Lincoln Electric IDEALARC SP-200 User's Manual
Contents
1. Adjust the wire speed using the control on the wire feeder Recommended wire speeds are given in the procedures TRAVEL SPEED Move the gun along the joint at a travel speed which keeps the arc just at the front edge of the weld puddle and produces the desired weld size Always maintain a uniform travel speed DRAG ANGLE Tilt the gun in the direction of travel about the same as required in stick electrode welding If slag tends to run ahead of the arc increase the drag angle slightly ELECTRODE ANGLE TO JOINT Point the electrode into the joint The wire angle to the joint should be about 45 for fillet welds MIG WELDING THE SP 200 15 AN EXCELLENT MACHINE FOR MIG WELDING WITH MILD STEEL STAINLESS STEEL ALUMINUM OR BRONZE FOR GALVANIZED STEEL FILLER WIRE AS WELL AS FOR AUTO STITCH AND AUTO SPOT WELDING THE MACHINE SETTING GUIDELINES SUPPLIED ABOVE SHOULD BE SUPPLEMENTED WITH APPROPRIATE MIG WELDING INFORMATION TO ENSURE THE CORRECT USE OF EQUIPMENT AND PROCEDURES THE LINCOLN ELECTRIC COMPANY DOES NOT SUPPLY PROCEDURES FOR ANY OF THE MIG PROCESSES HOW TO ORDER REPLACEMENT PARTS tion item number quantitv required and the number of the list used to get this information Any items indented in the Parts Name column are included in the assembly under which they are listed The indented items may be ordered separately If the entire assembly is needed do not order the indented parts2. Order parts only from Lincoln offices or from the Authorized Field Service Shops listed in the Service Directory Give the following information a From the nameplate machine model code and serial numbers b From this manual complete part name and descrip Need Welding Training The Lincoln Electric Company operates the oldest and most respected Arc Welding School in the United States at its corporate headquarters in Cleveland Ohio Over 60 000 students have graduated Tuition is low and the training is hands on For details write Lincoln Welding School 22801 St Clair Ave Cleveland Ohio 44117 1199 f and ask for bulletin ED 80 or call 216 481 8100 and ask for the Welding School Registrar THE LINCOLN ELECTRIC COMPANY World s Largest Manufacturer of Arc Welding Products Manufacturer of Industrial Motors Cleveland Ohio 44117 1199 U S A Sydney 2211 Australia Rouen 76120 France 5 4 Litho in U S A Sales and Service Worldwide Toronto M4G 2B9 Canada LINCOLN ELECTRIC Eff April 8
3. EEE _ fi DONT 101092 an NAD ba A 7 e 5 BIE 22YA FE UYOJ 2 2 0 2 YOLIVANOD N TINA ANNIA TOJNT 30020122 TI 0055321105 I TASA 434388 LIMIT SOLOW ee SS lt ai JUM FIM ASSL wo vite NOD OL x AYY Seal rv Lod YIT BUM M 0120509 Jd ER A vor NOEL 3013 fi Mp FAO za 138 U MOOI YT vor tall NS 5 ar La Wowie 4 MZ wale 98 73903 30103 OS 43 MOS TOZ bi MOS v z IOHLNUJ A 23 2 A NINO UT ISA YO ba an a mir Zits je 012 ITWLL TA 00531 SP 200 WIRING DIAGRAM SP 200 TIMER KIT INSTALLATION INSTRUCTJONS FOR K 341 STI KIT L Turn the Power Switch to CFF Open side door to wire feed section Observe jumper plug attached to six cavity connector in upper front corner of wire feed section 2 Detach jumper plug from six cavity connector Store plug on inside of timer kit case bottom 3 Remove hex nut and lockwasher from the 10 24 screw going through the nameplate on the door side of the front panel Remove hole plug from nameplate at Spot Seam Stitch switch hole L Remove the sheet metal screw from inner case panel 5 Connect six cavity connector to six cavity receptacle on P C Board of Timer Kit When making this connection be sure the connector is we
4. IDEALARC 52 0 SINGLE PHASE CONSTANT VOLTAGE DC ARC WELDING POWER SOURCE AND SEMIAUTOMATIC WIRE FEEDER This manual covers equipment which is obsolete and no longer in production bv The Lincoln Electric Co Specifications and availability of optional features may have changed SAFETY DEPENDS ON YOU Lincoln are welding equipment is designed and built with safety in mind However your overall safety can be increased by proper installation and thoughtful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS OPERAT ING MANUAL AND THE ARC WELDING SAFETY PRECAUTIONS ON THE INSIDE FRONT COVER And most importantly think before you act and be careful DAMAGE CLAIMS When this equipment is shipped title passes to the pur chaser upon receipt by the carrier Consequently claims for material damaged in shipment must be made by the pur chaser against the transportation company at the time the shipment is received a ARC WELDING SAFETY PRECAUTIONS WARNING PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH 0 FUMES AND GASES can be dangerous 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 on galvanized le
5. 5 PART NAME DESCRIPTION REQ D 1 Center Panel Assembly Includes Mag Amp Assembly Lift Bail Lift Bail Seal Fan Support Panel Assembly See P 139 D Front Panel Assembly See P 139 E Choke Coil Selector Switch Selector Switch Handle Handle Screw Capacitor Assembly Includes Capacitors Capacitor Jumper Capacitor Mounting Bracket Capacitor Insulation Base 8 Transformer Assembly includes Specify Single or Dual Voltage Base Transformer Assembly Specify voltage 1 Reconnect Pane Assembly See P 139 G 12 Case Back 13 Splash Shield Assembly 14 Case Door amp Hinge Assembly 15 Wire Feed Unit See P 139 H 16 Electrode Lead 17 Thermostat 18 Cable Hanger 19 Grommet Strip 21 Rectifier Assembly Includes Positive Diode Negative Diode Suppressor Assembly Rectifier Mtg Bracket 0 1 e ltems Not Illustrated Left Case Side f Access Door Left Case Side oo Ground Clamp Ground Cable Door Strike Lincoln Decal Mounts on Door Drive Roll 8 Guide Tube Kits See P 139 J Auxiliary Transformer Timer By Pass Jumper Plug SP 200 Procedure Sheet Mounts Inside Case Door Optional Equipment 10 to 25 Pound Spool Spindle Kit Gas Solenoid Kit Standard On AB Models Timer Kit Standard On AB Models See P 139 F 25 Foot Wire Drive Extension Cable 25 Or 50 Foot input Cables 8 6 See P 139 G Undercarriage With
6. mechanism are always hot 0 werk and ground and re main hot several seconds after the gun trigger is re leased E Wire Reel Brake 30 50 and 60 Pound Reel Mounting 1 The mount for standard 30 50 and 60 pound elec trode coils includes a two position brake assembly Generally the brake should be at the inner position nearest to the wire reel shaft for wire feed speeds below 400 in min If excessive wire reel overrun is encountered move the brake to the outer position 2 To adjust the brake position remove the wire reel Pull the cotter pin that holds the brake shoe to the arm move the shoe and replace the cotter pin Do not bend the cotter pin it is held in place by a friction fit F Wire Reel Loading Readi Reels and Spools To mount a 30 Ib Readi Reel package using the molded plastic K 363 P type adapter 1 Rotate the spindle and adapter so the retaining spring is at the 12 o clock position 2 Position the Readi Reel so that it will rotate in a clockwise direction when feeding wire is to be de reeled from top of coil 3 Set one of the Readi Reel inside cage wires on the slot in the retaining spring tab 4 Lower the Readi Reel to depress the retaining spring and align the other inside cage wire with the grooves in the molded adapter 5 Slide cage all the way onto the adapter until the retaining spring pops up fully To remove the Readi Reel from Adapter depress re t
7. 033032 24 LSQW DMa FQOZ AS NV 25210101140 SP 200 TIMER KIT WIRING DIAGRAM SP 200 DIMENSION PRINT TIG 250 250 5 05 DIK WHEEL 19 00 Dik WHEEL L 6480 3 8 85C 3 32 33 34 LINCOLN INNERSHIELD AND WIRE WELDING WITH YOUR sp 200 TE This chart is a ready reference for using the Idealarc SP 200 Refer to Lincoln bulletins and instruction manuals for details Be sure to read and understand the section on ARC WELDING SAFETY PRECAUTIONS Because design fabrication assembly and welding variables affect the results obtained in applying this type of information the serviceability of a product or assembly is the responsibility of the builder user INNERSHIELD WELDING Suggested settings Adjustments may have to be made to achieve optimum results under various conditions See Welding Procedures and Problem Solving sections of N675 and N677 AUTO STITCH AND AUTO SPOT WELDING Suggested settings Adjustments may have to be made to achieve optimum results under various conditions Also read section below on MIG Welding Volts Approx Spot Time for Material Elec Neg Current Coarse Voltage Fine Voltage Type Thickness DC Amps Setting Setting Wire Speed in min Material Thickness Application Electrode Size Type amp Stickout 18 Ga 048 2 5 16 i A ET ETE 5 METAL SHRINKI
8. 115V AC present Energizes control Remove dvnamic at 7 32A circuit and wire brake from wire Energizes primary of welding feed motor armature feed motor transformer Energizes auxiliary equipment if Voltmeter reads OCV connected to 7 32A gas solenoid Electrode is hot to work Wire feed motor starts feed wire Arc starts Welding Release gun trigger Opens 302 to 303 circuit De energizes Stitch Timer Spot Timer Burnback Kit De energizes ICR ifused 7 Closes 207 t Opens 531 to7 circuit Opens 207 circuit SAI chouit 0 De energizes line contactor 2CR De energizes De energizes control Apply dynamic auxiliary circuit and wire brake circuit De energizes welding transformer equipment feed motor armature to motor connected Voltmeter decays to zero to 7 32A Electrode cold to ground Wire feed motor stops Arc stops Unit ready for next weld 16 GENERAL ASSEMBLV P 139 C SEE SKETCH 2 SEE SKETCH 1 8 1 Te 1 TC N 5 TRANS FORMER 56446 o gt FLEX LEAD RECTIFIER MOUNTING DETAIL CABLE IE TT OFAN SUPPORT mwan 5 5 SEE DETAIL TEST PER E 2505 PANEL SKETCH 3 SEE RECORDS FOR LEADS LEAD MTGS E SLEEVING A BRASS HUT HIGH VOLTAGE TERMINAL MOUNTING SKETCH FLEX LEAD PLAN WASHER TRANSFORMER LEAD SELECTOR SWITCH MOUNTING SKETCH 2 L 6574 10 15 82F 17 Parts List P 139 C 1 m
9. Feeder Extension Assembly Install per the S 16984 instructions shipped with the kit K 343 25 and K 343 50 25 or 50 Foot Power Input Cable with Plug Install per the M 14253 instructions shipped with the kit K 840 Gas Cylinder Mounting amp Undercarriage Install per the S 18113 instruction sheet shipped with the kit K 778 Undercarriage Install per the T 14156 instruc tion sheet shipped with the kit Wire Drive Conversion Kits for Aluminum Electrode Use harder aluminum alloys for better feedability For 035 aluminum wire T 14629 035A For 3 4 aluminum wire T 14629 3 64A Install per the S 17083 instruction sheet shipped with the OUTPUT CONNECTIONS ELECTRIC SHOCK can kill e Do not touch electrically live parts such as output terminals or internal wiring WARNING Turn the welder off before making output connections Connect the electrode cable coming through the case front from the wire feed section to either the positive or negative output stud as determined by the welding process used Innershield electrode 062 and 068 dia use electrode negative polarity and L 50 solid wire 030 035 dia and 045 cored Outershield normally uses electrode positive polarity Polarity must be correct for the process used Connect the 15 foot 2 work cable to the output stud of the opposite polarity of the electrode cable Tighten both nuts with a wrench To attach clamp to
10. Overload Protection The SP 200 has a built in protective thermostat that responds to excessive temperature It opens the input contactor if the machine exceeds the maximum safe operating temperature because of a frequent overload or high room temperature plus overload The thermo stat automatically resets when the temperature reaches a safe operating level C Wire Feed Circuit Breaker The circuit breaker to the left of the Wire Speed con trol normally trips only when an overload occurs be cause of excessive loading in the wire feed cable a defective wire feed motor or a defective control com ponent The reset button gives a visual indication when the circuit breaker is tripped After allowing a minute for cooling push the reset button If it trips again be sure the wire feed cable is clean and that the cable and tip are the proper size for the wire diameter being fed If it still trips it may be caused by a defective electrical component Pressing the untripped circuit breaker once turns off the wire feed circuit Pressing it again turns it back on D Wire Drive Motor and Gear Box Every year inspect the gear box and paint the gear teeth with a moly disulfide filled grease ELECTRIC SHOCK can kill e Do not touch electrically live parts such as output terminals or internal wiring WARNING Have a qualified electrician do the main tenance and troubleshooting work Turn the input power off using the disco
11. Receptacle 1 4 Pin Receptacle 1 Wire Reel Stand See P 125 N Wire Reel Support Includes 5 7 m Wire Reel Shaft See P 107 P Col 3 Plug Retainer f 1 Thumb Screw 1 Wire Reel 1 24 M 14165 3 23 84M WIRE REEL STAND WIRE REEL SUPPORT we DETAIL A ADP MEW FULL SCALE gt SEE DETAW A L 6832 P 12 19 85G ee Parts List P 125 N NO ITEM PART NAME 8 DESCRIPTION REQ D Wire Reel Support Assembly Wire Reel Shaft Assembly 2 Spindle Assembly 3 Readi Reel Adapter 4 Insulating Washer 5 Insulator Bushing 6 Brake Disc Spacer 7 Plain Washer 8 Lock Washer 9 Hex Head Screw 10 Cable Clamp Thread Cutting Screw 12 Retaining Collar Not Illustrated 1 umh Readi Reel Decal Plain Washer Optional Not illustrated 10 Wire Ree Spacer gt 25 WIRE REEL SHAFT e KN Y Y AR ww wawawa Kw ZZZ TMB i So N 4 1 CP PLA ti Mw A TIN YO SUPPORT FRAME VA Co M 12460 10 28 83L Parts List P 107 P NO PART NAME amp DESCRIPTION REQ D Reel Mounting Shaft Assembly Includes Hex Head Bolt Lock Washer Brake Assembly includes Brake Cotter Pin 5 Plain Washer 7 Insulator Bushing 8 Insulating Washer
12. be doubled by rotating liner 180 The liner can be pulled out the back end of the nozzle by wedging the blade of a small screw driver in the 1 13 and pulling d Internal parts of nozzles can be removed and replaced by removing the internal hollow lock set screw from the contact tip end of the nozzle with a 3 32 Allen wrench The ceramic insert and retainer will normally fall out the end of the nozzle but if they do not gently drive the spring o 13 TROUBLESHOOTING ELECTRIC SHOCK can kill Do not touch electrically live parts such as output terminals or internal wiring WARNING Disconnect input power before servicing Only qualified personnel should install use or service this equipment PROBLEM POSSIBLE CAUSE WHAT TO DO Inspect gun cable and replace if necessary Remove wire from gun and cable feed in new wire Note any obstructions in gun and cable Replace gun and cable if necessary Check wire diameters stamped on drive rolls wire guides and drive roll spacers for correct combination for wire being used Remove clean install and tighten Clean per Sec G Replace and or reverse split drive roll type Replace Replace Replace contact tip Replace tip remove any spatter on end of tip Inspect repair or replace as necessary Be sure electrode lead is tight gun cable tight in wire feeder contact block gun nozzle and gun tip tight Se
13. double set of teeth so they can be re versed for additional life Between the two 068 knurled rolls is a shim washer which limits the damage to the electrode if wire feeding problems occur See Mechan ical Installation for roll changing instructions The drive roll for 023 thru 035 diameter electrode is a solid roll with two smooth v grooves one for 023 025 and one for 030 035 See Mechanical Installa tion for proper mounting for the wire size being used Wire Reel Mounting 30 50 and 60 Pound Coils To prolong the life of the wire reel shaft periodically coat it with a thin layer of grease If the brake shoe wears down to the rivet head replace the brake shoe assembly G Gun and Cable Maintenance 1 Gun Cable A dirty gun cable can cause rough and erratic wire feeding therefore the cable liner must be cleaned periodically Remove the cable from the wire feeder Lay it out straight on the floor Remove the contact tip from the gun Using an air hose and only partial pressure gently blow out the cable Work the full length of the cable by bending it back and forth and then blow it out again Repeat this procedure until no more dirt comes out 2 Gun Nozzles K 126 and K 309 Innershield Squirt guns a Replace worn contact tips as required b Remove spatter from tip or extension guide after each ten minutes of arc time or as required c Replace worn spring liners in nozzles The life of the liner can
14. is accessible While tightly holding the electrode cut off the bent end Straighten the first six inches and cut off the first inch Insert the free end through the incoming guide tube Press the gun trigger and push the electrode into the drive roll Inch the electrode through the gun If the electrode is not properly straightened it may not feed or may not go into the outgoing guide tube causing a birdnest Ad just the brake tension with the hex head screw or thumb screw on the spindle hub until the reel turns freely but with little or no overrun when wire feeding is stopped Make certain that the wire does not come loose on the spool or reel when feeding is stopped 11 ELECTRIC SHOCK can kill Do not touch electrically live parts such as output terminals or internal wiring WARNING When inching the electrode and drive mechanism are always hot to work and ground and re main hot several seconds after the gun trigger is re leased 0 Wire Reel Changing 1 At the end of a coil remove the last of the old electrode by laying the gun and cable out straight and pulling the electrode end out through the noz zle Load a new reel of electrode per the preceding instructions H Optional K 341 Stitch Timer Spot Timer Burn back Kit Std on SP 200 AB model The optional K 341 Timer Kit consists of a sheet metal case which contains the timer printed circuit board four adjustable controls and a
15. screws holding the saddle around the gun handle d Then hold the housing with the cable toward the floor and look into the switch cavity The tight side of the larger roll pins is to the right Drive these pins to the left They can be easily removed when they clear the right side of the casting e Do not remove the smaller roll pins unless the trigger is being replaced The height of the Z spring controls the operating point of the switch with respect to the trigger movement Set the spring so the switch operates at about the mid point of the trigger travel f To remove the handle from the cable slip the spatter shield out of the front of the handle Loosen the 1 a 20 socket head screw in the side of the handle Remove the snap ring The handle and connection clamp can then be slipped off the cable For K 426 045 GMA Gun Cable Maintenance re fer to manual supplied with gun Every six months check the motor brushes Replace them if they are less than 1 s long Drive Rolls and Guide Tubes After every coil of wire inspect the drive roll section Clean it as necessary Do not use solvents for cleaning the idle roll because it may wash the lubricant out of the bearing The drive roll and guide tubes are stamped with the wire sizes they will feed If a wire size other than that stamped on the roll is used the rolls and guide tubes must be changed The drive roll for 068 Innershield and 045 cored Out ershield has a
16. straightens the knob so it seats into the shaft when released Remove the reel 2 Lay the reel flat on the floor loosen the spinner nut and remove the cover plate 3 Before cutting the tie wires place the coil of elec trode on the reel so it unwinds as the reel rotates clockwise a Be sure the coil is placed so the spring loaded arms will not interfere with the later removal of the coil tie wires See photo b When loading 030 and 035 Lincoln electrode be certain the coil is placed on the reel so the spring loaded arms are at the center of the slots in the cardboard coil liner This provides the positive compression of the coil needed for trou ble free wire feeding See photo ELECTRIC SHOCK can kill Do not touch electrically live parts such as output terminals or internal wiring WARNING Check to be sure the retaining spring has fully returned to the locking position and has securely locked the Readi Reel cage in place Retaining spring must rest on the cage not the welding electrode MOLDED ADAPTER 2 0 0 SPINDLE RETAINING SPRING INSIDE CAGE WIRES THREADED LOCKING COLLAR To mount a 30 Ib Readi Reel package using the formed sheet metal K 363 obsolete type adapters 1 Remove the locking collar and remove the outside Readi Reel adapter arm 2 Engage the inside Readi Reel adapter arm in the brake driving pin and rotate the spindle until the inside adapter arm is in
17. three position mode switch The timer kit is installed in the wire feed section of the SP 200 on the back side of the case front per the in struction sheet shipped with the kit When installed the three position Weld Mode Selector switch projects through the SP 200 front nameplate next to the Wire Speed control allowing easy access to the switch The four timer control knobs are located on the timer kit case panel which is inside the wire feed section above the wire feed motor gearbox assembly To gain access to the timer control knobs on the inner panel open the door to the wire feed section The three position Weld Mode Selector switch is used to select the following modes of operation 1 The up position is for the SPOT welding mode which gives single timed welds To start the weld close and hold the gun trigger switch the weld will start and then automatically stop after a timed in terval To produce another timed weld release and re close and hold the gun trigger The time of the CAUTION DO NOT turn the coarse voltage selector switch while welding since this will damage it 8 To stop welding release the gun trigger and lift the gun from the work The wire feed motor stops and the welding circuit is de energized after the trigger is released If a solenoid is connected to the aux iliarv power terminals it is de energized when the trigger is released Refer to L 6591 52 200 Welding Pro
18. work cabie insert work cable through strain relief hole in work clamp and fasten securely with bolt and nut provided AUXILIARY EQUIPMENT CIRCUIT The power for 115 volt AC auxiliary control equipment such as a solenoid valve can be obtained from l s quick connect terminals located inside the wire feed section An insulation flap covers the two terminals The current draw from this circuit must not exceed 1 s 25 ampere The circuit is hot only when the gun trigger circuit is closed OPTIONAL FEATURES INSTALLATION K 162 H 2 O D Spindle Kit To mount the spindle kit remove wire feed unit from case Remove the shaft for the standard 50 60 pound wire coils from the mounting framework Install the spindle per the instructions shipped with the kit kit WIRE FEED WIRE WELD MODE di VOLTMETER CIRCUIT BREAKER SPEED SELECTOR OPTIONAL A Description of Controls 1 Power Switch Turns machine on and off 2 Coarse Are Voltage Control A five position se lector switch which changes the arc voltage by ap proximately 4 volts when switched from one position to the next The minimum range 15 for solid wire only 3 Fine Arc Voltage Control A continuously ad justable rheostat that gives approximately 5 15 of arc voltage control This control gives overlap ping ranges on each of the five coarse voltage con trol settings when using solid wire procedures and FINE ARC POWER VOLTAGE CONTROL VOLTAGE CO
19. 035 aluminum wire T 14629 035A For s aluminum wire T 14629 3 64A Install per the S 17083 instruction sheet shipped with the kit INNERSHIELD GUNS Lincoln s K 126 Squirtgun is used for welding with 068 or 072 Innershield electrode Install the insulated 6 extension or thread protector and the nozzle contact tip for the stickout and electrode size being used The T 14050 072 contact tip for 068 and 072 electrode and the T 14050 1 is for 062 electrode must be ordered separately shield wire For smaller wire sizes and aluminum wire the tension screw should be loosened further The set ting depends upon tvpe of wire surface condition lu brication and hardness The optimum idle roll setting can be determined when there are wire stoppages If the wire bird nests between the drive roll and the guide tube the idle roll spring pressure is set too high When properly set during a stoppage the drive rolls will slip and if the electrode is removed from the cable there will be a slight waviness in the electrode for about a foot beyond the slip marks on the electrode If there is no waviness the pressure is set too low H To change drive rolls and guide tubes for a different size reverse the above procedure IDLE ROLL TENSION ADJUSTING SCREW GUN AND CABLE ASSEMBLIES GENERAL The SP 200 may be used with various guns Use the ap propriate Lincoln gun and cable assembly for the electrode
20. 35 steel wire which is also usable for 023 and 030 steel wire is A Dia Hole To Be Concentric To Dia Within 008 F L M 749 747 030 amp 035 055 54 Drill 023 025 047 Drill 045 cored 062 As Drill 1 Lay the cable out straight Insert the connector on the welding conductor cable thru the large hole in the front panel of the SP 200 and into the brass conductor block on the front of the wire drive Note that the connector handle is to be angled down approximately 15 Make sure the connector is all the way in the conductor block and hand tighten the gun clamping screw securely Keep this connection clean and bright 2 Connect the gun trigger control cable polarized Am phenol plug Amphenol MS 3106 18 11P or equivalent into the mating receptacle on front of the wire drive unit CAUTION The gun trigger switch connected to the gun trigger control cable must be a normally open momentary switch The terminals of the switch must be insulated from the welding circuit Damage to the SP 200 will result if this switch is common to any electrical circuit other than the SP 200 trigger circuit 3 Connect the 316 I D gas hose from the gun to the barbed gas outlet fitting supplied for installation on the front of the SP 200 This fitting can be easily removed by loos ening the union nut OPTIONAL FEATURES INSTALLATION WIRE DRIVE CONVERSION KITS FOR ALUMINUM ELECTRODE For
21. 77 and the Operating Manual IM 312 for details Only 068 diameter Innershield electrodes can be used with the SP 200 Be sure the drives rolls and guide tubes are marked 068 Connect the wire feeder output leads for electrode negative Be sure to properly load the wire reel Use the K 126 gun and thread protector The insulated guide supplied with the K 126 gun should not be used with 068 electrode Choose the proper electrode and start by using the settings shown above Maintaining the proper electrical stickout the distance from the end of the contact tip to the weld puddle is very important ELECTRICAL STICKOUT Good weld quality requires using the electrical stickout specified Electrical stickout is the distance from the end of the actual contact tip to the end of the electrode STARTING THE ARC With the proper electrical stickout set position the gun with the wire lightly touching the work Press the gun trigger to start the weld Some weldors accustomed to stick electrode welding tend to push the gun into the joint as the wire burns away Since the wire is mechanically fed this is not necessary Remember it is very important to maintain the proper electrical stickout at all times To stop the arc release the trigger and pull the gun from the work SETTING VOLTAGE Adjust voltage with the controls on the power source Read the voltage on the power source voltmeter while the arc is lit SETTING WIRE SPEED CURRENT
22. 8 Wire Reel Shaft Assembly Roll Pin Pull Knob 26 27 QIS CL 6701 1 494 8 BPOD 43PjaM ayi 9 9 93819948 10 Juaw yedag 3911198 ayi 0 9311M 91189111 si WEJ EIP JU yi sjaued 3 au jo uo UO 9 1 8 ay SPISUI pajsed SI 11 90 e 40 Wesbelp 3 2945 JUL jenuew SIU Aq P213 035 SIUIYIBUI 8 10 31204133 you SI JI AJUO 33101313131 40 SI MEJ EIP SIUL 3 LON Le 6 vs 12 Sa Ladino nn eg IV 3 1 3 Y 440 00235 ALAVA SONYN OL 3121904 ALANIS 0 0 SMONS WIV SL TAN N ALAYO 80100310103 SALMAN ak ENDILWONgdv 350103 ONY JIVIQJWWI 39 372535 ALOGG any INan n 383 893 ADVI 03230038 3 35 Lam Sav ONAN 3781 MA dy KPY NARGANO 5 LON MONIS NO LON 1 090500080 ON davon 40 3515 47 gt MENTIRA ST HANNS TINT 3154143539 LM AVANSA ANL 88535 aN 320230035 011 13901 ALIAVD SNN dw 335 STAG L WAMDA AHYITIXOY 2e YO GGNWUSL INNO HINO YN 3S3LON ERKA VNOUVN 3133 Lara dad SWAwAS IVILI VS NY eee MHOM a GAWNOASNVEL 042 G AJHD OL BI 5 9 O 9 aN lt ANYO woy 5 BENITO was N SO a ann We SW Mach
23. ANEL Parts List P 139 G Reconnect Panel Assembly Includes 1 Terminal Bushing 2 1 Mounting Panel Assembly conduit clip Input Cable 6 Ft Standard 2 Contactor 1 6 Reconnect Panel Above 250V input Only Input Cable 6 Ft Standard Below 250V Input Cable 25 Ft Optional Below 250V In or Cable 50 Ft Optional Input Only Insulation Items Not illustrated Power input Receptacle Below 250V input Only 22 NO PART NAME amp DESCRIPTION REQ D M 14109 5 10 85K WIRE DRIVE ASSEMBLV L 6422 12 19 85G ITEM PART NAME 5 DESCRIPTION Wire Drive Assembly includes 1 Gear Box Assembly includes Drive Motor 2 Sems Screw 3 Collar Assembly 6 Key 9 Locator Bushing 10 Cord Clip NO 0 REQ D REQ D 1 18 idle Roll Pull Arm 20 Set Screw 22 Conductor Block 25 Hex Head Screw Lock Washer Plain Washer 2 1 26 Hex Head Screw j 1 2 1 28 Gear Box Mounting Plate 29 Gear Box Insulation 11 Set Screw 30 Gear Box Insulation 12 Groove Pin 81 Hex Head Screw 13 Idle Roll Assembly Plain Washer 14 Idle Roll Arm Bracket Lock Washer 15 Thread Cutting Screw Drive Roll and Guide Tube Kit 16 Spring Specifv wire size when ordering WIRE FEED UNIT Parts List P 139 H NO PART NAME 8 DESCRIPTION REQ D Wire Feed Unit Assembly Includes 1 Wire Drive Assembly See P 139 J Gear Box Support Platform Includes 1 Amphenol
24. NG The 55 200 can be used with a carbon rod to produce localized heating and when combined with water quenching can remove small dents and distortion in sheet metal For Metal Shrinking set WELD MODE SELECTOR to SEAM and COARSE and FINE arc voltage controls to lowest setting Press WIRE FEED CIRCUIT BREAKER to turn wire feed off Connect output leads for electrode positive Attach a carbon rod to the welding gun using a special attachment or use a separate electrode lead and stick electrode holder with a carbon rod Place the pointed end of the carbon rod do not use copper coated carbon rods firmly against the sheet metal in the distorted area Close the gun trigger and move the rod in a circular motion keeping in contact with work When distortion is reduced release trigger remove carbon and immediately quench area with a water soaked rag Repeat if required To prevent arcing carbon must be firmly against sheet metal whenever trigger is closed or opened METAL FILL This procedure is used to fill gaps holes and distorted areas in sheet metal NOTE This procedure should not be used where weld strength is required To Metal Fill on steel sheet metal set WELD MODE SELECTOR to SEAM plus COARSE and FINE voltage controls to lowest settings Set WIRE SPEED to 300 in min for 035 wire and 375 in min for 030 wire Connect wire feeder output leads for electrode postive An arc welding shield
25. NTROL SWITCH COARSE ARC Put the cover plate on the reel so the four arms of the cover straddle the spring loaded arms of the reel proper WIRE FEED COMPARTMENT it gives overlapping ranges on each of the upper four coarse arc voltage control settings when using Innershield procedures The Fine Arc Voltage Con trol is effective only while welding it does not con trol the open circuit voltage 4 Voltmeter This meter reads the voltage at the output studs of the machine The actual arc voltage at the workpiece is slightly lower due to the drop in the gun conductor cable and in the work cable 5 Wire Speed Controls the wire speed from 50 to 400 inches per minute The control can be preset on the dial plate to the desired wire speed and the actual wire speed while welding will be very close to that value 6 Wire Feed Circuit Breaker This control has a dual function It can be used as an on off switch to completely stop wire feed and it functions as an overload circuit breaker When the button is com pletely black the circuit breaker is closed and wire will feed when the gun trigger is pressed Press the button once to turn off the wire feed A white band will appear on the button To turn the wire feed back on press the button again See Maintenance Section B Polarity Check to see that the cable coming from the conductor block on the wire feed unit goes to the output stud that is of the polar
26. O SPOT Arc spot plug welds are used when continuous welds are not needed or to hold thin sheet metal together prior to Auto Stitch Welding or continuous welding Piug welds are made by punching a inch hole in the top sheet and arc welding through the hole into the back sheet To make an arc spot plug weld punch 34 holes in top sheet Set WELD MODE SELEC TOR to SPOT and the other controls per the above table Install spot weld nozzle if available on gun and press it against the top sheet so the top and bottom sheets are tight together Close trigger and hold it closed till the arc goes out If a spot weld nozzle is not used smoother welds will result by moving the welding wire in a small circle during the weld SPOTWELD TIME control sets welding time Higher settings increase penetration diameter and height of weld THE LINCOLN ELECTRIC COMPANY CLEVELAND OHIO U S A ou 068 NR 211 single or multiple 12 ga and to Y Electrical 75 18 4 5 Stickout pass mild steel thicker 14 1505 1 2 Electrical e Stickout steel up to 5 6 12 ga and sik max thickness 10 ga single pass uncoated or galvanized mild 068 NR 152 INNERSHIELD WELDING This process utilizes an easy to use self shielded flux cored electrode It is important to understand some of the special characteristics of Innershield electrodes and your SP 200 Refer to Lincoln booklets N675 and N6
27. a K 309 smoke removal type Innershield gun and Linconditioner vacuum unit can be used Instructions are shipped with the equipment CAUTION The gun trigger switch connected to the gun trigger control cable must be an electrically isolated nor mally open momentary switch Damage to the SP 200 may result if this switch is common to any electrical circuits other than the SP 200 trigger circuit All Lincoln gun trigger switches are of this type ASSEMBLY OF GUN CABLE TO SP 200 Lay the cable out straight Insert the connector on the weld ing conductor cable thru the large hole in the front panel of the SP 200 and into the brass block on the front of the gear box Make sure it is all the way in and tighten the locking screw with a 3 16 hex Allen wrench Keep this con nection clean and bright Connect the gun trigger control cable polarized amphenol plug into the mating receptacle on front of the wire drive unit WARNING Keep cylinder upright and chained to support Keep cylinder away from areas where it may be damaged Never lift welder with cylinder attached Never allow welding electrode to touch cylinder Keep cylinder away from welding or other live electrical circuits GAS CYLINDERS may explode if damaged ELECTRICAL INSTALLATION INPUT POWER AND GROUNDING CONNECTIONS Before starting the installation check with the local power company if there is any question about whether your power supply i
28. ad or cad mium plated steel and other metals which produce toxic fumes even greater care must be taken Do not weld in locations near chlorinated hydro carbon 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 instruc tions for this equipment and the consumables to be used including the material safety data sheet MSDS and follow your employer s safety prac tices WELDING SPARKS can cause fire or explosion 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 easilv go through small cracks and openings to adjacent areas Have a fire extinguisher readilv 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 op erating information for the equipment being used When not welding make certain no part of the electrode circuit is touching the work or g
29. aining spring tab with thumb while pulling the Readi Reel cage from the molded adapter with both hands Do not remove adapter from spindle 10 weld is adjustable from 1 to 3 seconds using the SPOTWELD TIME control on the inner panel Timer dials show increments from 1 to 10 They are not calibrated in seconds Since the timing starts when the gun trigger is pressed for consistent welds it is important that the electrode is either lightly touching or very near the work when the trigger is pressed 2 The center position of the Weld Mode Selector switch is for the SEAM welding mode which is normal continuous welding The weld starts when the gun trigger is closed and stops when the gun trigger is released 3 The down position of the Weld Mode Selector switch is for the STITCH welding mode This mode gives repeated timed welds and time off periods for as long as the gun trigger is held closed The on and off time intervals are independ ently adjustable from to 2 seconds using the STITCH OFF TIME and STITCH ON TIME controls located on the inner panel Timer dials show increments from to 10 They are not cali brated in seconds The electrode and auxiliary power terminals stay energized during the off time only the wire feed stops This mode which minimizes heat input is very useful when welding light gauge sheet metal 18 thru 24 gauge 048 024 whe
30. cedures at back of manual for further instructions J Output Rating The maximum rated output for the SP 200 and SP 200 AB 60 Hz model is 200 amps 26 volts at a 60 duty cycle Duty cycle is based on a 10 minute period Therefore the welder can be operated for 6 minutes out of every 10 minute period without overheating For 50 Hz models rated duty cycle is 50 I Test Weld 1 Setthe Coarse voltage selector switch knob to the voltage range desired 2 Set the Wire Speed knob to the speed desired 3 Set upa test plate and attach the work lead to it 4 Ifa Gas Metal Arc process is being used make any other required gas shielding adjustments for the process 5 Inch the electrode through the gun and then cut the end off so that the stickout is approximately 3 4 for Innershield electrode For 030 or 035 steel wire cut the end of the electrode within A of the gas nozzle cone 6 When using open arc processes it is necessary to use correct eye head and body protection 7 Place the gun into welding position with the end of the electrode approximately 1 s of an inch above the surface of the workpiece and pull the gun trig ger As the weld is being made observe the volt _ meter reading and adjust the fine voltage control knob to the desired value If it is necessary to change the coarse voltage selector switch stop welding before doing so MAINTENANCE B Welding Power
31. e pasted on the inside of the removable panel near the rear on the left side Use fuses and input wire sizes suitable for the input amperes specified on the nameplate Using the following instructions have a qualified electrician connect the receptacle to the input power lines and the sys tem ground per the National Electrical Code and any ap plicable local codes See the table for proper wire sizes For long runs over 100 larger copper wires should be used in the conduit Fuse the two hot lines with super lag type fuses as shown in the following diagram The center contact in the receptacle is for the grounding connection A green wire in the input cable connects this contact to the frame of the welder This ensures proper grounding of the welder frame when the welder plug is inserted into the receptacle Connect to a system grounding wire See the National Elec trical Code and or local codes for other details and means for proper grounding Green Connect to hot wires of a three wire single phase system or to one phase of a two or three phase system AWG Type 75 C Wire in Conduit input Copper Cond AWG Size Voltage Runs to 100 Runs over 100 Size 208 230 so e e w 20022050 e 656 10 e 800 415 so 10 8 to 4606 so iw s 101891 Ground ing Wire Copper Cond For locations where smoke accumulation is a problem and conventional exhaust systems are ineffective
32. e troubleshooting information in Bulletin N675 Innershield Production Welding Guide or Bulletin N677 Innershield NR 211 Welding Guide Correct problem Replace Re set circuit breaker Replace Correct problem Make certain jumper plug is in place See K 341 Timer Kit installation instruction page Repair If the gun trigger switch or control cable is in any way common to any electrical circuit other the the SP 200 24V trigger circuit damage to the SP 200 can result Replace See Problem 8 Gun cable kinked and or twisted Wire jammed in gun and cable a b Incorrect drive rolls and guide tubes Drive rolls loose Gun cabie dirty Worn drive roils Electrode rusty and or dirty Worn nozzle liner Partially flashed or melted contact tip Worn and or melted contact tip Wom or undersized work cable or poor work connection Loose electrode connections Dirty plate or improper procedures See Trouble 1 above Defective wire feed motor or gearbox Wire feed circuit breaker in off position Electrical component such as control printed circuit board has failed Blown 10 amp fuse on control P C board indicates that the control P C board has probably failed The 4 prong connector going to the wire feed unit or the optional extension cable may not be making contact If Timer Kit is not insta
33. il seated in the receptacis 6 Place the Timer Kit panel against back of front panel as shown below and re insert 10 24 screw Put lockwasher on and start nut do not tighten yet Make sure that no leads are pinched between the sheet metal parts and that the small toggle switch is thru the hole in the front of the machine 7 Insert the sheet metal screw through 5161 in kit panel and into inner case panel 8 Tighten down all screws FRONT PANEL K KAT SHEET METAL SCREW 10 24 x 375 SCREW LOCKWASHER L 10 24 HEX NUT S 16982 9 SEE SP 200 OPERATING MANUAL FOR OPERATING INSTRUCTIONS 35 14 5217 28 INSULATING FLAP 3 Ne a SP 200 Ya BUICK CONNECT CASE en FRONT VERN NALS INLET IN PORT To BE POINTING UP IDA JB SELF TAPPING SCREWS f 210 26 x SO THREAD CUTYING MACHINE SCREW STAR LOCKWASHER GROUNDING LEAD SOLENOID VALVE AND LEAD INSTALLATION M 14889 8 27 84C 29 30 18 01 0201 5 s 8 qa ONIWL HOLILS 3 31338 van v49 Ze 2 6 lt NA II lt I O 3318335 a ele gt ORS L 21 4 gt ole 7 AQOM 1MS gt L MZ 2001 EZY MZ 00 223 772 pog 2 AOL U 960 NZ AMI Sa LAD 5 7 5 23
34. ion se curely chained to an undercarriage or fixed sup port c Cylinders should be located e Away from areas where they may be struck or subjected to physical damage A safe distance from arc welding or cutting op erations 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 e Keep your head and face away from the cylinder valve outlet when opening the cylinder valve f Valve protection caps should always be in place and handtight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA pub lication P 1 Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 HAVE ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR WORK performed by qualified people For more detailed 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 Oct 7 3 work clamp Also includes one set of drive rolls and guide tubes for wire size specified For single phase input power Units having an input voltage under 250 volts include a 6 input cable plug and receptacle Units with inp
35. ity required for the process that is to be used Refer to Output Connections Page 6 Shown with optional K 341 Timer Kit and with top of case removed 4 Tighten the cover as much as possible by hand DO NOT hammer on the spinner nut arms Cut and remove only the tie wire holding the free end of the coil Insert the free end into one of the holes in the cover and secure it by bending it back Cut and remove the remaining tie wires CAUTION Always be sure the free end of the coil is securely held while the tie wires are being cut and until the wire is feeding through the drive rolls Failure to do this will result in back lashing of the coil which may tangle the wire A tangled coil will not feed so it must either be untangled or discarded Replace the reel on the wire feeder Grasp the shaft knob pull it out and swing it across the reel hub Turn the reel until the free end of the electrode is accessible While tightly holding the electrode cut off the bent end To Start the Welder Turn the Power Switch to ON This lights the red pilot light next to the switch and starts the cooling fan Operate the gun trigger for welder output and to en ergize the wire feed motor D Wire Reel Loading 30 50 and 60 Pound Coils 1 Open the side door for access to the wire feed com partment To remove the wire reel from its shaft grasp the spring loaded knob and pull it out This
36. lled jumper plug may not be properly seated in six cavity connector Faulty gun trigger switch or damaged control cable connected to gun trigger Gun trigger circuit not electrically isolated Input power contactor has failed Timer Kit may be defective 14 1 Rough wire feeding or wire not feeding but drive rolls turning Variable or hunting arc Weld porosity narrow and ropey bead or electrode stubbing into plate when welding Wire feed circuit breaker trips while welding No wire feed or no control of wire feed Contactor pulls in and voltmeter indicates voltage No wire feed and no output voltage Pilot light indicates input power to SP 200 PROBLEM POSSIBLE CAUSE WHAT TO DO 7 Wire feed control but output voltage continuously present with gun trigger off a Input power contactor has failed a Replace b Gun trigger circuit not electrically isolated b If the gun trigger switch or control cable is in any way common to any electrical circuit other than the SP 200 24V trigger circuit damage to the SP 200 can result See Problem 8 Check position of Weld Mode Selector switch Be certain that it is set for the mode desired b Make certain that the plugs connecting to the Timer P C Board are properly seated Check operation of machine c Remove Timer Kit see K 341 installation instruction page and install jum
37. nnect switch at the fuse box before work ing inside the machine Unplug power cable if it is con nected to a receptacle A General Maintenance 1 Whenever routine maintenance is performed on this machine or at least yearly inspect all nameplates and labels for legibility Replace those which are no longer clear Refer to the parts list for the replacement item number 2 The fan motor has sealed ball bearings which re quire no service 3 In extremely dusty locations dirt may clog the air passages causing the welder to run hot Blow dirt out of the welder at regular intervals 12 liner towards the outgoing end of the nozzle When re assembling nozzle make certain the ce ramic nozzle insert is placed next to the spring liner The hollow lock set screw is to be tight ened to give the dimension of 38 as measured from the end of the nozzle to the hollow lock set screw 3 Gun Disassembly K 126 and K 309 Innershield Squirtguns a To remove the nozzle from the gun loosen do not remove the 1 s 20 socket head screw with a Mis Allen wrench in the gun handle and pull the nozzle straight out To reinstall insert the nozzle into the gun handle Push it in as far as possible and tighten the Allen head screw b To disassemble Innershield Squirtguns first loosen the screws which hold the heat shield in place Remove the heat shield c To disassemble the switch housing from all these guns remove the four
38. ork clamp weld ing cable and welding machine in good safe op erating 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 be cause voltage between the two can be the total of the open circuit voltage of both welders When working above floor level protect yourself from a fall should you get a shock Also see Items 4c and 6 ARC RAYS can burn 2 8 Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc weld ing Headshield and filter lens should conform to ANSI Z87 1 standards Use suitable clothing made from durabie 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 themselves to the arc ravs or to hot spatter or metal 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 National Electrical Code all local codes and the manufac turer s recommendations b Ground the equipment in accordance with the Na tional Electrical Code and the manufacturer s rec ommendations FOR ENGINE p
39. out Gas Cylinder Rack Undercarriage With Gas Cylinder Rack _ 18 FAN SUPPORT PANEL L 6459 6 29 84J Parts List P 139 D NO PART NAME amp DESCRIPTION Fan Support Panel Assembly Includes Fan Support Panel Control Printed Circuit Board Does not include Item 3 Relav Grommet Resistor Round Head Screw Insulator Resistor Round Head Screw Insulator Resistor Fan Motor Fan Cable Hanger Cable Hanger 1 1 1 1 1 2 1 1 2 1 1 1 3 19 FRONT PANEL Parts List P 139 E NO ITEM PART NAME amp DESCRIPTION REG D Front Panel Assembly Includes 1 1 Front Panel 1 2 Pilot Light 1 3 Power Switch 1 5 Circuit Breaker 1 6 Voltage Rheostat 0 Output Terminal Replacement Kit 1 Voltmeter 1 Knob 1 Nameplate 1 Warning Decal 1 1 1 1 2 2 4 5 Grommet 7 Wire Feed Rheostat Rheostat Insulation 8 9 1 2 1 2 1 1 1 1 i Plug Button Std Machines Oniv 1 Solenoid AB Machines Only 1 0 Solenoid Nameplate AB Machines Only 1 20 1 460 3 15 85 K 341 TIMER KIT M 14139 10 2 81B Parts List P 139 F NO ITEM PART NAME amp DESCRIPTION REQ D Timer Assembly Includes Panel Timer Printed Circuit Board Inner Panel Rheostat Insulation Harness Includes Rheostats 85 R11 R22 8 R23 Mode Switch Switch Bracket Expansion Nut Nameplate 21 RECONNECT P
40. ower before servic ing Do not touch electrically live parts MOVING PARTS can injure s Keep away from moving parts Only qualified personnel should install use or service this qualified personnel should instali use or service this Only qualified personnel should install use or service this e Do not lift this machine using lift bale if it is equipped with a heavy accessory such as trailer or gas cylinder Lift only with equipment of adequate lifting capacity FALLING EQUIPMENT can cause injury Be sure machine is stable when lifting MECHANICAL INSTALLATION Location Locate the welder in a dry location where there is free circulation of clean air into the louvers in the back and out the front and bottom A location that minimizes the amount of smoke and dirt drawn into the louvers re duces the chance of dirt accumulation that can block air passages and cause overheating minimum of 12 inches of unrestricted space should be maintained between the back of the case or front panels and the nearest obstruction WIRE SIZE OR TYPE CONVERSION KITS The SP 200 AB model comes with the drive roll kit for 023 thru 035 steel wire factory installed The SP 200 welder as shipped from the factory does not have the drive rolls or guide tubes installed The drive roll kit for the electrode size specified on the order is shipped with the wire feed unit The drive roll kit for 0
41. owered equipment Turn the engine off before troubleshooting and maintenance work unless the mainte nance work requires it to be running Operate engines in open well ventilated areas or vent the engine exhaust fumes out doors 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 va porizing 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 elim inated 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 mov ing parts when starting operating or re pairing equipment In some cases it may be necessary to remove safety guards to perform required mainte nance Remove guards only when necessary and replace them when the maintenance re quiring 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 15 running To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work dis connect the spark plug wires distributor cap or magneto wire as ap
42. per plug which is stored at bottom of Timer Kit case Check operation of machine If problem is corrected Timer Kit is defective Replace Timer Kit may be defective 8 Suspected defective Timer Kit Improperly set machine Connector plugs not making contact Defective Timer 9 Poor welding characteristics and or cannot obtain full rated output of 200 amps at 26 volts a Capacitor s in power source output circuit failed A failure is indicated if the small vent plug on top ofa capacitor is raised or blown out a Replace entire bank of capacitors Do notreplace individual capacitors WARNING The Liquid electrelyte in these capacitors is toxic Avoid contact with any portion of your body Clean up vented electrolyte using rubber gloves and a water dampened cloth Any electrolyte which gets on skin clean with soap and water 15 5 200 SEQUENCE OF OPERATIONS Input power lines energized Primary of control transformer energized Power ON OFF switch to ON position Closes 31 to 531 ad 300 to 304 circuits Pilot light fan and contro circuits energized Press gun trigger Closes 302 to 303 circuit Energizes Stitch Timer h Spot Timer Burnback Kit Energizes ICR if connected Closes 531 to 7 circuit Opens 207 to Closes 207 circuit 541 circuit Energizes line contactor 2CR
43. propriate To avoid scalding do not remove the ra diator pressure cap when the engine is hot Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 80 from the American Welding Society see address below e Vent hollow castings or containers before heating cutting or welding They may explode f Sparks and spatter are thrown from the welding arc Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap over your hair Wear ear plugs when welding out of position or in confined places Always wear safety glasses with side shields when in a welding area g Connect the work cable to the work as close to the welding area as practical Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains crane cables or other alternate circuits This can create fire hazards or overheat lifting chains or ca bles until they fail h Also see item 7c CYLINDER may explode if damaged Use only compressed gas cylinders containing the correct shielding gas for the process used and prop erly operating regulators designed for the gas and pressure used All hoses fittings etc should be suit able for the application and maintained in good condition Always keep cylinders in an upright posit
44. push wire into drive roll Install longer guide tube in rear hole WARNING When inching with gun trigger elec Install other guide tube through front hole trode and drive mechanism are hot to work Fine wire chisel point tube must have largest and ground radius next to drive roll L 6591 Rev 2 86 35 030 20 Ga 036 name 20 Ga gt BURNBACK CONTROL This control sets the time the arc is on after wire feed stops Increase time only if welding wire sticks to the end of the weld STITCH TIMER AUTO STITCH Used to weld thin material where warpage and burnthrough are a problem Proper adjustment of ON and OFF times and arc travel speed permits welding 18 through 24 gage 048 024 sheet metal with small welds minimum distortion and no burn through To weld set WELD MODE SELECTOR to STITCH and the other controls per the above table Close trigger and hold it closed for length of seam Hold gun in one place during ON time and move gun just beyond edge of molten metal during OFF time STITCH ON TIME control sets welding time Raise setting to increase penetration and weld size lower to reduce burnthrough and distortion STITCH OFF TIME control sets off time Raise setting to reduce burnthrough lower to make weld flatter and smoother NOTE For smoothest welds on thinner metal point gun slightly towards direction of travel SPOTWELD TIMER AUT
45. re warpage and or burn through would otherwise be a problem The controls and travel speed along the seam should be set to give a series of overlapping welds in which the glow is allowed to almost disappear from the previous weld before the next weld begins Start with the OFF TIME control set at 2 on the dial and the ON TIME control set at about 2 5 on the dial Re adjust the controls as required to give the best results The BURNBACK CONTROL which is the top con trol on the inner panel gives an adjustable burnback of the electrode to prevent it from sticking in the puddle at the end of a weld Burnback is accomplished by pro viding an adjustable delay of up to 1 3 of a second after the gun trigger is released before the welding power shuts off The control should be set at minimum 1 on the dial and increased only if the electrode sticks in the puddle Increasing the control setting should normally be required only at wire feed speeds above 250 inches per minute The burnback control circuit is effective in all three modes of operation as follows 1 In the SPOT welding mode the burnback delay action automatically occurs at the end of the timed weld 2 In the SEAM welding mode the burnback delay action occurs when the gun trigger is released 3 In the STITCH welding mode the burnback de lay action occurs if the gun trigger is released during an ON cycle the free end of the electrode
46. round Accidental contact can cause overheating and cre ate 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 Recom mended Safe Practices for the Preparation for Also see item 7b ELECTRIC SHOCK can kill 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 In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot Insulate yourself from work and ground using dry insulation When welding in damp locations on metal framework such as floors gratings or scaf folds and when in positions such as sitting or lying make certain the insulation is large enough to cover your full area of physical contact with work and ground Always be sure the work cable makes a good elec trical 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 w
47. rshield drive roll is made up of two reversible drive rolls and a spacer Wipe the drive roll and spacer 068 only surface clean Wipe the output shaft and locating shoulder clean 188181 the drive roll on the out put shaft The 068 drive roll is to be installed with the spacer between the two drive rolls Install the drive roll clamping collar and hex head screw previously removed Tighten hex head screw securely Back out the two guide tube clamping set screws item 4 Insert the outgoing guide item 3 the one with the plastic insert into the front hole The guide tube for 023 thru 035 wire has a non symmetrical chisel end Be certain the contour with the larger radius and the exposed oval opening for the wire faces the grooved drive roll Push the guide tube back as far as it will go and tighten the clamping set screw Insert the incoming guide tube item 5 into the rear hole as far as it will go and tighten the clamping set screw These set screws are dog points When the two tubes are installed prop erly these dog points will lock into the annular grooves that are in each of the guide tubes Tighten the idle roll tension screw item 6 or remove the screwdriver used as a wedge in step A The tension screw should normally be tightened until it bottoms and then backed out two turns for 068 and 072 Inner WARNING HIGH VOLTAGE can kill Do not operate with covers removed Disconnect input p
48. s adequate for the voltage amperes phase and fre quency specified on the welder nameplate Also be sure the planned installation will meet the National Electrical Code and local code requirements This welder may be operated from a single phase line or from one phase of a two or three phase line The 208 230 volt 60 Hz and 200 220 380 415 volt 50 Hz models are shipped connected for the higher voltage If the welder is to be operated on the lower voltage it must be reconnected according to the instructions S 16962 on the inside of the removable panel near the rear on the left side Adjust the brake tension screw see Operation Sec on the spindle as needed 2 spindle is factory installed on SP 200 AB K 363 P 30 Ib Readi Reel Adapter Plastic hub for mounting 22 30 15 Readi Reels on a 2 O D spindle Fac tory installed on SP 200 AB K 438 60 Ib Readi Reel Adapter Required to feed 50 60 15 Readi Reel coils from K 162 H Spindle Kits In structions are included with the adapter NOTE Not for use on SP 200 AB K 435 Spindle Adapter for 14 Ib Coils Provides for mounting 14 15 Innershield coils on 2 O D spindles K 340 P Solenoid Valve Kit Install per the M 14889 instructions shipped with the kit Factory installed on SP 200 AB K 341 Stitch Timer Spot Timer Burnback Kit In stall per the S 16982 instructions shipped with the kit Fac tory installed on SP 200 AB K 342 25 Foot Wire
49. the vertical position 3 Set the Readi Reel on the adapter arm The Readi Reel must be installed so that it will rotate in a clockwise direction when feeding wire is dereeled from the top of the coil 4 The outside adapter arm is then to be placed on the spindle at an angle of 90 from the inside adapter and the locking collar installed Tighten the locking collar securely To mount 10 to 30 Ib spools 1 Remove the locking collar and the Readi Reel adapter shipped on the 2 inch dia spindle Readi Reel adapter is not required Use S 18221 Spindle Adapter for 8 O D spools 2 Place the spool on the spindle making certain the brake driving pin enters one of the holes in the back side of the spool Be certain the wire comes off the reel in a clockwise direction when dereeled from the top of the coil 3 Replace and tighten the locking collar To feed the electrode turn the Readi Reel or spool until 8 Straighten the first six inches and cut off the first inch Insert the free end through the incoming guide tube Press the gun trigger and push the electrode into the drive roll Inch the electrode through the gun If the electrode is not properlv straightened it mav not feed or mav not go into the outgoing guide tube causing a birdnest ELECTRIC SHOCK can kill Do not touch electrically live parts such as output terminals or internal wiring WARNING When inching the electrede and drive
50. type solid cored or Innershield and electrode size to be used GUN AND CABLE A gun and cable assembly suitable for the application is to be provided with the proper connectors per the infor mation below SWITCH RECKRREMENTS Va AMP AC 24 VOLTS iHDUICTIVE AMP D C 24 VOLTS INDUCTIYE SP 150 CABLE CONNECTOR FOR 023 035 WIAE PENS A 3 ku 512324 1 E PART NG HOTE CONNECTOR PART WITH 7400 747 DIA AMPHENOL 3057 10 OR EQUIVALENT MADE FROM BRASS IF IT S TOBE 512204 L E PART PARTOF THE WELDING CURRENT CARRYING CIRCUIT AMPHENOL MS 31069 18 11P OR EQUIVALENT ELECTRIC SHOCK can kill e Do not touch electrically live parts such as output terminals or internal wiring WARNING Make certain that the power cord is un plugged before removing the two screws that hold the ac cess panel in place The 208 230 volt 60 Hz and 200 220 volt 50 Hz models are shipped with the input cable and plug connected to the welder A matching receptacle is supplied with the machine Mount the receptacle in a suitable location using the screws provided Be sure it can be reached by the plug on the input cable attached to the welder Mount with the grounding terminal at the top to allow the power cable to hang down without bending NOTE Machines built for power lines over 250 volts are not equipped with a plug installed on the input cable nor a receptacle The instructions for wiring these machines ar
51. ut voltages above 250 volts have only a 6 input cable PRODUCT DESCRIPTION Complete semiautomatic arc welder with constant voltage transformer rectifier DC arc welding power source constant speed wire feeder and wire reel stand all in a common housing Includes a voltmeter and a 15 work cable with INSTALLATION T 15010 035S and the drive roll kit for 068 and 072 Innershield flux cored wire is T 13355 32 The drive roll kit for 062 Innershield flux cored wire is T 13355 1 is The 068 072 drive rolls and guide tubes are marked 068 64 and 3 32 DO NOT use the equipment for feeding 4 or 3 32 wire See Optional Features Installation for aluminum wire conversion kits Instructions to install the T 15010 035S and T 13355 12 drive roll kits on new machines or replace them on used machines are as follows A Loosen the idle roll tension screw item 6 approxi mately 5 full turns or use a screwdriver between the idle roll arm and the gear box boss at point A to pry the idle arm out until the idle roll clears the drive roll Remove hex head screw item 1 and the drive roll clamping collar item 2 On new machines remove the tape and drive roll key from the collar Insert the key into the keyway of the output shaft The 023 035 drive roll is one piece and should be installed with the required groove up The wire size being used can then be read on the top of the roll The 068 Inne
52. with a 8 filter must be used to protect the eyes from heat and brightness Start with the wire sticking out about 1 beyond the gun tip and the wire lightly touching the sheet metal Close the trigger and slowly weave the gun back and forth over the area to be filled If there is arcing and flashing increase the WIRE SPEED and or decrease the wire stickout If the wire pushes the gun back decrease the WIRE SPEED and or increase the wire stickout After filling set the WELD MODE SELECTOR for STITCH or SEAM and arc weld the fill metal to the base metal PROCEDURE TO INSTALL DRIVE ROLL AND GUIDE TUBES Turn off power 7 With tubes properly seated tighten set Remove hex screw and clamping collar from screws 8 Tighten idle roll pressure screw and back out 2 turns for larger wires For aluminum and 023 052 steel wire screw must be backed out to prevent buckling with wire stoppage see Operating Manual drive shaft with 1 2 wrench Loosen idle roll Install key and drive roll Double grooved drive roll for 023 035 to be installed with side stenciled for correct wire size facing out and with slotted spacer on top of roll Two piece drive rolls for 068 have spacer be 9 To start new electrode straighten the first tween rolls Replace collar and tighten hex 6 and cut off first inch Insert free end thru screw incoming guide tube Press gun trigger and Back out two guide tube set screws
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