Lincoln Electric IM710 User Manual
SP-170 T
OPERATOR’S MANUAL
IM710
October, 2001
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 machine Code Numbers
10842
• 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 •
Date of Purchase:
Serial Number:
Code Number:
Model:
Where Purchased:
Copyright © 2001 Lincoln Global Inc.
Made exclusive for Australia
RETURN TO MAIN INDEX
i
SAFETY
i
SP-170T
FOR ENGINE
powered equipment.
1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
1.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust
fumes outdoors.
____________________________________________________
1.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.
____________________________________________________
1.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.
____________________________________________________
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
For more detailed information it is strongly recommended that you purchase a copy of "Safety in Welding and Cutting - ANSI
Standard Z49.1" and WTIA Technical Note 7. All WTIA publications and ANSI/AWS Standards are available from the
Welding Technology Institute of Australia, PO Box 6165 Silverwater NSW 2128. For copies of various Australian Standards
contact your local S.A.A. office.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
WARNING
1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
1.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.
___________________________________________________
1.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.
___________________________________________________
1.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.
Oct ‘00
ii
SAFETY
ii
SP-170T
2.i.4 Connect the work cable to the work piece as close as
possible to the area being welded. (This is also a good
practice to eliminate a common problem on welding - a
poor work connection.
2.i.5 Do not work next to the welding power source.
ADDITIONAL PRECAUTIONS FOR
WELDERS WITH PACEMAKERS
2.j. There is no question that the fields in arc welding can interfere
with a pacemakers function. Generally the interference does
not permanently damage the pacemaker. Once the wearer
leaves the arc welding environment or stops welding, the pacemaker returns to normal functioning. The welding arc has little
or no effect on the operation of some pacemakers, especially
designs that are bi-polar or designed to filter out such interference.
2.k. For a welder or anyone working around electrical equipment
the selection of a pacemaker is very important. Get a doctor’s
advice about which pacemaker is the least sensitive to interference from welding while still being medically suitable.
2.l. In addition to the normal safety precautions, the following additional procedures should be adopted by welders with pacemakers.
2.l.1 Use gas welding when the application is suitable.
2.l.2 Use the lowest current setting appropriate for the application. Do not exceed 400 amps. Low current (75-200
amps) direct current (DC) welding should be used if arc
welding is necessary. Do not TIG weld with high frequency.
2.l.3 Do not use repeated, short welds. Wait about ten seconds between stopping one weld and starting the next.
When having difficulty starting an electrode, do not restrike the rod repeatedly.
2.l.4 If you feel light headed, dizzy or faint, immediately stop
welding. Lay the electrode holder down so that it does not
contact the work and move away from any welding being
performed. Arrange your work in advance so that, if you
become dizzy and drop the electrode holder it will not fall
on your body or strike the work.
2.l.5 Do not work on a ladder or other elevated position or in a
cramped, confined place.
2.l.6 Do not work alone. Work only in the presence of an individual who understands these precautions and the possible effect welding may have on your pacemaker.
2.l.7 Do not work near spot welding equipment.
2.l.8 If you have a pacemaker and wish to continue arc welding, discuss this and any other questions you may have
with your physician and follow his or her advice. The doctor may wish to contact the pacemaker manufacturer for a
recommendation. As mentioned before, the design of the
pacemaker significantly affects the degree to which it is
subject to interference from a welding circuit. Do not rely
on the fact that you know another welder with a pacemaker who has welded for years without experiencing a problem.That welder and his or her pacemaker may be quite
different from you and your pacemaker.
ELECTRIC AND
MAGNETIC FIELDS
may be dangerous
2.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
2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.
2.d. All welders should follow safe practices that minimize their
exposure to electric and magnetic fields (EMF).
2.e. For welders wearing implanted pacemakers, safe welding
practices are particularly important and additional procedures
should be followed by those who have decided to continue to
weld. (Hopefully in keeping with a doctor’s advice).
2.f. The following procedures will not eliminate exposure to EMF or
the possibility of arc welding having an effect on a pacemaker,
however if followed, they will significantly reduce exposure to
electric and magnetic fields. Electric and magnetic fields are
created any time electric current flows through a conductor,
however it is not clear whether such exposure affects ones
health.
2.g. Some researchers have reported that exposure to EMF may
cause leukemia or other illnesses. These claims originally
arose in relation to high voltage electric power lines and are
very much in dispute in the medical and scientific arena, however the best advice is to minimize your exposure to EMF to
protect your health should doctors eventually decide there is a
risk.
2.h. There are four fundamental facts about EMF:
2.h.1 With direct current (DC), the field strength is relatively
constant and does not change.
2.h.2 With alternating current (AC), the field strength constant-
ly changes.
2.h.3 The greater the current flow, i.e. the higher the amps,
the stronger the field created by the current
2.h.4 The closer the conductor or electrical device is to the
body the greater the exposure to the field.
MINIMIZE EXPOSURE TO EMF
2.i. All welders should use the following procedures to minimize
EMF exposure:
2.i.1 Route electrode or gun and work cables together. Secure
them with tape if possible.
2.i.2 Never coil the electrode lead around your body.
2.i.3 Do not place your body between the electrode and work
cables. If your electrode cable is on your right side the
work cable should also be on your right side.
Oct ‘00
iii
SAFETY
iii
SP-170T
ARC RAYS can burn.
4.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.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
4.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.
3.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.
3.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 lying, 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.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
3.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.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
3.f.
Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.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.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
FUMES AND GASES
can be dangerous.
5.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.
5.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.
5.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.
5.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.
5.e. Also see item 1.b.
Mar ‘95
iv
SAFETY
iv
SP-170T
FOR ELECTRICALLY
powered equipment.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install equipment in accordance with the National
Electrical Code, all local codes and the manufacturer’s
recommendations.
8.c. Ground the equipment in accordance with the National
Electrical Code and the manufacturer’s recommendations.
CYLINDER may explode
if damaged.
7.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.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
7.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.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.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 ‘95
WELDING SPARKS can
cause fire or explosion.
6.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.
6.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.
6.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.
6.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).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.f.
Sparks and spatter are thrown from the welding arc. Wear oil
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.
6.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.
6.h. Also see item 1.c.
SAFETY
v
v
INSTRUCTIONS FOR ELECTROMAGNETIC COMPATIBILITY
Conformance
Products displaying the C-Tick mark are in conformity with
Australian/New Zealand requirements for Electromagnetic
Compatibility (EMC) according to standard (emission) AS/NZS
3652 "Electromagnetic Compatibility – Arc Welding
Equipment".
Products displaying the CE mark are in conformity with
European Community Council Directive 89/336/EEC requirements for EMC by implementing EN50199 "Electromagnetic
Compatibility (EMC) – Product standard for arc welding equipment".
Products are:
• For use with other Lincoln Electric/LiquidArc equipment.
• Designed for industrial and professional use.
Introduction
All electrical equipment generates small amounts of electromagnetic emission. Electrical emission may be transmitted through power
lines or radiated through space, similar to a radio transmitter. When
emissions are received by other equipment, electrical interference
may result. Electrical emissions may effect many kinds of electrical
equipment: other nearby welding equipment, radio and TV transmitters and receivers, numerical controlled machines, telephone
systems, computers, etc. Be aware that interference may result
and extra precautions may be required when a welding power
source is used in a domestic establishment.
Installation and Use
The purchaser/user is responsible for installing and using the welding equipment according to the manufacturer’s instructions. If electromagnetic disturbances are detected then it shall be the responsibility of the purchaser/user of the welding equipment to resolve the
situation with the technical assistance of the manufacturer. In some
cases this remedial action may be as simple as earthing (grounding) the welding circuit (see note below). In other cases it could
involve constructing an electromagnetic screen enclosing the
power source and the work complete with associated input filters.
In all cases electromagnetic disturbances must be reduced to the
point where they are no longer troublesome.
Note: The welding circuit may or may not be earthed for safety reasons according to national codes. Changing the earthing arrangements should only be authorized by a person who is competent to
assess whether the changes increase the risk of injury, eg. by
allowing parallel welding current return paths which may damage
the earth circuits of other equipment.
Assessment of Area
Before installing welding equipment the purchaser/user shall make
an assessment of potential problems in the surrounding area.
The following shall be taken into account:
• Other supply cables, control cables, signalling and telephone
cables above, below and adjacent to the welding equipment;
• Radio and television transmitters and receivers;
• Computer and other control equipment;
• Safety critical safety equipment, eg. guarding of industrial
equipment;
• The health of people around, eg. the use of pacemakers and
hearing aids;
• Equipment used for calibration or measurement;
• The immunity of other equipment in the environment. The
purchaser/user shall ensure that other equipment being used
in the environment is compatible. This may require additional
protection measures;
• The time of the day that welding or other activities are to be
carried out.
The size of the surrounding area to be considered will depend on
the structure of the building and other activities that are taking
place. The surrounding area may extend beyond the boundaries of
the premises.
Methods of Reducing Emissions
Mains Supply
Welding equipment should be connected to the mains supply
according to the manufacturer’s recommendations.If interference
occurs, it may be necessary to take additional precautions such as
filtering the mains supply. Consideration should be given to shielding the supply cable of permanently installed welding equipment in
metallic conduit or equivalent. Shielding should be electrically continuous throughout its length. The shielding should be connected to
the welding power source so that good electrical contact is maintained between the conduit and the welding power source enclosure.
Maintenance of the Welding Equipment
The welding equipment should be routinely maintained according
to the manufacturer’s recommendations. All access and service
doors and covers should be closed and properly fastened when the
welding equipment is in operation. The welding equipment should
not be modified in any way except for those changes and adjustment covered in the manufacturer’s instructions. In particular, the
spark gaps of arc initiation and stabilizing devices should be adjusted and maintained according to the manufacturer’s recommendations.
Welding Cables
The welding cables should be kept as short as possible and should
be positioned close together, running at or close to the floor level.
Equipotential Bonding
Bonding of all metallic components in the welding installation and
adjacent to it should be considered. However, metallic components
bonded to the work piece will increase the risk that the operator
could receive a shock by touching these metallic components and
the electrode at the same time. The operator should be insulated
from all such bonded metallic components.
Earthing of the workpiece
Where the workpiece is not bonded to earth for electrical safety,
nor connected to earth because of its size and position, eg. ship’s
hull or building steelwork, a connection bonding the workpiece to
earth may reduce emissions in some, but not all instances. Care
should be taken to prevent the earthing of work pieces increasing
the risk of injury to users, or damage to other electrical equipment.
Where necessary, the connection of the workpiece to earth should
be made by direct connection to the workpiece, but in some countries where direct connection is not permitted, the bonding should
be achieved by suitable capacitance, selected according to national
regulations.
Screening and Shielding
Selective screening and shielding of other cables and equipment in
the surrounding area may alleviate problems of interference.
Screening of the entire welding installation may be considered for
special applications.
Portions of the preceding text are extracted from:
• Australian/New Zealand standard AS/NZS 3652. Permission to
reproduce has been granted by Standards Australia and
Standards New Zealand. For further explanation, readers should
be referred to the standard itself.
• British Standards Institution standard BS EN 50199:1995.
Reproduced with permission of BSI under license number
2000SK0631. Complete standards can be obtained from BSI
Customer Services, 389 Chiswick High Road, London W4 4AL.
United Kingdom. (Tel +44 (0) 20 8996 9001).
Copyright of above text is property of Standards Australia,
Standards New Zealand and British Standards Institution.
Permission to reproduce the text must be obtained.
JAN ‘01
SP-170T
Thank You
for selecting a QUALITY product by Lincoln Electric. We want you
to take pride in operating this Lincoln Electric Company product
••• as much pride as we have in bringing this product to you!
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or
loss of life.
This statement appears where the information must be followed to avoid minor personal injury or damage to
this equipment.
CAUTION
Please Examine Carton
and Equipment For
Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.
Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.
Model Name & Number _____________________________________
Code & Serial Number _____________________________________
Date of Purchase _____________________________________
Whenever you request replacement parts for or information on this equipment always supply the information
you have recorded above.
vivi
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vii
TABLE OF CONTENTS
Page
Installation.......................................................................................................Section A
Technical Specifications........................................................................................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-4
Gun Installation......................................................................................................A-4
Connecting Gun Cable to the SP-170T...........................................................A-4
Gas Connection.....................................................................................................A-4
Input Connections..................................................................................................A-5
Electrical Input Connection for Rated Output ........................................................A-6
Line Cord Connection .....................................................................................A-6
Operation.........................................................................................................Section B
Safety Precautions ................................................................................................B-1
General Description...............................................................................................B-1
Recommended Processess............................................................................B-1
Optional Features and Controls......................................................................B-1
Design Features and Advantages .........................................................................B-1
Welding Capability.................................................................................................B-2
Limitations..............................................................................................................B-2
Controls and Settings ............................................................................................B-2
Welding Operations...............................................................................................B-3
Sequence of Operations .................................................................................B-3
Wire Loading..............................................................................................B-3
Friction Brake Adjustments........................................................................B-3
Wire Threading...........................................................................................B-4
Making a Weld ...........................................................................................B-5
Cleaning Tip and Nozzle............................................................................B-5
Process Guidelines................................................................................................B-5
Changing Over to Feed Other Wire Sizes.............................................................B-6
Welding with GMAW..............................................................................................B-6
Welding with FCAW...............................................................................................B-6
Learning to Weld .......................................................................................................B-7
Overload Protection...............................................................................................B-7
Output Overload..............................................................................................B-7
Thermal Protection..........................................................................................B-7
Electronic Wire Drive Motor Protection...........................................................B-7
Learning to Weld....................................................................................................B-7
The Arc-Welding Circuit..................................................................................B-7
The Self-Shielded FCAW Welding Arc............................................................B-8
The GMAW (MIG) Welding Arc.......................................................................B-8
Process Selection ...........................................................................................B-9
For GMAW (MIG) Process.........................................................................B-9
For FCAW (Innershield) Process...............................................................B-9
Common Metals..............................................................................................B-9
Joints Types and Positions .............................................................................B-9
Butt Welds..................................................................................................B-9
Penetration...............................................................................................B-10
Fillet Welds...............................................................................................B-10
SP-170T
viii
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TABLE OF CONTENTS
Page
Learning to Weld (Continues)......................................................................................------
Welding in a Vertical Position........................................................................B-10
Vertical-up and Overhead Welding.........................................................B-10
Vertical-down Welding ............................................................................B-11
Machine Set Up for the Self-Shielded FCAW Process .................................B-11
Welding Techniques for the Self-Shielded FCAW Process ..........................B-11
The Correct Welding Position .................................................................B-11
The Correct Way to Strick an Arc............................................................B-12
The Correct Electrical Stick Out..............................................................B-12
The Correct Welding Speed....................................................................B-12
Helpful Hints..................................................................................................B-13
Practice.........................................................................................................B-13
Machine Set Up for the GMAW (MIG) Process.............................................B-14
Welding Techniques for the GMAW (MIG) Process......................................B-14
The Correct Welding Position .................................................................B-14
The Correct Way to Strick an Arc............................................................B-14
The Correct Electrical Stick Out..............................................................B-15
The Correct Welding Speed....................................................................B-15
Helpful Hints..................................................................................................B-15
Practice.........................................................................................................B-15
Troblreshooting Welds..................................................................................B-16
To Eliminate Porosity.............................................................................B-16
To Eliminate a Ropy Convex Bead........................................................B-16
To Reduce Spatter.................................................................................B-16
To Correct Poor Penetration..................................................................B-16
If Arc Blow Occurs..................................................................................B-16
To Eliminate Stubbing............................................................................B-16
Proper Gun Handling .............................................................................B-17
Application Chart.....................................................................................................B-18
Maintenance ....................................................................................................Section D
Safety Precautions ................................................................................................D-1
Routine Maintenance.............................................................................................D-1
Wire Feed Compartment.................................................................................D-1
Fan Motor........................................................................................................D-1
Wire Reel Spindle...........................................................................................D-1
Gun and Cable................................................................................................D-1
Gun Cable Cleaning................................................................................D-1
Contact Tips, Nozzles, and Gun Tubes..................................................D-1
Component Replacement Procedures ..................................................................D-2
Changing the Contact Tip...............................................................................D-2
Changing Drive Roll........................................................................................D-2
Changing Liner................................................................................................D-3
Gun Handle Parts ...........................................................................................D-3
Ground Test Procedure.........................................................................................D-4
Troubleshooting..............................................................................................Section E
Safety Precautions.................................................................................................E-1
How to Use Troubleshooting Guide.......................................................................E-1
Troubleshooting Guide.............................................................................E-2 thru E-4
Wiring Diagrams..............................................................................................Section F
SP-170T Wiring Diagram.......................................................................................F-1
SP-170T Parts .......................................................................................P259,P202,P189
A-1
A-1
INSTALLATION
Fuse or
Output Mode Input Voltage Breaker Size Input Amps Power Cord
RATED 240V/50Hz 25 Super Lag 12.7 15Amp, 240V,
Three Pin Plug
TECHNICAL SPECIFICATIONS – SP-170T
INPUT – SINGLE PHASE ONLY
RATED OUTPUT
OUTPUT
RECOMMENDED INPUT CABLE AND FUSE SIZES
Height
Width Depth Weight
305 mm 248 mm 419 mm 25.9 kg
PHYSICAL DIMENSIONS
Standard
Voltage/Frequency AS
1966.1
240V/50Hz Rated Input Current
12.7 Amps
Duty Cycle Amps Volts at Rated Amperes
20% 130 20
Welding Current Range
Maximum Open Circuit Voltage Auxiliary Power
Rated DC Output: 30 – 170 amps 33 N/A
SP-170T
A-2
INSTALLATION
Read entire installation section before starting
installation.
SAFETY PRECAUTIONS
IDENTIFY AND LOCATE
COMPONENTS
If you have not already done so, unpack the SP-170T
from its carton and remove all packing material
around the SP-170T. Remove the following loose
items from the carton (see Figure A.1):
1. SP-170T
2. Gun and cable assembly
(1)
3. Literature and miscellaneous including:
a) This operating manual
b) A separate .030" (0.8 mm) contact tip
c) Hex key wrench for removal of drive roll.
4. 10 ft (3,0 m) work cable.
5. Work clamp.
6. Adjustable mixed-Gas Regulator & Hose.
(1)
The gun is ready to feed .023" – .025" (0.6 mm)
diameter wire.
ELECTRIC SHOCK can kill.
• Only qualified personnel should perform
this installation.
• Only personnel that have read and understood the SP-170T 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-170T 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-2
SP-170T
WELDING AMP RANGE
25-125
1
WELDING AMP RANGE
2
SP-170T
2
5-125
4
3
5
6
A-3
INSTALLATION
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-170T’s cannot be stacked.
TILTING
Each machine must be placed on a secure, level surface, either directly or on the recommended cart. 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.
6. Wire Feed Gearbox.
7. Cable Hanger.
8. Thumbscrew.
Work Clamp Installation
Attach the work clamp per the following: Refer to
Figure A-3.
WELDING AMP RANGE
30-70
FIGURE A.3
1. Insert the work cable terminal lug with the larger
hole through the strain relief hole in the work clamp
as shown above.
2. Fasten securely with the bolt and nut provided.
FIGURE A.2
A-3
SP-170T
E
WELDING AMP RANGE
30-70
SP-170 T
5
8
+
-
9
10
4
1
2
3
6
7
A-4
A-4
INSTALLATION
Work Cable Installation
Refer to Figure A.2.
1. Open the wire feed section door on the right side of
the SP-170T.
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.
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 delivered, the machine is connected for positive electrode polarity. This is the appropriate configuration
for the GMAW (MIG) 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 (required for the Innershield
process), 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
NOTE: If .035" or .045" (0.9 mm or 1.2 mm)
Innershield flux-cored wire is to be used, the appropriate Innershield kit is required.
Connecting Gun Cable to the SP-170T
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 up the inside of the
case front, behind the gas line.
3. Insert the connector on the gun conductor cable
through the Gun Cable Access Hole (2) in the
SP-170T case front. Make sure the connector is all
the way in the brass connector block to obtain
proper gas flow. If the gun connector will not fully
insert, unscrew the thumbscrew on the connector
block a few turns. Rotate the connector so control
leads are on the underside and tighten the
Thumbscrew on the connector block.
4. Connect the gun trigger control lead terminals to
the two insulated 1/4" (6,4 mm) tab terminal connector bushings located above the “Gun Trigger
Connection” decal in the wire feed section (4).
Either lead can go to either connector.
If the gun trigger switch being used is other than
that supplied, 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-170T may result if this
switch shorts to the SP-170T welding output circuit or is common to any electrical circuit other
than the SP-170T trigger circuit.
GAS CONNECTION
The SP-170T is supplied with a mixed gas Regulator
and a 3m gas hose. A cylinder of an appropriate
shielding gas must be obtained from your gas distributor.
CAUTION
GUN INSTALLATION
As shipped from the factory, the SP-170T gun is ready
to feed .023" – .025"(.6mm) solid wire. If .030" (0.8
mm) solid wire is to be used, change the contact tip to
the appropriate size.
2
4
3
1
SP-170T
A-5
INSTALLATION
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.
3. Attach the flow regulator to the cylinder valve and
tighten the union nut securely with a wrench..
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-170T Gas
Solenoid Inlet Fitting (5/8-18 female threads — for
CGA — 032 fitting). Make certain the gas hose is
not kinked or twisted.
5. Reinstall case side before connecting input power.
INPUT CONNECTIONS
FIGURE A.6
Refer to Figure A.6.
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.
BUILDUP OF SHIELDING GAS may
harm health or kill.
• Shut off shielding gas supply
when not in use.
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. Refer to Figure A.5.
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.
WARNING
Cylinder Valve
Gas Hose
Flow Regulator
WARNING
WARNING
A-5
SP-170T
GAS SOLENOID
INLET FITTING
POWER INPUT
CABLE
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