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SP-100

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1. S Q CONTROL P C BOARD G1842 F cls RE SE SI SP 100 CONTROL S u a ER O fases a n 2 gt a BR G1842 fet D O HL R61 Q5 DIS c2 c3 ka P on nee Ga Ga E 5 Ra ag 6 pla Pal at L v ees c6 L e
2. Q MACHINE SCHEMATIC Codes Below 9794 a 2 gt Loces below Se ks ON OFF z SWITCH o g si OUTPUT 2 z o BID La 32 A H ee ji Z CHOKE o G E 1 E E gt z 2 QU 1 FAN D2 p2 2 Z 2 un 1 MOTOR 85A lt gt 204 8 2 115VAC i 115AC p ZX 300v WELDING SS a Z 8 Mm o 60 HZ M gl 80 fa felso 1922 POWER Za Ea S T gei HA 15w 2 2 15w I 22 OUTPUT ES ou E z o 1 A 100V o ug Z 6500 e L1 31 Bois Sa atk I sy o lt O _ _ E oO gs SERB UE 5 30A be ui u ZZ 2 Fe gt lt Loi 3 E CIRCUIT lt 3 E 4112 ou 3 QU T BREAKER c2 T 20 EBS 825 TO GND 1 55 A A De Za 5 CC zk 400v 600v EI R69 EE LES op ee SEN 15V D16 5 zz ou 3 5 o A 3A 5W EE ao EE UU o L ax a a 200V 5 ox Z OS a e o S 15V gt Saou lt z am Soot I mn mn e mn mmm m A 15 0K Sua Z Sot Ga ES 2 Fe gt 29 a 04 z25 Das Di zZz al 3 Sor lt SE 2N4123 S28 ZI 2332 w 2 opaz 55A E 09 10K SEI a225 2 2 LS m Ka elt 14000 D See K as STOP 322 9 8B ez gt Di D2 2N4123 ese Ll yes oO a J2 5 E Z gt ot
3. Q MACHINE SCHEMATIC Codes 9794 and Ab a 2 gt Coqes an ove e EC QU o 51 ON OFF E D SWITCH 5 3 OUTPUT 2 8 leo 17 32 32 CHOKE a 5 Ca ses E z5gz2z un Pi F 3538 8 E G olo eee n n ee TED 282 FO E A 025 T 282233 ZIN FAN MOTOR L 1 c22 WELDING 228 62832 e HSVAC W 24V 2 POWER Seer HEST 0047 100V OUTPUT 8 9 ZS E Woe 5 115VAC 400VDC Sseee OL 2 3 60 HZ S 125VAC 531 SES ER OG UV AR Di Seil H OD fdr ni im 125VAC 1 750 gt a 400v a A se a w SCRI 3 o u N 4 ka OP EE 15V E SEE 55A 3 S d Es a 600V A S kb GE qa aS GND MR 75 a ES H 3 SCR 3 a 01K 3 01 Sf 3 01 585 De El L E EEE ofS pi la BEB BEE J2 15V 226 D Vv A 3 R2 R4 9 Zo eg see 1 0K 00K BS i FIRING 21 Rng Z 2828 OJo ca e oct THERMOSTAT Z S p U A y aa 32 O gt d R74 600mA g z 2 Ya Dig Dig Ce 40V SE E 10K ule ES Ae SWITCH D GESER D ER 32 Ae 2500D Q Sooma MOTOR a 382 2 gt le TAI P 40v T 2253 1 00 MT2 Zz S lt 2 slk clm oar Ta D GEEF Ke GAS SOLENOID 15V un GE O CONTROL 3 HH 400V A o 120VAC _ DE A Fn Jak
4. o o LL a ao N 3 cc S lt 2 Alo Wj EI 8 Ole Zlo r Flo uw Oju 5 O S rio ol E ol lt 8 0 m OI o mia ken 5 gt O A E E D 3 E 5 2 2 2 Y S D S 9 8 Z O O a DOL181SeN 0 una y DOL181SeN 0 una y 201 JEISEe N 0 Una y 201 189ISe W 01 una y DOL UOR3SSS 0 uns 4 DOL HO 0 uns 4 901 HO 0 uns 4 DOL HO 0 UNO 4 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Hir OJO E ela al un gis EJE gt D OI VU ojo Return to Section TOC Return to Master TOC ds TROUBLESHOOTING amp REPAIR NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM 10 volts Div This is the typical output voltage waveform generated from a properly operating machine Note that each vertical division represents 10 volts and that each hor izontal division represents 20 milliseconds in time Note Scope probes connected at machine output ter minals Positive probe to terminal negative probe to terminal SP 100 SCOPE SETTINGS Volts Div Horizontal Sweep Coupling Trigger LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Hir OJO E ela al un gis EJE 3 D OI VU im Return to Section TOC
5. cnn rca nn B 6 Overload Protection EE and B 6 2 Output OVENO mitico ica di ad B 6 E Thermal Protection Lu ee B 6 Wire Feed Overload Protection sees eee eee eee eee B 6 Q Q E k Oo D un Wl fei C L I Pe i a Retum to Master TOC LINCOLN amp SP 100 Bal OPERATION Read entire operation section before operating the SP 100 WARNING ELECTRIC SHOCK can kill e Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground Return to Section TOC Return to Master TOC To e Always wear dry insulating gloves FUMES AND GASES can be dangerous e Keep your head out of fumes e Use ventilation or exhaust to remove fumes from breathing zone O E E Hs Q Wl n q eg L Ei oO E Return to Master TOC WELDING SPARKS can cause fire or explosion e Keep flammable material away e Do not weld on closed contain ers Q U dk SI HE ARC RAYS can burn eyes de Z and skin pa P CZ e Wear eye ear and body protec 212 tion AE Observe all safety information throughout this manual Return to Section TOC Return to Master TOC LINCOLN 8 SP 100 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Hir OJO EJE Elia al un gis EJE 5 el pla vu VU ojo Return to Section TOC Return to Master TOC OPERATI
6. 1 2 Electrical Stickout EEE 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 l min use 20 25 CFH 10 12 l min when welding out of position or in a drafty location for CO For argon mixed gas trigger to release gas pressure and turn off the adjust the flow to give 25 30 CFH 12 14 l min 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 See the Application Guide on the inside of wire feed section door for information on setting the SP 100 controls Set the Voltage V and Wire Speed olo con trols to the settings suggested for the welding wire and base metal thickness being used Check that the polarity is correct for the welding wire being used and that the gas supply if required is turned on When using Innershield electrode remove the gas nozzle and install the gasless nozzle This will improve visibility of the arc and protect the gas dif fuser from weld spatter Refer to the MAINTE NANCE section for details on no
7. CAPACITOR PEF 0 1 400V 10 ZENER DIODE 1W 16V 5 1N4745A ZENER DIODE 1W 10V 5 1N4740A ZENER DIODE 1W 43V 5 1N4755A ZENER DIODE 1W 5 1V 5 1N4733A TRANSISTOR N T226 0 5A 40V 2N4401 DIODE AXLDS 3A 200V 1N5402 DIODE AXLDS 0 15A 75W 1N914 CONNECTOR TAB QC VERTICAL 1 4 CONNECTOR TAB QC VERTICAL 3 16 RESISTOR WW 5W 0 5 5 SQ RESISTOR MF 1 4W 100 1 RESISTOR MF 1 4W 1 00K 1 RESISTOR MF 1 4W 10 0K 1 RESISTOR MF 1 4W 10 0K 1 RESISTOR MF 1 4W 1 00M RESISTOR MF 1 4W 1 30K 1 RESISTOR MF 1 4W 150 1 RESISTOR MF 1 4W 15 0K 1 R12 R38 R39 R60 R61 R75 R22 R46 R78 R79 R80 R21 R35 R44 R11 R10 R62 R23 R24 R17 R25 R29 R30 R76 R19 R65 R14 R20 R13 Q7 X1 X2 X3 Q1 Q6 R37 R83 R34 R81 R82 R56 R6 R1 RESISTOR MF 1 4W 22 1K 1 RESISTOR MF 1 4W 267 1 RESISTOR MF 1 4W 267K 1 RESISTOR MF 1 4W 3 32K 1 RESISTOR MF 1 4W 33 2K 1 RESISTOR MF 1 4W 392K 1 RESISTOR MF 1 4W 4 75K 1 RESISTOR MF 1 4W 47 5K 1 RESISTOR MF 1 4W 562 1 RESISTOR MF 1 4W 56 2K 1 RESISTOR MF 1 4W 681 1 RESISTOR MF 1 4W 6 81K 1 RESISTOR MF 1 4W 68 1K 1 RESISTOR MF 1 4W 82 5K 1 TRANSISTOR PMF T220 6A 100V IRF9520 C OP AMP QUAD GEN PURPOSE 224N TRANSISTOR N T226 0 5A 300V MPS A42 RESISTOR MF 1 4W 2 00K 1 RESISTOR MF 1 4W 3 01K 1 TRIMMER ST 1 2W 10K 10 LINEAR RESISTOR WW 5W 2
8. ELECTRICAL DIAGRAMS SECTION Q O g un Electrical Diagrams sise Section G o SP 100 Wiring Diagram codes 9794 and above G 2 E SP 100 Wiring Diagram codes below 9794 G 3 E Control PC Board G1842 Components nee G 4 E Control PC Board G2314 Components G 6 Machine Schematic codes 9794 and above G 8 Machine Schematic below code 9794 G 9 Return to Master TOC Q O E LD i D un fei C L I Pe i a Retum to Master TOC SP 100 sjoued ainsoj9ue y JO auo UO aulyoeu y apISU paysed SI apos JejnNoWed e 104 WeiBeip 21109059 y enuew siy Aq Pp818A09 saulyoeu je JO ajenooe eq jou Aew yy AjUO 89U819 81 104 SI WeJBEIP el 3 LON 9LS9LIN wen OIHO GNV13A319 91419313 MEG ZL LL duvog 40 3018 LNINOANOD ol NIOINM LINCOLN 2 ONIHOV11V38 NAHM IVANVA DNILYVYIdO 338 SSI Baas S ANNO4N ON LNIOF SHINDSY SNOLLOINNOO NANINNTY 031108 ON Y V38 WOH GAIMAIA LNSNOdNOD ON AIRNESS SION 188 Nes 13NVd Y31N30 3H1 OL 1838019 SI HOIHM SARA MORAGA ayan a YNISLY3H JOISNI SHL NO G3LNNON 38V va 8 20 SIDONIA EN TE 3 3 3 YNISLV3H 3GISLNO 3HL NO GSLNNOW SHV EG 8 LA S320010 VN 18913 Yad STOEINAS TYOIYLO373 SCH SILON D YAEGWNN ALIAVO HOLOINNOD AYOM eoz OL n 2 Sl Loge ze lt Q BOR ER A0 10 ON ei lt SE U Se on 7 5 S 2197 NAD voz SS GE lt a HS VE LINOUIO
9. QI OU OJO EJE Elia al un gis EJE p P im Return to Section TOC Return to Master TOC INSTALLATION ads es Route the cable under and around the back of the Wire Feed Gearbox 6 S 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 instal lation 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 al 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 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 ma for contact tip installation details CONNECTING GUN CABLE TO THE SP 100 1 Refer to Unplug the machine or turn power switch to the off O position 2 Pass the insulated terminals of the gun trigger con trol 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 Gearb
10. 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 MISADJUSTMENT S FEEDING PROBLEMS 1 If the wire drive motor is running check to see if the correct wire is in the machine If the wire drive motor is running make sure that the correct drive rolls are installed in the machine Check for clogged cable liner or feeding problems 1 Make sure that the wire speed control is not set at maximum 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 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 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 The control board may be faulty Replace Remove main supply power to machine Disconnect plug J2 from the control board Te
11. 10 m min The control can be preset on the dial to the setting specified on the SP 100 Application Guide locat ed on the inside of the wire feed section door Wire speed is not affected when changes are made in the voltage control OJO Wire Speed SP 100 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC FIGURE B 1a E C D G I S Oj ARC VOLTS EN l EA CO WIRE SPEED SP 100 ARC WELDING POWER SOURCE AND WIRE FEEDER 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 SP 100 OPERATION The recommended gas and electrode for GMAW is welding grade CO gas 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 CO gas 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 CO is recommended for welding on heavier gauge 1
12. How To Use Troubleshooting Guide F 1 PC Board Troubleshooting Procedures sss essere eee eee eee F 2 Troubleshooting ee sun F 3 Oscilloscope Waveforms see ee eee eee ee ee e F 9 Replacement Procedures su F 12 Retest After Repair iii F 14 Electrical Diagrams sens Section G SP 100 Parts Manual eege EES SE P 180 LINCOLN TABLE OF CONTENTS Section A 3 INSTALLATION SECTION g 8 Installation esa Section A E Technical Specifications EE A 1 Input and Output Specifications sse eee ee e eee eee A 1 S Cable and FUSE SIZES e A 1 Physical DIMENSIONS cocina ita A 1 Identify and Locate Components nnt A 2 Select Suitable Location sur A 3 Ell e TEE A 3 AO a ate rear cre tree ll A 3 luede EE A 3 Work Clamp Installation sese eee eee ee eee eee A 3 v Work Cable Installation sse eee eee eee e eee A 3 O Gun Installation circa dr dra stas A 4 3 Connecting Gun Cable to the SP 100 sees eee A 4 2 Gas CONNECTION issena e iia di A 4 2 A EN A 5 o Code Requirements For Input Connections A 6 e Requirements For Rated Output A 6 E Requirements For Maximum Output A 6 L Requirements For CSA Rated Output cccccccccscsssscsescecsesteeeetesessseseees A 6 Extension Gord Usage tentes amet A 6 Q O E p i D un fei c L I Pe i a Retum to Master TOC LINCOLN amp SP 100 RA INSTALLATION TECHNICAL SPECIFICATIONS SP 100 INPUT SINGLE PHASE ON
13. Refer to Figure B 4 FIGURE B 4 The Wire Drive Feed Roll can accommodate two wire sizes by flipping the wire drive feed roll over The sizes are stenciled on the drive roll 1 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 sten ciled 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 nor mally 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 SP 100 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Hir OJO EJE Elia al un gis EJE 5 e
14. Return to Master TOC TROUBLESHOOTING amp REPAIR F 10 TYPICAL OUTPUT VOLTAGE WAVEFORM MACHINE LOADED 10 volts This is the typical output voltage waveform generated from a properly operating machine Note that each vertical division represents 10 volts and that each hor izontal 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 vde Note Scope probes connected at machine output ter minals Positive probe to terminal negative probe to terminal LINCOLN C1 MMAAANANANAN MMANANANANA h da bd ad dd k ed fed h SCOPE SETTINGS Volts Div Horizontal Sweep Coupling Trigger SP 100 Return to Section TOC Return to Section TOC Return to Master TOC QI OU OJO E El al un gis EJE 13 D ojo Return to Section TOC Return to Master TOC Return to Master TOC F 11 TROUBLESHOOTING amp REPAIR ABNORMAL OPEN CIRCUIT VOLTAGE WAVEFORM 10 volts This is NOT the typical output voltage waveform The output capacitor was disconnected from the circuit Note the increased ripple in the waveform This condi tion simulates the faulty output filter capacitor Each vertical division represents 10 volts and that each hor izontal division represents 20 milliseconds in time Note Scope probes connected at machine output ter minals Positive probe to terminal nega
15. took 100K S R50 R51 ar a 1 2 2 5 b lt V amp 562 Ta 4 FIRING X z MOTOR a on 10K 1 00K E C gt D11 Kelten 208 13 VOLTAGE AR 1 0 gt J2 5 5 Y Se V ai FEEDBACK 35V Sim y EH Y SCHT mir 33 2K WIRE 5K EI 209 pe R49 QU QU 56 2K SPEED ow s la R42 ZA SPEED 2 21K V V B Va D15 GC T Mos Pe SET q i a x 205 SOLENOID Le F 2 21K WIRE 200V ARC 206 J1 CONTROL ES V V LS T h R73 FEED VOLTS 6 MOTOR i 2 10K d 5K ras 9 cf V LOAD CURRENT Jo w ag Zu FEEDBACK y a 207 co 56 2K Ti L AJ D ra 10 7 ARC VOLTAGE V Raa R45 A N ERROR AMPLIFIER J V J2 e 392K 18 2K e 3 32K 204 18V pop Z E 1 T A 1 00M 12 15V D 2 562 Y 5W eln ARC VOLTAGE Ad 1 Vv FEEDBACK D20 Det leel E 15V 4 4 a K K R75 V Gm R28 A A 267 14 Tras 1 SS wie le pep Lon xt o2 x2 Lots x3 1 3 1 5 sha EG 56 2K Ge T av p zb zu LM224 LM224 LM224 LEAD COLOR CODE O O O O O O O O WW SEK LE T y 1 1 S GENERAL INFORMATION W WHITE O O O O O O O O ELECTRICAL SYMBOLS PER E1537 gt V CAPACITORS MFD VOLT 022 50V UNLESS OTHERWISE SPECIFIED GE 4 6 6 10 RESISTORS OHMS 1 4WATT UNLESS OTHERWISE SPECIFIED o S Latok E DIODES 1A 400V UNLESS OTHERWISE SPECIFIED a y1 J2 5 V de COMMON CONNECTION CONNECTOR CAVITY NUMBERING SEQUENCE SOURCE POINT CIRCUIT LOCATION V VIEWED FROM COMPONENT SIDE OF BOARD NOTE This machine schedmatic is provided for reference only and may not be totally applicable to every code covered i
16. 5 1N4755A ZENER DIODE 1W 5 1V 5 1N4733A TRANSISTOR N T226 0 5A 40V 2N4401 DIODE AXLDS 3A 200V 1N5402 DIODE AXLDS 0 15A 75V 1N914 CONNECTOR TAB QC VERTICAL 1 4 CONNECTOR TAB QC VERTICAL 3 16 RESISTOR WW 5W 0 5 5 SQ RESISTOR MF 1 4W 100 1 RESISTOR MF 1 4W 1 00K 1 RESISTOR MF 1 4W 10 0K 1 RESISTOR MF 1 4W 100K 1 RESISTOR MF 1 4W 1 00M RESISTOR MF 1 4W 1 30K 1 RESISTOR MF 1 4W 150 1 RESISTOR MF 1 4W 15 0K 1 R12 R38 R39 R60 R61 R75 R22 R46 R78 R79 R80 R21 R35 R44 R11 R10 R62 R23 R24 R17 R25 R29 R30 R76 R19 R65 R14 R20 R13 Q7 X1 X2 X3 Q1 Q6 R37 R83 R34 R81 R82 R56 R6 R1 RESISTOR MF 1 4W 22 1K 1 RESISTOR MF 1 4W 267 1 RESISTOR MF 1 4W 267K 1 RESISTOR MF 1 4W 3 32K 1 RESISTOR MF 1 4W 33 2K 1 RESISTOR MF 1 4W 39 2K 1 RESISTOR MF 1 4W 392K 1 RESISTOR MF 1 4W 4 75K 1 RESISTOR MF 1 4W 47 5K 1 RESISTOR MF 1 4W 47 5 1 RESISTOR MF 1 4W 562 1 RESISTOR MF 1 4W 56 2K 1 RESISTOR MF 1 4W 681 1 RESISTOR MF 1 4W 6 81K 1 RESISTOR MF 1 4W 68 1K 1 RESISTOR MF 1 4W 82 5K 1 TRANSISTOR PMF T220 6A 100V IRF9520 C OP AMP OUAD GEN PURPOSE 224N TRANSISTOR N T226 0 5A 300V MPS A42 RESISTOR MF 1 4W 2 00K 1 RESISTOR MF 1 4W 3 01K 1 TRIMMER ST 1 2W 10K 10 LINEAR RESISTOR WW 5W 25 5 SQ RESISTOR WW 5W 150 5 SQ NOTE Lincoln Electric
17. Back and Bottom Assembly Center Panel Assembly Case Front Assembly Case Side Assembly Rectifier amp Fan Motor Assembly Wire Drive Assembly Return to Section TOC Return to Master TOC LINCOLN amp SP 100 LINCOLN 8 NOTES D 5 SP 100 DOL181SeN 0 una y DOL181SeN 0 una y D0OL181SeN 0 Una y 201 49ISe W 01 una y DOL U0ON28S 0 UINISY DOL U0N28S 0 UINISY DO LU0N2S 0 net DO LU0N2S 0 LUJO Y TABLE OF CONTENTS Section E THEORY OF OPERATION S E T 17 2 Theory of Operation Section E E Input Line Voltage Fan Motor and Main Transformer E 1 3 Output Control Rectification and Voltage Feedback E 2 cc Trigger Gas Solenoid and Wire Drive sss sees eee eee eee E 3 SCR Operation EE E 4 Thermal ei ee E 5 Return to Master TOC Q O E LD i D un fei C L I Pe i a Retum to Master TOC E THEORY OF OPERATION FIGURE E 1 Input Power Circuits WIRE SPEED CONTROL ARC VOLTAGE CONTROL CIRCUIT BREAKER GAS SOLENOID CONTROL INPUT BOARD RECEPTACLE TRIGGER RECEPTACLE Return to Section TOC Return to Master TOC 115VAC VOLTAGE FEEDBACK AND MOTOR POWER Return to Section TOC Return to Master TOC OUTPUT TERMINALS 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 con
18. D14 R59 D R15 R12 RL c1 E SP 100 CONTROL WW e R16 s Ta e R22 D12 R R31 J1 R24 R palba N papalbepe 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 trou bleshooting 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 SP 100 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Hir OJo EJE cl JE al un gis EJE 3 p P oO VU ojo Return to
19. 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 SP 100 LINCOLN 8 NOTES B 7 SP 100 DOL 48ISe W 0 LUS 201 48ISe W 0 una y 201 JeISe N 0 Una y 201 49ISe W 01 una y DOL U0ON28S 0 UINISY DOL U0N28S 0 UINISY DO LU0N2S 0 net DO LU0N2S 0 net Return to Master TOC Return to Master TOC Q O E p i D un fei c L I Pe i a Retum to Master TOC LINCOLN TABLE OF CONTENTS Section C ACCESSORIES SECTION EES SOEN NENNEN coran vanen NENNEN sauvecnduacuenentecventaveadbacdeusnavis Section C DIE C 1 Replacement Parts sise C 1 SP 100 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Hir OJO EJE El al un gis EJE 3 p P oO VU ojo Return to Section TOC Return to Master TOC C 1 SP 100 ACCESSORIES LINCOLN GAS REGULATOR KITS The Lincoln K463 CO or K499 Ar mixed Gas Regulator and Hose Kit is recommend ed for use with the SP100 K463 CO Regulator The K463 kit includes a preset non adjustable pressure flow regulator for use on CO cylinders The K463 CO pressure flow regulator is preset at the factor
20. 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 sur face either directly or on a recommended undercar riage 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 INSTALLATION 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 Strain Relief Hole Work Cable Work Clamp 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 termi nal lug with the smaller hole through the Work Cable Access Hole 1 in the case front FIGURE A 2 SP 100 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC
21. lala a chan e 3 32 lt la SS 2 BI TT s GIE 7 S E OVERCURRENT E SI S NEES 016 o lt 1 SHUTDOWN E 2 PZ K E ot 15V ER o UV 15V 500mA 22 Ela VOLTAGE A 300v 026 E 14 REGULATOR a 100k S D13 F 28 Da T MC7815CTDS yt LZ el 5 15V SUPPLY e 71 gj 5W 22 Ao Yo i A 85 E 24VAC ES 3 22 1k 352 X4 6 E RE N OUT SW E L ZW Z Vo An FT c6 g 02 228 i AT A x2 R39 600mA R61 DZ3 c23 885 TS o 35V k al IBT 40V 15V IK tox e DE 55300 Bos 15 0K A E IW 50V 35 2 255 Y 3 22 1x 3 SEE T Da S Bar a B a v v j 4 75K 100K 100V lt lt v as Se sis E Q 23 ES N d QE agy E O lu RE R13 WELD TEK D12 eg 1 00k C19 1w 248 O 22 1K 82 5K c8 ES 18 Q5 SC O Ai 20V 600mA 22 Er E Kos sv 267K 35V LOW 40V GET a ES TRIM D14 ER clu SAWTOOTH REN SET gt av 47 5 ges AE ET 4 We E SEER wi 252 Cer 68 1K a TRIM o ig 100K gar 2 OU 218 681 SEGS 415V e S v SET ws 22 1 E un N Io A 14 RIS SC H V Y e 1w 1N814 1 3K ES R53 S E o V 100K 215 lt 2 Jo iv 7 e Y fis J2 la 100K R52 V MOTOR z R50 R51 els ae 862 oas 1K S 100K VOLTAGE slota 10 DER ZE SOLENOID Ai Vos 18 FESTER Ti 4 00k J2 D Jj CONTROL gt SCR WIRE g si 35v Zi Ke EZ v 2 OG R17 gt FIRING SEN SPEED 206 x2 R49 ajo A 56 2K 2 oc av E fe 1 R42 in 221K V e Y Ge ow j SPEED 54 205 100K ct6 SET Sim WIRE J pts sr E st vie dE s Y L 42 eg Ch aL T e volts Jz e KS CURRENT 3
22. on control board If 115 vac is NOT present remove main supply power to machine Test continuity zero ohms of leads 32 and 31A Seel Figure If 115 vac is present at lead 31A to plug 3J1 lead 32 then control board may be faulty Replace See Figure Ed CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed call 216 383 2531 or 1 800 833 9353 LINCOLN Return to Section TOC Return to Master TOC SP 100 ES TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS Check the circuit breaker in the RECOMMENDED COURSE OF ACTION CODE 9794 and ABOVE 1 Check for 24 vac at plug 2J1 to Return to Section TOC Return to Master TOC No Wire feed weld output or gas flow when the gun trigger is pulled Fan operates normally machine Located in the wire drive compartment Reset if tripped The thermostat may be tripped due to overheating Let machine cool Weld within the duty cycle or remove any air obstruction to machine Wire feed motor may be over loaded correct feeding prob 6J1 on the control board If volt age is not present check conti nuity o
23. tain the small key is in place in the key way Replace the washer and retaining screw FIGURE D 2 Liner trim length for the Magnum 100L gun red trigger Set Screw Brass Cable Connector Liner Assembly y Liner bushing to be sealed tight against brass cable connector Gas Diffuser A Gas Nozzle or Gasless Nozzle 1 1 4 31 8 mm Liner Trim Length a SP 100 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Hir OJO EJE El al un gis EJE gt p P oO VU ojo Return to Section TOC Return to Master TOC D 3 SP 100 MAINTENANCE CHANGING LINER NOTICE The variation in cable lengths pre vents 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 locat ed 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 li
24. the installation meeting applicable electrical code requirements consult a qualified electrician CAUTION Do not connect the SP 100 to an input power sup ply 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 cir cuit 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 LINCOLN 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 installa tion the SP 100 can be used at an output of 100 amps 17 volts 30 duty cycle Refer to the ACCESSORIES section for specific infor mation 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 con nected to a 15 amp branch circuit with a nominal volt age rating of 115 volts to 125 volts 60 hertz AC only With this ins
25. 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 4 Test the machine to determine if the fail ure 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 har ness junction blocks and the termi nal 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 PROB LEM will help avoid denial of legitimate PC board warranty claims SP 100 ES TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual Return to Section TOC Return to Master TOC PROBLEMS SYMPTOMS Maj
26. 2 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 Hir OJO E cla al un gis EJE gt IEN O VU ojo If the correct voltage is not pre sent at leads 531 to 82 then check the arc voltage control potentiometer Rl and associated wires 205 206 and 207 for loose or broken connections See wiring diagram The control board may be faulty Replace CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed call 216 383 2531 or 1 800 833 9353 LINCOLN Return to Section TOC Return to Master TOC SP 100 TROUBLESHOOTING amp REPAIR F 4 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS POSSIBLE AREAS OF MISADJUSTMENT S RECOMMENDED COURSE OF ACTION Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Hir OJO E ela al un gis EJE Ga DIE ojo 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 OUTP
27. 2 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 multi ple passes are required for 1 4 and 5 16 6 0 and 8 0 mm SEQUENCE OF OPERATION WIRE LOADING Refer to Figure BA 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 eda B 3 Remove the thumb screw at the end of the shaft an
28. 5 5 SQ RESISTOR WW 5W 150 5 SQ 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 avail able 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 LINCOLN SP 100 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Hir OJO EJE El al un gis EJE 3 p P oO VU ojo Return to Section TOC Return to Master TOC G 6 ELECTRICAL DIAGRAMS CONTROL P C BOARD G2314 C27 c2 R78 Yi R80 R11 DZ1 c3 ma R10 D6 D5 SCR1 B32 e R3 8 o a H G c5 c D8 R60 13 LR74 E R71 Ka pz3 l R70 c19
29. C aM XNV In a 3M0HO LAdLNO ES voz Ps Z V HOLON 0333 381M 3009 1V91810373 oc LL 689 TVNOILVN Hd Q M ANNOYD OL O S eLz r g ANISLV3H 20010 P OL GLNNON ee 602 r reg 3 re GE Go EG 4 IVLSOWHSHL H399IHL NND 02 soz et T 1 O 6 8 2 98 p z I 9 GS z 1 vie LES H AN AN D T m i FFT TTT FFF TTT ULI lt ON Cazads um Le V A V i eg zi ul A QION3708 a l pret veto ae O QUIYOBW SIU 97195 agv Ae l l Z JO gen 8 SU Pinoys suosiad paljenb UO e b i sped al fR911198 8 YONO JOU OG e BEN S S LC AG l GYVOS O d IOHLNOO I Lg IDIM 1 109 19M H H BuiBBn dun dq lemod ul Pasuuoosig Se AIN SR SSS o Daag JAA0J YIM 8121840 jou 00 e ONINUV AV E N o 5 T WVH9VIQ ONIHIM OOL dS x T o DOL181SeN 0 una y D0OL181SeN 0 una y DOL JEISE N 0 LUS 201 49ISe W 01 una y DOL HOH 0 uns 4 901 HO 0 UNIoY DOL HO 0 UNO Y DOLUON3SS 0 UNO Y Soup SiNSOjOUd y jo SUD UO SUIYOeW y SPISUI pajsed SI apos 1enoryed e 104 WeiBeip 91109805 ay yenuew SIU q p918409 saulyoeu E JO aye4nooe aq jou Aew 1 AjUO a89U9J9 9 104 SI WeIBEIP SIUL 3LON G 3 SP 100 D 91419374 22 S IN WVYOVIG ONIHIM S020129 dS YOM OL EUZ 9 NIOINM ce LOG YN zoz 3009 1V91419313 TWNOILVN 83d aNNOH9 OL 901 19ISe IN 0 UJNJSY DOL 19ISe W 0 UlNJSy DOL uon gt 2s Oure
30. ETIC 8 a Electric current flowing through any conductor causes localized Electric and Magnetic Fields EMF Welding current creates EMF fields around welding cables and 7 b Operate engines in open well ventilated i welding machines areas or vent the engine exhaust fumes y 9 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 Return to Master TOC EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding Exposure to EMF fields in welding may have other health effects which are now not known All welders should use the following procedures in order to 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 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 Return to Master TOC Keep all equipment safety guards covers and devices in position and in good repair Keep hand
31. JM L fasl l js ee ag a 3 Last j 9 T art T R70 2 R5 R58 SCR1 4 O Ss 62 50 sei 8 A TRIL E J 7 4 LL ins Te ete T R8 IT pl Les d fe x IS E y JEJE x 0 T c25 de T T as 18 ITT T R30 wir a 22 p20 E z ei AN DES 7 L la ls EF R2 Om S ge Ello Ed kl 99 AIS d Ev S S TI y ay 5 E Q QD R6 R7 B7 T T as lt 1 O O et H S E HH 21 ES R72 aa rT a J2 F D GT SCR2 ENNEN E R33 sus LI edie ols c22 aes UT UV 2 A pis i o e k 4 EN L eo L 4 KAY ei c c gt D ab Laa Qj i R32 E EE gb Cast a 5 Y o del 0 VU GC LS Hir OJO EJE El al un gis EJE 3 p P oO VU ojo 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 trou bleshooting 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 LINCOLN E SP 100 Return to Section TOC Return to Master TOC Return to Section TOC Retu
32. 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 LINCOLN F 12 FIGURE F 2 FIGURE F 3 Gas Solenoid FIGURE F 4 Thermostat 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 SP 100 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Hir OJO E ela al un gis EJE 3 D OI VU im Return to Section TOC Return to Master TOC F 13 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 e 5 16 nutdriver or socket wrench e 1 4 nutdriver or socket wrench Phillips head screwdriver e Needle nos
33. LY Standard Voltage Frequency Input Current 115V 60Hz 20 Amps Rated Output 115V 60Hz 25 Amps Maximum Output 115V 60Hz 12 Amps CSA Rated output RATED OUTPUT Duty Cycle Amps Volts at Rated Amperes 20 Duty Cycle 90 30 Duty Cycle 100 20 Duty Cycle CSA Rated Output 63 OUTPUT Welding Current Range Continuous Maximum Open Circuit Voltage Auxiliary Power Rated DC Output 0 90 amps N A Maximum DC Output 0 100 amps CSA Rated DC Output 0 63 amps Return to Section TOC Return to Master TOC RECOMMENDED INPUT CABLE AND FUSE SIZES Return to Section TOC Return to Master TOC Fuse or RATED 115V 60Hz 20 Amp 20 15 Amp 125V Three Conductor Three Prong Plug 14 AWG NEMA Type 5 15P 2 1 mm 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 mm Three Prong Plug For lengths up to NEMA Type 5 15P 50 Ft 15 m PHYSICAL DIMENSIONS Hir OJO EJE Ela olse TER gis EJE gt D ojo Return to Section TOC Return to Master TOC LINCOLN 2 SP 100 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Hir OJO E Elia al un gis EJE 3 DIE ojo Return to Section TOC Return to Master TOC INSTALLATION Read entire installation section before starting installation SAFETY P
34. ON B 2 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 e Solid state output control e Cold electrode until gun trigger is pressed for an added measure of safety e Overload protection incorporates both a thermo stat and a circ
35. RECAUTIONS 44 WARNING ELECTRIC SHOCK can kill e Only qualified personnel should perform this installation e Only personnel that have read and under stood the SP 100 Operating Manual should install and operate this equipment e Machine must be plugged into a receptacle which is grounded per any national local or other applicable electrical codes e 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 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 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 Gun is ready to feed 025 0 6 mm diameter wire also 023 and 024 diameter wire LINCOLN OPERATORS MANUAL FIGURE A 1 A 2 SP 100 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC QI OU OJO EJE ela al un gis EJE 5 2 D OI UV ojo Return to Section TOC Return to Master TOC A 3 SELECT SUITABLE LOCATION Locate the welder in a dry location where there is free circulation of clean air into the louvers in the back
36. Se E y Ea PE va 2 C3 R2 R4 SEP 4 a lt gt 0 1 1000 1000 SCR Hee 382 z 15V mo GE 400V 1 2W 1 2W FIRING 211 A V Sc m Ege a 5 3 sl oc R66 200 Z 2420 es THERMOSTAT lt 20 l 2498 ul E D8 Vois ca 1 co 10K 10K zee Ol un zo O o TP 2 TRIGGER E E 15 0K SE 5 E R5 S Suen ES OSCILLATOR SEKR re B32A 100 213 os al 523 1K 1 2W 3 a ol OU de co 1 2W rs x3 i ro pu PC w 150 ZN 2 lata 33 4 un ik ME GAS SOLENOID 1 2W J2 Ss ax P EE s f Le E D GAS amp Jow 454 a ocn CONAN OVERCURRENE a RD Jf o SOLENOID as TRI SHUTDOWN 300V Sow S fen un 120VAC YA ate E olo SC 5 1 00K S gt lt 2 ply 87 H 858 E Zuch 15V 15V 293 2 L 5 3 c26 R61 LEZZ 2 22 1K SNA K VOLTAGE ma GE E REGULATOR age la ZA ui 3 x ie 15V SUPPLY D8 L MC78150TD5 E to D 8 Ti x amp 89 2K V 2 lt 3 oo D3 D4 15V R59 8 is l T A s 100K a2 5 J ra E N 4 our 200mA 2 22 1k 2 e 5 27 D7 3 30V d S 8 Yo An 1 2W _c5 Cp 06 Shi5 ok 3 1 00K I 47 5K 2150 ort ES 2 019 50V 35V 18 20V V Gol 15V Sns 4 75K 15V th R19 K A ER lt X2 6 81K E D12 22 1K S L olo BURNBACK h Dae AE 10K B 3 H 35 e OJO Zoo 3 mA 4 2w 2N4123 FI 2 gt SAWTOOTH Ld e 15V 2 clo D d Ri Zl b o lv Sy Ban vaw PK a c7 o os R53 SE n 15V Gel ew 100K OU y 221 A K Sos T ioov E V LC 00K Y D A S 68 1K V 500mW D10 1 3K G un S 1N914 v R52 o R16 SCR pa chan 33
37. Section TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G 7 CONTROL P C BOARD G2314 Item Identification Item Identification SCR1 SCR2 SCR 81 HEATSINK ASBLY R45 RESISTOR MF 1 4W 18 2K 1 X4 C VOLT REG FIXED 3 T 1A 15V R28 R31 R47 R49 RESISTOR MF 1 4W 2 21 K 1 C4 C9 C11 C12 C13 C14 C16 C20 C21 C24 C26 J1 C5 D1 D2 D3 D4 D5 D6 CAPACITOR CEMO 022 50V 20 CONNECTOR MOLEX MINI PCB 6 PIN CAPACITOR ALEL 150 50V 150 10 DIODE AXLDS 1A 400V D7 D8 D9 D11 D12 D13 D14 D17 D18 D19 D20 D21 R32 R33 C19 C6 C17 C15 C8 C10 C18 C23 OCH OCI2 TRI J2 C7 C22 C1 C25 C2 C3 C27 DZ3 DZ1 DZ4 DZ2 Q2 Q3 Q4 Q5 D15 D16 D10 B31 A B531 B7 B32 R69 R72 R5 R2 R4 R8 R26 R27 R41 R48 R51 R55 R58 R70 R50 R57 R66 R68 R71 R73 R74 R42 R52 R53 R54 R55 R43 R15 R16 R18 R3 R36 R63 R64 R67 RESISTOR WW 15W 80 5 SQ CAPACITOR TAEL 1 8 20V 10 CAPACITOR TAEL 4 7 35V 10 CAPACITOR TAEL 18 15V 10 CAPACITOR TAEL 1 0 35V 10 CAPACITOR ALEL 3300 50V 30 10 OPTOCOUPLER TRIAC DRIVER 3023 TRIAC T220 6A 400V 2500D CONNECTOR MOLEX MINI PCB 10 PIN CAPACITOR PEF 0 1 100V 10 CAPACITOR PEF 0 22 100V 10 CAPACITOR CD 0047 005 1400V 20 CAPACITOR PEF 0 1 400V 10 ZENER DIODE 1W 16V 5 1N4745A ZENER DIODE 1W 10V 5 1N4740A ZENER DIODE 1W 43V
38. TION SP 100 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 self resetting once the machine cools sufficient ly 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 cor rected Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Hir OJo EJE El al un gis EJE 3 D oO VU ojo Return to Section TOC Return to Master TOC LINCOLN 8 SP 100 Return to Master TOC Return to Master TOC Q Q E k Oo D un Wl fei C L I Pe i a Retum to Master TOC LINCOLN TABLE OF CONTENTS TROUBLESHOOTING SECTION Troubleshooting rrrnnnnnnvennnnnnnnvnnnnnnnnnnnnnnnnnnnennnnnnnnnnnnnnnnnnennnnnnnnennnnnnnnennnnnnnnnnr Section F Safety TEE F 1 How To Use Troubleshooting Guide sss sese eee eee F 1 PC Boar
39. UT PROBLEMS Arc voltage may be set too low Gun tip may be worn Replace Check for correct input voltage to machine Gun or work cable may be faulty Check the circuit breaker locat ed in the machine s wire drive compartment Reset if tripped The thermostat may be tripped due to overheating Let machine cool Weld within the duty cycle or remove any air obstruction to machine Wire feed motor may be over loaded Correct feeding prob lem Gun trigger may be faulty 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 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 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 H an open circuit or high resis tance 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 Check for 115 vac at lead 31A to plug 3J1
40. Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot 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 Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling 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 When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 4 c and 6 SP 100 2 b ARC RAYS can burn 2 a Use a shield with the proper filter and cover L plates to protect your eyes from sparks and AAA the rays of the arc when welding or observing open arc welding Headshield and filter lens should conform to ANSI Z87 standards Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays Protect other nearby personnel with suitable non flammable screenin
41. and correct possible machine malfunctions or misadjustments Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMPTOMS This column describes pos sible 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 con tribute to the machine symptom Perform these tests checks in the order listed In general these tests can be conducted with out removing the case wrap around cover Step 3 PERFORM COMPONENT TESTS The last column labeled Recommended Course of Action lists the most likely com ponents 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 referen
42. ard 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 WIRE SPEED CONTROL GAS SOLENOID VOLTAGE FEEDBACK AND MOTOR POWER OUTPUT TERMINALS reflected at the transformer secondary wind ing 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 ter minals NOTE Unshaded areas of block logic diagram are the subject of discussion SP 100 E 3 THEORY OF OPERATION FIGURE E 3 Trigger Gas Solenoid and Wire Drive Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Hir OJO EJE Ela olse un gis EJE 3 D OI VU ojo Return to Section TOC Return to Master TOC INPUT RECEPTACLE 115VAC SP 100 ARC VOLTAGE CONTROL TRIGGER RECEPTACLE CIRCUIT BREAKER FAN MOTOR MAIN TRANSFORMER 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 volt age is developed at the output terminals and fed back to the control board This welding output volta
43. 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 avail able 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 LINCOLN SP 100 ELECTRICAL DIAGRAMS G 8
44. autour de n importe quelle PR CAUTIONS DE S RET POUR partie du corps Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les zones o Pon pique le laitier Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s 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 loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de lev age cables de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas forte ment tox
45. cautions de s ret g n rales suivantes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s 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 couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le cable de soudage et la machine souder en bon et s r tat defonctionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines soud er parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se pro t ger contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode
46. ced electrical wiring diagrams and schematics See Electrical Diagram Section A CAUTION 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 LINCOLN Return to Section TOC Return to Section TOC Return to Master TOC Hir OJO EJE El al un gis EJE 3 p P oO VU ojo Return to Section TOC Return to Master TOC Return to Master TOC LINCOLN TROUBLESHOOTING amp REPAIR F 2 PC BOARD TROUBLESHOOTING PROCEDURES A WARNING ELECTRIC SHOCK can Ke kill Have an electrician install and service this equip ment Turn the input power OFF and unplug the machine before work ing 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 replac ing PC boards please use the following procedure 1 Determine to the best of your technical ability that the PC board is the most like ly component causing the failure symp tom nm Check for loose connections at the PC board to assure that the PC board is properly connected C If the problem persists replace the sus pect PC board using standard practices
47. ct sk R25 Ja FEEDBACK SN W 539 aw 207 9 562 D T s5v fo I ras o V 2 T ARC VOLTAGE A clean se N ERROR AMPLIFIER E me ss V J2 15V C15 1 4 A too S Fi 3 562 Z 15V V E ARC VOLTAGE Cl sw SIK FEEDBACK V V D20 1 R28 GA A 267 2 21K xt 4 R29 P ero 8 La xt og x2 cta x3 lioo Ba Ka Ka Ka 203 S Seu e Shine LM224 LM224 LM224 rc 56 2K Le SI CO an a v Si 022 A R 1W V V NOTE This machine schedmatic is provided for reference only and may not be totally applicable to every code covered in this manual INCOLN SP 100 O lo Oojo GIS AE amp 0 KAES EE CIE y es D oov im ELECTRICAL DIAGRAMS G 9
48. d Keep cylinder upright and chained to support e Keep cylinder away from areas where it may be damaged e Never lift welder with cylinder attached e Never allow welding electrode to touch cylinder e Keep cylinder away from welding or other live electrical circuits SP 100 AD INSTALLATION 3 Attach the flow regulator to the cylinder valve and WARNING tighten the union nut securely with a wrench The Qjo ele ua 5 5 3 BUILDUP OF SHIELDING GAS may flow regulator for carbon dioxide must have a plas D harm health or kill tic washer seated in the fitting that attaches to the le Se cylinder to prevent leakage o e e Shut off shielding gas supply E when not in use 4 Refer to Figure A 6 Attach one end of inlet gas 2 3 SEE AMERICAN NATIONAL hose to the outlet fitting of the flow regulator and E cc STANDARD Z 49 1 SAFETY IN tighten the union nut securely with a wrench WELDING AND CUTTING PUB Connect the other end to the SP 100 Gas Solenoid LISHED BY THE AMERICAN Inlet Fitting 5 8 18 female threads for CGA WELDING SOCIETY 032 fitting Make certain the gas hose is not kinked or twisted 1 Chain the cylinder to a wall or other stationary sup port to prevent the cylinder from falling over Insulate the cylinder from the work circuit and earth INPUT CONNECTIONS ground Refer to Figure A 6 FIGURE A 5 The SP 100 has two input connections the power input cable and the Gas Sole
49. d 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 Vent hollow castings or containers before heating cutting or welding They may explode 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 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 cir cuits This can create fire hazards or overheat lifting chains or cables until they fail 4 h Also see item 7c LINCOLN 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 Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Cylinders sho
50. d Troubleshooting Procedures sss sese F 2 Troubleshooting Guide F 3 Output Problems sr manne A A A AEEA F 3 Feeding Problems ss F 6 Gas Flow Problems tt sen sdeegek be tcp date ttes sense F 7 Welding Stee EE F 7 PC Board Connector Locations su F 8 Oscilloscope Waveforms Normal Open Circuit Voltage Waveform sse eee eee eee eee eee eee eee F 9 Typical Output Voltage Waveform Machine Loaded sss sss sese eee F 10 Abnormal Open Circuit Voltage Waveform F 11 Replacement Procedures Fan Blade and Motor Removal sessies azz cnn F 12 Wire Drive Assembly Removal nenen nenn F 13 Retest After Repalr umi ita id F 14 Section F SP 100 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Hir OJO EJE El al un gis EJE 3 p P ojo Return to Section TOC Return to Master TOC F 1 TROUBLESHOOTING amp REPAIR HOW TO USE TROUBLESHOOTING GUIDE WARNING 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 SP 100 manual This Troubleshooting Guide is provided to help you locate
51. d 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 diame ter shaft and held in place with the previously removed thumb screw Make certain that the thumbscrew is LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Hir OJO E El al un gis EJE 3 D OI VU ojo Return to Section TOC Return to Master TOC OPERATION e FIGURE B 2 Wire Spool Spindle 8 Wire Spool Be sure that this stud engages the hole in the wire spool 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 clock wise when wire is dereeled 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 Wire Spindle Shaft 4 Wire Spool Thumb Screw To Wire Drive 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 neces sary LINCOLN WIRE THREADING
52. e pliers e Knife or side cutters e Screwdriver slot head PROCEDURE Refer to Figure F 5 1A FOR CODES ABOVE 10000 Cut heads off of two plastic fastener buttons locat ed 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 SP 100 TROUBLESHOOTING amp 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
53. ee SP 1 00 For use with machines having Code Numbers 9284 10050 Return to Master TOC View Safety Info 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 thought ful 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 Return to Master TOC View Safety Info 3 F 2 JE E Z 2 9 z 2 gt ke E SERVICE MANUAL AAA G 150 9002 Ss A Frey LZ Eu Lace Co the tar Quality Program Certified ABS Quality Evaluations inc S LINCOLN pe World s Leader in Welding and Cutting Products ELECTRIC Premier Manufacturer of Industrial Motors e 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 View Safety Info Return to Master TOC Return to Master TOC Return to Master TOC Q O E LD Qu D un d c L I Pe i a Retum to Master TOC SAFETY A WARNING 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 follo
54. f leads to fan motor If leads are OK replace fan motor SeelFigure F 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 trig lem circuit is OK Sed Figure EH Gun trigger may be faulty H an open circuit or high resis tance is indicated in Step 2 then check leads 211 212 and 213 for loose or broken con nections Also check the normal ly closed thermostat mounted on the diode heat sink assembly Return to Section TOC Return to Master TOC The control board may be faulty Replace Hir OJO E Ela al un gis EJE 3 DIE ojo CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed call 216 383 2531 or 1 800 833 9353 LINCOLN Retum to Section TOC Retum to Master TOC SP 100 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Qjo OJO E ela al un gis EJE 3 DIE ojo Return to Section TOC Return to Master TOC TROUBLESHOOTING amp REPAIR F 6 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED COURSE OF ACTION
55. g and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal 3 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 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 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 Read and understand the manufacturer s instructions for this equipment and the consumables to be used including the mater
56. ge is also used to power the wire drive motor aa CONTROL BOARD WIRE SPEED CONTROL GAS SOLENOID VOLTAGE FEEDBACK AND MOTOR POWER OUTPUT TERMINALS The welding output voltage that powers the wire drive motor is varied and controlled on the control board The control board moni tors the drive motor armature current and voltage and compares the feedback infor mation 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 over loads NOTE Unshaded areas of block logic diagram are the subject of discussion LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Hir OJO EJE Elia al un gis EJE 3 p P oO VU ojo Return to Section TOC Return to Master TOC LINCOLN Cathode THEORY OF OPERATION SCR OPERATION A silicon controlled rectifier SCR is a three terminal device used to control large cur rents to a load An SCR acts very much like a switch When it is turned on there is cur rent 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 sugge
57. i D 2 Replace Line tintin dida liarla D 3 Replace Internal Gun Handle Parts As Necessary eee eee eee eee D 3 Location of Components ur D 4 Section D SP 100 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Hir OJO EIC q ES un gis EJE 5 el pla 0 VU ojo Return to Section TOC Return to Master TOC SP 100 MAINTENANCE SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill e Disconnect input power by removing plug from receptacle before work ing inside SP 100 Use only grounded recepta cle Do not touch electri cally hot parts inside SP 1 00 e Have qualified person nel do the maintenance and trouble shooting work ITEMS REQUIRING NO MAINTENANCE e Drive Motor and Gearbox Lifetime lubrication e Fan Motor Lifetime lubrication e Wire Reel Spindle Do NOT lubricate shaft ROUTINE AND PERIODIC MAINTENANCE BEFORE EACH USE e 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 e Clean nozzle to avoid bridging between nozzle and contact tip which results in shorted nozzle poor welds and overheat ed gun Hint Anti stick spray or gel avail able from a welding supply distributor may reduce buildup and aid in spatter remova
58. ial safety data sheet MSDS and follow your employer s safety practices MSDS forms are available from your welding distributor or from the manufacturer Also see item 7b LINCOLN Return to Master TOC Return to Master TOC Q O E L i 3 un A C I 5 oO a Retum to Master TOC SAFETY 7 WELDING SPARKS can lt gt 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 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 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 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 Recommende
59. ine 115 vac Check for proper electrode polarity for process Check gun tip for wear or dam age Replace Check for proper gas and flow rate for process Check work cable for loose or faulty connections Check gun for damage or breaks 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 dia gram 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 Control board may be faulty Replace RECOMMENDED COURSE OF ACTION Check for correct open circuit voltage OCV at machine s out put terminals 10 vdc to 28 vde depending on arc voltage con trol setting If correct OCV is present check gun and work cable If OCV is low check output capacitor and output diodes Check arc voltage control poten tiometer and associated wires 205 206 and 207 for loose or broken connections See wiring diagram Control board may be faulty Replace CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed call 216 383 2531 or 1 800 833 9353 SP 100 LINCOLN
60. ique ou autres produits irritants Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 LES MACHINES A SOUDER A Un coup d arc peut tre plus s v re qu un coup de soliel TRANSFORMATEUR ET A REDRESSEUR donc a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du rayonnement de l arc et des projections quand on soude ou quand on regarde Parc Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflamma bles Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dis positif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de I huile tels que les gants en cuir chemise paisse pantalons sans revers et chaussures montantes Mar LINCOLN debrancher l interrupteur la boite de fusible
61. l AFTER EACH SPOOL OF WIRE FEED Remove contact tip and clean inside diam eter with short piece of wire e Clean cable liner when rough and erratic wire feeding occur AFTER FEEDING 50 OF FLUX CORED WIRE OR 300 OF SOLID WIRE e Unplug machine or turn power switch to OFF O position Remove gun and cable from machine Remove gas nozzle and contact tip from gun e Lay cable out straight blow out gently with compressed air Bend cable back and forth blow out again Repeat until clean 44 CAUTION Excessive pressure at start may cause the dirt to form a plug PERIODICALLY AS REQUIRED e Unplug machine or turn power switch to OFF 0 position e 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 e Blow dirt out of Rectifier amp Fan Motor Assembly PC Board located on Case Side Assembly and Center Assembly components Refer to Figure D 4 e Vacuum accumulated dirt from gear box and wire feed section Refer to Figure D 4 e Inspect the incoming guide tube and clean inside diameter if necessary Replace when excessively worn e Replace Contact Tip when hole is enlarged or elongated refer to Changing Contact Tip below LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC QI OU OJO EJE Elia al un gis EJE 3 p P
62. l pla oO VU ojo Return to Section TOC Return to Master TOC OPERATION FIGURE B 5 Gun Handle Gas Diffuser Contact Tip Gas vs WARNING 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 con tact 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 CO 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 CO open the cylinder very slowly For argon mixed gas open cylinder valve slowly a fraction of a turn When the cylinder pressure gauge pointer stops moving open the valve fully SP 100 FIGURE B 6 Contact Tip Wire Electrode 3 8
63. n DOL uon gt as 0 met DOL 19ISe W 0 UlNJSy DOL UONDSS 0 uno y 901 19ISe W 0 UNS DOL UONDISS 0 Uno y nor 19 whe 9018 Ton wr ON YOLONGNOD E Es 02 31479 NNO Y HG LINE Havasu LEG YLE LINODHID GE LE SC 02 3MOHO LNALNO O voz air MI a Ir HOLON O HOLON 0334 381M Nv4 lt 2 se M 5 elz a de f LIZ l p EUZ goo LYS 80z Ces goz boa 7 669 Q NISLVSH 30010 Lip soz DE EN T F 4 Pa Fe OL G3LNNOW LVISONHAHL 8399141 NNO 802 802 LC O I po 6 8 9 S y 6 T 9 S Z L vie Leg i O KR L TTL T TIT FEIET i D I on E I LI I 0338 SHIM i Ji sir i Er ar i st l K YZE O l vee DC i 00 i GIONS10 O aHvO4 JO 2019 LNANOdNO l I gyp a 30N3N03S ONINASWNN ALIAVO 902 L 1 a HOLYA 102 502 IG i EN l IH l O EC ON GuVO8 9 d TOHINOO l Z L 3JOVLTOA 9HY Zz DH 1 DE YAGWNAN ALIAVO HOLOANNOO L j ez eer EE Rea SKS gig pe gt Og E on geg Wee KN Se NG PE Sei ALIHM M X9V18 9 TAN vd HILNIO El a ONIHOVLLV3Y 3H1 OL 1838019 SI HOIHM ANISLVIH SGISNI 2 3009 40109 aval N3HM IN ONILYH3dO 338 ONNOANOO 3H1 NO G3LNNON 38v P 8 0 920010 EN PS Ze 1NIOP 381N038 SNOLLOINNO9 WNNINNTY 031708 ON YINISLVAH 3018110 8 D 26913 did SIOSWAS 1VOIH19312 EVA NOV AMAIA LNJNOdINOO O N JHL NO G3LNNON 3UV EG LO 30010 WN M 15427 2 V G 4 ELECTRICAL DIAGRAMS
64. n this manual INCOLN SP 100 O lo O lO GIS AE amp 0 KAES EE CIE y es D oov ojo Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O O O Flr CIS Oo a als ES ply GC lC Return to Section TOC Return to Master TOC 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 col umn 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 LINCOLN
65. ner 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 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 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 clock wise 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 screwdriv er 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 0 LINCOLN MAINTENANCE edi FIGURE DA LOCATION OF COMPONENTS Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC QI OU OJO EJE cla al un gis EJE 13 D OI VU ojo SP 100 SUB ASSEMBLIES Case
66. noid Inlet Fitting Both Flow Regulator Cylinder Valve connections are located on the rear of the machine Return to Section TOC Return to Master TOC FIGURE A 6 Gas Hose Gas Solenoid Inlet Fitting 2 With the cylinder securely installed remove the Power cylinder cap Stand to one side away from the out Input let and open the cylinder valve very slightly for an Cable instant This blows away any dust or dirt which may have accumulated in the valve outlet WARNING 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 Hir OJO E El al un gis EJE gt D OI UV ojo Return to Section TOC Return to Master TOC LINCOLN 8 SP 100 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Hir OJO EJE Elia al un gis EJE 3 p P OI VU ojo Return to Section TOC Return to Master TOC INSTALLATION a CODE REQUIREMENTS FOR INPUT CONNECTIONS WARNING This welding machine must be connected to power source in accordance with applicable elec trical 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
67. o 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 sec tion 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 elec trode installing the gasless nozzle will improve visibili ty 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 ACCESS OS ed 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 cir cuit to protect the wire feed motor
68. o install optional features refer to in structions included with the kit REPLACEMENT PARTS Complete Gun and Cable Assembly 17538 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 518704 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 518704 6 Black Trigger 519728 Red Trigger Gas Nozzle 518704 7 Black Trigger M16294 Red Trigger Gasless Nozzle Innershield Only 518704 14 Black Trigger M16418 Red Trigger LINCOLN Return to Master TOC Return to Master TOC Q O E p Qu D un fei c L I Pe i a Retum to Master TOC LINCOLN TABLE OF CONTENTS MAINTENANCE SECTION Maintenance 0e dende krenke anm ann Section D Safety EE D 1 Items Requiring No Maintenance sse sese e sees ee essere sees sese e eee eee ener eenn D 1 Routine and Periodic Maintenance D 1 Before Each US Girmesini iania ai aaa D 1 After 5 Minutes of Weidig D 1 After Each Spool of Wire Feed D 1 Component Replacement Procedures sss sese eee eee eee D 2 Changing The Contact Tip D 2 Changing Drive Roll ii
69. oO VU ojo Return to Section TOC Return to Master TOC LINCOLN MAINTENANCE e Replace Liner when wire feeding prob lems occur and other items have been checked refer to Changing Liner in this section COMPONENT REPLACE MENT 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 0 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 FIGURE D 1 Wire size is stenciled on the ends of the drive roll Make certain the SP 100 power switch is off O Open the Spring Loaded Pressure Arm 2 Lift up the Idle Roll Arm 3 Remove the drive roll retaining screw and washer 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 cer
70. or physical or electrical damage is evident No wire feed weld output or gas flow when gun trigger is pulled Fan does NOT operate POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS Contact your LOCAL LINCOLN AUTHORIZED FIELD SERVICE FACILITY Make sure correct voltage is applied to the machine 115 vac RECOMMENDED COURSE OF ACTION Contact the Lincoln Electric Service Department 216 383 2531 or 1 800 833 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 dia Make certain that power switch gram is in the ON position If 115 vac is not present at leads 31 to 32 then check the power switch and input line cord Sl No weld output or wire feed when gun trigger is pulled Fan runs and gas flows normally Contact your LOCAL LINCOLN AUTHORIZED FIELD SERVICE FACILITY 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 cor rect AC voltage is present check the output diodes and connec tions Also check the output ca pacitor C1 See wiring diagram Return to Section TOC Return to Master TOC If the correct AC voltage is not present at the diode heat sink leads 202 to 201 then check the AC voltage on the trans former TI primary leads 531 to 3
71. ox 6 and through the Cable Hanger 7 on the inner panel LINCOLN 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 CAUTION 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 Fiqure A 5 When using the GMAW process a cylinder of carbon dioxide CO 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 ACCES SORIES section WARNING CYLINDER may explode if dam age
72. rn to Master TOC Return to Section TOC Hir OJO EJE El al un GE EJE 3 p P oO VU ojo Return to Section TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G 5 CONTROL P C BOARD G1842 Item Identification Item Identification SCR1 SCR2 SCR amp HEATSINK ASBLY R45 RESISTOR MF 1 4W 18 2K 1 X4 C VOLT REG FIXED 3 T 1A 15V R28 R31 R47 R49 RESISTOR MF 1 4W 2 21K 1 C4 C9 C11 C12 C13 C14 C16 C20 C21 C24 C26 Ji C5 D1 D2 D3 D4 D5 D6 D7 D8 D9 D11 D12 D13 D14 D17 D18 D19 D20 D21 R32 R33 C19 C6 C17 C15 C8 C10 C18 C23 OCI OCI2 TRH J2 C7 C22 C1 C25 C2 C3 C27 DZ3 DZ1 DZ4 DZ2 Q2 Q3 Q4 Q5 D15 D16 D10 B31A B531 B7 B32 R69 R72 R5 R2 R4 R8 R26 R27 R41 R48 R51 R55 R58 R70 R50 R57 R53 R54 R71 R73 R74 R42 R52 R53 R54 R59 R43 R15 R16 R18 R3 R36 R63 R64 R67 CAPACITOR CEMO 022 50V 20 CONNECTOR MOLEX MINI PCB 6 PIN CAPACITOR ALEL 150 50V 150 10 DIODE AXLDS 1A 400V RESISTOR WW 15W 80 5 SQ CAPACITOR TAEL 1 8 20V 10 CAPACITOR TAEL 4 7 35V 10 CAPACITOR TAEL 18 15V 10 CAPACITOR TAEL 1 0 35V 10 CAPACITOR ALEL 3300 50V 30 10 OPTOCOUPLER TRIAC DRIVER 3023 TRIAC T220 6A 400V 2500D CONNECTOR MOLEX MINI PCB 10 PIN CAPACITOR PEF 0 1 100V 10 CAPACITOR PEF 0 22 100V 10 CAPACITOR CD 0047 005 1400V 20
73. s Garder tous les couvercles et dispositifs de s ret leur place 93 SP 100 SP 100 RETURN TO MAIN INDEX MASTER TABLE OF CONTENTS FOR ALL SECTIONS Page Installation ic Section A Technical Specifications ss A 1 Identify and Locate Components A 2 Select Suitable Location A 3 Output CONNeCtiONnS 35225528 caida cesdaeecesasesnencieeanast nl bd dla and egen khat A 3 Input CONNECTIONS iii ea eis ia A 5 Code Requirements issues A 6 Operation eebe Seege Section B Safety Precautions viii nana ennemie RAR Ai liant B 1 General Description is B 2 Design Features and Advantages eee eee ee eee B 2 Welding Capability ss B 2 Limnt tons iuuyeunuaussna ied pees bo B 2 Controls and Settings B 2 Welding Operations iras thin navn dain B 3 Overload Protection sise B 6 EES ENEE Section C ee C 1 Replacement Parts ici at utile dd tentes C 1 Maintenance nid diner nid EEN Section D Safety Precauti ns cima a li id D 1 Items Requiring No Maintenance e eesse esse sees sees esse essere tesse enesenn enne D 1 Routine and Periodic Maintenance D 1 Component Replacement Procedures sss sese D 2 Location of Components ur D 4 Theory of Operation siennes 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 cui a ees E 4 Thermal Prot ction 22 8 ti E 5 Troubleshooting and Repair ns Section F
74. s hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing equipment 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 Mar 93 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 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 Q O E k i D un Pe c L I Pe 0 a 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 Retum to Master TOC LINCOLN 8 5P 100 Return to Master TOC Return to Master TOC OU Q E Le Y ba un o py C E D J ka Retum to Master TOC SAFETY PRECAUTIONS DE SURETE Pour votre propre protection lire et observer toutes les instruc tions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr
75. st the resistance from lead 539 2J2 in the harness plug to the wire feed motor case If the resis tance is below 500 000 ohms replace the drive motor Check the wire speed control potentiometer and associated wires 208 209 and 203 for loose or broken connections The control board may be faulty Replace A CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed call 216 383 2531 or 1 800 833 9353 LINCOLN SP 100 E TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED COURSE OF ACTION Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Hir OJO E Elia al un gis EJE gt 3 D O VU ojo Return to Section TOC Return to Master TOC SYMPTOMS Low or no gas flow when gun trigger is pulled Wire feed weld output and fan operate normally PROBLEMS SYMPTOMS Arc is unstable Poor starting MISADJUSTMENT S GAS FLOW PROBLEMS Check gas supply flow regulator and gas hoses Check gun connection to machine for obstruction or leaky seals POSSIBLE AREAS OF MISADJUSTMENT S WELDING PROBLEMS Check for correct input voltage to mach
76. sts 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 posi tive than the cathode When an AC supply voltage is applied to the SCR the device spends a certain por tion 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 OUTPUT E 4 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 cur rent 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 hold ing current the SCR will shut off This nor mally 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 Note As the gate pulse is applied later in the cycle the SCR output is decreased FIGURE E 4 SCR OPERA
77. tallation 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 mm or larger The recommended maximum lengths are 25 ft 7 5 m if 14 AWG 2 1 mm is used and 50 ft 15 m if 12 AWG 3 3 mm is used SP 100 LINCOLN 8 NOTES A7 SP 100 DOL181SeN 01 UNS y DOL181SeN 0 una y D0OL181SeN 0 Una y 201 49ISe W 01 una y DOL U0ON28S 0 UINISY DOL U0N28S 0 UINISY DO LU0N2S 0 net DO LU0N2S 0 net TABLE OF CONTENTS Section B OPERATION SECTION Q O H el E TE Section B 9 Safety eT eT B 1 General Description iii B 2 8 Recommended Processes sn B 2 E Operational Features and Controls B 2 Design Features and Advantage sees eee eee B 2 ES Welding Capability eee dv olntaessintsucacasionsnticneibatiuctesiasdleetnts B 2 Bt te ua dedikere tbe nn B 2 Controls and Settings is B 2 Welding Operations eiietavialntisl inten alanine B 3 Process Guidelines ss B 3 Sequence of Operations ir B 3 Wire LOAN nine ld B 3 Friction Brake Adjustments 52x 227 R 29 ac EART B 4 U Wire Thr ading T B 4 O Shielding asian a daba B 5 E Making a Weld eegene B 5 2 Cleaning Tip andNozzle nc B 6 Z Changing Machine Over To Feed Other Wire Sizes sees eee ee B 6 o Welding With Innershield
78. the bearing which will remain attached to the front housing 3 Remove motor with rear housing 4 Remove two screws holding motor to rear hous ing 5 Separate motor from rear housing LINCOLN TROUBLESHOOTING amp REPAIR F 14 RETEST AFTER REPAIR Should a machine under test be rejected for any reason requiring the removal of any mechani cal part that could affect the machine s electrical characteristics or if any electrical components are repaired or replaced the machine must be retested Return to Section TOC Return to Master TOC MAIN TRANSFORMER SECONDARY VOLTAGES TEST POINTS VOLTAGES LEADS 201 202 2 20 vac Dependent on arc voltage control Located on Output Diode Heat Sinks setting min to max INPUT AMPS AT RATED OUTPUT INPUT AMPS AC OUTPUT DC OPEN CIRCUIT VOLTAGES TEST POINTS VOLTAGES OUTPUT TERMINALS 10 to 27 vdc Dependent on arc voltage control setting min to max Return to Section TOC Return to Master TOC WIRE SPEED RANGE 50 to 400 in min Dependent on wire speed control setting 1 2 to 10 2 m min Hir OJO EIC Elia al un gis EJE 5 p P ojo Return to Section TOC Return to Master TOC 1205 arun LINCOLN 8 NOTES F 15 SP 100 DOL 48ISe W 0 una y 201 48ISe W 0 una y 201 JEISe N 0 Una y 201 49ISe W 01 una y DOL U0N28S 0 UINISY DOL U0N28S 0 UINISY DO LU0N2S 0 net DO LU0N2S 0 LUJO Y TABLE OF CONTENTS Section G
79. tive probe to terminal SP 100 SCOPE SETTINGS Volts Div Horizontal Sweep Coupling Trigger LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Hir OJO E Elia al un gis EJE 3 D OI VU ojo Return to Section TOC Return to Master TOC TROUBLESHOOTING amp REPAIR FAN BLADE REMOVAL PROCEDURE DESCRIPTION AND MOTOR 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 e 5 16 nutdriver or socket wrench e 7 16 nutdriver or socket wrench e 7 16 open end wrench Phillips head screwdriver e Needle nose pliers PROCEDURE 1 Using the 5 16 nut driver remove the three self tapping 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
80. trol board and main transformer through a line switch located on the front panel A circuit breaker is incorpo rated 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 trans former changes the high voltage low cur rent input power to a low voltage high cur rent output for welding Hir OJO EJE ela al un gis EJE gt 1 3 D OI VU im NOTE Unshaded areas of block logic diagram are the subject of discussion Return to Section TOC Return to Master TOC LINCOLN E SP 100 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Qjo OJO E El al un gis EJE 3 D OI VU ojo Return to Section TOC Return to Master TOC INPUT RECEPTACLE 115VAC LINCOLN THEORY OF OPERATION E 2 FIGURE E 2 Output Circuits ARC VOLTAGE CONTROL TRIGGER RECEPTACLE CIRCUIT BREAKER paren CONTROL BOARD FAN MOTOR MAIN TRANSFORMER OUTPUT CONTROL RECTIFICA TION AND VOLTAGE FEEDBACK N ES H gt o The AC voltage that is applied to the main transformer primary is controlled at the con trol 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 bo
81. uit breaker e Quality wire drive with electronic overload protec tion e Easy to set continuous range controls for precise setting of arc voltage and wire speed amp Continuous voltage control e Quick Release idle roll pressure arm is easily adjusted LINCOLN O 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 NRO 211 MP electrode e 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 lt 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 On O Off 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 1 Power ON OFF Switch 2 Voltage Control contin uous control that gives full range adjustment of power source output voltage Voltage can be adjusted while welding V Arc Volts 3 Wire Speed Control Controls the wire feed speed from 50 400 in min 1 3
82. uld 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 Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication PL Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 6 a Turn off input power using the disconnect switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Mar 93 SP 100 iii SAFETY FIELDS may be dangerous powered equipment 7 a Turn the engine off before troubleshooting and maintenance N work unless the maintenance work requires it to be running IN FOR ENGINE 3 ELECTRIC AND MAGN
83. wing safety highlights For additional safety information it is strongly recommended that you pur chase a copy of Safety in Welding 8 Cutting ANSI Standard Z49 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is available from the Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE PER FORMED ONLY BY QUALIFIED INDIVIDUALS 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 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
84. y to pro vide 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 CO pressure 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 pres sure and flow regulator for use on argon mixed 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 dia meter 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 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 T
85. zzle replacement LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC QI OU OJO EJE Elia al un gis EJE 3 p P oO VU ojo Return to Section TOC Return to Master TOC OPERATION BG FIGURE B 7 Gun Cable 6 Refer to Figure B 7 Connect work clamp to metal to be welded Work clamp must make good elec trical contact to the workpiece The workpiece must also be grounded as stated in Arc Welding Safety Precautions in the beginning of this manu al 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 spat ter removal LINCOLN CHANGING MACHINE OVER TO FEED OTHER WIRE SIZES The SP 100 is shipped from the factory ready t

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