Lincoln Electric IM795 User's Manual
Contents
1. B 1 General Description ss B 2 Design Features and B 2 Welding Capability sis B 2 LIMITATION ER UT M B 2 Controls and Settings us B 2 Welding Operations reped oet nn ere mi ete et B 3 Wire Ce B 3 Wire Threading E B 4 Making a Weld ME B 5 Process Guidelines ior deir eor Miami int B 5 Chaning Over to Feed Other Wire 5 2 B 6 Welding with GMAW a ee B 6 Welding with 6 Overload Protections near nf B 6 Application 7 2 2 2 1 Section P C 1 Replacement Parts issues C 2 Maintenance 2 2 2 Section D Safety Precautlons co v ated D 1 Routine sn D 1 Gunvand Cable D 2 Configuration of Components in Wire Feeding D 2 Component Replacement Procedures D 2 Troubleshooting cci router Section E Saf2. Turn power off before servicing Desconectar el cable de ali mentaci n de poder de la m quina antes de iniciar cualquier servicio e D branchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine anhalten opere com as tampas removidas Desligue a corrente antes de fazer servico e N o toque as partes el tricas nuas AVFFVA F EAZLRUP ET BRAY FE e HE BIS SHA AGS XA Do not operate with panel open or guards off No operar con panel abierto o guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s e Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen e Mantenha se afastado das partes moventes opere com os paineis abertos ou guardas removidas OSILDI RALE CHkBEELZVCNEUS CHRRIARRARS Ro e 20 Sel Sepe Asal WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATENCAO BIR Chinese Qai oe dul jua Sarin e os uui ARI ge cal ue Aie Ao pha J oes gail e Ads cuts gall l y e ue Ll gt LEIA E COMPREENDA AS INSTRUCOES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PRATICAS DE SEGURANCA DO EMPREGADOR SRM
3. vi SAFETY vi ELECTROMAGNETIC COMPATIBILITY EMC The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place The surrounding area may extend beyond the boundaries of the premises Methods of Reducing Emissions Mains Supply Welding equipment should be connected to the mains supply according to the manufacturer s recommendations If interference occurs it may be necessary to take additional precautions such as filtering of the mains supply Consideration should be given to shielding the supply cable of permanently installed welding equipment in metallic conduit or equivalent Shielding should be electrically continuous throughout its length The shielding should be connected to the welding power source so that good electrical contact is maintained between the conduit and the welding power source enclosure Maintenance of the Welding Equipment The welding equipment should be routinely maintained according to the manufacturer s recommendations All access and service doors and covers should be closed and properly fastened when the welding equipment is in operation The welding equipment should not be modified in any way except for those changes and adjustments covered in the manufacturers instructions In particular the spark gaps of arc striking and stabilizing devices should be adjusted and maintained according to the manufacturer s recommendations Welding C
4. PROBLEMS SYMPTOMS Major physical or electrical damage is evident No wire feed weld output or gas flow when gun trigger is pulled Fan does NOT operate No wire feed weld output or gas flow when gun trigger is pulled Fan operates normally RECOMMENDED COURSE OF ACTION POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS None Contact your local Authorized Field Service Facility Make sure correct voltage is applied to the machine See Installation section Electrical Connections Make certain that power switch is in the ON position Contact your local Lincoln Make sure circuit breaker is reset The thermostat may be tripped due to overheating Let machine cool Weld at lower duty cycle Check for obstructions in air flow Check Gun Trigger connections See Installation section Gun trigger may be faulty 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 SP 170 1 LINCOLN Authorized Field Service Facility E 3 TROUBLESHOOTING ES Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION FEEDING PROBLEMS No wire feed when gun trigger is 1 If the wire drive motor is running pulled Fan runs gas
5. work cables If the electrode cable is on your right side the work cable should also be on your right side AR Connect the work cable to the workpiece as close as possible to the area being welded 1 0 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 Do not work next to welding power source Mar 95 LINCOLN 5 SAFETY ELECTRIC SHOCK can kill 3 a The electrode and work or ground circuits are electrically hot when the welder is on Do not touch these hot parts with your bare skin or wet clothing Wear dry hole free gloves to insulate hands 3 b Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground In addition to the normal safety precautions if welding must be performed under electrically hazardous conditions in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying if there is a high risk of unavoidable or accidental contact with the workpiece or ground use the following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In
6. 1v201 ON IVNOLLVN T 430 Hd GNNOYD 3MOHO 02 E HOLIMS HlNV3 OL INdLNO LS MNIS LV3H OL GALNNOW NEL ees NNO 602 804 SSVH8 902 109 0358 N aal OL GALNNOW Leges ONIONIM 1VLSONWHAHL HS I1VISOWS3HL qaads JYNINYIL GSNNIL YOLOW ZHOS A0EZ WIRING DIAGRAMS ueo 14 S AOVLIOA H9IH GION310S 10 asn ejsui pinoys suosjed payienb juo e Svo ZHOS AOEC syed Ajeoujoeje jou e a Bupiues eJ0jeq Jewod jndui jpeuuoosiq e QHVO8 IOHLNOO jou oq e 1 011 dS F 1 SP 170 I LINCOLN lt NOTES SP 170 LINCOLN NOTES SP 170 LINCOLN WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATENCAO Japanese BIR Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja a e Aislese del trabajo y de la tierra Ne laissez ni la peau ni des v te ments mouill
7. Assembly Liner bushing to be seated tight against brass cable connector FIGURE D 2b Liner trim length for gun Magnum 100L SP 170 LINCOLN 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 require ment Refer to Figure D 2a or D 2b 1 Remove the gas nozzle from the gun threadless slip fit or threaded 2 Remove the existing contact tip from the gun by twisting counter clockwise 3 If the gun is a Magnum 100L Fig D 2b Remove the gas diffuser from the gun tube by unscrewing counter clockwise 4 Lay the gun and cable out straight on a flat surface Loosen the set screw located in the brass connector at the wire feeder end of the cable Pull the liner out of the cable 5 Insert a new untrimmed liner into the con nector end of the cable Be sure the liner bushing is stenciled appropriately for the wire size being used 6 Fully seat the liner bushing into the con nector Tighten the set screw on the brass cable connector 7A For Gun Shown in Fig D 2a With the torch extended straight out cut the liner flush with the end of the diffuser Rotate the gun clockwise until the liner protrudes out the end of the diffuser enough to cut off an additional 2 coils approx 2mm Rotate the handle back to the original positio
8. Code provides standards for amperage handling capability of supply con ductors based on duty cycle of the welding source If there is any question about the installation meeting applicable electrical code requirements consult a qualified electrician SP 170 LINCOLN B 1 OPERATION 1 Read entire operation section before operating the SP 170 I WARNING ELECTRIC SHOCK can kill Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground Always wear dry insulating gloves 3 FUMES AND GASES can be dangerous Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone WELDING SPARKS can cause fire or explosion Keep flammable material away 4 yi Do not weld on closed contain ers 2 ARC RAYS can burn eyes and skin 2 Wear eye ear and body protec tion Observe all safety information throughout this manual GENERAL DESCRIPTION The SP 170 is a complete semiautomatic constant voltage DC portable arc welder Included is a tap switch controlled single phase constant voltage trans former rectifier power source and a wire feeder with welding gun for feeding 025 0 6 mm through 030 0 8 mm solid steel electrode and 035 0 9 mm Innershield9 NR 211 MP It is ideally suited for individuals having access to 230V 50 60 Hz AC input power and want the ease of u
9. FCAW Conversion in this sec tion for installation instructions and MAINTE NANCE section for proper feeding component con figuration and installation K491 045 1 2 mm Innershield amp Welding Kit ncludes a contact tip a gasless nozzle and a 035 045 0 9 1 2 mm cable liner to permit the gun and cable to use 045 1 2 mm diameter flux cored electrode The fitting on the end of the liner is stenciled with the maximum rated wire size 045 1 2 mm Also included is 10 15 4 5 kg spool of 045 1 2 mm Innershield NR 211 MP and a knurled drive roll for 035 0 9mm and 045 1 2mm wire For use with Lincoln Electric amp gun with black trigger The end of the brass fitting on the end of the 035 045 0 9 1 2mm liner is color coded green The 023 030 0 6 0 8mm liner is color coded orange See Innershield FCAW Conversion in this sec tion for installation instructions and MAINTE NANCE section for proper feeding component con figuration and installation din ACCESSORIES C2 MIG GMAW CONVERSION Several changes are needed to convert the unit for operation with the MIG GMAW process The follow ing conversions should be reviewed before welding with GMAW 1 Change the output polarity to DC See Work Cable Installation in Installation section for details 2 Install proper drive roll for the wire size selected See Changing Drive Roll in Maintenance section fo
10. WAWILdO 401 158 31819373 ea 401 S9NILI3S 0315399 5 Rt SP 170 I LINCOLN Z C 1 OPTIONAL ACCESSORIES See Maintenance section for instructions on installing drive roll cable liner contact tip and their proper configuration 1 KP665 045C Drive Roll Optional Knurled drive roll for feeding 035 045 0 9 1 2 mm diameter flux cored electrode 2 K520 Utility Cart Designed to transport the Lincoln family of small welders Has provisions for mounting a single gas cylinder Has front casters and large rear wheels Handle height is easily adjustable Bottom tray provided for tools and accessories Easy assembly required takes less than 15 minutes SP 170 I LINCOLN 5 ACCESSORIES C1 3 K464 035 0 9 mm Innershield amp Welding Kit ncludes a contact tip a gasless nozzle and a 035 045 0 9 1 2 mm cable liner to permit the gun and cable to use 035 0 9 mm diameter flux cored electrode The fitting on the end of the liner is stenciled with the maximum rated wire size 045 1 2 mm Also included is 10 15 4 5 kg spool of 035 0 9 mm Innershield9 NR 211 MP For use with Lincoln Electric amp gun with black trigger The end of the brass fitting on the end of the 035 045 0 9 1 2mm liner is color coded green The 023 030 0 6 0 8mm liner is color coded orange See Innershield
11. flows and make sure that the correct drive machine has correct open circuit rolls are installed in the machine voltage 33 VDC maximum weld Contact your local Lincoln output 2 Check for clogged cable lineror Authorized Field Service Facility contact tip 3 Check for proper size cable liner and contact tip PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION GAS FLOW PROBLEMS Low or no gas flow when gun 1 Check gas supply flow regulator trigger is pulled Wire feed weld and gas hoses Contact your local Lincoln output and fan operate normally Authorized Field Service Facility 2 Check gun connection to machine for obstruction or leaky seals CAUTION If for any reason you do not understand the test procedures or unable to perform the tests repairs safely contact your LOCAL AUTHORIZED LINCOLN ELECTRIC FIELD SERVICE FACILITY for assistance before you proceed SP 170 LINCOLN E TROUBLESHOOTING ET Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION WELDING PROBLEMS Arc is unstable P oor starting Check for correct input voltage to machine See Installation sec tion Electrical Input Connections Check for proper electrode polarity for process Check gun tip for wear or dam age and proper size Replace Contact your local Lincoln Ch
12. 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 6 h Also see item 1 c LINCOLN za CYLINDER may explode isi if damaged 7 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 should be located Away from areas where they may be struck or subjected to physical damage A safe distance from arc welding or cutting operations and any other source of heat sparks or flam
13. 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 c ble 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 souder 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 prot ger contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle partie du corps Un coup d arc peut tre plus s v re qu un coup de soliel donc a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du ray
14. on it For On Line Registration Go to our WEB SITE at www lincolnelectric com Choose Quick Links and then Product Registration Please complete the form and submit your registration Read this Operators Manual completely before attempting to use this equipment Save this manual and keep it handy for quick reference Pay particular attention to the safety instructions we have provided for your protection The level of seriousness to be applied to each is explained below A WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment viii TABLE OF CONTENTS Page INSTANAtION Section A Technical Specifications ci bas eda ck ce eel eee A 1 Identify and Locate Components 2 Select 5 ct ii 3 Output Connections sise A 3 Work Clamp Installation E GRE ee A 3 Work Cable Installation A 3 Gun Installation incerto RM rio ERR Leve A 4 Gas COMMECHON REDE A 4 Input CONnNeCHONS M A 5 Line Cord Connection sis A 6 Section B Safety
15. onnement de l arc et des projections quand on soude ou quand on regarde l arc b Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc c Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les zones l on pique le laitier 6 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 c bles 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 rompen
16. s entrer en contact avec des pi ces sous tension Isolez vous du travail et de la terre e Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem oder feuchter Kleidung Isolieren Sie sich von den Elektroden und dem Erdboden e toque partes el tricas e elec trodos com a pele ou roupa molha da Isole se da pega e terra o REPOR 7 amp nf dchsn zucct E GUB Oa CRM ER Xe uc Bp Weal AMI ous uil el jad oa Y O ay Ast celal AL usu DA dax ule Y Jio moe Keep flammable materials away Mantenga el material combustible fuera del rea de trabajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material e Mantenha inflam veis bem guarda dos e naedoe6 0o08 CIE REA IEEE eis Jo ALD al pis e Ac AI Wear eye ear and body protection Prot jase los ojos los o dos y el cuerpo Prot gez vos yeux vos oreilles et votre corps e Tragen Sie Augen Ohren und K r perschutz Use prote o para a vista ouvido corpo HAUSHERMRELTTF HEBS SOSRSHR ez 119 59 s ESSAI dise ule Lily vues al ad n
17. technician and machine operator and will invalidate your factory warranty For your safety and to avoid Electrical Shock please observe all safety notes and precautions detailed throughout this manual This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMP TOMS This column describes possible symptoms that the machine may exhibit Find the listing that best describes the symptom that the machine is exhibiting Step 2 POSSIBLE CAUSE The second column labeled POSSIBLE CAUSE lists the obvious external possibilities that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause generally it states to contact your local Lincoln Authorized Field Service F acility If you do not understand or are unable to perform the Recommended Course of Action safely contact your local Lincoln Authorized Field Service F acility CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed SP 170 LINCOLN TROUBLESHOOTING Observe Safety Guidelines detailed in the beginning of this manual
18. the pressure should be increased until the wire feeds properly WARNING When inching the welding wire the drive rolls the gun connector block and the gun contact tip are electrically energized relative to work and ground and remain energized for several seconds after the gun trigger is released OPERATION B 4 The Wire Drive Feed Roll can accommodate two wire sizes by flipping the wire drive feed roll over Gun Handle Gas Diffuser Contact Tip Gas FIGURE B 5 7 Refer to Figure B 5 Remove gas nozzle and con tact tip from end of gun 8 Turn the SP 170 1 ON 1 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 Turn the SP 170 OFF 12 Replace contact tip and gas nozzle 13 Refer to Figure B 6 Cut the wire off 3 8 1 2 10 12 mm from the end of the tip The SP 170 is now ready to weld SP 170 LINCOLN B 5 OPERATION B 5 Contact Tip Wire Electrode 3 8 1 2 10 12 mm Contact Tip To Work Distance CTWD FIGURE B 6 Making A Weld 1 See Process Guidelines in this section for selec tion of welding wire and shielding gas and for range of metal thicknesses that can be welded 2 See the Application chart on the inside of the wire fe
19. to Figure B 1b Items 5 6 5 Circuit Breaker Protects machine from damage if maximum output is exceeded Button will extend out when tripped Manual reset SP 170 6 Gun Trigger Activates welding output wire feed and gas solenoid operation Releasing the trigger deactivates welding and simultaneously activates the burnback function so that the welding wire does not stick in the weld puddle FIGURE B 1a Qus ARC VOLTS SP 170 1 FIGURE B 1b LINCOLN B B 3 OPERATION p WELDING OPERATIONS SEQUENCE OF OPERATION Wire Loading Refer to Figures B 2 and B 3 The machine power switch should be turned to the OFF O position before working inside the wire feed enclosure The welder is shipped from the factory ready to feed 8 200 mm diameter spools with 2 2 56 mm maxi mum width These spools fit on a 2 51 mm diameter spindle that has a built in adjustable friction brake to prevent overrun of the spool and excess slack in the wire Note When loading and removing the 8 Spools make sure that the wing nut inside the wire spool spindle hub is turned 90 from the wire spool spindle locking tab If the wing nut is positioned in line with the locking tab the tab cannot be depressed to load or unload the wire spool 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 push
20. LDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding amp Cutting ANSI Standard Z49 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is available from the Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS powered equipment 1 Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 3 SX 1 h To avoid scalding do not remove the radiator pressure cap when the engine is hot 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors ELECTRIC AND 3 MAGNETIC FIELDS may be dangerous 1 c Do not add the fuel near an open flame welding arc or when the engine is running Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporiz ing 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 elimi
21. OBHOX HD OHBRBEE lt K MA CUCRITEOSSXSUEIL HS ET REL BE EE RU Rr de OE D EL FEE fS AXIS SAAD FAIS HHR ele EFSA BEHE TT gl illai Qui al gll Gail guet ag ls 1 A LINCOLN amp World s Leader in Welding and Cutting P roducts 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
22. P 170 1 e Itis important when changing between welding with steel wire and aluminum to exchange feeding components due to the lubricant applied to steel wire Failure to do so may result in contaminated welds when welding aluminum SP 170 I LINCOLN P zia MAINTENANCE BS COMPONENT REPLACEMENT PROCEDURES CHANGING THE CONTACT TIP These instructions pertain to the Lincoln Electric gun The instructions for the Magnum 100L gun are similar except that the gas nozzle is threaded 1 Refer to Figure D 2a or D 2b Remove the gas noz zle from the gun by pulling and rotating it clockwise off the diffuser Threadless slip fit 2 Remove the existing contact tip from the gun by gripping it with pliers and twisting counter clock wise Tip will now slip out of diffuser 3 Insert new tip into diffuser Grip it with pliers push tip into diffuser until it bottoms then twist clockwise to tighten 4 Replace gas nozzle CHANGING DRIVE ROLL The drive roll has two grooves one for 023 025 0 6 mm solid steel electrode and a larger groove for 030 0 8 mm solid and 035 0 9 mm flux cored steel electrode As shipped the drive roll is installed in the 030 035 0 8 0 9mm position If 023 025 0 6mm wire is to be used the drive roll must be reversed as follows 1 Connect the machine to its rated input power per instructions in Installation section 2 Release the spring loaded pressure arm and lift
23. RETURN TO MAIN MENU IM795 SP 1704 For use with machine Code Numbers 10982 10983 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 OPERATOR S MANUAL 150 9001 pum ons X Under a eum ET 3 s T N C OLN e Copyright 2004 Lincoln Global Inc World s Leader in Welding and Cutting Products 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 i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer birth defects or other reproductive harm The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHI
24. SPINDLE Requires no maintenance Do not lubricate shaft SP 170 LINCOLN 5 D 2 MAINTENANCE D 2 GUN AND CABLE MAINTENANCE Gun Cable Cleaning Clean cable liner after using approximately 300 Ibs 136 kg of solid wire or 50 Ibs 23 kg of flux cored wire Remove the cable from the wire feeder and lay it out straight on the floor Remove the contact tip from the gun Using low pressure air gently blow out the cable liner from the gas diffuser end CAUTION Excessive pressure at the start may cause the dirt to form a plug Flex the cable over its entire length and again blow out the cable Repeat this procedure until no further dirt comes out Contact Tips Nozzles and Gun Tubes 1 Dirt can accumulate in the contact tip hole and restrict wire feeding After each spool of wire is used remove the contact tip and clean it by push ing a short piece of wire through the tip repeatedly Use the wire as a reamer to remove dirt that may be adhering to the wall of the hole through the tip 2 Replace worn contact tips as required A variable or hunting arc is a typical symptom of a worn con tact tip To install a new tip choose the correct size contact tip for the electrode being used wire size is stenciled on the side of the contact tip and screw it snugly into the gas diffuser 3 Remove spatter from inside of gas nozzle and from tip after each 10 minutes of arc time or as required 4 Be sure the gas nozzle
25. ables The welding cables should be kept as short as possible and should be positioned close together running at or close to the floor level Equipotential Bonding Bonding of all metallic components in the welding installation and adjacent to it should be considered However metallic components bonded to the work piece will increase the risk that the operator could receive a shock by touching these metallic components and the electrode at the same time The operator should be insulated from all such bonded metallic components Earthing of the Workpiece Where the workpiece is not bonded to earth for electrical safety not connected to earth because of its size and position e g ships hull or building steelwork a connection bonding the workpiece to earth may reduce emissions in some but not all instances Care should be taken to prevent the earthing of the workpiece increasing the risk of injury to users or damage to other electrical equipment Where necessary the connection of the workpiece to earth should be made by a direct connection to the workpiece but in some countries where direct connection is not permitted the bonding should be achieved by suitable capacitance selected according to national regulations Screening and Shielding Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of interference Screening of the entire welding installation may be considered for special applic
26. ation of the laws of the Member States relating to electromagnetic compatibility 89 336 EEC It was manufactured in conformity with a national standard that implements a harmonized standard EN 50 199 Electromagnetic Compatibility EMC Product Standard for Arc Welding Equipment It is for use with other Lincoln Electric equipment It is designed for industrial and professional use Introduction All electrical equipment generates small amounts of electromagnetic emission Electrical emission may be transmitted through power lines or radiated through space similar to a radio transmitter When emissions are received by other equipment electrical interference may result Electrical emissions may affect many kinds of electrical equipment other nearby welding equipment radio and TV reception numerical controlled machines telephone systems computers etc Be aware that interference may result and extra precautions may be required when a welding power source is used in a domestic establishment Installation and Use The user is responsible for installing and using the welding equipment according to the manufacturer s instructions If electromagnetic disturbances are detected then it shall be the responsibility of the user of the welding equipment to resolve the situation with the technical assistance of the manufacturer In some cases this remedial action may be as simple as earthing grounding the welding circuit see Note In other cases it could invo
27. ations 1 Portions of the preceding text are contained in EN50199 Electromagnetic Compatibility EMC product standard for arc welding equipment 3 1 96H L10093 vii vii for selecting a QUALITY product by Lincoln Electric We want you Thank You io take pride in operating this Lincoln Electric Company product eee as much pride as we have in bringing this product to you Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped title passes to the purchaser upon receipt by the carrier Consequently Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received Please record your equipment identification information below for future reference This information can be found on your machine nameplate Product Model Number Code Number or Date Code Serial Number Date Purchased Where Purchased Whenever you request replacement parts or information on this equipment always supply the information you have recorded above The code number is especially important when identifying the correct replacement parts On Line Product Registration Register your machine with Lincoln Electric either via fax or over the Internet For faxing Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed
28. ble for 035 0 9 mm aluminum wire and 023 035 0 6 0 9 mm stainless wire Refer to Table B 1 for Recommended Procedure Settings Aluminum wire requires an Aluminum Welding kit See ACCESSORIES section CAUTION It is important when changing between welding with steel wire and aluminum to exchange feeding components due to the lubricant applied to steel wire Failure to do so may result in contaminated welds when welding aluminum TABLE SP 170 WELDING PROCEDURES Shielding Voltage Wire Speed Welding Wire Gas 22 16 12 1 6 3 16 1 4 035 Dia 0 9mm 100 Argon 7 E9 G 9 4043 Aluminum Wire 16 ga 030 Dia 98 308L Stainless 2 Oxygen Steel Wire CHANGING MACHINE OVER TO FEED OTHER WIRE SIZES The SP 170 is shipped from the factory ready to feed 0 035 0 9 mm Innershield diameter wire To operate the SP 170 with other sizes of wire it maybe neces sary 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 MAINTE NANCE section for specific information on these pro cedures WELDING WITH GMAW MIG Shielding Gas When using the GMAW process obtain and install a gas regulator and hose kit If using 100 CO a CO adapter is required sold separately 1 For open the cylinder very slowly For argon mixed gas open cylinder valve slowly a fracti
29. d dirt drawn into the rear louvers reduces the chance of dirt accumulation that can block air pas sages and cause overheating STACKING SP 170 1 5 cannot be stacked TILTING Each machine must be placed on a secure level sur face either directly or on the recommended cart The machine may topple over if this procedure is not fol lowed LIMITATIONS The SP 170 cannot be used for pipe thawing MIG welding and flux cored arc welding are the only processes supported by the SP 170 The handle can not be used for transport by crane OUTPUT CONNECTIONS Refer to Figure A 2 1 Work Cable Access Hole 2 Gun Cable and Control Lead Access Hole olo 2 D B SP 170 1 3 Connector Block 4 Gun Trigger Lead Connectors 5 Positive and negative output terminals 6 Wire Feed Gearbox Feedplate 7 Cable Hanger 8 Thumbscrew Refer to the Accessories Section for available optional equipment Work Clamp Installation Attach the work clamp per the following Refer to Figure A 3 FIGURE A 3 STRAIN RELIEF HOLE WORK CABLE NUT AND BOLT WORK CLAMP 1 Insert the work cable terminal lug with the larger hole through the strain relief hole in the work clamp as shown above 2 Fasten securely with the bolt and nut provided FIGURE A 2 SP 170 LINCOLN id INSTALLATION A 4 Work Cable Installation Refer to Figure A 2 1 Open the wir
30. e 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 Precautions for Safe Handling of Compressed Gases in Oylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 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 95 SAFETY iv PR CAUTIONS DE S RET Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes 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
31. e 4 aun y READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER S SAFETY PRACTICES SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER STELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res piraci n e Mantenga la cabeza fuera de los humos Utilice ventilaci n o aspiraci n para gases e Gardez la t te l cart des fum es Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail e Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie f r gute Be und Entliiftung des Arbeitsplatzes e Mantenha seu rosto da fumaca Use ventilac o e exhaust o para remover fumo da zona respirat ria eti ADP55UtRc5cuc 9 fsUPBHEILTASESUCFEU EUR fE 24752 else e SUAS MAS sis PARAH 7
32. e feed section door on the right side of the SP 170 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 3 Route the cable under the feedplate 6 and in front of the Wire Feed Motor 4 For Innershield Only Refer to Figure A 2 As delivered the machine is connected for negative electrode polarity This is the appropriate configu ration for the Innershield process To complete installation use the provided wing nut to connect the work cable s terminal lug to the positive out put terminal 4 located above the Wire Feed Gearbox 5 Make sure that both wing nuts are tight 5 For GMAW Only Refer to Figure A 4 To wire for positive polarity required for the GMAW process connect the short cable attached to the connector block 1 to the positive output terminal 4 and the work cable 3 to the negative terminal 2 FIGURE A 4 GUN INSTALLATION As shipped from the factory the SP 170 gun is ready to feed 035 Innershield If other wire is to be used change the contact tip to the appropriate size Connecting Gun Cable to the SP 170 1 As shipped the gun is fitted with a liner suitable for all wire diameters from 025 035 0 6mm 9mm and has an 035 0 9mm contact tip installed 1 Refer to Figures A 2 and A 4 Unplug the machine or turn power switch to the OFF O position 2 Pass the
33. eck for proper gas and flow Authorized Field Service Facility rate for process For MIG only Check work cable for loose or faulty connections Check gun for damage or breaks Check for proper drive roll orien tation and alignment Check liner for proper size 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 SP 170 I LINCOLN Sjeued Jo uo paysed si e 104 dyads Aq parao seulu2euu 10 jou 3 20 SI Weep SIUL 3 LON F 1 quivog 30 LNANOdNO NAHM SONANOAS gt ONINHO9 MOQ GNNOdWOD 268211 79 AYINDAY SNOLLO3NNOO Q3 L108 uvas LN3NOdINOO 8 2LIHM M i 1ANVd H31N39 JHL OL ASOT l 1598010 SI HOIHM ANISLVAH YOLONGNOD 3009 318VO NNO 2919 43 SIOANAS IVOIH LO3 T3 No ev eee MNISLVAH ACIS LNO AHL NO 33v Sq ea ra HOLIMS YOLOATAS 6 LINDYID anis 12119919 9 d l8VOllddv dsvo
34. ed 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 Load an 8 200 mm diameter spool on the wire spool spindle shown in Figure B 2 To use 4 100 mm diameter spools the 2 50 mm diameter spindle must be removed See Figure B 3 Remove the wing nut and spacer at the end of the shaft and remove the outside plastic wire spool spin dle The spindle can be stored in the wire feed com partment A 4 100 mm diameter spool is mounted directly on the 5 8 16 mm diameter shaft and held in place with the previously removed hardware Also make certain the start end of the wire which may pro trude through the side of the spool does not contact any metallic case parts Wire Spindle Shaft lal i and Spacer To Wire Drive FIGURE B 3 Friction Brake Adjustment With wire spool installed on the spindle shaft and the wing nut loose turn the spool by hand while slowly tightening the wing nut until a light drag is felt Tighten the wing nut an additional 1 4 turn Note When properly adjusted the brake should pro vide only enough drag to prevent overrun of the spool and excess slack in the wire Too much drag may result in wire feeding problems and may cause pre mature wear of wire drive system components SP 170 LINCOLN 5 B 4 Refer to Figure B 4 1 Release the Spring Loaded Pressure Arm 1 rotate the Idle Roll Arm 2 away fro
35. ed compartment door for information on setting the SP 170 I controls Refer to Table for alu minum and stainless wire 3 Set the Voltage V and Wire Speed olo con trols to the settings suggested for the welding wire and base metal thickness being used refer to Applications chart on the inside of the wire drive compartment door 4 Check that the polarity is correct for the welding wire being used and that the gas supply if required is turned on 5 When using Innershield electrode remove the gas nozzle and install a 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 nozzle replacement 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 GUN CABLE WORKPIECE WORK CLAMP FIGURE B 7 10 When no more welding is to be done close valve on gas oylinder if used momentarily operate
36. el that have read and under stood the SP 170 Operating Manual should install and operate this equipment Machine must be plugged into a receptacle which is grounded per any national local or other applicable electrical codes SP 170 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 170 1 from its carton and remove all packing material around the SP 170 Remove the following loose items from the carton see Figure A 1 1 SP 170 2 Gun and cable assembly 3 Literature and miscellaneous including a This operating manual b Contact tips SP 170 1 2 025 0 6mm for solid wire 2 030 0 8mm for solid wire 1 035 0 9mm for cored wire c 5 64 2 0 mm Hex key wrench for removal of drive roll 10 ft 3 0 m work cable Work clamp 4 5 6 14 0 ft 4 3 m 19 4 8 mm dia gas hose 7 2 Hose clamps 8 Gas nozzle The gun is ready to feed 035 0 9mm diameter SP 170 LINCOLN OPERATORS MANUAL FIGURE gt 4 A 3 INSTALLATION Aa SELECT SUITABLE LOCATION The SP 170 I has an IP21S rating Locate the welder in a dry location where there is free circulation of clean air into the louvers in the back and out the front of the unit A location that minimizes the amount of smoke an
37. er to the ACCESSORIES section SP 170 1 LINCOLN 5 A 5 INSTALLATION n WARNING CYLINDER may explode if dam aged Keep cylinder upright and chained to support gt Keep cylinder away from areas ON where it may be damaged Never lift welder with cylinder attached Never allow welding electrode to touch cylinder Keep cylinder away from welding or other live electrical circuits WARNING BUILDUP OF SHIELDING GAS may 2 harm health or kill Shut off shielding gas supply when not in use SEE AMERICAN NATIONAL STANDARD Z 49 1 SAFETY IN WELDING AND CUTTING PUB LISHED BY THE AMERICAN WELDING SOCIETY 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 ground Refer to Figure A 5 Flow Regulator Cylinder Valve Gas Hose FIGURE A 5 2 With the cylinder securely installed remove the cylinder cap Stand to one side away from the out let and open the cylinder valve very slightly for an instant This blows away any dust or dirt which may have accumulated in the valve outlet WARNING BE SURE TO KEEP YOUR FACE AWAY FROM THE VALVE OUTLET WHEN CRACKING THE VALVE Never stand directly in front of or behind the flow regulator when opening the cylinder valve Always stand to one side 3 Attach the flow regulator to the cylinder valve and tighten the
38. ety Precautions si E 1 How to Use Troubleshooting Guide E 1 Troubleshooting 2 Wiring 5 41 1 rene nimm nar Section F SP 170 Wiring Diagramme F 1 SP 170 1 m P467 Series Wire Drive Assembly P189 D LINCOLN 5 viii di INSTALLATION Ani TECHNICAL SPECIFICATIONS SP 170 1 INPUT SINGLE PHASE ONLY Standard Voltage Frequency Input Current 230V 50 60Hz 20 Amps Rated Output RATED OUTPUT Duty Cycle Amps Volts at Rated Amperes 2596 125 20 25 6096 85 18 25 10096 70 17 50 OUTPUT Welding Current Range Maximum Open Circuit Voltage Wire Speed Range Rated DC Output 30 175 amps 33 50 400IPM 1 3 10 2m min RECOMMENDED INPUT CABLE AND FUSE SIZES Fuse or Output Mode Input Voltage Breaker Size Power Cord RATED 230V 50 60Hz 30 Super Lag 20 16 Amp 230V Two Prong International Cord Set Supplied PHYSICAL DIMENSIONS The SP170 is designed for industrial and professional use in accordance with the standard EN 60974 1 IEC 974 1 SP 170 I LINCOLN di INSTALLATION A 2 Read entire installation section before starting installation SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill Only qualified personnel should perform this installation Only personn
39. gun trigger to release gas pressure and turn off the SP 170 1 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 PROCESS GUIDELINES The SP 170 can be used for welding mild steel stainless steel and aluminum using the MIG process and also for welding mild steel with the gasless self shielded Innershield process FCAW The recommended gases and electrodes for MIG GMAW are welding grade gas an blended gas 75 to 80 argon and 25 to 20 CO and 025 0 6 mm and 030 0 8mm diameter Lincoln L 56 mild steel welding wire supplied on 12 1 2 Ib 5 7 kg spools The blended gas is recom mended for welding on heavier steel 14 gauge 2 0 mm for example The recommended electrode for the self shielded process is Lincoln Innershield NR 211 MP on 10 Ib 4 5 kg spools This electrode is available as 035 0 9 mm and 045 1 2 mm NR 211 MP for all posi tion welding of 18 gauge 1 2 mm through 5 16 8 0 mm steel Thickness of 1 4 6 4 mm and 5 16 7 9 mm require multiple passes both wire sizes can also be used for the welding of galvanized coated sheet metal SP 170 LINCOLN 5 B 6 OPERATION B 6 The SP 170 is suita
40. hemselves to the arc rays or to hot spatter or metal 23 FUMES AND GASES can be dangerous 5 a Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and below Threshold Limit Values TLV using local exhaust or mechanical ventilation In confined spaces or in some circumstances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel 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 prod ucts 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 material safety data sheet MSDS and follow your empl
41. ing gas is required when used with Lincoln Innershield 035 0 9 mm NR 211 MP electrode Spindle accommodates both 8 in 200 mm diame ter and 4 in 100 mm diameter spools of wire WELDING CAPABILITY The SP 170 is rated at 125 amps 20 25 volts at 25 duty cycle on a ten minute basis It is capable of higher output currents at lower duty cycles Actual welding outputs will range between 30 and 175 amps for the recommended processes LIMITATIONS Arc Gouging cannot be performed with the SP 170 The SP 170 is not recommended for pipe thawing or TIG welding CONTROLS AND SETTINGS Refer to Figures B 1a Items 1 thru 4 1 Power ON OFF Switch When the power is on the fan motor will run and air will be exhaust ed out the louvers in the front of the machine The welding out put and wire feeder remain off until the gun trigger is pressed 2 Voltage Control A 5 position tap selector switch gives full range adjustment of power source output voltage Do not switch while welding ON OFF 3 Wire Speed Control Controls ARC VOLTS the wire feed speed from 50 400 in min 1 3 10 2 m min The control can be preset on the dial to the setting specified on the SP 170 1 Application WIRE SPEE Chart located on the inside of the wire feed section door E D 4 Temperature Light Indicates thermostat has cut the output The fan will be running Thermostat resets automatical ly Refer
42. insulated terminals of the gun trigger con trol leads one at a time through the Gun Cable and Control Lead Access Slot A 2 2 in the case front The leads are to be routed up the inside of the case front behind the gas line 3 Insert the connector on the gun conductor cable through the Gun Cable Access Hole A 2 2 in the SP 170 I case front Make sure the connector is all the way in the brass connector block to obtain proper gas flow If the gun connector will not fully insert unscrew the thumbscrew on the connector block a few turns Rotate the connector so control leads are on the underside and tighten the Thumbscrew on the connector block 4 Connect the gun trigger control lead terminals to the two insulated 1 4 6 4 mm tab terminal con nector bushings located above the Gun Trigger Connection decal in the wire feed section A 4 Either lead can go to either connector CAUTION If the gun trigger switch being used is other than that supplied the switch must be a normally open momentary switch The terminals of the switch must be insulated from the welding circuit Malfunction of the SP 170 I may result if this switch shorts to the SP 170 welding output cir cuit or is common to any electrical circuit other than the SP 170 I trigger circuit GAS CONNECTION When using the MIG process a cylinder of shielding gas must be obtained See Table B 1 Additionally a flow regulator is required For more information ref
43. is fully screwed onto the diffuser for gas shielded processes For the Innershield process the gasless nozzle should be screwed onto the diffuser 5 To remove gun tube from gun remove gas nozzle or gasless nozzle and remove diffuser from gun tube Remove the four screws from the gun handle and separate the handle halves For L8311 5 gun and cable handle half says magnum 100L Remove both collars from each end of the gun handle and separate the handle halves Loosen the locking nut holding the gun tube in place against the gun end cable connector Unscrew gun tube from cable connector To install gun tube screw the locking nut on the gun tube as far as possible Then screw the gun tube into the cable connector until it bottoms Then unscrew no more than one turn the gun tube until its axis is perpen dicular to the flat sides of the cable connector and pointed in the direction of the trigger Tighten the locking nut so as to maintain the proper relation ship between the gun tube and the cable connec tor Replace the gun handle trigger and diffuser Replace the gas nozzle or gasless nozzle CONFIGURATION OF COMPONENTS IN WIRE FEEDING SYSTEM ns Contact Tip Cable Liner Drive Roll Components shipped with 035 0 9mm 025 035 0 6 9mm KP 665 035 2 Smooth grooves Small 025 0 6mm Large 030 0 8mm If other size wire feeding is desired use the additional Contact Tips shipped loose with your S
44. lve constructing an electromagnetic screen enclosing the power source and the work complete with associated input filters In all cases electromagnetic disturbances must be reduced to the point where they are no longer troublesome Note The welding circuit may or may not be earthed for safety reasons according to national codes Changing the earthing arrangements should only be authorized by a person who is competent to assess whether the changes will increase the risk of injury e g by allowing parallel welding current return paths which may damage the earth circuits of other equipment Assessment of Area Before installing welding equipment the user shall make an assessment of potential electromagnetic problems in the surrounding area The following shall be taken into account a other supply cables control cables signaling and telephone cables above below and adjacent to the welding equipment radio and television transmitters and receivers computer and other control equipment safety critical equipment e g guarding of industrial equipment the health of the people around e g the use of pacemakers and hearing aids equipment used for calibration or measurement the immunity of other equipment in the environment The user shall ensure that other equipment being used in the environment is compatible This may require additional protection measures the time of day that welding or other activities are to be carried out L10093
45. m the Wire Feed Drive Roll 3 Ensure that the groove size in the feeding position on the drive roll match es the wire size being used This occurs when the desired groove is located on the inside toward the feedplate See Maintenance section for further information 2 Carefully detach the end of the wire from the spool To prevent the spool from unwinding main tain tension on 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 ingoing guide tube 4 over the drive roll 3 and into the outgoing guide tube 5 Check the alignment of the wire over the drive roll groove and adjust if necessary If alignment adjustment is necessary use the allen wrench provided to loosen the drive roll move it to the desired position and then retighten 5 Close the idle roll arm 2 and latch the spring loaded pressure arm 1 in place Rotate the spool counterclockwise if required to take up extra slack in the wire 6 The idle roll pressure adjustment wing nut is factory set to approximately five full turns from where the wing nut first engages the threads of the pressure arm 1 If feeding problems occur because the wire is flatened excessively turn the pressure adjust ment 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
46. n 7B ForGun Shown in Fig D 2b With the gas nozzle and diffuser removed from the gun tube be sure the cable is straight and then trim the liner to the length shown in the Figure D 2b Remove any burrs from the end of the liner Screw the gas diffuser onto the end of the gun tube and securely tighten 8 Replace the contacttip and nozzle p MAINTENANCE D 5 GUN HANDLE PARTS Lincoln Electric GUN HANDLE PARTS Magnum 100L The gun handle consists of two halves that are held The gun handle consists of two halves that are held together with four screws To open up the gun handle together with a collar on each end To open up the assembly remove the four screws and pry down the handle turn the collars approximately 60 degrees trigger handle half with a screwdriver See Figure D 3 counter clockwise until the collar reaches a stop Then FIGURE D 3 pull the collar off the gun handle If the collars are diffi cult to turn position the gun handle against a corner place a screwdriver against the tab on the collar and give the screwdriver a sharp blow to turn the collar past internal locking rib See Figure D 4 Screwdriver Wess Cable FIGURE D 4 SP 170 LINCOLN 5 E 1 TROUBLESHOOTING 1 HOW USE TROUBLESHOOTING GUIDE A 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
47. nated 2 a Electric current flowing through any conductor causes localized Electric and Magnetic Fields EMF Welding current creates EMF fields around welding cables and welding machines EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding 1 d Keep all equipment safety guards covers and devices in position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing equipment 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 1 e In some cases it may be necessary to remove safety MS aM minimize exposure to EMF fields from the welding circuit 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 2 d 1 Route the electrode and work cables together Secure them with tape when possible 2 d 2 Never coil the electrode lead around your body 1 f Do not put your hands near the engine fan Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running 2 d 3 Do not place your body between the electrode and
48. on of a turn When the cylinder pressure gauge pointer stops moving open the valve fully 2 If using a regulator with an adjustable flow meter close the gun trigger and adjust the flow to give 15 20 cubic ft per hour 7 10 l min use 20 25 CFH 10 12 l min when welding out of position or in a drafty location 3 Keep the cylinder valve closed except when using the SP 170 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 170 1 WELDING WITH FCAW Innershield When using the FCAW process the correct drive roll and electrode polarity must be used See Work Cable Installation in INSTALLATION section for changing the polarity Innershield welding kits K549 1 for 035 and K549 2 for 045 are also available OVERLOAD PROTECTION Output Overload The SP 170 is equipped with a circuit breaker which protects the machine from damage if a severe over load occurs The circuit breaker button will extend out when tripped The circuit breaker must be manually reset Thermal Protection The SP 170 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 reason able operating temperature This is an automatic func tion of the SP 170 and does not require user inter vention The fan continues
49. oyer s safety practices MSDS forms are available from your welding distributor or from the manufacturer 5 e Also see item 1 b Mar 95 SAFETY 7 WELDING SPARKS gt cause fire or explosion 6 a Remove fire hazards from the welding area If this is not possible cover them to prevent the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available 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 Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent
50. r details 3 Install the proper gun liner and tip for the wire size selected See Component Replacement in Maintenance section for details 4 Remove gasless nozzle if installed and install gas nozzle 5 Load wire into machine and thread into gun and cable per Welding Wire Loading section REPLACEMENT PARTS Complete Gun and Cable Assembly Code 10983 L11951 Complete Gun and Cable Assembly Code 10982 L8311 5 SP 170 LINCOLN 5 D 1 MAINTENANCE ES MAINTENANCE SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill oe Disconnect input power by removing plug from receptacle before working inside 170 1 Use only grounded receptacle Do not touch electrically hot parts inside SP 170 Have qualified personnel do the mainte nance and trouble shooting work ROUTINE MAINTENANCE POWER SOURCE COMPARTMENT In extremely dusty locations dirt may clog the air passages causing the welder to run hot Blow dirt out of the welder with low pressure air at regular intervals to eliminate excessive dirt and dust build up on interval parts WIRE FEED COMPARTMENT 1 When necessary vacuum accumulated dirt from gearbox and wire feed section 2 Occasionally inspect the incoming guide tube and clean inside diameter if necessary 3 Motor and gearbox have lifetime lubrication and require no maintenance FAN MOTOR Has lifetime lubrication requires no maintenance WIRE REEL
51. se quality and dependability of both gas metal arc welding or GMAW also known as MIG welding and the Innershield9 process self shielded flux cored or FCAW A convenient chart is mounted inside the wire feed section door for setting welding procedures for 24 gauge 60 mm through 5 16 8 0 mm mild steel The machine is rugged and reliable and is designed for dependable service and long life RECOMMENDED PROCESSES The SP 170 can be used for welding mild steel stainless steels and aluminum using the GMAW sin gle pass process MIG which requires a supply of shielding gas or it can be used for the self shielded Innershield process FCAW OPERATIONAL FEATURES AND CONTROLS The SP 170 1 has the following controls as standard Power ON OFF Switch Voltage Control Wire Speed Control Trigger Switch and a Circuit Breaker DESIGN FEATURES AND ADVANTAGES Cold electrode until gun trigger is pressed for an added measure of safety Overload protection incorporates both a thermo stat and a circuit breaker Quality wire drive with electronic overload protec tion Quick Release idle roll pressure arm is easily adjusted Reversible dual groove drive roll shipped ready to feed 030 0 8 mm diameter solid wire or 035 diameter flux cored wire The drive roll is easily reversed to feed 025 0 6 mm diameter solid wire SP 170 I LINCOLN B 2 OPERATION Ee No external shield
52. 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 6 c and 8 LINCOLN ARC RAYS can burn 4 a Use a shield with the proper filter and cover 22 plates to protect your eyes from sparks the rays of the arc when welding or observing open arc welding Headshield and filter lens should conform to ANSI Z87 standards 4 b Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose t
53. t 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 fortement toxique 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 PR CAUTIONS DE S RET POUR LES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR 1 Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif 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 debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place Mar 93 LINCOLN SAFETY ELECTROMAGNETIC COMPATIBILITY EMC Conformance Products displaying the CE mark are in conformity with European Community Council Directive of 3 May 1989 on the approxim
54. the idle roll arm away from the drive roll 3 Turn the power switch to ON marked 4 4 Set the wire speed to minimum and jog the drive unit with the trigger switch until the drive roll set screw is facing up CAUTION When inching the welding wire the drive rolls gun connector block and gun contact tip are energized relative to work and ground and remain energized for several seconds after the gun trig ger is released 5 Turn the power switch to OFF marked O 6 Loosen the drive roll set screw with the 5 64 2 0 mm hex wrench supplied 7 Remove the drive roll flip over and reinstall with the 023 025 0 6mm groove the smaller groove closest to the gearbox 8 Push a length of straightened welding wire through the wire feeder guide tubes and adjust the position of the drive roll so that the groove is centered on the wire Make certain the set screw is located on the flat portion of the shaft and tighten FIGURE D 1 SP 170 LINCOLN 5 p MAINTENANCE D 4 Gas Contact Tip Allen Brass Cable Gas Nozzle or Gasless Nozzle Head Screw Connector Slip F it Liner Assembly Liner bushing to be seated tight against brass cable connector FIGURE D 2a Liner trim length for gun Lincoln Electric 1 1 4 31 8 mm Liner Trim Length Gas mse Contact Tip Head Screw Connector Gas Nozzle or Gasless 4 Threaded Allen Brass Cable N Liner
55. to run during cooling Electronic Wire Drive Motor Protection The SP 170 1 has built in protection for wire drive motor overload SP 170 LINCOLN APPLICATION CHART B B 7 F0ZLdS 2220 ayy Jo Ayijiqisuodsas ayy 51 Ajquiasse e jo Ajiqeaaijes 3y ed siu HurAjdde ayy pue Ajqwasse asnesag enue 0 ayy Ul SNOLLQV23Hd 134 5 9HV UO 101995 y pue 14 uo sBuruew ay puejsjapun pue aans ag Jenueui aas pajjejsur aq snw diy ayeudoidde pue 20 platysiauuy 221 Spo papnjoui cpi pue 10 pioa aaup paunuy jeuondo 03400 11 340049 340049 531549 30089 30049 43H11 43H11 LEc amp HN QT3IHSH3NNI aM 13IHSH3NNI JHM 14315 01105 13318 01105 21 epo vig 6 0 ceo Vig 90 020 vig 970 620 d LL2 UN via uni cvy c 53189 wid 6 0 ui ceo 202 02 92 08 54 92 10 029 13315 01105 8 0 ur geo 202 02 52 uofuy 08 92 522 10 022 13315 01105 vig 90 599 8 l ONIGTIIHS JHM ONIGTSM Em IWANVW 33S SONILL3S 133158 SSTINIVLS ONIGT3M
56. union nut securely with a wrench NOTE If connecting to 100 CO cylinder make certain the plastic washer is seated in the fitting that attaches to the cylinder 4 Refer to Figure A 6 Attach one end of inlet gas hose to the outlet fitting of the flow regulator and tighten the gas line hose clamp Connect the other end to the SP 170 1 Gas Solenoid Inlet nipple Make certain the gas hose is not kinked or twisted Tighten the gas line hose clamp INPUT CONNECTIONS Refer to Figure A 6 GAS SOLENOID INLET NIPPLE POWER INPUT CABLE FIGURE A 6 SP 170 LINCOLN 5 A INSTALLATION Line Cord Connection A 3 conductor international cordset with a 16 amp 230 volt two prong plug is factory installed Connect this plug to a mating grounded receptacle which is connected to an appropriate power supply per any applicable local codes Grounding Type 75 C Wire Wire in Conduit Copper Input Copper Cond Cond Voltage AWG Size AWG Size 230 5060 8 10 40 CONNECT TO A SYSTEM GROUNDING WIRE SEE THE UNITED STATES NATIONAL ELECTRICAL CODE AND OR LOCAL CODES FOR OTHER DETAILS AND MEANS FOR PROPER GROUNDING CONNECT TO HOT WIRES OF A THREE WIRE SINGLE PHASE SYSTEM OR TO ONE PHASE OF A TWO OR THREE PHASE SYSTEM WARNING This welding machine must be connected to a power source in accordance with applicable elec trical codes The National Electrical
Download Pdf Manuals
Related Search