter wire. To operate the SP-100 with other sizes of wire, it is necessary to change the contact tip and change the drive roll over to other sizes. Refer to Changing the Contact Tip and Changing the Drive Roll, in the MAINTENANCE section, for specific information on these procedures.

WELDING WITH INNERSHIELD

Welding with Innershield requires an Innershield Welding Kit. A gasless nozzle is provided in the Innershield Welding Kit. When using Innershield electrode, installing the gasless nozzle will improve visibility of the arc and protect the gas diffuser from weld spatter. Additionally included is a gun cable liner to permit proper feeding of .035” (0,9 mm) Innershield wire. Refer to the ACCESSORIES section for details on obtaining this kit.

OVERLOAD PROTECTION

OUTPUT OVERLOAD

The SP-100 is equipped with a circuit breaker which protects the machine from damage if maximum output is exceeded. The circuit breaker button will extend out when tripped. The circuit breaker must be manually reset.

THERMAL PROTECTION

The SP-100 has a rated output duty cycle of 20%. If the duty cycle is exceeded, a thermal protector will shut off the output until the machine cools to a normal operating temperature. This is an automatic function of the SP-100 and does not require user intervention.

WIRE FEED OVERLOAD PROTECTION

The SP-100 has an automatic electronic protection circuit to protect the wire feed motor. If excessive motor overload occurs (due to excessive feeding force jammed drive rolls, or shorted motor leads) the circuit will shut down the wire feed motor and the welding power output.

The wire feed shut-down circuit will reset automatically when the gun trigger is released. However shut-down will reoccur if the overload situation is not corrected.

FIGURE B.7

Gun Cable

Work Piece

Arc

B-7

SP-100

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NOTES

SP-100

Section C

TABLE OF CONTENTS

– ACCESSORIES SECTION –

Accessories.....................................................................................................Section C

Accessories...........................................................................................................C-1

Replacement Parts................................................................................................C-1

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SP-100

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C-1

ACCESSORIES

K467 INPUT LINE CORD

The K467 Input Line Cord is the same as the line cord supplied with the SP-100, but has a NEMA type 5-20P plug for use on 25 amp branch circuits.

To install optional features, refer to instructions included with the kit.

REPLACEMENT PARTS

Complete Gun and Cable Assembly

L7538 – Black Trigger; L8311-2 (K530-2) – Red Trigger

Contact Tip 0.025” (0,6 mm)

S18704-1 – Black Trigger; S19726-1 – Red Trigger

Contact Tip 0.030” (0,8 mm)

S18704-2 – Black Trigger; S19726-2 – Red Trigger

Contact Tip 0.035” (0,9 mm)

S18704-3 – Black Trigger; S19726-3 – Red Trigger

Liner 0.023 - 0.030” (0,6 - 0,8 mm)

S18704-4 – Black Trigger; M16291-2 – Red Trigger

Liner 0.035” (0,9 mm)

S18704-5 – Black Trigger; M16291-1 – Red Trigger

Gas Diffuser

S18704-6 – Black Trigger; S19728 – Red Trigger

Gas Nozzle

S18704-7 – Black Trigger; M16294 – Red Trigger

Gasless Nozzle (Innershield Only)

S18704-14 – Black Trigger; M16418 – Red Trigger

LINCOLN GAS REGULATOR KITS

The Lincoln K463 CO2or K499 Ar-mixed Gas Regulator and Hose Kit is recommended for use with the SP100.

K463 CO2Regulator

The K463 kit includes a preset, nonadjustable pressure flow regulator for use on CO2cylinders. The K463 CO2pressureflow regulator is preset at the factory to provide a flow rate of 20 cubic feet per hour (10 l/min). This setting cannot be changed. Also included is a 10 foot (3,0 m) gas hose which connects to the rear of the SP-100.

The K463 CO2pressure-flow regulator can be used with a cylinder of argon mixed gas if a CGA-580-320 (Western Enterprises No.

810) adapter is used between the cylinder and the regulator.

Weld shielding gas may be obtained from a welding supply distributor.

K499 Ar-Mixed Gas Regulator

K499 Ar-Mixed Gas Regulator and Hose Kit – Includes a preset, non-adjustable pressure and flow regulator for use on argonmixed gas cylinders. Also included is a 10 foot (3 0 m) gas hose which connects to the rear of the SP-100.

INNERSHIELD WELDING KITS

0.035 (0.9 mm) Innershield Welding Kit – Includes a contact tip, a gasless nozzle and a cable liner to permit the SP-100 gun and cable to use a 0.035” (0,9 mm) diameter flux-cored electrode. Also included is a spool of 0.035 (0,9 mm) Innershield NR-211-MP.

Two kits are available:

K549-1 kit is for use with Magnum 100L gun (with red trigger).

K464 kit is for use with the original Lincoln Electric gun (with black trigger).

DRIVE ROLL

M15448-1 Reversible Drive Roll with double knurled grooves for 0.035 (0,9 mm) cored electrode.

SP-100

Section D

TABLE OF CONTENTS

– MAINTENANCE SECTION –

Maintenance ...................................................................................................Section D

Safety Precautions ...............................................................................................D-1

Items Requiring No Maintenance .........................................................................D-1

Routine and Periodic Maintenance........................................................................D-1

Before Each Use.............................................................................................D-1

After 5 Minutes of Welding..............................................................................D-1

After Each Spool of Wire Feed .......................................................................D-1

Component Replacement Procedures ..................................................................D-2

Changing The Contact Tip..............................................................................D-2

Changing Drive Roll .......................................................................................D-2

Replace Liner..................................................................................................D-3

Replace Internal Gun Handle Parts As Necessary.........................................D-3

Location of Components........................................................................................D-4

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SP-100

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AFTER EACH SPOOL OF WIRE FEED

• Remove contact tip and clean inside diameter with short piece of wire

• Clean cable liner – when rough and erratic wire feeding occur.

AFTER FEEDING 50# OF FLUX CORED WIRE OR 300# OF SOLID WIRE

• Unplug machine or turn power switch to OFF – “O” position. Remove gun and cable from machine.

• Remove gas nozzle and contact tip from gun

• Lay cable out straight - blow out gently with compressed air. Bend cable back and forth – blow out again – Repeat until clean.

Excessive pressure at start may cause the dirt to form a plug.

PERIODICALLY AS REQUIRED

• Unplug machine or turn power switch to

OFF – “O” position.

• Blow dirt out of the welder with low pres-

sure air to eliminate excessive dirt and dust buildup that could cause welder to run hot.

• Blow dirt out of: Rectifier & Fan Motor

Assembly; PC Board located on Case Side Assembly; and Center Assembly components. Refer to Figure D.4.

• Vacuum accumulated dirt from gear-

box and wire feed section. Refer to

Figure D.4

• Inspect the incoming guide tube and

clean inside diameter if necessary. Replace when excessively worn.

• Replace Contact Tip – when hole is

enlarged or elongated (refer to Changing Contact Tip, below).

D-1

MAINTENANCE

SAFETY PRECAUTIONS

ELECTRIC SHOCK can kill.

• Disconnect input power by removing plug from receptacle before working inside SP-100.Use only grounded receptacle. Do not touch electrically “hot” parts inside SP-1 00.

• Have qualified personnel do the maintenance and trouble shooting work.

ITEMS REQUIRING NO MAINTENANCE

• Drive Motor and Gearbox – Lifetime lubrication

• Fan Motor- Lifetime lubrication.

• Wire Reel Spindle – Do NOT lubricate shaft.

ROUTINE AND PERIODIC MAINTENANCE

BEFORE EACH USE

• Check over machine and accessories for any obvious condition that may prevent safe performance or operation, repair or replace items as necessary to correct any abnormal condition.

AFTER 5 MINUTES OF WELDING or when spatter accumulates in nozzle

• Clean nozzle to avoid bridging between nozzle and contact tip which results in shorted nozzle, poor welds and overheated gun. Hint: Anti-stick spray or gel available from a welding supply distributor may reduce buildup and aid in spatter removal.

WARNING

CAUTION

SP-100

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D-2

MAINTENANCE

1. Make certain the SP-100 power switch is off “O”.

2. Open the Spring Loaded Pressure Arm (2); Lift up the Idle Roll Arm (3).

3. Remove the drive roll retaining screw and washer.

4. Remove the drive roll, flip over and install with the 0.030/0.035” (0.8/0.9 mm) stencil visible (away from gearbox). Make certain the small key is in place in the keyway.

5. Replace the washer and retaining screw.

• Replace Liner – when wire feeding problems occur and other items have been checked (refer to Changing Liner, in this section).

COMPONENT REPLACEMENT PROCEDURES

CHANGING THE CONTACT TIP

1. Refer to Figure D.2. Remove the gas nozzle from the gun by unscrewing counter-clockwise.

2. Remove the existing contact tip from the gun by unscrewing counter-clockwise.

3. Insert and hand tighten desired contact tip.

4. Replace gas nozzle.

CHANGING DRIVE ROLL

The SP-100 Wire Feed Drive Roll (1 ) has two grooves; one for 0.023” – 0.025” (0,6 mm) solid steel electrode and the other for

0.030” (0,8 mm) solid and 0.035” (O,9 mm)

flux-cored steel electrode. See Figure D.1. As shipped, the drive roll is installed in the

0.023” – 0.025” (0,6 mm) position (as indi-

cated by the stenciling on the exposed side of the drive roll). If 0.030” (0,8 mm) or

0.035” (0,9 mm) wire is to be used, the drive

roll must be reversed as follows:

Wire size is stenciled on the ends of the drive roll.

1-1/4 (31.8 mm) Liner Trim Length

Gas Diffuser

Gas Nozzle or Gasless Nozzle

Set Screw Brass Cable

Connector

Liner Assembly (Liner bushing to be sealed tight against brass cable connector)

FIGURE D.2

Liner trim length for the Magnum 100L gun (red trigger)

FIGURE D.1

SP-100

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D-3

MAINTENANCE

REPLACE INTERNAL GUN HANDLE PARTS AS NECESSARY

The gun handle consists of two halves that are held together with a collar on each end. To open up the handle, turn the collars approximately 60 degrees counter-clockwise (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 difficult 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

CHANGING LINER

NOTICE: The variation in cable lengths prevents the interchangeability of liners. Once a liner has been cut for a particular gun, it should not be installed in another gun unless it can meet the liner cutoff length requirement. Refer to Figure D.2.

1. Remove gun and cable assembly from machine.

2. Remove the gas nozzle from the gun by unscrewing counter-clockwise.

3. Remove the existing contact tip from the gun by unscrewing counter-clockwise.

4. Remove the gas diffuser from the gun tube by unscrewing counter-clockwise.

5. Lay the gun and cable out straight on a flat surface. Loosen the set screw located in the brass connector at the wire feeder end of the cable. Pull the liner out of the cable.

6. Insert a new untrimmed liner into the

connector end of the cable. Be sure the liner bushing is stenciled appropriately for the wire size being used.

7. Fully seat the liner bushing into the con-

nector. Tighten the set screw on the brass cable connector. At this time, the gas diffuser should not be installed onto the end of the gun tube.

8. With the gas nozzle and diffuser

removed from the gun tube, be sure the cable is straight, and then trim the liner to the length shown in the Figure D.2. Remove any burrs from the end of the liner.

9. Screw the gas diffuser onto the end of

the gun tube and securely tighten.

10.Replace the contact tip and nozzle.

➣

Counter-clockwise

SP-100

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D-4

MAINTENANCE

FIGURE D.4 – LOCATION OF COMPONENTS

1 Case Back and Bottom Assembly 2 Center Panel Assembly 3 Case Front Assembly 4 Case Side Assembly 5 Rectifier & Fan Motor Assembly 6 Wire Drive Assembly

SP-100 SUB ASSEMBLIES



SP-100

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D-5

NOTES

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SP-100

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

Section E

TABLE OF CONTENTS

– THEORY OF OPERATION –

SP-100

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E-1

THEORY OF OPERATION

NOTE: Unshaded areas of block logic diagram are the subject of discussion.

INPUT LINE VOLTAGE, FAN MOTOR AND MAIN TRANSFORMER

The 115 vac input power is applied to the SP-100 through a receptacle located on the rear panel. The input power is connected to the fan motor, control board and main transformer through a line switch located on the front panel. A circuit breaker is incorporated in the 115 vac circuit to protect the unit from current overloads. The fan motor employs a 24 vac auxiliary winding which powers the control board. The main transformer changes the high voltage, low current input power to a low voltage, high current output for welding.

FIGURE E.1 – Input Power Circuits



SP-100

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E-2

THEORY OF OPERATION

NOTE: Unshaded areas of block logic diagram are the subject of discussion.

OUTPUT CONTROL, RECTIFICATION AND VOLTAGE FEEDBACK

The AC voltage that is applied to the main transformer primary is controlled at the control board by two SCR’s (Silicon Controlled Rectifiers). The SCR’s are controlled by a pulse signal developed on the control board. The control board compares the commands of the arc voltage control with the voltage feedback signal. The board circuitry then sends a pulse to turn on the SCR’s. In this manner, the voltage applied to the primary of the transformer is varied and controlled. This variable and controlled voltage is

FIGURE E.2 – Output Circuits



reflected at the transformer secondary winding and is applied to the rectifier diode bridge. This rectified DC voltage is filtered by the output capacitor and choke circuit and is applied to the machine’s output terminals.

SP-100

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E-3

THEORY OF OPERATION

NOTE: Unshaded areas of block logic diagram are the subject of discussion.

TRIGGER, GAS SOLENOID AND WIRE DRIVE

Closure of the trigger circuit (pulling the gun trigger) signals the control board to start several functions. 115 vac is applied to the gas solenoid to allow shielding gas to flow. The SCRs are activated and voltage is applied to the main transformer. Output voltage is developed at the output terminals and fed back to the control board. This welding output voltage is also used to power the wire drive motor.

FIGURE E.3 – Trigger, Gas Solenoid and Wire Drive



The welding output voltage that powers the wire drive motor is varied and controlled on the control board. The control board monitors the drive motor armature current and voltage and compares the feedback information with the commands sent from the wire speed control. The control board varies and controls power to the drive motor, which, in turn, controls the speed of the wire drive. The SP-100 also has an automatic protection circuit which protects the wire drive motor from excessive motor overloads.

SP-100

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E-4

THEORY OF OPERATION

An SCR is fired by a short burst of current into the gate. This gate pules must be more positive than the cathode voltage. Since there is a standard PN junction between gate and cathode, the voltage between these terminals must be slightly greater than 0.6V. Once the SCR has fired, it is not necessary to continue the flow of gate current. As long as current continues to flow from anode to cathode, the SCR will remain on. When the anode to cathode current drops below a minimum value, called holding current, the SCR will shut off. This normally occurs as the AC voltage passes through zero into the negative portion of the sine wave. If the SCR is turned on early in the positive half cycle, the conduction time is longer, resulting in greater SCR output. If the gate firing occurs later in the cycle, the conduction time is less, resulting in lower SCR output.

SCR OPERATION

A silicon controlled rectifier (SCR) is a three terminal device used to control large currents to a load. An SCR acts very much like a switch. When it is turned on there is current flow from anode to cathode. In the ON state, the SCR acts like a closed switch. When the SCR is turned OFF, there is no current flow from anode to cathode, thus the device acts like an open switch. As the name suggests, the SCR is a rectifier, so it passes current only during positive half cycles of the AC supply. The positive half cycle is the portion of the sine wave in which the anode of the SCR is more positive than the cathode.

When an AC supply voltage is applied to the SCR, the device spends a certain portion of the AC cycle time in the ON state and the remainder of the time in the OFF state. The amount of time spent in each state is controlled by the Gate.

Note: As the gate pulse is applied later in the cycle, the SCR output is decreased.

FIGURE E.4 SCR OPERATION

SP-100

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E-5

THEORY OF OPERATION

THERMAL PROTECTION

A thermostat protects the machine from excessive operating temperatures. Excessive operating temperatures may be caused by lack of cooling or operating the machine beyond the duty cycle and output rating. If excessive operating temperature should occur, the thermostat will prevent voltage and wire drive. The fan will remain on during this period. The thermostat is selfresetting once the machine cools sufficiently. If the thermostat shutdown is caused by excessive output or duty cycle and the fan is running normally, the power switch may be left on and the reset should occur within a 15 minute period. If the fan is not turning or the air intake louvers are obstructed then the input power must be removed and the fan problem or air obstruction must be corrected.

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SP-100

Section F

TABLE OF CONTENTS

– TROUBLESHOOTING SECTION –

Troubleshooting .............................................................................................Section F

Safety Precautions ................................................................................................F-1

How To Use Troubleshooting Guide .....................................................................F-1

PC Board Troubleshooting Procedures.................................................................F-2

Troubleshooting Guide...........................................................................................F-3

Output Problems .............................................................................................F-3

Feeding Problems...........................................................................................F-6

Gas Flow Problems.........................................................................................F-7

Welding Problems ..........................................................................................F-7

PC Board Connector Locations .............................................................................F-8

Oscilloscope Waveforms

Normal Open Circuit Voltage Waveform.........................................................F-9

Typical Output Voltage Waveform – Machine Loaded .................................F-10

Abnormal Open Circuit Voltage Waveform ..................................................F-11

Replacement Procedures

Fan Blade and Motor Removal......................................................................F-12

Wire Drive Assembly Removal......................................................................F-13

Retest After Repair .............................................................................................F-14

SP-100

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F-1

TROUBLESHOOTING & REPAIR

Step 1. LOCATE PROBLEM (SYMPTOM).

Look under the column labeled “PROBLEM (SYMPTOMS)”. This column describes possible symptoms that the machine may exhibit. Find the listing that best describes the symptom that the machine is exhibiting.

Symptoms are grouped into the following categories: Output Problems; Feeding Problems; Gas Flow Problems; and Welding Problems.

Step 2. PERFORM EXTERNAL TESTS.

The second column labeled “POSSIBLE AREAS OF MISADJUSTMENT(S)” lists the obvious external possibilities that may contribute to the machine symptom. Perform these tests/checks in the order listed. In general, these tests can be conducted without removing the case wrap-around cover.

Step 3. PERFORM COMPONENT TESTS.

The last column labeled “Recommended Course of Action” lists the most likely components that may 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 number of possible components check the components

in the order listed

to eliminate one possibility at a time until you locate the cause of you problem.

All the needed test specifications and repair procedures are described in detail on the referenced pages. All the needed electrical test points, terminal strips, junctions, etc., can be found on the referenced electrical wiring diagrams and schematics. See Electrical Diagram Section.

HOW TO USE TROUBLESHOOTING GUIDE

Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.

__________________________________________________________________________

WARNING

If for any reason you do not understand the test procedures or are unable to Perform the tests/repairs safely, contact your LOCAL AUTHORIZED LINCOLN ELECTRIC FIELD SERVICE FACILITY for assistance before you proceed. Call 216-383-3531 or 1-800-833-9353

_______________________________________________________

CAUTION

This Troubleshooting Guide is provided to help you locate and correct possible machine malfunctions or misadjustments. Simply follow the three-step procedure listed below.

SP-100

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F-2

TROUBLESHOOTING & REPAIR

4. Test the machine to determine if the failure symptom has been corrected by the replacement PC board.

NOTE: Allow the machine to heat up so that all electrical components can reach their operating temperature.

5. Remove the replacement PC board and substitute it with the original PC board to recreate the original problem.

a. If the original problem does not reap-

pear by substituting the original board, then the PC board was not the problem. Continue to look for bad connections in the control wiring harness, junction blocks, and the terminal strips.

b. If the original problem is recreated by

the substitution of the original board, then the PC board was the problem. Reinstall the replacement PC board and test the machine.

6. Always indicate that this procedure was followed when warranty reports are to be submitted.

NOTE: Following this procedure and writing on the warranty report, “INSTALLED AND Switched PC BOARDS TO VERIFY PROBLEM,” will help avoid denial of legitimate PC board warranty claims.

ELECTRIC SHOCK can kill.

Have an electrician install and service this equipment. Turn the input power OFF and unplug the machine before working on equipment. Do not touch electrically hot parts.

CAUTION: Sometimes machine failures

appear to be due to PC board failures. These problems can sometimes be traced to poor electrical connections. To avoid problems when troubleshooting and replacing PC boards, please use the following procedure:

1. Determine to the best of your technical ability that the PC board is the most likely component causing the failure symptom.

2. Check for loose connections at the PC board to assure that the PC board is properly connected.

3. If the problem persists, replace the suspect PC board using standard practices to avoid static electrical damage and electrical shock. (Read the warning inside the static resistant bag.)

NOTE: It is desirable to have a spare (known good) PC board available for PC board troubleshooting.

PC BOARD TROUBLESHOOTING PROCEDURES

WARNING

SP-100

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F-3

TROUBLESHOOTING & REPAIR

Observe Safety Guidelines

detailed in the beginning of this manual.

TROUBLESHOOTING GUIDE

PROBLEMS (SYMPTOMS)

Major physical or electrical damage is evident.

No wire feed, weld output or gas flow when gun trigger is pulled. Fan does NOT operate.

No weld output or wire feed when gun trigger is pulled. Fan runs and gas flows normally.

POSSIBLE AREAS OF MISADJUSTMENT(S)

Contact your LOCAL LINCOLN AUTHORIZED FIELD SERVICE FACILITY.

1. Make sure correct voltage is applied to the machine (115 vac).

2. Make certain that power switch is in the ON position.

Contact your LOCAL LINCOLN

AUTHORIZED FIELD SERVICE FACILITY.

RECOMMENDED COURSE OF ACTION

Contact the Lincoln Electric Service Department. (216) 383-2531 or 1800-833-9353 (WELD)

1. Check for 115 VAC at input to fan motor (leads #31 to #32). If correct voltage is present and fan motor does not function, replace the fan motor. See wiring diagram.

2. If 115 vac is not present at leads #31 to #32, then check the power switch and input line cord. (SI)

1. Check voltage from leads #202 to #201 at the output diode heat sinks. Normal voltage is from 2 vac to 20 VAC, depending on arc voltage control setting. If the correct AC voltage is present, check the output diodes and connections. Also check the output capacitor, C1. See wiring diagram.

2. If the correct AC voltage is not present at the diode heat sink leads #202 to #201, then check the AC voltage on the transformer (TI) primary leads #531 to #32 (normal is 115 vac with arc voltage control at maximum). If the correct voltage is present at the transformer primaries (#531 to #32), the transformer may be faulty. See wiring diagram.

3. If the correct voltage is not present at leads #531 to #32, then check the arc voltage control potentiometer (RI)and associated wires #205, #206 and #207 for loose or broken connections. See wiring diagram.

4. The control board may be faulty – Replace.

OUTPUT PROBLEMS

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed call 216-383-2531 or 1-800-833-9353.

CAUTION

SP-100

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F-4

TROUBLESHOOTING & REPAIR

Observe Safety Guidelines detailed in the beginning of this manual.

TROUBLESHOOTING GUIDE

PROBLEMS (SYMPTOMS)

No weld output when gun trigger is pulled. Fan runs, gas flows and wire feeds normally.

BELOW CODE 9794 ONLY

No wire feed, weld output or gas flow when gun trigger is pulled Fan operates normally.

POSSIBLE AREAS OF MISADJUSTMENT(S)

1. Arc voltage may be set too low.

2. Gun tip may be worn – Replace.

3. Check for correct input voltage to machine.

4. Gun or work cable may be faulty.

1. Check the circuit breaker located in the machine’s wire drive compartment. Reset if tripped.

2. The thermostat may be tripped due to overheating. Let machine cool. Weld within the duty cycle or remove any air obstruction to machine.

3. Wire feed motor may be overloaded. Correct feeding problem.

4. Gun trigger may be faulty.

RECOMMENDED COURSE OF ACTION

1. Check for open circuit voltage (OCV) at the machine’s output terminals, located in wire drive compartment. Normal OCV is from 10 vdc to 28 vdc depending on arc voltage control setting. If correct OCV is present, check gun and work cable.

2. If correct OCV is not present at the output terminals, then check for broken leads at the output choke or at the positive output terminal.

1. Remove main power supply to SP-100. With gun trigger pulled, check for continuity (zero ohms) from 8J2 (lead #213) to 9J2 (lead #211 ) at harness plug. If zero ohms is indicated, then trigger circuit is OK. See wiring diagram and Figure F.1.

2. If an open circuit or high resistance is indicated in Step 1, then check leads #211,#212 and #213 for loose or broken connections. Also check the normally closed thermostat mounted on the diode heat sink assembly. See wiring diagram.

3. Check for 115 vac at lead #31A to plug 3J1 on control board. If 115 vac is NOT present, remove main supply power to machine. Test continuity (zero ohms) of leads #32 and #31A. See Figure F.1.

4. If 115 vac is present at lead #31A to plug 3J1 (lead #32), then control board may be faulty – Replace. See Figure F.1.

OUTPUT PROBLEMS

CAUTION

SP-100

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F-5

TROUBLESHOOTING & REPAIR

TROUBLESHOOTING GUIDE

Observe Safety Guidelines

detailed in the beginning of this manual.

PROBLEMS (SYMPTOMS)

CODE 9794 and ABOVE

No Wire feed, weld output or gas flow when the gun trigger is pulled Fan operates normally.

POSSIBLE AREAS OF MISADJUSTMENT(S)

1. Check the circuit breaker in the machine – Located in the wire drive compartment. Reset if tripped.

2. The thermostat may be tripped due to overheating. Let machine cool. Weld within the duty cycle or remove any air obstruction to machine.

3. Wire feed motor may be overloaded – correct feeding problem.

4. Gun trigger may be faulty.

RECOMMENDED COURSE OF ACTION

1. Check for 24 vac at plug 2J1 to 6J1 on the control board. If voltage is not present, check continuity of leads to fan motor. If leads are OK, replace fan motor. See Figure F.1

2. Remove main power supply to SP-100. With gun trigger pulled check for continuity (zero ohms) from 8J2 (lead #213) to 9J2 (lead #211) at harness plug. If zero ohms is indicated then trigger circuit is OK. See Figure F.1.

3. If an open circuit or high resistance is indicated in Step 2, then check leads #211, #212 and #213 for loose or broken connections. Also check the normally closed thermostat mounted on the diode heat sink assembly.

4. The control board may be faulty – Replace.

OUTPUT PROBLEMS

CAUTION

SP-100

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F-6

TROUBLESHOOTING & REPAIR

Observe Safety Guidelines detailed in the beginning of this manual.

TROUBLESHOOTING GUIDE

CAUTION

PROBLEMS (SYMPTOMS)

No wire feed when gun trigger is pulled. Fan runs, gas flows and machine has correct open circuit voltage (28 vdc maximum) – weld output.

Wire feed speed motor runs very fast. Weld output, gas flow and fan operate normally.

POSSIBLE AREAS OF MISADJUSTMENT(S)

1. If the wire drive motor is running check to see if the correct wire is in the machine.

2. If the wire drive motor is running make sure that the correct drive rolls are installed in the machine.

3. Check for clogged cable liner or feeding problems.

1. Make sure that the wire speed control is not set at maximum.

RECOMMENDED COURSE OF ACTION

1. Check for a DC voltage at wire drive motor armature (leads #539 to #541). The voltage should be between 2 vdc and 10 vdc. This voltage will vary with the wire speed control setting. If the correct voltage is present, the drive motor may be faulty. Replace. See wiring diagram.

2. If the motor armature voltage is not present, then check for OCV at leads #203 (3J2) and #204 (4J2) on the control board. If correct voltage is present, go to Step 3. If OCV is not present at leads #203 and #204, check continuity (zero ohms) of leads.

3. If the motor armature voltage is not present, then check the wire speed control potentiometer and associated wires #208, #209 and #203 for faulty connections.

4. The control board may be faulty. Replace.

1. Remove main supply power to machine. Disconnect plug J2 from the control board. Test the resistance from lead #539 (2J2) in the harness plug to the wire feed motor case. If the resistance is below 500,000 ohms, replace the drive motor.

2. Check the wire speed control potentiometer and associated wires #208, #209 and #203 for loose or broken connections.

3. The control board may be faulty. Replace.

FEEDING PROBLEMS

SP-100

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F-7

TROUBLESHOOTING & REPAIR

Observe Safety Guidelines detailed in the beginning of this manual.

TROUBLESHOOTING GUIDE

CAUTION

PROBLEMS (SYMPTOMS)

Low or no gas flow when gun trigger is pulled. Wire feed, weld output and fan operate normally.

POSSIBLE AREAS OF MISADJUSTMENT(S)

1. Check gas supply, flow regulator and gas hoses.

2. Check gun connection to machine for obstruction or leaky seals.

RECOMMENDED COURSE OF ACTION

1. Check for 115 vac at the gas solenoid leads #7 to #32A. If the correct voltage is present but the solenoid does not activate, replace solenoid. See wiring diagram .

2. If voltage is not present at leads #7 to #32A, remove main supply power to machine. Test leads #7 and #32A for continuity (zero ohms) to the control board.

3. Control board may be faulty. Replace.

GAS FLOW PROBLEMS

PROBLEMS (SYMPTOMS)

Arc is unstable – Poor starting

POSSIBLE AREAS OF MISADJUSTMENT(S)

1. Check for correct input voltage to machine – 115 vac.

2. Check for proper electrode polarity for process.

3. Check gun tip for wear or damage – Replace.

4. Check for proper gas and flow rate for process.

5. Check work cable for loose or faulty connections.

6. Check gun for damage or breaks.

RECOMMENDED COURSE OF ACTION

1. Check for correct open circuit voltage (OCV) at machine’s output terminals, 10 vdc to 28 vdc, depending on arc voltage control setting. If correct OCV is present check gun and work cable.

2. If OCV is low, check output capacitor and output diodes.

3. Check arc voltage control potentiometer and associated wires #205, #206 and #207 for loose or broken connections. See wiring diagram.

4. Control board may be faulty. Replace.

WELDING PROBLEMS

SP-100

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F-8

TROUBLESHOOTING & REPAIR

PC BOARD CONNECTOR LOCATIONS

FIGURE F.1

Codes 9794 and above

Codes below 9794

6J1 10J2

1J1 1J2

6J1

10J2

1J1

1J2

SP-100

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F-9

TROUBLESHOOTING & REPAIR

SCOPE SETTINGS

Note: Scope probes connected at machine output terminals. Positive probe to (+) terminal, negative probe to (–) terminal.

NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM

0 volts

10 volts/Div 20 ms/Div

Volts/Div ........................................................10/Div

Horizontal Sweep.....................................20 ms/Div

Coupling .............................................................DC

Trigger ..........................................................Internal

SP-100

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F-10

TROUBLESHOOTING & REPAIR

SCOPE SETTINGS

This is the typical output voltage waveform generated from a properly operating machine. Note that each vertical division represents 10 volts and that each horizontal division represents 20 milliseconds in time. The machine was loaded with a resistance grid bank. The ammeter read 90 amps and the voltmeter read 19 vdc.

Note: Scope probes connected at machine output terminals. Positive probe to (+) terminal, negative probe to (–) terminal.

TYPICAL OUTPUT VOLTAGE WAVEFORM – MACHINE LOADED

0 volts

10 volts 20 ms

Volts/Div ........................................................10/Div

Horizontal Sweep.....................................20 ms/Div

Coupling .............................................................DC

Trigger ..........................................................Internal

SP-100

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F-11

TROUBLESHOOTING & REPAIR

SCOPE SETTINGS

This is NOT the typical output voltage waveform. The output capacitor was disconnected from the circuit. Note the increased ripple in the waveform. This condition simulates the faulty output filter capacitor. Each vertical division represents 10 volts and that each horizontal division represents 20 milliseconds in time.

Note: Scope probes connected at machine output terminals. Positive probe to (+) terminal, negative probe to (–) terminal.

ABNORMAL OPEN CIRCUIT VOLTAGE WAVEFORM

0 volts

10 volts 20 ms

Volts/Div ........................................................10/Div

Horizontal Sweep.....................................20 ms/Div

Coupling .............................................................DC

Trigger ..........................................................Internal

SP-100

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F-12

TROUBLESHOOTING & REPAIR

FIGURE F.2

FIGURE F.3

FIGURE F.4

FAN BLADE AND MOTOR REMOVAL

PROCEDURE DESCRIPTION

The following procedure will aid in the removal and replacement of the fan blade and/or fan motor. It will also provide reasonable access to the output diode heat sinks.

TOOLS REQUIRED

● 5/16” nutdriver or socket wrench

● 7/16” nutdriver or socket wrench

● 7/16” open end wrench

● Phillips head screwdriver

● Needle nose pliers

PROCEDURE

1. Using the 5/16” nut driver, remove the three selftapping screws holding the fan bracket to the rear panel.

Refer to Figure F-2.

2. Remove the two aluminum transformer secondary leads from the diode heat sinks.

Note: When reassembling, use Dow 340 Heat Sink Compound on connection surfaces.

3. Remove three large black leads and one small blue lead from the large choke lead.

4. Remove leads #211 and #212 from the thermostat located on the diode heat sink.

5. Remove the four leads from the fan motor noting their positions. (TWO LEADS ON CODES BELOW 9794.)

6. Remove the three wires connected to the input receptacle. Note lead placement and connections. (L1, L2, and green ground lead.)

7. Remove the four self tapping screws holding the line cord and input receptacle to the back panel.

8. Remove input receptacle.

9. Remove the two Phillips head screws holding the gas solenoid to the center baffle – See Figure F.3.

10. Remove the gas solenoid and set aside.

11. Lift up the rectifier fan motor bracket assembly and support it near the top of the machine. This should provide access to the fan blade and motor.



12. Slide the blade from the motor shaft,

taking note

of blade placement on motor shaft.

(Shaft Indented approximately 0.10” from blade hub) -– Figure F.4.

13. Remove the two Phillips head screws holding the motor to the bracket. Remove the motor.

14. If the output diodes are to be removed, the leads must be removed from the diodes and the heat

Gas Solenoid

Thermostat

Diodes

SP-100

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F-13

TROUBLESHOOTING & REPAIR

FIGURE F.5

Two plastic fastener buttons attach the Connector Block to the Front Panel at these points. To remove the Connector Block, cut the heads off of the two fastener buttons.

FIGURE F.6

FIGURE F.7

Note: Slight resistance as rear housing is separated from the front is caused by the bearing, which will remain attached to the front housing.

WIRE DRIVE ASSEMBLY REMOVAL

PROCEDURE DESCRIPTION

The following procedure will aid in the removal of the entire wire drive unit for possible motor or gear box replacement.

TOOLS REQUIRED

● 5/16” nutdriver or socket wrench

● 1/4” nutdriver or socket wrench

● Phillips head screwdriver

● Needle nose pliers

● Knife or side cutters

● Screwdriver (slot head)

PROCEDURE

Refer to Figure F.5.

1A. FOR CODES ABOVE 10000

Cut heads off of two plastic fastener buttons located on the front panel. (Order new fastener buttons – Part No. T14659-3)

1B. FOR CODES BELOW 10000

Remove two flat head screws holding conductor block to front panel.

2. Remove gas hose from Connector block.

3. Remove cable running from output terminal to Connector block (1).

4. With 5116’’ nutdriver, remove mounting screw at rear of wire drive assembly.

5. With 5/16” nutdriver, remove screw holding the front panel to the case bottom. Carefully move front panel forward 1/2”.

6. Carefully slide out wire drive unit until motor leads are visible. Using needle nose pliers, remove motor leads, taking note of lead positions.

7. Remove wire drive unit from machine.

MOTOR REMOVAL PROCEDURE

Refer to Figure F.6

1. Remove one Phillips head screw connecting front to rear housing (1).

2. Using 1/4” nutdriver, remove two 8-32X1” thread forming screws connecting front to rear housing (2).

Refer to Figure F-7

3. Remove motor with rear housing.

4. Remove two screws holding motor to rear housing.

5. Separate motor from rear housing.

SP-100

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F-14

TROUBLESHOOTING & REPAIR

RETEST AFTER REPAIR

Should a machine under test be rejected for any reason requiring the removal of any mechanical part that could affect the machine’s electrical characteristics, or if any electrical components are repaired or replaced, the machine must be retested.

MAIN TRANSFORMER SECONDARY VOLTAGES

INPUT AMPS AT RATED OUTPUT

OPEN CIRCUIT VOLTAGES

WIRE SPEED RANGE

TEST POINTS VOLTAGES

LEADS #201 – #202 2-20 vac Dependent on arc voltage control

Located on Output Diode Heat Sinks. setting (min. to max.)

TEST POINTS VOLTAGES

OUTPUT TERMINALS 10 to 27 vdc Dependent on arc voltage

control setting (min. to max.)

50 to 400 in /min. Dependent on wire speed control setting

(1,2 to 10,2 m/min.)

INPUT AMPS (AC) @ OUTPUT (DC)

20 amps 90 amps @ 18 vdc

12/95

SP-100

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F-15

NOTES:

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SP-100

Section G

TABLE OF CONTENTS

– ELECTRICAL DIAGRAMS SECTION –

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

SP-100 Wiring Diagram (codes 9794 and above)................................................G-2

SP-100 Wiring Diagram (codes below 9794)........................................................G-3

Control PC Board (G1842) Components...............................................................G-4

Control PC Board (G2314) Components...............................................................G-6

Machine Schematic (codes 9794 and above).......................................................G-8

Machine Schematic (below code 9794) ................................................................G-9

SP-100

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G-2

WIRING DIAGRAMS

SP-100 WIRING DIAGRAM: CODES 9794 and Above

CLEVELAND, OHIO U.S.A.

11-12-93K

M16576

531

TO GROUND

PER NATIONAL

ELECTRICAL CODE

SWITCH

202

201

204

203

59,000 f

40V

203

204

OUTPUT CHOKE

GUN CABLE

CONDUCTOR

BLOCK

WORK

ELECTRICAL SYMBOLS PER E1537

CIRCUIT

BREAKER

31A

123

456

LATCH

FAN

MOTOR

1234

LATCH

678910

CAVITY NUMBERING SEQUENCE

1234

8910

GAS

SOLENOID

32A

CONTROL P.C. BOARD

539

541

207

205

206

541

539

203

204

203

209

213

208

211

531

31A

WIRE FEED MOTOR

212

213

211

GUN TRIGGER THERMOSTAT

(MOUNTED TO

DIODE HEATSINK)

208

209

203

WIRE SPEED

205

206

207

( J1 )

( J2 )

CONNECTOR CAVITY NUMBER

ARC VOLTAGE

(W)

(B)

32A

N.A.

N.C.

ON-OFF

N.C.

N.D.

24 VAC

AUX WDG.

NOTES:

N.A. DIODES D1 & D3 ARE MOUNTED ON THE OUTSIDE HEATSINK.

N.C. COMPONENT VIEWED FROM REAR.

HIGH VOLTAGE

can kill

Only qualified persons should install, use or

service this machine.

Do not operate with covers removed.

Do not touch electrically live parts

Disconnect input power by unplugging

power cord before servicing

SP 100 WIRING DIAGRAM

N.D. BOLTED ALUMINUM CONNECTIONS REQUIRE JOINT COMPOUND.

SEE OPERATING MANUAL WHEN REATTACHING.

N.B. DIODES D2 & D4 ARE MOUNTED ON THE INSIDE HEATSINK,

WHICH IS CLOSEST TO THE CENTER PANEL.

LEAD COLOR CODE:

B-BLACK W-WHITE

N.B., N.D.

(COMPONENT SIDE OF BOARD)

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is

pasted inside the machine on one of the enclosure panels.

G-3

SP-100

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WIRING DIAGRAMS

32 531

TO GROUND

PER NATIONAL

ELECTRICAL CODE

SWITCH

202

201

204

203

59,000 mf

40V

203

204

OUTPUT CHOKE

GUN CABLE

CONDUCTOR

BLOCK

WORK

ELECTRICAL SYMBOLS PER E1537

CIRCUIT

BREAKER

31A

LEAD COLOR CODE:

B-BLACK

W-WHITE

123

456

LATCH

FAN

MOTOR

1234

LATCH

678910

CAVITY NUMBERING SEQUENCE

( COMPONENT SIDE OF BOARD )

1234

8910

GAS

SOLENOID

32A

CONTROL P.C. BOARD

539

541

207

205

206

541

539

203

204

203

209

213

208

211

531

31A

WIRE FEED MOTOR

212

213

211

GUN TRIGGER THERMOSTAT

(MOUNTED TO

DIODE HEATSINK)

208

209

203

WIRE SPEED

205

206

207

( J1 )

( J2 )

CONNECTOR CAVITY NUMBER

ARC VOLTAGE

(W)

(B)

32A

N.B.

N.A.

N.C.

N.C. COMPONENT VIEWED FROM REAR.

ON-OFF

N.C.

15427

8-1-91D

SP WELDERS

WIRING DIAGRAM

15427

N.D.

N.A. DIODES D1 & D3 ARE MOUNTED ON THE

OUTSIDE HEATSINK.

N.B. DIODES D2 & D4 ARE MOUNTED ON THE

INSIDE HEATSINK, WHICH IS CLOSEST TO THE

CENTER PANEL.

N.D. BOLTED ALUMINUM CONNECTIONS REQUIRE JOINT

COMPOUND. SEE OPERATING MANUAL WHEN

REATTACHING.

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.

The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels.

SP-100 WIRING DIAGRAM: CODES Below 9794

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G-4

ELECTRICAL DIAGRAMS

SP-100

NOTE: Lincoln Electric assumes no responsibility for liabilities resulting from board level troubleshooting. PC Board

repairs will invalidate your factory warranty. This Printed Circuit Board schematic is provided for reference only. It may not be totally applicable to your machine’s specific PC board version. This diagram is intended to provide general information regarding PC board function. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in Danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.

CONTROL P.C. BOARD G1842

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G-5

ELECTRICAL DIAGRAMS

SP-100

NOTE: Lincoln Electric assumes no responsibility for liabilities resulting from board level troubleshooting. PC Board

repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages

board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.

Item IdentificationItem Identification

CONTROL P.C. BOARD G1842

SCR1, SCR2 SCR & HEATSINK ASBLY X4 C-VOLT REG, FIXED, 3-T, (+), 1A, 15V C4, C9, C11, C12, C13, CAPACITOR-CEMO, .022, 50V, 20%

C14, C16, C20, C21, C24, C26

J1 CONNECTOR, MOLEX, MINI, PCB,

6-PIN C5 CAPACITOR-ALEL, 150, 50V, +150/-10% D1 D2 D3, D4, D5, DIODE-AXLDS, 1A, 400V

D6 D7 D8, D9, D11, D12, D13, D14 D17,

D18, D19, D20, D21 R32, R33 RESISTOR-WW, 15W, 80, 5%, SQ C19 CAPACITOR-TAEL, 1.8, 20V, 10% C6, C17 CAPACITOR-TAEL, 4.7, 35V, 10% C15 CAPACITOR-TAEL, 18, 15V, 10% C8, C10, C18 CAPACITOR-TAEL, 1.0, 35V, 10% C23 CAPACITOR-ALEL, 3300, 50V, +30/-10% OCI1, OCI2 OPTOCOUPLER-TRIAC DRIVER, 3023 TRI1 TRIAC-T220, 6A, 400V, 2500D J2 CONNECTOR, MOLEX, MINI, PCB,

10-PIN C7 CAPACITOR-PEF, 0.1,100V, 10% C22 CAPACITOR-PEF, 0.22, 100V, 10% C1, C25 CAPACITOR-CD, .0047/.005, 1400V,

20% C2, C3, C27 CAPACITOR-PEF, 0.1, 400V, 1o% DZ3 ZENER DIODE-1W, 16V, 5%, 1N4745A DZ1 ZENER DIODE-1W, 10V, 5%, 1N4740A DZ4 ZENER DIODE-1W, 43V, 5%, 1N4755A DZ2 ZENER DIODE-1W, 5.1V, 5%, 1N4733A Q2, Q3, Q4, Q5 TRANSISTOR-N, T226, 0.5A, 40V,

2N4401 D15, D16 DIODE-AXLDS, 3A, 200V, 1N54o2 D10 DIODE-AXLDS, 0.15A, 75W, 1N914 B31A, B531 CONNECTOR, TAB, QC, VERTICAL, 1/4 B7, B32 CONNECTOR, TAB, QC, VERTICAL,

3/16 R69, R72 RESISTOR-WW, 5W, 0.5, 5%, SQ R5 RESISTOR-MF, 1/4W, 100, 1%

R2, R4, R8, R26, R27, RESISTOR-MF, 1/4W, 1.00K, 1%

R41, R48, R51, R55, R58, R70

R50, R57, R53, R54, RESISTOR-MF, 1/4W, 10.0K, 1%

R71, R73, R74

R42, R52, R53, R54, RESISTOR-MF, 1/4W,10.0K, 1%

R59 R43 RESISTOR-MF, 1/4W, 1.00M, % R15, R16, R18 RESISTOR-MF, 1/4W, 1.30K, 1% R3 RESISTOR-MF, 1/4W, 150, 1% R36, R63, R64, R67 RESISTOR-MF, 1/4W, 15.0K, 1%

R45 RESISTOR-MF, 1/4W, 18.2K, 1% R28, R31, R47, R49 RESISTOR-MF, 1/4W, 2.21K, 1% R12, R38, R39, R60, RESISTOR-MF, 1/4W, 22.1K, 1%

R61 R75 RESISTOR-MF, 1/4W, 267, 1% R22 RESISTOR-MF, 1/4W, 267K, 1% R46, R78, R79, R80 RESISTOR-MF, 1/4W, 3.32K, 1% R21, R35 RESISTOR-MF, 1/4W, 33.2K, 1% R44 RESISTOR-MF, 1/4W, 392K, 1% R11 RESISTOR-MF, 1/4W, 4.75K, 1% R10, R62 RESISTOR-MF, 1/4W, 47.5K, 1% R23, R24 RESISTOR-MF, 1/4W, 562, 1% R17, R25, R29, R30 RESISTOR-MF, 1/4W, 56.2K, 1% R76 RESISTOR-MF, 1/4W, 681, 1% R19, R65 RESISTOR-MF, 1/4W, 6.81K, 1% R14, R20 RESISTOR-MF, 1/4W, 68.1K, 1% R13 RESISTOR-MF, 1/4W, 82.5K, 1% Q7 TRANSISTOR-PMF, T220, 6A, 100V,

IRF9520

X1, X2, X3 C-OP-AMP, QUAD, GEN-PURPOSE,

224N

Q1, Q6 TRANSISTOR-N, T226, 0.5A, 300V,

MPS-A42 R37, R83 RESISTOR-MF, 1/4W, 2.00K, 1% R34, R81, R82 RESISTOR-MF, 1/4W, 3.01K, 1% R56 TRIMMER-ST, 1/2W, 10K, 10%, LINEAR R6 RESISTOR-WW, 5W, 25, 5%, SQ R1 RESISTOR-WW, 5W, 150, 5%, SQ

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G-6

ELECTRICAL DIAGRAMS

SP-100

NOTE: Lincoln Electric assumes no responsibility for liabilities resulting from board level troubleshooting. PC Board

CONTROL P.C. BOARD G2314

C16

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G-7

ELECTRICAL DIAGRAMS

SP-100

NOTE: Lincoln Electric assumes no responsibility for liabilities resulting from board level troubleshooting. PC Board

Item IdentificationItem Identification

CONTROL P.C. BOARD G2314

SCR1, SCR2 SCR 81 HEATSINK ASBLY X4 C-VOLT REG, FIXED, 3-T, (+),1A, 15V C4, C9, C11, C12, C13, CAPACITOR-CEMO, .022, 50V, 20%

C14, C16, C20, C21, C24, C26

J1 CONNECTOR, MOLEX, MINI, PCB,

6-PIN

C5 CAPACITOR-ALEL, 150, 50V, +150/

–10%

D1, D2, D3, D4, D5, D6, DIODE-AXLDS, 1A, 400V

D7, D8, D9, D11 , D12, D13, D14, D17, D18,

D19, D20, D21 R32, R33 RESISTOR-WW, 15W, 80,5%, SQ C19 CAPACITOR-TAEL, 1.8, 20V, 10% C6, C17 CAPACITOR-TAEL, 4.7, 35V, 10% C15 CAPACITOR-TAEL, 18,15V, 10% C8, C10, C18 CAPACITOR-TAEL, 1.0, 35V, 10% C23 CAPACITOR-ALEL, 3300, 50V, +30/-10% OCI1 OCI2 OPTOCOUPLER-TRIAC DRIVER, 3023 TRI1 TRIAC-T220, 6A, 400V, 2500D J2 CONNECTOR, MOLEX, MINI, PCB,

10-PIN C7 CAPACITOR-PEF, 0.1,100V, 10% C22 CAPACITOR-PEF, 0.22, 100V, 10% C1, C25 CAPACITOR-CD, .0047/.005, 1400V,

20% C2 C3 C27 CAPACITOR-PEF, 0.1, 400V, 10% DZ3 ZENER DIODE-1W, 16V, 5%,1N4745A DZ1 ZENER DIODE-1W, 10V, 5%,1N4740A DZ4 ZENER DIODE-1W, 43V, 5%,1N4755A DZ2 ZENER DIODE-1W, 5.1V, 5%,1N4733A Q2, Q3, Q4, Q5 TRANSISTOR-N, T226, 0.5A, 40V,

2N4401 D15, D16 DIODE-AXLDS, 3A, 200V, 1N5402 D10 DIODE-AXLDS, 0.15A, 75V, 1N914 B31 A, B531 CONNECTOR, TAB, QC, VERTICAL,

1/4 B7, B32 CONNECTOR, TAB, QC, VERTICAL,

3/16 R69, R72 RESISTOR-WW, 5W, 0.5,5%, SQ R5 RESISTOR-MF, 1/4W, 100, 1% R2, R4, R8, R26, R27, RESISTOR-MF, 1/4W, 1.00K, 1%

R41, R48, R51, R55, R58, R70

R50, R57, R66, R68, RESISTOR-MF, 1/4W, 10.0K, 1%

R71, R73, R74

R42, R52, R53, R54, RESISTOR-MF, 1/4W, 100K, 1%

R55 R43 RESISTOR-MF, 1/4W, 1.00M, % R15, R16, R18 RESISTOR-MF, 1/4W, 1.30K, 1% R3 RESISTOR-MF, 1/4W, 150,1% R36, R63, R64, R67 RESISTOR-MF, 1/4W, 15.0K, 1%

R45 RESISTOR-MF, 1/4W, 18.2K, 1% R28, R31, R47, R49 RESISTOR-MF, 1/4W, 2.21 K, 1% R12, R38, R39, R60, RESISTOR-MF, 1/4W, 22.1K, 1%

R61 R75 RESISTOR-MF, 1/4W, 267,1 % R22 RESISTOR-MF, 1/4W, 267K, 1% R46, R78, R79, R80 RESISTOR-MF, 1/4W, 3.32K, 1% R21 RESISTOR-MF, 1/4W, 33.2K, 1% R35 RESISTOR-MF, 1/4W, 39.2K, 1% R44 RESISTOR-MF, 1/4W, 392K, 1% R11 RESISTOR-MF, 1/4W, 4.75K, 1% R10 RESISTOR-MF, 1/4W, 47.5K, 1% R62 RESISTOR-MF, 1/4W, 47.5,1% R23, R24 RESISTOR-MF, 1/4W, 562,1% R17, R25, R29, R30 RESISTOR-MF, 1/4W, 56.2K, 1% R76 RESISTOR-MF, 1 /4W, 681 ,1 % R19, R65 RESISTOR-MF, 1/4W, 6.81K, 1% R14, R20 RESISTOR-MF, 1/4W, 68.1K, 1% R13 RESISTOR-MF, 1/4W, 82.5K, 1% Q7 TRANSISTOR-PMF, T220, 6A, 100V,

IRF9520

X1 , X2, X3 C-OP-AMP, OUAD, GEN-PURPOSE,

224N

Q1, Q6 TRANSISTOR-N, T226, 0.5A, 300V,

MPS-A42 R37, R83 RESISTOR-MF, 1/4W, 2.00K, 1% R34, R81, R82 RESISTOR-MF, 1/4W, 3.01K, 1% R56 TRIMMER-ST, 1/2W, 10K, 10%,

LINEAR R6 RESISTOR-WW, 5W, 25, 5%, SQ R1 RESISTOR-WW, 5W, 150, 5%, SQ

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G-8

ELECTRICAL DIAGRAMS

SP-100

MACHINE SCHEMATIC: Codes 9794 and Above

GND

OUT

4.7 35V

MC7815CTDS

REGULATOR

30A

125VAC

CIRCUIT BREAKER

+15V

+15V SUPPLY

+15V

150 50V

39.2K

R35

VOLTAGE

1.3K

R16

OCI1

1.0 35V

C10

56.2K

R29

2.21K

R28

56.2K

R30

1N914

D10

1.00K

R26

4.75K

R11

82.5K

R13

56.2K

R25

1.00K

R27

10V

DZ1

ARC

562

R23

205

22.1K

R12

206

562

R24

68.1K

R14

ARC VOLTAGE FEEDBACK

VOLTS

.15A 75V

SAWTOOTH

CONTROL

SOLENOID

GAS

47.5K

R10

+15V

204

+15V

1.3K

R15

207

LM224

L 8552

BURNBACK

WELD

ARC VOLTAGE ERROR AMPLIFIER

SCR

PWM

OCI2

+15V

C24

100V

1.3K

R18

C11

5.1V

DZ2

56.2K

R17

D11

2.21K

R31

FIRING

LM224

267K

R22

68.1K

R20

+15V

C12

C13

LM224

33.2K

R21

6.81K

R19

1.0 35V

+15V

HIGH

SET

TRIM

WIRE

SPEED

D12

100K

R42

100K

R52

392K

R44

18 15V

C15

1.00M R43

100K

R53

10K

R57

100K

R54

C16

209

208

18.2K

R45

2.21K

R47

681

R76

1.00K

R55

2.21K

R49

203

100K

R59

1.8 20V

C19

1.00K

R58

TRIM SET

LOW

SET

MOTOR

FEEDBACK

CURRENT

SPEED

FEEDBACK

VOLTAGE

MOTOR

D14

10K

R56

400V

C27

MT2

MT1

2500D TRI1

100

3.32K

R78

OCI1

1400V

.0047

1.00K

400V

3.32K

R79

SCR2

3.32K

R80

OCI2

1.00K

150

600V

55A

SCR1

400V

GAS

120VAC

CONTROL

GAS SOLENOID

SOLENOID

WDG

31A

125VAC

24V

115VAC

AUX

31A

R69

15.0K

R63

22.1K

R39

1.00K R41

D13

6.81K

R65

C20

15.0K

R64

D17

10K

R68

10K

R66

22.1K

R61

6A 100V

16V

DZ3

203

+15V

ERROR

AMP

OSCILLATOR

SHUTDOWN

203

PWM

1.00K R70

22.1K

R38

C26

40V

600mA

500mA 300V

C14

22.1K

R60

3300 50V

C23

200V

D16

10K

R71

R37

R83

D19

204

+15V

SUPPLY

LEAD COLOR CODE

B - BLACK

MFD

1A, 400V

15W

R32

211

3.01K

R34

3.01K

R81

1.00K

3.01K

R82

C21

40V

600mA

15.0K

R67

150

213

40V

600mA

D18

47.5

R62

4.7 35V

C17

3.32K

R46

10K

R50

40V

600mA

1.0 35V

C18

1.00K

R51

1.00K

R48

10K

R73

D20

MOTOR

SWITCH

ON-OFF

FEED

WIRE

24VAC

GND

60 HZ

115VAC

FAN

300V

500mA

D21

539

541

R72

85A 300V

C-

D-

43V

DZ4

R-

3A 200V

D15

FRAME CONNECTION

DZ-4

LATCH

LAST NO. USED

POWER SUPPLY SOURCE POINT

SCHEMATIC

SP 100 CONTROL

(UNLESS OTHERWISE SPECIFIED)

UNLESS OTHERWISE SPECIFIED)

POWER

DIODES =

CAPACITORS =

RESISTORS = Ohms (

.022/50V

1/4W

(

GENERAL INFORMATION

ELECTRICAL SYMBOLS PER E1537

LABELS

WELDING

OUTPUT

W - WHITE

1400VDC

.0047

C25

MOTOR

203

EARTH GROUND CONNECTION

8552

COMMON CONNECTION

VOLTAGE NET

NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE

WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY

N.A. SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE

NUMBER.

NOTES :

267

R75

OUTPUT

80 15W

R33

TRIGGER

212

SWITCH

MOTOR

STOP

203

10K

R74

CHOKE

531

OVERCURRENT

SCR

THERMOSTAT

300V

85A

300V

D4 85A

40V

59K

FIRING

100V

.22

C22

15.0K

R36

203

10-22-93L

NOTE: This machine schedmatic is provided for reference only and may not be totally applicable to every code covered

in this manual.

G-9

ELECTRICAL DIAGRAMS

SP-100

MACHINE SCHEMATIC: Codes Below 9794

LAST NO. USEDLDCR

N.A. SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE

WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY

NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE

NUMBER.

GENERAL INFORMATION

VOLTAGE NETSUPPLY

(connector cavity representations)

NOTES :

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

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

CAPACITORS = d (.022/50V UNLESS OTHERWISE SPECIFIED)

ELECTRICAL SYMBOLS PER E-1537

LABELS

FRAME CONNECTIONPOWER SUPPLY SOURCE POINT

EARTH GROUND CONNECTION

COMMON CONNECTION

7619

SCHEMATIC

203

203 203

100V

WIRE FEED MOTOR

47.5

R62

GENERAL INFORMATION

.5 5W

R72

16V

DZ3

3300 50V

C23

10K

R71

539

541

43V

DZ4

3A 200V

D15

1.0 35V

208

+15V

203

100K

R53

SPEED

22.1K

R39

LM224

100K

R54

LM224

R40

D13

D20

C13

1.00K

R41

18 15V

C15

15.0K

R36

10K

R56

+15V

SHUTDOWN

100K

R52

+15V

392K

R44

209

203

2.21K

R49

1.00M

R43

C16

39.2K

R35

100K

R42

D12

LATCH

1.00K

R55

C26

C14

30V

200mA

22.1K

R38

10K

R57

OUTPUT

1.8 20V

C19

1.00K

R58

SWITCH

115VAC 60 HZ

TO GND.

D14

B531

OVERCURRENT

P2 J2

300V

85A

D1 D2

85A 300V

D3 85A 300V

D4 85A 300V

40V

59K

P2 J2

500mA

300V

24V

1N914

D10

68.1K

R20

OCI2

33.2K

R21

56.2K

R30

562

R23

100V

1.3K

R18

7619

CONNECTOR CAVITY NUMBERING SEQUENCE (VIEWED FROM COMPONENT SIDE OF BOARD)

205

1.3K

R15

+15V

206 J1

LM224

C11

OCI1

56.2K

R25

VOLTS

BURNBACK

PWM

FIRING

SCR

ARC

ARC VOLTAGE

CONTROL

SOLENOID

FEEDBACK

ERROR AMPLIFIER

D11

GAS

C24

56.2K

R17

ARC VOLTAGE

68.1K

R14

SAWTOOTH

MOTOR

2.21K

R31

2.21K

R47

56.2K

R29

500mW

5.1V

DZ2

267K

R22

562

R24

2.21K

R28

500mW

10V

DZ1

22.1K

R12

1.00K

R26

207

1.0 35V

C10

C12

1.00K

R27

82.5K

R13

ON-OFF

+15V

GAS SOLENOID

MOTOR

1.3K

R16

FEEDBACK

SPEED

120VAC

SET

LOAD CURRENT

.5 5W

R69

FEEDBACK

VOLTAGE

MOTOR STOP

ELECTRICAL SYMBOLS PER E1537 CAPACITORS = MFD/VOLT (.022/50V,UNLESS OTHERWISE SPECIFIED) RESISTORS = OHMS (1/4WATT,UNLESS OTHERWISE SPECIFIED) DIODES = 1A/400V (UNLESS OTHERWISE SPECIFIED)

= COMMON CONNECTION = SOURCE POINT CIRCUIT LOCATION

2N4123

4.75K

R11

+15V

1.00K

R70

+15V

22.1K

R61

100K

R59

6.81K

R19

22.1K

R60

2N4123

300V

500mA

1.00K

R51

10K

R50

1/2W

47.5K

R10

GND

IN OUT

1/2W

1000

1/2W

150

.0047 1400V

1400V

.0047

C25

.1 400V

B31A

10K

400V

1/2W

150V 45J

TP2

FIRING

REGULATOR

VOLTAGE

1/2W

100

GAS SOLENOID

CONTROL

31A

115AC

MOTOR

FAN

BREAKER

CIRCUIT

30A

+15V SUPPLY

24VAC

+15V

150 50V

D18

4.7 35V

2500D

TRI1

120

600V

55A

SCR1

OCI1

600V

55A

SCR2

OCI2

MC7815CTDS

D19

SCR

1/2W

1000

B32A

OSCILLATOR

PWMERROR

AMP

CHOKE

213

D17

10K

R74

WELDING POWER

OUTPUT

3A 200V

D16

80 15W

R32

203

10K

R66

204

10K

R68

SWITCH

THERMOSTAT

TRIGGER

+15V

15.0K

R67

211

100V

.22

C22

+15V

C21

2N4123

15.0K

R63

1.00K

R34

1.00K

R37

15.0K

R64

+15V

C20

80 15W

R33

6.81K

R65

WIRE

LEAD COLOR CODE

204

3.32K

R46

267

R75

B - BLACK W - WHITE

D21

10K

R73

1.00K

R48

4.7 35V

C17

1.0 35V

C18

18.2K

R45

1/2W

DZ4

SP 100 WELDERS

7-27-90J

NOTE: This machine schedmatic is provided for reference only and may not be totally applicable to every code covered

in this manual.

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SVM ERROR REPORTING FORM

We need to know if there are errors in our manuals. We also value any suggestions as to additional tests or procedures that would make this SVM a better tool for you.

If you discover new or different “Problems or Symptoms” that are not covered in the three column troubleshooting chart, please share this information with us. Please include the machine’s code number and how the problem was resolved.

Thank You, Technical Services Group Lincoln Electric Co. 22801 ST. Clair Ave. Cleveland, Ohio 44117-1199

FAX 216-481-2309

SVM Number ___________________________ Page Number if necessary__________________ Your Company__________________________ Your Name_____________________________

Please give detailed description below: ___________________________________________________________________________

___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________

SD287 01/99

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Lincoln SP-100 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual