return to master toc sp-100 - eden prairie · 8.a. electric current flowing through any conductor...
TRANSCRIPT
SP-100
SERVICE MANUAL
SVM102-AMarch, 1999
Safety Depends on YouLincoln arc welding and cuttingequipment is designed and builtwith safety in mind. However, youroverall safety can be increased byproper installation ... and thought-ful operation on your part. DONOT INSTALL, OPERATE ORREPAIR THIS EQUIPMENTWITHOUT READING THISMANUAL AND THE SAFETYPRECAUTIONS CONTAINEDTHROUGHOUT. And, mostimportantly, think before you actand be careful.
For use with machineshaving Code Numbers 9284-10050
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• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
World's Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors
i SAFETY
SP-100
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDRENAWAY. 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 pur-chase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040,Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from theLincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PER-FORMED ONLY BY QUALIFIED INDIVIDUALS.
ARC RAYS can burn.2.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards.
2.b. Use suitable clothing made from durable flame-resistantmaterial to protect your skin and that of your helpers fromthe arc rays.
2.c. Protect other nearby personnel with suitable, non-flammablescreening and/or warn them not to watch the arc nor exposethemselves to the arc rays or to hot spatter or metal.
ELECTRIC SHOCK cankill.1.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.Do not touch these “hot” parts with your bareskin or wet clothing. Wear dry, hole-freegloves to insulate hands.
1.b. Insulate yourself from work and ground using dry insulation.Make certain the insulation is large enough to cover your fullarea of physical contact with work and ground.
In addition to the normal safety precautions, if weldingmust be performed under electrically hazardousconditions (in damp locations or while wearing wetclothing; on metal structures such as floors, gratings orscaffolds; when in cramped positions such as sitting,kneeling or Iying, if there is a high risk of unavoidable oraccidental contact with the workpiece or ground) usethe following equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.• DC Manual (Stick) Welder.• AC Welder with Reduced Voltage Control.
1.c. In semiautomatic or automatic wire welding, the electrode,electrode reel, welding head, nozzle or semiautomaticwelding gun are also electrically “hot”.
1.d. Always be sure the work cable makes a good electricalconnection with the metal being welded. The connectionshould be as close as possible to the area being welded.
1.e. Ground the work or metal to be welded to a good electrical(earth) ground.
1.f. Maintain the electrode holder, work clamp, welding cable andwelding machine in good, safe operating condition. Replacedamaged insulation.
1.g. Never dip the electrode in water for cooling.
1.h. Never simultaneously touch electrically “hot” parts ofelectrode holders connected to two welders because voltagebetween the two can be the total of the open circuit voltageof both welders.
1.i. When working above floor level, use a safety belt to protectyourself from a fall should you get a shock.
1.j. Also see Items 4.c. and 6.
WARNING ARC WELDING can be hazardous.
FUMES AND GASEScan be dangerous.3.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing thesefumes and gases.When welding, keepyour head out of the fume. Use enoughventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. Whenwelding with electrodes which require specialventilation such as stainless or hard facing (seeinstructions on container or MSDS) or on lead orcadmium plated steel and other metals or coatingswhich produce highly toxic fumes, keep exposure aslow as possible and below Threshold Limit Values (TLV)using local exhaust or mechanical ventilation. Inconfined spaces or in some circumstances, outdoors, arespirator may be required. Additional precautions arealso required when welding on galvanized steel.
3.b. Do not weld in locations near chlorinated hydrocarbon vaporscoming from degreasing, cleaning or spraying operations.The heat and rays of the arc can react with solvent vapors toform phosgene, a highly toxic gas, and other irritating products.
3.c. Shielding gases used for arc welding can displace air andcause injury or death. Always use enough ventilation,especially in confined areas, to insure breathing air is safe.
3.d. Read and understand the manufacturer’s instructions for thisequipment and the consumables to be used, including thematerial safety data sheet (MSDS) and fol low youremployer’s safety practices. MSDS forms are available fromyour welding distributor or from the manufacturer.
3.e. Also see item 7b.
Apr. ‘93
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ii
SP-100
SAFETY
FOR ELECTRICALLYpowered equipment.
6.a. Turn off input power using the disconnectswitch at the fuse box before working onthe equipment.
6.b. Install equipment in accordance with the U.S. NationalElectrical Code, all local codes and the manufacturer’srecommendations.
6.c. Ground the equipment in accordance with the U.S. NationalElectrical Code and the manufacturer’s recommendations.
CYLINDER may explodeif damaged.5.a. Use only compressed gas cylinders
containing the correct shielding gas for theprocess used and properly operatingregulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable forthe application and maintained in good condition.
5.b. Always keep cylinders in an upright position securelychained to an undercarriage or fixed support.
5.c. Cylinders should be located:• Away from areas where they may be struck or subjected tophysical damage.
• A safe distance from arc welding or cutting operations andany other source of heat, sparks, or flame.
5.d. Never allow the electrode, electrode holder or any otherelectrically “hot” parts to touch a cylinder.
5.e. Keep your head and face away from the cylinder valve outletwhen opening the cylinder valve.
5.f. Valve protection caps should always be in place and handtight except when the cylinder is in use or connected foruse.
5.g. Read and follow the instructions on compressed gascylinders, associated equipment, and CGA publication P-l,“Precautions for Safe Handling of Compressed Gases inCylinders,” available from the Compressed Gas Association1235 Jefferson Davis Highway, Arlington, VA 22202.
Mar. ‘93
WELDING SPARKS cancause fire or explosion.4.a. Remove fire hazards from the welding area.
If this is not possible, cover them to preventthe welding sparks from starting a fire.Remember that welding sparks and hot
materials from welding can easily go through small cracksand openings to adjacent areas. Avoid welding nearhydraulic lines. Have a fire extinguisher readily available.
4.b. Where compressed gases are to be used at the job site,special precautions should be used to prevent hazardoussituations. Refer to “Safety in Welding and Cutting” (ANSIStandard Z49.1) and the operating information for theequipment being used.
4.c. When not welding, make certain no part of the electrodecircuit is touching the work or ground. Accidental contactcan cause overheating and create a fire hazard.
4.d. Do not heat, cut or weld tanks, drums or containers until theproper steps have been taken to insure that such procedureswill not cause flammable or toxic vapors from substancesinside. They can cause an explosion even though they havebeen “cleaned”. For information, purchase “RecommendedSafe Practices for the Preparation for Welding and Cutting ofContainers and Piping That Have Held HazardousSubstances”, AWS F4.1 from the American Welding Society(see address above).
4.e. Vent hollow castings or containers before heating, cutting orwelding. They may explode.
4.f. Sparks and spatter are thrown from the welding arc. Wear oilfree protective garments such as leather gloves, heavy shirt,cuffless trousers, high shoes and a cap over your hair. Wearear plugs when welding out of position or in confined places.Always wear safety glasses with side shields when in awelding area.
4.g. Connect the work cable to the work as close to the weldingarea as practical. Work cables connected to the buildingframework or other locations away from the welding areaincrease the possibility of the welding current passingthrough lifting chains, crane cables or other alternate cir-cuits. This can create fire hazards or overheat lifting chainsor cables until they fail.
4.h. Also see item 7c.
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iii SAFETY
SP-100
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Mar. ‘93
ELECTRIC AND MAGNETICFIELDSmay be dangerous
8.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines
8.b. EMF fields may interfere with some pacemakers, andwelders having a pacemaker should consult their physicianbefore welding.
8.c. Exposure to EMF fields in welding may have other healtheffects which are now not known.
8d. All welders should use the following procedures in order tominimize exposure to EMF fields from the welding circuit:
8.d.1. Route the electrode and work cables together - Securethem with tape when possible.
8.d.2. Never coil the electrode lead around your body.
8.d.3. Do not place your body between the electrode andwork cables. If the electrode cable is on your right side, the work cable should also be on your right side.
8.d.4. Connect the work cable to the workpiece as close aspossible to the area being welded.
8.d.5. Do not work next to welding power source.
FOR ENGINEpowered equipment.
7.a. Turn the engine off before troubleshooting and maintenancework unless the maintenance work requires it to be running.
____________________________________________________
7.b. Operate engines in open, well-ventilatedareas or vent the engine exhaust fumes outdoors.
____________________________________________________
7.c. Do not add the fuel near an open flamewelding arc or when the engine is running.Stop the engine and allow it to cool beforerefueling to prevent spil led fuel fromvaporizing on contact with hot engine partsand igniting. Do not spill fuel when fillingtank. If fuel is spilled, wipe it up and do notstart engine unti l fumes have beeneliminated.
____________________________________________________
7.d. Keep all equipment safety guards, coversand devices in position and in good repair.Keep hands, hair, clothing and tools awayfrom V-belts, gears, fans and all othermoving parts when starting, operating orrepairing equipment.
____________________________________________________
7.e. In some cases it may be necessary to remove safetyguards to perform required maintenance. Removeguards only when necessary and replace them when themaintenance requiring their removal is complete.Always use the greatest care when working near movingparts.
7.f. Do not put your hands near the engine fan. Do notattempt to override the governor or idler by pushing onthe throttle control rods while the engine is running.
7.g. To prevent accidentally starting gasoline engines whileturning the engine or welding generator during maintenancework, disconnect the spark plug wires, distributor cap ormagneto wire as appropriate.
___________________________________________________
7.h. To avoid scalding, do not remove theradiator pressure cap when the engine ishot.
ivSAFETY
SP-100
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OC PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les instruc-tions et les précautions de sûreté specifiques qui parraissentdans ce manuel aussi bien que les précautions de sûretégénérales suivantes:
Sûreté Pour Soudage A L’Arc1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous tensionquand la machine à souder est en marche. Eviter toujourstout contact entre les parties sous tension et la peau nueou les vétements mouillés. Porter des gants secs et sanstrous pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand onsoude dans des endroits humides, ou sur un planchermetallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles unegrande partie du corps peut être en contact avec lamasse.
c. Maintenir le porte-électrode, la pince de masse, le câblede soudage et la machine à souder en bon et sûr étatdefonctionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour lerefroidir.
e. Ne jamais toucher simultanément les parties sous tensiondes porte-électrodes connectés à deux machines à soud-er parce que la tension entre les deux pinces peut être letotal de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source decourant pour soudage semi-automatique, ces precautionspour le porte-électrode s’applicuent aussi au pistolet desoudage.
2. Dans le cas de travail au dessus du niveau du sol, se pro-téger contre les chutes dans le cas ou on recoit un choc. Nejamais enrouler le câble-électrode autour de n’importe quellepartie du corps.
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,donc:
a. Utiliser un bon masque avec un verre filtrant appropriéainsi qu’un verre blanc afin de se protéger les yeux durayonnement de l’arc et des projections quand on soudeou quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger lapeau de soudeur et des aides contre le rayonnement del‘arc.
c. Protéger l’autre personnel travaillant à proximité ausoudage à l’aide d’écrans appropriés et non-inflamma-bles.
4. Des gouttes de laitier en fusion sont émises de l’arc desoudage. Se protéger avec des vêtements de protectionlibres de l’huile, tels que les gants en cuir, chemise épaisse,pantalons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de sécurité dans la zone desoudage. Utiliser des lunettes avec écrans lateraux dans leszones où l’on pique le laitier.
6. Eloigner les matériaux inflammables ou les recouvrir afin deprévenir tout risque d’incendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé dela masse. Un court-circuit accidental peut provoquer unéchauffement et un risque d’incendie.
8. S’assurer que la masse est connectée le plus prés possiblede la zone de travail qu’il est pratique de le faire. Si on placela masse sur la charpente de la construction ou d’autresendroits éloignés de la zone de travail, on augmente le risquede voir passer le courant de soudage par les chaines de lev-age, câbles de grue, ou autres circuits. Cela peut provoquerdes risques d’incendie ou d’echauffement des chaines et descâbles jusqu’à ce qu’ils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.Ceci est particuliérement important pour le soudage de tôlesgalvanisées plombées, ou cadmiées ou tout autre métal quiproduit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenantd’opérations de dégraissage, nettoyage ou pistolage. Lachaleur ou les rayons de l’arc peuvent réagir avec lesvapeurs du solvant pour produire du phosgéne (gas forte-ment toxique) ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté,voir le code “Code for safety in welding and cutting” CSAStandard W 117.2-1974.
PRÉCAUTIONS DE SÛRETÉ POURLES MACHINES À SOUDER ÀTRANSFORMATEUR ET ÀREDRESSEUR
1. Relier à la terre le chassis du poste conformement au codede l’électricité et aux recommendations du fabricant. Le dis-positif de montage ou la piece à souder doit être branché àune bonne mise à la terre.
2. Autant que possible, I’installation et l’entretien du posteseront effectués par un électricien qualifié.
3. Avant de faires des travaux à l’ interieur de poste, ladebrancher à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leurplace.
Mar. ‘93
MASTER TABLE OF CONTENTS FOR ALL SECTIONS
Page
Installation .......................................................................................................Section ATechnical Specifications ........................................................................................A-1Identify and Locate Components ...........................................................................A-2Select Suitable Location ........................................................................................A-3Output Connections...............................................................................................A-3Input Connections..................................................................................................A-5Code Requirements ..............................................................................................A-6
Operation .........................................................................................................Section BSafety Precautions ................................................................................................B-1General Description ...............................................................................................B-2
Design Features and Advantages...................................................................B-2Welding Capability ..........................................................................................B-2Limitations .......................................................................................................B-2Controls and Settings......................................................................................B-2
Welding Operations ...............................................................................................B-3Overload Protection...............................................................................................B-6
Accessories .....................................................................................................Section CAccessories ...........................................................................................................C-1Replacement Parts ................................................................................................C-1
Maintenance ....................................................................................................Section DSafety Precautions ................................................................................................D-1Items Requiring No Maintenance ..........................................................................D-1Routine and Periodic Maintenance........................................................................D-1Component Replacement Procedures ..................................................................D-2Location of Components........................................................................................D-4
Theory of Operation ........................................................................................Section EInput Line Voltage, Fan Motor and Main Transformer ...........................................E-1Output Control, Rectification and Voltage Feedback.............................................E-2Trigger, Gas Solenoid and Wire Drive ...................................................................E-3SCR Operation ......................................................................................................E-4Thermal Protection ................................................................................................E-5
Troubleshooting and Repair...........................................................................Section FHow To Use Troubleshooting Guide......................................................................F-1PC Board Troubleshooting Procedures .................................................................F-2Troubleshooting Guide...........................................................................................F-3Oscilloscope Waveforms .......................................................................................F-9Replacement Procedures ....................................................................................F-12Retest After Repair ..............................................................................................F-14
Electrical Diagrams.........................................................................................Section G
SP-100 Parts Manual .............................................................................................P-180
v
SP-100
RETURN TO MAIN INDEX
Installation ......................................................................................................Section ATechnical Specifications ........................................................................................A-1
Input and Output Specifications ......................................................................A-1Cable and Fuse Sizes .....................................................................................A-1Physical Dimensions .......................................................................................A-1
Identify and Locate Components ...........................................................................A-2Select Suitable Location ........................................................................................A-3
Stacking ..........................................................................................................A-3Tilting...............................................................................................................A-3
Output Connections ..............................................................................................A-3Work Clamp Installation .................................................................................A-3Work Cable Installation ..................................................................................A-3Gun Installation ...............................................................................................A-4Connecting Gun Cable to the SP-100 ............................................................A-4Gas Connection ..............................................................................................A-4
Input Connections..................................................................................................A-5Code Requirements For Input Connections....................................................A-6
Requirements For Rated Output...............................................................A-6Requirements For Maximum Output ........................................................A-6Requirements For CSA Rated Output .....................................................A-6
Extension Cord Usage ...................................................................................A-6
Section ATABLE OF CONTENTS– INSTALLATION SECTION –
SP-100
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A-1 INSTALLATION
SP-100
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Fuse orOutput Mode Input Voltage Breaker Size Input Amps Power Cord Extension Cord
RATED 115V/60Hz 20 Amp 20 15 Amp, 125V, Three ConductorThree Prong Plug #14 AWG
(NEMA Type 5-15P) (2.1 mm2) or LargerFor lengths up to
MAXIMUM 115V/60Hz 25 Amp 25 25 Amp, 125V, 25 Ft. (7.5 m)Three Prong Plug
(NEMA Type 5-20P) Three Conductor#12 AWG
CSA 115V/60Hz 15 Amp 12 15 Amp, 125V, (3.3 mm2)Three Prong Plug For lengths up to
(NEMA Type 5-15P) 50 Ft. (15 m)
TECHNICAL SPECIFICATIONS – SP-100INPUT – SINGLE PHASE ONLY
RATED OUTPUT
OUTPUT
RECOMMENDED INPUT CABLE AND FUSE SIZES
Height Width Depth Weight12.0 in 9.75 in 16.5 in 54 Ibs305 mm 248 mm 419 mm 24.3 kg
PHYSICAL DIMENSIONS
Standard Voltage/Frequency Input Current115V/60Hz 20 Amps - Rated Output115V/60Hz 25 Amps - Maximum Output115V/60Hz 12 Amps - CSA Rated output
Duty Cycle Amps Volts at Rated Amperes20% Duty Cycle 90 1830% Duty Cycle 100 17
20% Duty Cycle - CSA Rated Output 63 20
Welding Current Range (Continuous) Maximum Open Circuit Voltage Auxiliary PowerRated DC Output: 0 - 90 amps 28 N/A
Maximum DC Output: 0 - 100 ampsCSA Rated DC Output: 0 - 63 amps
A-2INSTALLATION
SP-100
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installation.
SAFETY PRECAUTIONS
IDENTIFY AND LOCATE COMPONENTS
If you have not already done so, unpack the SP-100from its carton and remove all packing materialaround the SP-100. Remove the following loose itemsfrom the carton (see Figure A.1):
1. SP-100
2. Gun and cable assembly(1)
3. Literature envelope which contains:
a) This operating manual
b) A contact tip for .030” (0,8 mm) diameter wire.
4. 10 ft (3,0 m) work cable.
5. Work clamp.
(1) Gun is ready to feed .025" (0.6 mm) diameter wire(also .023 and .024 diameter wire).
ELECTRIC SHOCK can kill.
• Only qualified personnel should performthis installation.
• Only personnel that have read and under-stood the SP-100 Operating Manual shouldinstall and operate this equipment.
• Machine must be plugged into a receptaclewhich is grounded per any national, localor other applicable electrical codes.
• The SP-100 power switch is to be in theOFF (“O”) position when installing workcable and gun and when connecting powercord to input power.
WARNING
FIGURE A.1
1
2
3a
3b
4
5
A-3 INSTALLATION
SP-100
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OC SELECT SUITABLE LOCATION
Locate the welder in a dry location where there is freecirculation of clean air into the louvers in the back andout the front of the unit. A location that minimizes theamount of smoke and dirt drawn into the rear louversreduces the chance of dirt accumulation that can blockair passages and cause overheating.
STACKING
SP-100’s cannot be stacked.
TILTING
Each machine must be placed on a secure, level sur-face, either directly or on a recommended undercar-riage. The machine may topple over if this procedureis not followed.
OUTPUT CONNECTIONS
Refer to Figure A.2.
1. Work Cable Access Hole.
2. Gun Cable and Control Lead Access Hole.
3. Connector Block.
4. Gun Trigger Lead Connectors.
5. Positive (+) and negative (–) output terminals.
WORK CLAMP INSTALLATION
Attach the work clamp per the following:
1. Unplug the machine or turn the power switch to the“OFF” position.
2. Insert the work cable terminal lug with the largerhole through the strain relief hole in the work clampas shown in Figure A-3.
3. Fasten securely with the bolt and nut provided.
FIGURE A.3
WORK CABLE INSTALLATION
Refer to Figure A.2.
1. Open the wire feed section door on the right side ofthe SP-100.
2. Pass the end of the work cable that has the termi-nal lug with the smaller hole through the WorkCable Access Hole (1) in the case front.
Strain Relief Hole
Nut & Bolt
Work Clamp
Work Cable
FIGURE A.2
21
3
4
5
67
8
A-4 INSTALLATION
SP-100
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Wire Feed Gearbox (6).
4. For GMAW Only: Refer to Figure A.2. As deliv-ered, the SP-100 is wired for positive polarity. Thisis the appropriate configuration for the Gas MetalArc Welding (GMAW) process. To complete instal-lation, use the provided wing nut to connect thework cable’s terminal lug to the negative (–) outputterminal (5) located above the Wire Feed Gearbox(6). Make sure that both wing nuts are tight.
5. For Innershield Only: Refer to Figure A.4. To wirefor negative polarity, connect the short cableattached to the connector block (1) to the negative(–) output terminal (2) and the work cable (3) to thepositive (+) terminal (4).
FIGURE A.4
3. Insert the connector on the gun conductor cableinto the Gun Cable Access Hole (2) in the SP-100case front. Make sure the connector is all the wayin the metal connector block to obtain proper gasflow. Rotate the connector so control leads are onthe underside and tighten the Thumbscrew (8) inthe connector block.
4. Connect the gun trigger control lead terminals tothe two insulated 1/4" (6,4 mm) tab connectorbushings located above the “Gun TriggerConnection” decal in the wire feed section (4).Either lead can go to either connector. Form theleads so that they are as close as possible to theinside panel.
If the gun trigger switch being used is other thanthat supplied with the SP-100, the switch must bea normally open, momentary switch. The terminalsof the switch must be insulated from the weldingcircuit. Malfunction of the SP-100 may result if thisswitch shorts to the SP-100 welding output circuitor is common to any electrical circuit other thanthe SP-100 trigger circuit.
GAS CONNECTION
Refer to Figure A.5
When using the GMAW process, a cylinder of carbondioxide (CO2) or argon-carbon dioxide mixed shieldinggas, flow regulator, and an inlet gas hose must beobtained. For more information about selecting gascylinders for use with the SP-100, refer to the ACCES-SORIES section.
CYLINDER may explode if dam-aged. Keep cylinder upright andchained to support
• Keep cylinder away from areaswhere it may be damaged.
• Never lift welder with cylinderattached.
• Never allow welding electrode totouch cylinder.
• Keep cylinder away from weldingor other live electrical circuits.
GUN INSTALLATION
As shipped from the factory, the SP-100 gun is readyto feed 0.023 - 0.025” (0,6 mm) wire. If 0.030” (0,8mm) wire is to be used install the 0.030” (0.8 mm)contact tip. Refer to the MAINTENANCE section forcontact tip installation details.
CONNECTING GUN CABLE TO THE SP-100
1. Refer to Figure A.2. Unplug the machine or turnpower switch to the off “O” position.
2. Pass the insulated terminals of the gun trigger con-trol leads, one at a time, through the Gun Cableand Control Lead Access Slot (2) in the case front.The leads are to be routed under the Wire FeedGearbox (6) and through the Cable Hanger (7) onthe inner panel.
CAUTION
WARNING
1
2
34
3. Attach the flow regulator to the cylinder valve andtighten the union nut securely with a wrench. Theflow regulator for carbon dioxide must have a plas-tic washer seated in the fitting that attaches to thecylinder to prevent leakage.
4. Refer to Figure A.6. Attach one end of inlet gashose to the outlet fitting of the flow regulator andtighten the union nut securely with a wrench.Connect the other end to the SP-100 Gas SolenoidInlet Fitting (5/8-18 female threads — for CGA —032 fitting). Make certain the gas hose is notkinked or twisted.
INPUT CONNECTIONS
Refer to Figure A.6.
The SP-100 has two input connections, the powerinput cable, and the Gas Solenoid Inlet Fitting. Bothconnections are located on the rear of the machine.
FIGURE A.6
BUILDUP OF SHIELDING GAS mayharm health or kill.
• Shut off shielding gas supplywhen not in use.
• SEE AMERICAN NATIONALSTANDARD Z-49.1, “SAFETY INWELDING AND CUTTING” PUB-LISHED BY THE AMERICANWELDING 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 earthground.
FIGURE A.5
2. With the cylinder securely installed, remove thecylinder cap. Stand to one side away from the out-let and open the cylinder valve very slightly for aninstant. This blows away any dust or dirt which mayhave accumulated in the valve outlet.
BE SURE TO KEEP YOUR FACE AWAY FROM THEVALVE OUTLET WHEN “CRACKING” THE VALVE.Never stand directly in front of or behind the flowregulator when opening the cylinder valve. Alwaysstand to one side.
A-5 INSTALLATION
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WARNING
Cylinder Valve
Gas Hose
Flow Regulator
Gas SolenoidInlet Fitting
PowerInputCable
A-6 INSTALLATION
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CONNECTIONS
This welding machine must be connected topower source in accordance with applicable elec-trical codes.
The United States National Electrical Code (Article630-B, 1990 Edition) provides standards for amperagehandling capability of supply conductors based onduty cycle of the welding source.
If there is any question about the installation meetingapplicable electrical code requirements, consult aqualified electrician.
Do not connect the SP-100 to an input power sup-ply with a rated voltage that is greater than 125volts.
Do not remove the power cord ground prong.
REQUIREMENTS FOR RATED OUTPUT
A power cord with a 15 amp, 125 volt, three prongplug (NEMA Type 5-15P) is factory installed on theSP-100. Connect this plug to a mating groundedreceptacle which is connected to a 20 amp branch cir-cuit with a nominal voltage rating of 115 to 125 volts,60 Hertz, AC only.
The rated output with this installation is 90 amps, 18Volts, 20% duty cycle (2 minutes of every 10 minutesused for welding).
REQUIREMENTS FOR MAXIMUM OUTPUT
An optional power cord (K467 Input Line Cord) isavailable to permit the SP-100 to be connected to a25 amp branch circuit with a nominal voltage rating of115 to 125 volts, 60 Hertz, AC only. With this installa-tion the SP-100 can be used at an output of 100amps, 17 volts, 30% duty cycle.
Refer to the ACCESSORIES section for specific infor-mation about the K467 Input Line Cord
REQUIREMENTS FOR CSA RATED OUTPUT
A line cord with a 15 amp, 125 volt, three-prong plug(NEMA Type 5-15P) is factory installed. Connect thisplug to a mating grounded receptacle which is con-nected to a 15 amp branch circuit with a nominal volt-age rating of 115 volts to 125 volts, 60 hertz, AC only.With this installation, the SP-100 can be used at anoutput of 63 amps, 20 volts, 20% duty cycle.
EXTENTION CORD USAGE
If an extension cord is required, use one that is ratedfor the application and is 3 conductor #14 AWG (2.1mm2) or larger. The recommended maximum lengthsare 25 ft (7.5 m) if #14 AWG (2.1 mm2) is used and 50 ft (15 m) if #12 AWG* (3.3 mm2) is used.
WARNING
CAUTION
A7 NOTES
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SP-100
TABLE OF CONTENTS– OPERATION SECTION –
Operation ...........................................................................................................Section BSafety Precautions ......................................................................................................B-1General Description ....................................................................................................B-2
Recommended Processes.....................................................................................B-2Operational Features and Controls........................................................................B-2Design Features and Advantages .........................................................................B-2Welding Capability ................................................................................................B-2Limitations .............................................................................................................B-2
Controls and Settings...................................................................................................B-2Welding Operations......................................................................................................B-3
Process Guidelines................................................................................................B-3Sequence of Operations........................................................................................B-3Wire Loading..........................................................................................................B-3Friction Brake Adjustments....................................................................................B-4Wire Threading ......................................................................................................B-4Shielding Gas .......................................................................................................B-5Making a Weld ......................................................................................................B-5Cleaning Tip and Nozzle........................................................................................B-6Changing Machine Over To Feed Other Wire Sizes .............................................B-6Welding With Innershield .......................................................................................B-6
Overload Protection .....................................................................................................B-6Output Overload ....................................................................................................B-6Thermal Protection ................................................................................................B-6Wire Feed Overload Protection ............................................................................B-6
Section B
B-1
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OPERATION
Read entire operation section beforeoperating the SP-100.
ELECTRIC SHOCK can kill.• Do not touch electrically live
parts or electrode with skin orwet clothing. Insulate yourselffrom work and ground.
• Always wear dry insulatinggloves.
FUMES AND GASES can bedangerous.• Keep your head out of fumes.
• Use ventilation or exhaust toremove fumes from breathingzone.
WELDING SPARKS cancause fire or explosion.• Keep flammable material away.
• Do not weld on closed contain-ers.
ARC RAYS can burn eyesand skin.• Wear eye, ear and body protec-
tion.
Observe all safety information throughoutthis manual.
WARNING
B-2
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OPERATIONGENERAL DESCRIPTION
The SP-100, Type K462, is a complete semiautomaticconstant voltage DC arc welding machine. Included isa solid state controlled, single phase constant voltagetransformer/ rectifier power source and a wire feederfor feeding solid steel electrode and cored electrode.
The SP-100 is ideally suited for individuals havingaccess to 115 volt AC input power, and wanting theease of use, quality and dependability of both gasmetal arc welding or GMAW (also known as MIGwelding) and the Innershield electrode process (selfshielded flux cored or FCAW). The SP-100 is arugged and reliable machine that has been designedfor dependable service and long life.
RECOMMENDED PROCESSES
The SP-100 can be used for welding mild steel usingthe GMAW, single pass, process which requires asupply of shielding gas or it can be used for the selfshielded, Innershield electrode process (FCAW). TheSP-100 is configured for use with the GMAW (MIG)process as delivered from the factory.
OPERATIONAL FEATURES AND CONTROLS
The SP-100 has the following controls as standard:Power ON/OFF Switch, Voltage Control, Wire SpeedControl, and a Circuit Breaker.
DESIGN FEATURES AND ADVANTAGES
● Operates on 115 volt input — no special wiringrequired.
● Solid state output control.
● “Cold electrode” until gun trigger is pressed for anadded measure of safety.
● Overload protection — incorporates both a thermo-stat and a circuit breaker.
● Quality wire drive with electronic overload protec-tion.
● Easy-to-set continuous range controls for precisesetting of arc voltage and wire speed.
● Continuous voltage control.
● “Quick Release” idle roll pressure arm is easilyadjusted.
● Reversible, dual groove drive roll. Drive roll willfeed .023-.025” (0,6- 0,9 mm) diameter wire.
● Accommodates both 8” (200 mm) diameter and 4”(100 mm) diameter spools of wire.
● No external shielding gas is required when usedwith Lincoln Innershield .035” (0,9 mm) NR®-211-MP electrode.
● Easy to change polarity.
WELDING CAPABILITY
The SP-100 is rated at 90 amps, 18 volts, at 20% dutycycle on a ten minute basis. It is capable of higherduty cycles at lower output currents.
LIMITATIONS
Arc Gouging cannot be performed with the SP-100.The SP-100 is not recommended for pipe thawing.
CONTROLS AND SETTINGS
Refer to Figure B.1a.
1. Power ON/OFF Switch —When the power is on thefan motor will run and air willbe exhausted out the louversin the front of the machine.The welding output and wirefeeder remain off until thegun trigger is pressed.
2. Voltage Control — A contin-uous control that gives fullrange adjustment of powersource output voltage.Voltage can be adjustedwhile welding.
3. Wire Speed Control —Controls the wire feed speedfrom 50 – 400 in /min (1.3 –10 m/min). The control canbe preset on the dial to thesetting specified on the SP-100 Application Guide locat-ed on the inside of the wirefeed section door. Wirespeed is not affected whenchanges are made in thevoltage control.
I On
O Off
VArc Volts
o|oWire Speed
B-3
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OPERATIONFIGURE B.1a
Refer to Figure B-1b.
4. Circuit Breaker - Protects machine from damage ifmaximum output is exceeded. Button will extendout when tripped (Manual reset).
FIGURE B.1b
WELDING OPERATIONS
PROCESS GUIDELINES
The SP-100 can be used for welding mild steel usingthe GMAW, single pass, process which requires asupply of shielding gas or it can be used for the selfshielded, Innershield electrode process.
The recommended gas and electrode for GMAW iswelding grade CO2 gas and 0.025” (0 6 mm) diameterLincoln L-56 mild-steel welding wire [supplied on121/2 Ib (6 kg) spools]. For 14 gauge (2,0 mm) andthinner, CO2 gas is recommended because it givesequal or better performance than a blended gas at alower cost. A mixed gas consisting of 75 to 80% Argonand 20 to 25% CO2 is recommended for welding onheavier gauge [12 gauge (2,5 mm) for example] steel.
The recommended electrode for the self-shieldedprocess is 0.035” (0,9 mm) diameter LincolnInnershield NR-211-MP on 10 Ib (4,5 kg) spools. Thiselectrode can be used for all position welding of 20gauge through 5/16” (1 0 – 8,0 mm) thick steel [multi-ple passes are required for 1/4” and 5/16” (6,0 and 8,0mm)].
SEQUENCE OF OPERATION
WIRE LOADINGRefer to Figure B.2. and B.3.
The machine power switch should be turned to theOFF (“O”) position before working inside the wire feedenclosure.
The machine is shipped from the factory ready tofeed 8” (200 mm) diameter spools [2.2” (56 mm)max. width]. These spools fit on a 2” (50 mm) diame-ter spindle that has a built-in adjustable* friction braketo prevent overrun of the spool and excess slack inthe wire. The thumb screw at the end of the shaft isnot intended to be loosened. It should be tightened fullclockwise. NOTE: If full tightening of the spindlethumbscrew causes too much tension in the wirespool, the thumb screw stop point should beadjusted.
*Earlier spindle shafts did not include a set screw toadjust brake friction. If a set screw is desired, orderLincoln part number T12932-2.
Load an 8” (200 mm) diameter spool on the wire spoolspindle shown in Figure B.2.
To use 4” (100 mm) diameter spools, the 2” (50mm) diameter spindle must be removed (See FigureB.3). Remove the thumb screw at the end of the shaftand remove the spindle. The spindle can be stored inthe wire feed compartment. A 4’ (100 mm) diameterspool is mounted directly on the 5/8” (16 mm) diame-ter shaft and held in place with the previously removedthumb screw. Make certain that the thumbscrew is
3
21
4
B-4
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OPERATION
tightened fully clockwise. Also make certain the startend of the wire, which may protrude through the sideof the spool does not contact any metallic case parts.
FIGURE B.3
FRICTION BRAKE ADJUSTMENTS1. Remove the Wire Spool thumbscrew.
2. Using a 3/16” (4,8 mm) hex wrench, turn the setscrew, located inside the tapped hole in the spindleshaft, one or two turns counter-clockwise.
3. Fully reinstall the thumbscrew and check for properbrake force to prevent spool overrun, but still allowsmooth and easy wire feeding. Readjust, if neces-sary.
WIRE THREADING Refer to Figure B-4
1. Release the Spring Loaded Pressure Arm (1)rotate the Idle Roll Arm (2) away from. the WireFeed Drive Roll (3). Ensure that the visible, .sten-ciled size on the drive roll matches the wire sizebeing used.
2. Carefully detach the end of the wire from thespool. To prevent the spool from unwinding, donot release the wire until after step 5.
3. Cut the bent portion of wire off and straighten thefirst 4” (100 mm).
4. Thread the wire through the In-going guide tube(4), over the drive roll (3), and into the out-goingguide tube (5).
5. Close the idle roll arm and latch the spring loadedpressure arm (2) in place (now you may releasethe welding wire).
6. The idle roll pressure adjustment wing nut is nor-mally set for mid-position on the pressure armthreads. If feeding problems occur because thewire is flattened excessively, turn the pressureadjustment counter-clockwise to reduce distortionof the wire. Slightly less pressure may be requiredwhen using 0.023 – 0.025” (0,6 mm) wire. If thedrive roll slips while feeding wire, the pressureshould be increased until the wire feeds properly.
FIGURE B.4
The Wire Drive Feed Roll canaccommodate two wire sizes byflipping the wire drive feed rollover. The sizes are stenciled onthe drive roll.
1
2
345
Wire Spindle Shaft 4" Wire Spool
Thumb Screw
To Wire Drive
Wire Spool must be pushed all the way on the spindle so that thespindle’s tab will hold it in place. The Wire Spool will rotate clock-wise when wire is dereeled.
8” Wire SpoolWire Spool Spindle
Be sure that this stud engagesthe hole in the wire spool.
To Wire Drive
FIGURE B.2
B-5
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OPERATION
When inching the welding wire, the drive rolls, thegun connector block and the gun contact tip arealways energized relative to work and ground andremain energized several seconds after the guntrigger is released.
7. Refer to Figure B.5. Remove gas nozzle and con-tact tip from end of gun.
8. Turn the SP-100 ON (“I”).
9. Straighten the gun cable assembly.
10. Depress the gun trigger switch and feed weldingwire through the gun and cable. (Point gun awayfrom yourself and others while feeding wire.)Release gun trigger after wire appears at end ofgun.
11. Replace contact tip and gas nozzle.
12. Refer to Figure B-6. Cut the wire off 1/4” – 3/8” (6– 10 mm) from the end of the tip. The SP-100 isnow ready to weld.
SHIELDING GASWhen using the GMAW process, a cylinder of carbondioxide (CO2) or argon-carbon dioxide mixed shieldinggas, flow regulator, and an inlet gas hose must beobtained. Refer to the ACCESSORIES section formore information about selecting gas cylinders for usewith the SP-100.
1. For CO2, open the cylinder very slowly. For argon-mixed gas, open cylinder valve slowly a fraction ofa turn. When the cylinder pressure gauge pointerstops moving, open the valve fully.
FIGURE B.6FIGURE B.5
Gun Handle
Gas Diffuser/Contact Tip
Gas Nozzle
WARNING2. If using a regulator with an adjustable flow meter,
close the gun trigger and adjust the flow to give 15– 20 cubic ft per hour (CFH) (7 – 10 I/min) [use 20-– 25 CFH (10 – 12 I/min) when welding out ofposition or in a drafty location for CO2]. For argonmixed gas, trigger to release gas pressure, andturn off the adjust the flow to give 25 – 30 CFH(12 – 14 I/min).
3. Keep the cylinder valve closed, except when usingthe SP-100. When finished welding:
a) Close the cylinder valve to stop gas flow.
b) Depress the gun trigger briefly to release thepressure in the gas hose.
c) Turn off the SP-100.
MAKING A WELD1. See Recommended Processes And Equipment
section for selection of welding wire and shieldinggas and for range of metal thicknesses that can bewelded.
2. See the Application Guide on the inside of wirefeed section door for information on setting theSP-100 controls.
3. Set the Voltage (“V”) and Wire Speed (“olo’”) con-trols to the settings suggested for the welding wireand base metal thickness being used.
4. Check that the polarity is correct for the weldingwire being used and that the gas supply, ifrequired, is turned on.
5. When using Innershield electrode, remove the gasnozzle and install the gasless nozzle. This willimprove visibility of the arc and protect the gas dif-fuser from weld spatter. Refer to the MAINTE-NANCE section for details on nozzle replacement.
3/8" – 1/2" Electrical Stickout
Contact Tip
Wire Electrode
B-6
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OPERATION
6. Refer to Figure B.7. Connect work clamp to metalto be welded. Work clamp must make good elec-trical contact to the workpiece. The workpiecemust also be grounded as stated in “Arc WeldingSafety Precautions” in the beginning of this manu-al.
7. Position gun over joint. End of wire may be lightlytouching the work.
8. Lower welding helmet, close gun trigger, andbegin welding Hold the gun so the contact tip towork distance is about 3/8 inch (10 mm).
9. To stop welding, release the gun trigger and thenpull the gun away from the work after the arc goesout
10. When no more welding is to be done, close valveon gas cylinder (if used), momentarily operate guntrigger to release gas pressure, and turn off theSP-100.
CLEANING TIP AND NOZZLEClean the contact tip and nozzle to avoid arc bridgingbetween the nozzle and contact tip which can result ina shorted nozzle, poor welds and an overheated gun.Hint: Anti-stick spray or gel, available from a weldingsupply distributor, may reduce buildup and aid in spat-ter removal.
CHANGING MACHINE OVER TO FEEDOTHER WIRE SIZES
The SP-100 is shipped from the factory ready to feed0.023-0.025” (0,6 mm) diameter wire. To operate theSP-100 with other sizes of wire, it is necessary tochange the contact tip and change the drive roll overto other sizes. Refer to Changing the Contact Tip andChanging the Drive Roll, in the MAINTENANCE sec-tion, for specific information on these procedures.
WELDING WITH INNERSHIELD
Welding with Innershield requires an InnershieldWelding Kit. A gasless nozzle is provided in theInnershield Welding Kit. When using Innershield elec-trode, installing the gasless nozzle will improve visibili-ty of the arc and protect the gas diffuser from weldspatter. Additionally included is a gun cable liner topermit proper feeding of .035” (0,9 mm) Innershieldwire. Refer to the ACCESSORIES section for detailson obtaining this kit.
OVERLOAD PROTECTION
OUTPUT OVERLOADThe SP-100 is equipped with a circuit breaker whichprotects the machine from damage if maximum outputis exceeded. The circuit breaker button will extend outwhen tripped. The circuit breaker must be manuallyreset.
THERMAL PROTECTIONThe SP-100 has a rated output duty cycle of 20%. Ifthe duty cycle is exceeded, a thermal protector willshut off the output until the machine cools to a normaloperating temperature. This is an automatic functionof the SP-100 and does not require user intervention.
WIRE FEED OVERLOAD PROTECTIONThe SP-100 has an automatic electronic protection cir-cuit to protect the wire feed motor. If excessive motoroverload occurs (due to excessive feeding forcejammed drive rolls, or shorted motor leads) the circuitwill shut down the wire feed motor and the weldingpower output.
The wire feed shut-down circuit will reset automaticallywhen the gun trigger is released. However shut-downwill reoccur if the overload situation is not corrected.
FIGURE B.7
Gun Cable
Work Piece
Arc
B-7
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NOTES
SP-100
Section C TABLE OF CONTENTS– ACCESSORIES SECTION –
Accessories .....................................................................................................Section CAccessories ...........................................................................................................C-1Replacement Parts ................................................................................................C-1
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C-1 ACCESSORIESK467 INPUT LINE CORD
The K467 Input Line Cord is the same asthe line cord supplied with the SP-100, buthas a NEMA type 5-20P plug for use on 25amp branch circuits.
To install optional features, refer to in-structions included with the kit.
REPLACEMENT PARTS
Complete Gun and Cable AssemblyL7538 – Black Trigger; L8311-2 (K530-2) –Red Trigger
Contact Tip 0.025” (0,6 mm)S18704-1 – Black Trigger; S19726-1 – RedTrigger
Contact Tip 0.030” (0,8 mm)S18704-2 – Black Trigger; S19726-2 – RedTrigger
Contact Tip 0.035” (0,9 mm)S18704-3 – Black Trigger; S19726-3 – RedTrigger
Liner 0.023 - 0.030” (0,6 - 0,8 mm)S18704-4 – Black Trigger; M16291-2 – RedTrigger
Liner 0.035” (0,9 mm)S18704-5 – Black Trigger; M16291-1 – RedTrigger
Gas DiffuserS18704-6 – Black Trigger; S19728 – RedTrigger
Gas NozzleS18704-7 – Black Trigger; M16294 – RedTrigger
Gasless Nozzle (Innershield Only)S18704-14 – Black Trigger; M16418 – RedTrigger
LINCOLN GAS REGULATOR KITS
The Lincoln K463 CO2 or K499 Ar-mixedGas Regulator and Hose Kit is recommend-ed for use with the SP100.
K463 CO2 RegulatorThe K463 kit includes a preset, non-adjustable pressure flow regulator for useon CO2 cylinders. The K463 CO2 pressure-flow regulator is preset at the factory to pro-vide a flow rate of 20 cubic feet per hour (10l/min). This setting cannot be changed. Alsoincluded is a 10 foot (3,0 m) gas hose whichconnects to the rear of the SP-100.
The K463 CO2 pressure-flow regulator canbe used with a cylinder of argon mixed gasif a CGA-580-320 (Western Enterprises No.810) adapter is used between the cylinderand the regulator.
Weld shielding gas may be obtained from awelding supply distributor.
K499 Ar-Mixed Gas RegulatorK499 Ar-Mixed Gas Regulator and Hose Kit– Includes a preset, non-adjustable pres-sure and flow regulator for use on argon-mixed gas cylinders. Also included is a 10foot (3 0 m) gas hose which connects to therear of the SP-100.
INNERSHIELD WELDING KITS
0.035 (0.9 mm) Innershield Welding Kit– Includes a contact tip, a gasless nozzleand a cable liner to permit the SP-100 gunand cable to use a 0.035” (0,9 mm) dia-meter flux-cored electrode. Also includedis a spool of 0.035 (0,9 mm) InnershieldNR-211-MP.
Two kits are available:
K549-1 kit is for use with Magnum 100Lgun (with red trigger).
K464 kit is for use with the originalLincoln Electric gun (with black trigger).
DRIVE ROLL
M15448-1 Reversible Drive Roll with doubleknurled grooves for 0.035 (0,9 mm) coredelectrode.
SP-100
Section D TABLE OF CONTENTS– MAINTENANCE SECTION –
Maintenance ...................................................................................................Section DSafety Precautions ...............................................................................................D-1Items Requiring No Maintenance .........................................................................D-1Routine and Periodic Maintenance........................................................................D-1
Before Each Use.............................................................................................D-1After 5 Minutes of Welding..............................................................................D-1After Each Spool of Wire Feed .......................................................................D-1
Component Replacement Procedures ..................................................................D-2Changing The Contact Tip ..............................................................................D-2Changing Drive Roll .......................................................................................D-2Replace Liner..................................................................................................D-3Replace Internal Gun Handle Parts As Necessary .........................................D-3
Location of Components........................................................................................D-4
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FEED
• Remove contact tip and clean inside diam-eter with short piece of wire
• Clean cable liner – when rough and erraticwire feeding occur.
AFTER FEEDING 50# OF FLUXCORED WIRE OR 300# OF SOLIDWIRE• Unplug machine or turn power switch to
OFF – “O” position. Remove gun andcable from machine.
• Remove gas nozzle and contact tip fromgun
• Lay cable out straight - blow out gentlywith compressed air. Bend cable back andforth – blow out again – Repeat until clean.
Excessive pressure at start may causethe dirt to form a plug.
PERIODICALLY AS REQUIRED
• Unplug machine or turn power switch toOFF – “O” position.
• Blow dirt out of the welder with low pres-sure air to eliminate excessive dirt anddust buildup that could cause welder torun hot.
• Blow dirt out of: Rectifier & Fan MotorAssembly; PC Board located on CaseSide Assembly; and Center Assemblycomponents. Refer to Figure D.4.
• Vacuum accumulated dirt from gear-box and wire feed section. Refer to Figure D.4
• Inspect the incoming guide tube andclean inside diameter if necessary.Replace when excessively worn.
• Replace Contact Tip – when hole isenlarged or elongated (refer to ChangingContact Tip, below).
D-1 MAINTENANCESAFETY PRECAUTIONS
ELECTRIC SHOCK cankill.
• Disconnect input powerby removing plug fromreceptacle before work-ing inside SP-100.Useonly grounded recepta-cle. Do not touch electri-cally “hot” parts insideSP-1 00.
• Have qualified person-nel do the maintenanceand trouble shootingwork.
ITEMS REQUIRING NOMAINTENANCE
• Drive Motor and Gearbox – Lifetime lubrication
• Fan Motor- Lifetime lubrication.• Wire Reel Spindle – Do NOT lubricate
shaft.
ROUTINE AND PERIODICMAINTENANCE
BEFORE EACH USE• Check over machine and accessories for
any obvious condition that may preventsafe performance or operation, repair orreplace items as necessary to correct anyabnormal condition.
AFTER 5 MINUTES OF WELDING or when spatter accumulates innozzle
• Clean nozzle to avoid bridging betweennozzle and contact tip which results inshorted nozzle, poor welds and overheat-ed gun. Hint: Anti-stick spray or gel avail-able from a welding supply distributor mayreduce buildup and aid in spatter removal.
WARNING
CAUTION
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D-2MAINTENANCE
1. Make certain the SP-100 power switch isoff “O”.
2. Open the Spring Loaded Pressure Arm(2); Lift up the Idle Roll Arm (3).
3. Remove the drive roll retaining screw andwasher.
4. Remove the drive roll, flip over and installwith the 0.030/0.035” (0.8/0.9 mm) stencilvisible (away from gearbox). Make cer-tain the small key is in place in the key-way.
5. Replace the washer and retaining screw.
• Replace Liner – when wire feeding prob-lems occur and other items have beenchecked (refer to Changing Liner, in thissection).
COMPONENT REPLACE-MENT PROCEDURES
CHANGING THE CONTACT TIP
1. Refer to Figure D.2. Remove the gasnozzle from the gun by unscrewingcounter-clockwise.
2. Remove the existing contact tip from thegun by unscrewing counter-clockwise.
3. Insert and hand tighten desired contacttip.
4. Replace gas nozzle.
CHANGING DRIVE ROLL
The SP-100 Wire Feed Drive Roll (1 ) hastwo grooves; one for 0.023” – 0.025” (0,6mm) solid steel electrode and the other for0.030” (0,8 mm) solid and 0.035” (O,9 mm)flux-cored steel electrode. See Figure D.1.As shipped, the drive roll is installed in the0.023” – 0.025” (0,6 mm) position (as indi-cated by the stenciling on the exposed sideof the drive roll). If 0.030” (0,8 mm) or0.035” (0,9 mm) wire is to be used, the driveroll must be reversed as follows:
Wire size is stenciledon the ends of thedrive roll.
3
2
1
1-1/4 (31.8 mm)Liner Trim Length
Gas Diffuser
Gas Nozzle orGasless Nozzle
Set Screw Brass CableConnector
Liner Assembly (Liner bushing to be sealed tightagainst brass cable connector)
FIGURE D.2Liner trim length for the Magnum 100L gun (red trigger)
FIGURE D.1
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D-3 MAINTENANCEREPLACE INTERNAL GUN HANDLE PARTS AS NECESSARY
The gun handle consists of two halves thatare held together with a collar on each end.To open up the handle, turn the collarsapproximately 60 degrees counter-clock-wise (the same direction as removing a righthand thread) until the collar reaches a stop.Then pull the collar off the gun handle. If thecollars are difficult to turn, position the gunhandle against a corner, place a screwdriv-er against the tab on the collar and give thescrewdriver a sharp blow to turn the collarpast an internal locking rib. See Figure D-3.
FIGURE D.3
CHANGING LINER
NOTICE: The variation in cable lengths pre-vents the interchangeability of liners. Oncea liner has been cut for a particular gun, itshould not be installed in another gununless it can meet the liner cutoff lengthrequirement. Refer to Figure D.2.
1. Remove gun and cable assembly frommachine.
2. Remove the gas nozzle from the gun byunscrewing counter-clockwise.
3. Remove the existing contact tip from thegun by unscrewing counter-clockwise.
4. Remove the gas diffuser from the guntube by unscrewing counter-clockwise.
5. Lay the gun and cable out straight on aflat surface. Loosen the set screw locat-ed in the brass connector at the wirefeeder end of the cable. Pull the liner outof the cable.
6. Insert a new untrimmed liner into theconnector end of the cable. Be sure theliner bushing is stenciled appropriatelyfor the wire size being used.
7. Fully seat the liner bushing into the con-nector. Tighten the set screw on thebrass cable connector. At this time, thegas diffuser should not be installed ontothe end of the gun tube.
8. With the gas nozzle and diffuserremoved from the gun tube, be sure the cable is straight, and then trim theliner to the length shown in the FigureD.2. Remove any burrs from the end ofthe liner.
9. Screw the gas diffuser onto the end ofthe gun tube and securely tighten.
10.Replace the contact tip and nozzle.
➣
Counter-clockwise
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D-4 MAINTENANCE
FIGURE D.4 – LOCATION OF COMPONENTS
1 Case Back and Bottom Assembly2 Center Panel Assembly3 Case Front Assembly4 Case Side Assembly5 Rectifier & Fan Motor Assembly6 Wire Drive Assembly
SP-100 SUB ASSEMBLIES
1
2
3
4
5
6
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D-5 NOTES
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SP-100
Theory of Operation ........................................................................................Section EInput Line Voltage, Fan Motor and Main Transformer ...........................................E-1Output Control, Rectification and Voltage Feedback.............................................E-2Trigger, Gas Solenoid and Wire Drive ..................................................................E-3SCR Operation ......................................................................................................E-4Thermal Protection ................................................................................................E-5
Section E TABLE OF CONTENTS– THEORY OF OPERATION –
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E-1 THEORY OF OPERATION
NOTE: Unshaded areas of block logic diagram are the subject of discussion.
INPUT LINE VOLTAGE, FANMOTOR AND MAIN TRANSFORMER
The 115 vac input power is applied to theSP-100 through a receptacle located on therear panel. The input power is connected tothe fan motor, control board and maintransformer through a line switch located onthe front panel. A circuit breaker is incorpo-rated in the 115 vac circuit to protect theunit from current overloads. The fan motoremploys a 24 vac auxiliary winding whichpowers the control board. The main trans-former changes the high voltage, low cur-rent input power to a low voltage, high cur-rent output for welding.
FIGURE E.1 – Input Power Circuits
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E-2 THEORY OF OPERATION
NOTE: Unshaded areas of block logic diagram are the subject of discussion.
OUTPUT CONTROL, RECTIFICA-TION AND VOLTAGE FEEDBACK
The AC voltage that is applied to the maintransformer primary is controlled at the con-trol board by two SCR’s (Silicon ControlledRectifiers). The SCR’s are controlled by apulse signal developed on the control board.The control board compares the commandsof the arc voltage control with the voltagefeedback signal. The board circuitry thensends a pulse to turn on the SCR’s. In thismanner, the voltage applied to the primaryof the transformer is varied and controlled.This variable and controlled voltage is
FIGURE E.2 – Output Circuits
reflected at the transformer secondary wind-ing and is applied to the rectifier diodebridge. This rectified DC voltage is filteredby the output capacitor and choke circuitand is applied to the machine’s output ter-minals.
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E-3 THEORY OF OPERATION
NOTE: Unshaded areas of block logic diagram are the subject of discussion.
TRIGGER, GAS SOLENOID AND WIRE DRIVE
Closure of the trigger circuit (pulling the guntrigger) signals the control board to startseveral functions. 115 vac is applied to thegas solenoid to allow shielding gas to flow.The SCRs are activated and voltage isapplied to the main transformer. Output volt-age is developed at the output terminals andfed back to the control board. This weldingoutput voltage is also used to power the wiredrive motor.
FIGURE E.3 – Trigger, Gas Solenoid and Wire Drive
The welding output voltage that powers thewire drive motor is varied and controlled onthe control board. The control board moni-tors the drive motor armature current andvoltage and compares the feedback infor-mation with the commands sent from thewire speed control. The control board variesand controls power to the drive motor,which, in turn, controls the speed of the wiredrive. The SP-100 also has an automaticprotection circuit which protects the wiredrive motor from excessive motor over-loads.
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E-4 THEORY OF OPERATIONAn SCR is fired by a short burst of currentinto the gate. This gate pules must be morepositive than the cathode voltage. Sincethere is a standard PN junction betweengate and cathode, the voltage betweenthese terminals must be slightly greaterthan 0.6V. Once the SCR has fired, it is notnecessary to continue the flow of gate cur-rent. As long as current continues to flowfrom anode to cathode, the SCR will remainon. When the anode to cathode currentdrops below a minimum value, called hold-ing current, the SCR will shut off. This nor-mally occurs as the AC voltage passesthrough zero into the negative portion of thesine wave. If the SCR is turned on early inthe positive half cycle, the conduction timeis longer, resulting in greater SCR output. Ifthe gate firing occurs later in the cycle, theconduction time is less, resulting in lowerSCR output.
SCR OPERATION
A silicon controlled rectifier (SCR) is a threeterminal device used to control large cur-rents to a load. An SCR acts very much likea switch. When it is turned on there is cur-rent flow from anode to cathode. In the ONstate, the SCR acts like a closed switch.When the SCR is turned OFF, there is nocurrent flow from anode to cathode, thus thedevice acts like an open switch. As thename suggests, the SCR is a rectifier, so itpasses current only during positive halfcycles of the AC supply. The positive halfcycle is the portion of the sine wave inwhich the anode of the SCR is more posi-tive than the cathode.
When an AC supply voltage is applied tothe SCR, the device spends a certain por-tion of the AC cycle time in the ON stateand the remainder of the time in the OFFstate. The amount of time spent in eachstate is controlled by the Gate.
Note: As the gate pulse is applied later in the cycle, the SCR output is decreased.
FIGURE E.4 SCR OPERATION
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E-5 THEORY OF OPERATIONTHERMAL PROTECTION
A thermostat protects the machine fromexcessive operating temperatures.Excessive operating temperatures may becaused by lack of cooling or operating themachine beyond the duty cycle and outputrating. If excessive operating temperatureshould occur, the thermostat will preventvoltage and wire drive. The fan will remainon during this period. The thermostat is self-resetting once the machine cools sufficient-ly. If the thermostat shutdown is caused byexcessive output or duty cycle and the fanis running normally, the power switch maybe left on and the reset should occur withina 15 minute period. If the fan is not turningor the air intake louvers are obstructed thenthe input power must be removed and thefan problem or air obstruction must be cor-rected.
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SP-100
Section F TABLE OF CONTENTS– TROUBLESHOOTING SECTION –
Troubleshooting .............................................................................................Section FSafety Precautions ................................................................................................F-1How To Use Troubleshooting Guide .....................................................................F-1PC Board Troubleshooting Procedures .................................................................F-2Troubleshooting Guide...........................................................................................F-3
Output Problems .............................................................................................F-3Feeding Problems ...........................................................................................F-6Gas Flow Problems .........................................................................................F-7Welding Problems ..........................................................................................F-7
PC Board Connector Locations .............................................................................F-8Oscilloscope Waveforms
Normal Open Circuit Voltage Waveform .........................................................F-9Typical Output Voltage Waveform – Machine Loaded .................................F-10Abnormal Open Circuit Voltage Waveform ..................................................F-11
Replacement ProceduresFan Blade and Motor Removal......................................................................F-12Wire Drive Assembly Removal......................................................................F-13
Retest After Repair .............................................................................................F-14
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F-1 TROUBLESHOOTING & REPAIR
Step 1. LOCATE PROBLEM (SYMPTOM).Look under the column labeled “PROBLEM(SYMPTOMS)”. This column describes pos-sible symptoms that the machine mayexhibit. Find the listing that best describesthe symptom that the machine is exhibiting.
Symptoms are grouped into the followingcategories: Output Problems; FeedingProblems; Gas Flow Problems; andWelding Problems.
Step 2. PERFORM EXTERNAL TESTS.The second column labeled “POSSIBLEAREAS OF MISADJUSTMENT(S)” lists theobvious external possibilities that may con-tribute to the machine symptom. Performthese tests/checks in the order listed. Ingeneral, these tests can be conducted with-out removing the case wrap-around cover.
Step 3. PERFORM COMPONENT TESTS.The last column labeled “RecommendedCourse of Action” lists the most likely com-ponents that may have failed in yourmachine. It also specifies the appropriatetest procedure to verify that the subjectcomponent is either good or bad. If thereare a number of possible componentscheck the components in the order listed toeliminate one possibility at a time until youlocate the cause of you problem.
All the needed test specifications and repairprocedures are described in detail on thereferenced pages. All the needed electricaltest points, terminal strips, junctions, etc.,can be found on the referenced electricalwiring diagrams and schematics. SeeElectrical Diagram Section.
HOW TO USE TROUBLESHOOTING GUIDE
Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.Unauthorized repairs performed on this equipment may result in danger to the technician andmachine operator and will invalidate your factory warranty. For your safety and to avoidElectrical Shock, please observe all safety notes and precautions detailed throughout thismanual.__________________________________________________________________________
WARNING
If for any reason you do not understand the test procedures or are unable to Performthe tests/repairs safely, contact your LOCAL AUTHORIZED LINCOLN ELECTRICFIELD SERVICE FACILITY for assistance before you proceed. Call 216-383-3531or 1-800-833-9353_______________________________________________________
CAUTION
This Troubleshooting Guide is provided to help you locate and correct possible machinemalfunctions or misadjustments. Simply follow the three-step procedure listed below.
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F-2 TROUBLESHOOTING & REPAIR
4. Test the machine to determine if the fail-ure symptom has been corrected by thereplacement PC board.
NOTE: Allow the machine to heat up so thatall electrical components can reach theiroperating temperature.
5. Remove the replacement PC board andsubstitute it with the original PC board torecreate the original problem.
a. If the original problem does not reap-pear by substituting the originalboard, then the PC board was notthe problem. Continue to look for badconnections in the control wiring har-ness, junction blocks, and the termi-nal strips.
b. If the original problem is recreated bythe substitution of the original board,then the PC board was the problem.Reinstall the replacement PC boardand test the machine.
6. Always indicate that this procedure wasfollowed when warranty reports are to besubmitted.
NOTE: Following this procedure and writingon the warranty report, “INSTALLED ANDSwitched PC BOARDS TO VERIFY PROB-LEM,” will help avoid denial of legitimate PCboard warranty claims.
ELECTRIC SHOCK cankill.
Have an electrician installand service this equip-ment. Turn the inputpower OFF and unplugthe machine before work-ing on equipment. Do nottouch electrically hotparts.
CAUTION: Sometimes machine failuresappear to be due to PC board failures.These problems can sometimes be tracedto poor electrical connections. To avoidproblems when troubleshooting and replac-ing PC boards, please use the followingprocedure:
1. Determine to the best of your technicalability that the PC board is the most like-ly component causing the failure symp-tom.
2. Check for loose connections at the PCboard to assure that the PC board isproperly connected.
3. If the problem persists, replace the sus-pect PC board using standard practicesto avoid static electrical damage andelectrical shock. (Read the warninginside the static resistant bag.)
NOTE: It is desirable to have a spare(known good) PC board available for PCboard troubleshooting.
PC BOARD TROUBLESHOOTING PROCEDURES
WARNING
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F-3 TROUBLESHOOTING & REPAIRObserve Safety Guidelines
detailed in the beginning of this manual.TROUBLESHOOTING GUIDE
PROBLEMS(SYMPTOMS)
Major physical or electrical damageis evident.
No wire feed, weld output or gasflow when gun trigger is pulled. Fandoes NOT operate.
No weld output or wire feed whengun trigger is pulled. Fan runs andgas flows normally.
POSSIBLE AREAS OFMISADJUSTMENT(S)
Contact your LOCAL LINCOLNAUTHORIZED FIELD SERVICEFACILITY.
1. Make sure correct voltage isapplied to the machine (115vac).
2. Make certain that power switchis in the ON position.
Contact your LOCAL LINCOLNAUTHORIZED FIELD SERVICEFACILITY.
RECOMMENDEDCOURSE OF ACTION
Contact the Lincoln Electric ServiceDepartment. (216) 383-2531 or 1-800-833-9353 (WELD)
1. Check for 115 VAC at input tofan motor (leads #31 to #32). Ifcorrect voltage is present and fanmotor does not function, replacethe fan motor. See wiring dia-gram.
2. If 115 vac is not present at leads#31 to #32, then check the powerswitch and input line cord. (SI)
1. Check voltage from leads #202to #201 at the output diode heatsinks. Normal voltage is from 2vac to 20 VAC, depending on arcvoltage control setting. If the cor-rect AC voltage is present, checkthe output diodes and connec-tions. Also check the output ca-pacitor, C1. See wiring diagram.
2. If the correct AC voltage is notpresent at the diode heat sinkleads #202 to #201, then checkthe AC voltage on the trans-former (TI) primary leads #531 to#32 (normal is 115 vac with arcvoltage control at maximum). Ifthe correct voltage is present atthe transformer primaries (#531to #32), the transformer may befaulty. See wiring diagram.
3. If the correct voltage is not pre-sent at leads #531 to #32, thencheck the arc voltage controlpotentiometer (RI)and associatedwires #205, #206 and #207 forloose or broken connections.See wiring diagram.
4. The control board may be faulty– Replace.
OUTPUT PROBLEMS
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the LincolnElectric Service Department for technical troubleshooting assistance before you proceed call 216-383-2531 or 1-800-833-9353.
CAUTION
SP-100
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F-4 TROUBLESHOOTING & REPAIRObserve Safety Guidelinesdetailed in the beginning of this manual.
TROUBLESHOOTING GUIDE
PROBLEMS(SYMPTOMS)
No weld output when gun trigger ispulled. Fan runs, gas flows andwire feeds normally.
BELOW CODE 9794 ONLY
No wire feed, weld output or gasflow when gun trigger is pulled Fanoperates normally.
POSSIBLE AREAS OFMISADJUSTMENT(S)
1. Arc voltage may be set too low.
2. Gun tip may be worn – Replace.
3. Check for correct input voltageto machine.
4. Gun or work cable may befaulty.
1. Check the circuit breaker locat-ed in the machine’s wire drivecompartment. Reset if tripped.
2. The thermostat may be trippeddue to overheating. Let machinecool. Weld within the duty cycleor remove any air obstruction tomachine.
3. Wire feed motor may be over-loaded. Correct feeding prob-lem.
4. Gun trigger may be faulty.
RECOMMENDEDCOURSE OF ACTION
1. Check for open circuit voltage(OCV) at the machine’s outputterminals, located in wire drivecompartment. Normal OCV isfrom 10 vdc to 28 vdc dependingon arc voltage control setting. Ifcorrect OCV is present, checkgun and work cable.
2. If correct OCV is not present atthe output terminals, then checkfor broken leads at the outputchoke or at the positive outputterminal.
1. Remove main power supply toSP-100. With gun trigger pulled,check for continuity (zero ohms)from 8J2 (lead #213) to 9J2 (lead#211 ) at harness plug. If zeroohms is indicated, then triggercircuit is OK. See wiring diagramand Figure F.1.
2. If an open circuit or high resis-tance is indicated in Step 1, thencheck leads #211,#212 and #213for loose or broken connections.Also check the normally closedthermostat mounted on the diodeheat sink assembly. See wiringdiagram.
3. Check for 115 vac at lead #31Ato plug 3J1 on control board. If115 vac is NOT present, removemain supply power to machine.Test continuity (zero ohms) ofleads #32 and #31A. See FigureF.1.
4. If 115 vac is present at lead#31A to plug 3J1 (lead #32), thencontrol board may be faulty –Replace. See Figure F.1.
OUTPUT PROBLEMS
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the LincolnElectric Service Department for technical troubleshooting assistance before you proceed call 216-383-2531 or 1-800-833-9353.
CAUTION
SP-100
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F-5 TROUBLESHOOTING & REPAIRTROUBLESHOOTING GUIDE Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS(SYMPTOMS)
CODE 9794 and ABOVE
No Wire feed, weld output or gasflow when the gun trigger is pulled -Fan operates normally.
POSSIBLE AREAS OFMISADJUSTMENT(S)
1. Check the circuit breaker in themachine – Located in the wiredrive compartment. Reset iftripped.
2. The thermostat may be trippeddue to overheating. Let machinecool. Weld within the duty cycleor remove any air obstruction tomachine.
3. Wire feed motor may be over-loaded – correct feeding prob-lem.
4. Gun trigger may be faulty.
RECOMMENDEDCOURSE OF ACTION
1. Check for 24 vac at plug 2J1 to6J1 on the control board. If volt-age is not present, check conti-nuity of leads to fan motor. Ifleads are OK, replace fan motor.See Figure F.1
2. Remove main power supply toSP-100. With gun trigger pulledcheck for continuity (zero ohms)from 8J2 (lead #213) to 9J2(lead #211) at harness plug. Ifzero ohms is indicated then trig-ger circuit is OK. See FigureF.1.
3. If an open circuit or high resis-tance is indicated in Step 2, thencheck leads #211, #212 and#213 for loose or broken con-nections. Also check the normal-ly closed thermostat mounted onthe diode heat sink assembly.
4. The control board may be faulty– Replace.
OUTPUT PROBLEMS
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the LincolnElectric Service Department for technical troubleshooting assistance before you proceed call 216-383-2531 or 1-800-833-9353.
CAUTION
SP-100
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F-6 TROUBLESHOOTING & REPAIRObserve Safety Guidelinesdetailed in the beginning of this manual.
TROUBLESHOOTING GUIDE
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the LincolnElectric Service Department for technical troubleshooting assistance before you proceed call 216-383-2531 or 1-800-833-9353.
CAUTION
PROBLEMS(SYMPTOMS)
No wire feed when gun trigger ispulled. Fan runs, gas flows andmachine has correct open circuitvoltage (28 vdc maximum) – weldoutput.
Wire feed speed motor runs veryfast. Weld output, gas flow and fanoperate normally.
POSSIBLE AREAS OFMISADJUSTMENT(S)
1. If the wire drive motor is runningcheck to see if the correct wireis in the machine.
2. If the wire drive motor is runningmake sure that the correct driverolls are installed in themachine.
3. Check for clogged cable liner orfeeding problems.
1. Make sure that the wire speedcontrol is not set at maximum.
RECOMMENDEDCOURSE OF ACTION
1. Check for a DC voltage at wiredrive motor armature (leads#539 to #541). The voltageshould be between 2 vdc and 10vdc. This voltage will vary withthe wire speed control setting. Ifthe correct voltage is present,the drive motor may be faulty.Replace. See wiring diagram.
2. If the motor armature voltage isnot present, then check for OCVat leads #203 (3J2) and #204(4J2) on the control board. Ifcorrect voltage is present, go toStep 3. If OCV is not present atleads #203 and #204, checkcontinuity (zero ohms) of leads.
3. If the motor armature voltage isnot present, then check the wirespeed control potentiometer andassociated wires #208, #209and #203 for faulty connections.
4. The control board may be faulty.Replace.
1. Remove main supply power tomachine. Disconnect plug J2from the control board. Test theresistance from lead #539 (2J2)in the harness plug to the wirefeed motor case. If the resis-tance is below 500,000 ohms,replace the drive motor.
2. Check the wire speed controlpotentiometer and associatedwires #208, #209 and #203 forloose or broken connections.
3. The control board may be faulty.Replace.
FEEDING PROBLEMS
SP-100
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F-7 TROUBLESHOOTING & REPAIRObserve Safety Guidelinesdetailed in the beginning of this manual.
TROUBLESHOOTING GUIDE
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the LincolnElectric Service Department for technical troubleshooting assistance before you proceed call 216-383-2531 or 1-800-833-9353.
CAUTION
PROBLEMS(SYMPTOMS)
Low or no gas flow when guntrigger is pulled. Wire feed, weldoutput and fan operate normally.
POSSIBLE AREAS OFMISADJUSTMENT(S)
1. Check gas supply, flow regulatorand gas hoses.
2. Check gun connection tomachine for obstruction or leakyseals.
RECOMMENDEDCOURSE OF ACTION
1. Check for 115 vac at the gassolenoid leads #7 to #32A. If thecorrect voltage is present butthe solenoid does not activate,replace solenoid. See wiring dia-gram .
2. If voltage is not present at leads#7 to #32A, remove main supplypower to machine. Test leads #7and #32A for continuity (zeroohms) to the control board.
3. Control board may be faulty.Replace.
GAS FLOW PROBLEMS
PROBLEMS(SYMPTOMS)
Arc is unstable – Poor starting
POSSIBLE AREAS OFMISADJUSTMENT(S)
1. Check for correct input voltageto machine – 115 vac.
2. Check for proper electrodepolarity for process.
3. Check gun tip for wear or dam-age – Replace.
4. Check for proper gas and flowrate for process.
5. Check work cable for loose orfaulty connections.
6. Check gun for damage orbreaks.
RECOMMENDEDCOURSE OF ACTION
1. Check for correct open circuitvoltage (OCV) at machine’s out-put terminals, 10 vdc to 28 vdc,depending on arc voltage con-trol setting. If correct OCV ispresent check gun and workcable.
2. If OCV is low, check outputcapacitor and output diodes.
3. Check arc voltage control poten-tiometer and associated wires#205, #206 and #207 for looseor broken connections. Seewiring diagram.
4. Control board may be faulty.Replace.
WELDING PROBLEMS
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F-8 TROUBLESHOOTING & REPAIRPC BOARD CONNECTOR LOCATIONS
FIGURE F.1
Codes 9794 and above
Codes below 9794
6J1 10J2
1J1 1J2
6J110J2
1J1 1J2
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F-9 TROUBLESHOOTING & REPAIR
SCOPE SETTINGSThis is the typical output voltage waveform generatedfrom a properly operating machine. Note that eachvertical division represents 10 volts and that each hor-izontal division represents 20 milliseconds in time.
Note: Scope probes connected at machine output ter-minals. Positive probe to (+) terminal, negative probeto (–) terminal.
NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM
0volts
10 volts/Div 20 ms/Div
C1
Volts/Div ........................................................10/Div
Horizontal Sweep .....................................20 ms/Div
Coupling .............................................................DC
Trigger..........................................................Internal
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F-10TROUBLESHOOTING & REPAIR
SCOPE SETTINGSThis is the typical output voltage waveform generatedfrom a properly operating machine. Note that eachvertical division represents 10 volts and that each hor-izontal division represents 20 milliseconds in time.The machine was loaded with a resistance grid bank.The ammeter read 90 amps and the voltmeter read19 vdc.
Note: Scope probes connected at machine output ter-minals. Positive probe to (+) terminal, negative probeto (–) terminal.
TYPICAL OUTPUT VOLTAGE WAVEFORM – MACHINE LOADED
0volts
10 volts 20 ms
C1
Volts/Div ........................................................10/Div
Horizontal Sweep .....................................20 ms/Div
Coupling .............................................................DC
Trigger..........................................................Internal
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F-11 TROUBLESHOOTING & REPAIR
SCOPE SETTINGSThis is NOT the typical output voltage waveform. Theoutput capacitor was disconnected from the circuit.Note the increased ripple in the waveform. This condi-tion simulates the faulty output filter capacitor. Eachvertical division represents 10 volts and that each hor-izontal division represents 20 milliseconds in time.
Note: Scope probes connected at machine output ter-minals. Positive probe to (+) terminal, negative probeto (–) terminal.
ABNORMAL OPEN CIRCUIT VOLTAGE WAVEFORM
0volts
10 volts 20 ms
C1
Volts/Div ........................................................10/Div
Horizontal Sweep .....................................20 ms/Div
Coupling .............................................................DC
Trigger..........................................................Internal
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F-12 TROUBLESHOOTING & REPAIRFIGURE F.2
FIGURE F.3
FIGURE F.4
FAN BLADE AND MOTORREMOVAL
PROCEDURE DESCRIPTION
The following procedure will aid in the removal andreplacement of the fan blade and/or fan motor. It willalso provide reasonable access to the output diodeheat sinks.
TOOLS REQUIRED● 5/16” nutdriver or socket wrench● 7/16” nutdriver or socket wrench● 7/16” open end wrench● Phillips head screwdriver● Needle nose pliers
PROCEDURE1. Using the 5/16” nut driver, remove the three self-
tapping screws holding the fan bracket to the rearpanel.
Refer to Figure F-2.
2. Remove the two aluminum transformer secondaryleads from the diode heat sinks.
Note: When reassembling, use Dow 340 HeatSink Compound on connection surfaces.
3. Remove three large black leads and one smallblue lead from the large choke lead.
4. Remove leads #211 and #212 from the thermostatlocated on the diode heat sink.
5. Remove the four leads from the fan motor notingtheir posit ions. (TWO LEADS ON CODESBELOW 9794.)
6. Remove the three wires connected to the inputreceptacle. Note lead placement and connections.(L1, L2, and green ground lead.)
7. Remove the four self tapping screws holding theline cord and input receptacle to the back panel.
8. Remove input receptacle.
9. Remove the two Phillips head screws holding thegas solenoid to the center baffle – See Figure F.3.
10. Remove the gas solenoid and set aside.
11. Lift up the rectifier fan motor bracket assemblyand support it near the top of the machine. Thisshould provide access to the fan blade and motor.
12. Slide the blade from the motor shaft, taking noteof blade placement on motor shaft. (ShaftIndented approximately 0.10” from blade hub) -–Figure F.4.
13. Remove the two Phillips head screws holding themotor to the bracket. Remove the motor.
14. If the output diodes are to be removed, the leadsmust be removed from the diodes and the heat
Gas Solenoid
Thermostat
Diodes
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F-13 TROUBLESHOOTING & REPAIRFIGURE F.5
Two plastic fastener buttons attach the Connector Block to theFront Panel at these points. To remove the Connector Block, cutthe heads off of the two fastener buttons.
FIGURE F.6
FIGURE F.7
Note: Slight resistance as rear housing is separated from the frontis caused by the bearing, which will remain attached to the fronthousing.
WIRE DRIVE ASSEMBLY REMOVAL
PROCEDURE DESCRIPTION
The following procedure will aid in the removal of theentire wire drive unit for possible motor or gear boxreplacement.
TOOLS REQUIRED● 5/16” nutdriver or socket wrench● 1/4” nutdriver or socket wrench● Phillips head screwdriver● Needle nose pliers● Knife or side cutters● Screwdriver (slot head)
PROCEDURERefer to Figure F.5.
1A. FOR CODES ABOVE 10000Cut heads off of two plastic fastener buttons locat-ed on the front panel. (Order new fastener buttons– Part No. T14659-3)
1B. FOR CODES BELOW 10000Remove two flat head screws holding conductorblock to front panel.
2. Remove gas hose from Connector block.
3. Remove cable running from output terminal toConnector block (1).
4. With 5116’’ nutdriver, remove mounting screw atrear of wire drive assembly.
5. With 5/16” nutdriver, remove screw holding thefront panel to the case bottom. Carefully movefront panel forward 1/2”.
6. Carefully slide out wire drive unit until motor leadsare visible. Using needle nose pliers, removemotor leads, taking note of lead positions.
7. Remove wire drive unit from machine.
MOTOR REMOVAL PROCEDURERefer to Figure F.6
1. Remove one Phillips head screw connecting frontto rear housing (1).
2. Using 1/4” nutdriver, remove two 8-32X1” threadforming screws connecting front to rear housing(2).
Refer to Figure F-7
3. Remove motor with rear housing.
4. Remove two screws holding motor to rear hous-ing.
5. Separate motor from rear housing.
1
SP-100
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F-14 TROUBLESHOOTING & REPAIRRETEST AFTER REPAIR
Should a machine under test be rejected for any reason requiring the removal of any mechani-cal part that could affect the machine’s electrical characteristics, or if any electrical componentsare repaired or replaced, the machine must be retested.
MAIN TRANSFORMER SECONDARY VOLTAGES
INPUT AMPS AT RATED OUTPUT
OPEN CIRCUIT VOLTAGES
WIRE SPEED RANGE
TEST POINTS VOLTAGES
LEADS #201 – #202 2-20 vac Dependent on arc voltage control Located on Output Diode Heat Sinks. setting (min. to max.)
TEST POINTS VOLTAGES
OUTPUT TERMINALS 10 to 27 vdc Dependent on arc voltagecontrol setting (min. to max.)
50 to 400 in /min. Dependent on wire speed control setting(1,2 to 10,2 m/min.)
INPUT AMPS (AC) @ OUTPUT (DC)
20 amps 90 amps @ 18 vdc
12/95
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F-15 NOTES:
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SP-100
Section G TABLE OF CONTENTS– ELECTRICAL DIAGRAMS SECTION –
Electrical Diagrams ........................................................................................Section GSP-100 Wiring Diagram (codes 9794 and above)................................................G-2SP-100 Wiring Diagram (codes below 9794) ........................................................G-3Control PC Board (G1842) Components...............................................................G-4Control PC Board (G2314) Components...............................................................G-6Machine Schematic (codes 9794 and above) .......................................................G-8Machine Schematic (below code 9794) ................................................................G-9
SP-100
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G-2 WIRING DIAGRAMS
SP-100 WIRING DIAGRAM: CODES 9794 and Above
CLE
VE
LA
ND
, O
HIO
U.S
.A.
11
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93K
M
1657
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L2
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D2
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20
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7
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13
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11
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208
209
203
5K
WIR
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205
206
207
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( J
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achi
ne.
Do n
ot o
pera
te w
ith c
over
s re
mov
ed.
Do n
ot to
uch
elec
trica
lly li
ve p
arts
Disc
onne
ct in
put p
ower
by
unpl
uggi
ngpo
wer c
ord
befo
re s
ervi
cing
S
P 1
00
WIR
ING
DIA
GR
AM
N.D
. B
OLT
ED
ALU
MIN
UM
CO
NN
EC
TIO
NS
RE
QU
IRE
JO
INT
CO
MP
OU
ND
.S
EE
OP
ER
ATI
NG
MA
NU
AL
WH
EN
RE
ATT
AC
HIN
G.
N.B
. D
IOD
ES
D2
& D
4 A
RE
MO
UN
TED
ON
TH
E I
NS
IDE
HE
ATS
INK
,W
HIC
H I
S C
LOS
ES
T TO
TH
E C
EN
TER
PA
NE
L.L
EA
D C
OL
OR
CO
DE
: B
-BL
AC
K
W-W
HIT
E
N.B
., N
.D.
(CO
MP
ON
EN
T S
IDE
OF
BO
AR
D)
NO
TE
:T
his
diag
ram
is fo
r re
fere
nce
only
. It
may
not
be
accu
rate
for
all m
achi
nes
cove
red
by th
is m
anua
l. T
he s
peci
fic d
iagr
am fo
r a
part
icul
ar c
ode
ispa
sted
insi
de th
e m
achi
ne o
n on
e of
the
encl
osur
e pa
nels
.
G-3
SP-100
Ret
urn
to S
ectio
n T
OC
Ret
urn
to S
ectio
n T
OC
Ret
urn
to S
ectio
n T
OC
Ret
urn
to S
ectio
n T
OC
Ret
urn
to M
aste
r T
OC
Ret
urn
to M
aste
r T
OC
Ret
urn
to M
aste
r T
OC
Ret
urn
to M
aste
r T
OC
WIRING DIAGRAMS
L1L2
31
32
3253
1
TO G
RO
UN
DP
ER
NA
TIO
NA
LE
LEC
TRIC
AL
CO
DES1
SW
ITC
H
202
201
D1
D3
D2
D4
204
204
204
203
203
203
C1
59,0
00 m
f40
V
203
204
-
+O
UTP
UT
CH
OK
E
GU
N C
AB
LEC
ON
DU
CTO
RB
LOC
K
TOW
OR
K
ELE
CTR
ICA
L S
YM
BO
LS P
ER
E15
37
CIR
CU
ITB
RE
AK
ER
31A
LEA
D C
OLO
R C
OD
E:
B-B
LAC
KW
-WH
ITE
12
3
45
6
LATC
H
31
FAN
MO
TOR
12
34
LATC
H
5
67
89
10
J1J2
CA
VIT
Y N
UM
BE
RIN
G S
EQ
UE
NC
E(
CO
MP
ON
EN
T S
IDE
OF
BO
AR
D )
12
34
56
12
34
56
78
910
GA
S
SO
LEN
OID
7 32A
CO
NTR
OL
P.C
. B
OA
RD
539
541
207
205
206
541
539
203
204
203
209
213
208
211
531
31A
T1
WIR
E F
EE
D M
OTO
R
212
213
211
GU
N T
RIG
GE
RTH
ER
MO
STA
T(M
OU
NTE
D T
OD
IOD
E H
EATS
INK)
+
208
209
203
5K
WIR
E SP
EED
205
206
207
5K
32( J1
)(
J2 )
*
*
*CON
NE
CTO
R C
AV
ITY
NU
MB
ER
ARC
VO
LTAG
E
R1
R2
(W)
(B)
7 32A
HI
LO
N.B
.
N.A
.
N.C
.
N.C
.
N.C
. C
OM
PO
NE
NT
VIE
WE
D F
RO
M R
EA
R.
ON
-OFF
N.C
.
15427
8-
1-91
D
SP
WE
LDE
RS
W
IRIN
G D
IAG
RA
M
1542
7
M
M
N.D
.N
.D.
N.A
. D
IOD
ES
D1
& D
3 A
RE
MO
UN
TED
ON
TH
E
OU
TSID
E H
EA
TSIN
K.
N.B
. D
IOD
ES
D2
& D
4 A
RE
MO
UN
TED
ON
TH
E
INS
IDE
HE
ATS
INK
, W
HIC
H I
S C
LOS
ES
T TO
TH
E
CE
NTE
R P
AN
EL.
N.D
. B
OLT
ED
ALU
MIN
UM
CO
NN
EC
TIO
NS
RE
QU
IRE
JO
INT
CO
MP
OU
ND
. S
EE
OP
ER
ATI
NG
MA
NU
AL
WH
EN
RE
ATT
AC
HIN
G.
NO
TE
:T
his
diag
ram
is fo
r re
fere
nce
only
. It
may
not
be
accu
rate
for
all m
achi
nes
cove
red
by th
is m
anua
l.T
he s
peci
fic d
iagr
am fo
r a
part
icul
ar c
ode
is p
aste
d in
side
the
mac
hine
on
one
of th
e en
clos
ure
pane
ls.
SP-100 WIRING DIAGRAM: CODES Below 9794
Ret
urn
to S
ectio
n T
OC
Ret
urn
to S
ectio
n T
OC
Ret
urn
to S
ectio
n T
OC
Ret
urn
to S
ectio
n T
OC
Ret
urn
to M
aste
r T
OC
Ret
urn
to M
aste
r T
OC
Ret
urn
to M
aste
r T
OC
Ret
urn
to M
aste
r T
OC
G-4 ELECTRICAL DIAGRAMS
SP-100
NOTE: Lincoln Electric assumes no responsibility for liabilities resulting from board level troubleshooting. PC Boardrepairs will invalidate your factory warranty. This Printed Circuit Board schematic is provided for referenceonly. It may not be totally applicable to your machine’s specific PC board version. This diagram is intendedto provide general information regarding PC board function. Lincoln Electric discourages board level trou-bleshooting and repair since it may compromise the quality of the design and may result in Danger to theMachine Operator or Technician. Improper PC board repairs could result in damage to the machine.
CONTROL P.C. BOARD G1842
A
Ret
urn
to S
ectio
n T
OC
Ret
urn
to S
ectio
n T
OC
Ret
urn
to S
ectio
n T
OC
Ret
urn
to S
ectio
n T
OC
Ret
urn
to M
aste
r T
OC
Ret
urn
to M
aste
r T
OC
Ret
urn
to M
aste
r T
OC
Ret
urn
to M
aste
r T
OC
G-5 ELECTRICAL DIAGRAMS
SP-100
NOTE: Lincoln Electric assumes no responsibility for liabilities resulting from board level troubleshooting. PC Boardrepairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not avail-able from Lincoln Electric. This information is provided for reference only. Lincoln Electric discouragesboard level troubleshooting and repair since it may compromise the quality of the design and may result indanger to the Machine Operator or Technician. Improper PC board repairs could result in damage to themachine.
Item IdentificationItem Identification
CONTROL P.C. BOARD G1842
SCR1, SCR2 SCR & HEATSINK ASBLYX4 C-VOLT REG, FIXED, 3-T, (+), 1A, 15VC4, C9, C11, C12, C13, CAPACITOR-CEMO, .022, 50V, 20%
C14, C16, C20, C21,C24, C26
J1 CONNECTOR, MOLEX, MINI, PCB, 6-PIN
C5 CAPACITOR-ALEL, 150, 50V, +150/-10%D1 D2 D3, D4, D5, DIODE-AXLDS, 1A, 400V
D6 D7 D8, D9, D11,D12, D13, D14 D17,D18, D19, D20, D21
R32, R33 RESISTOR-WW, 15W, 80, 5%, SQC19 CAPACITOR-TAEL, 1.8, 20V, 10%C6, C17 CAPACITOR-TAEL, 4.7, 35V, 10%C15 CAPACITOR-TAEL, 18, 15V, 10%C8, C10, C18 CAPACITOR-TAEL, 1.0, 35V, 10%C23 CAPACITOR-ALEL, 3300, 50V, +30/-10%OCI1, OCI2 OPTOCOUPLER-TRIAC DRIVER, 3023TRI1 TRIAC-T220, 6A, 400V, 2500DJ2 CONNECTOR, MOLEX, MINI, PCB,
10-PINC7 CAPACITOR-PEF, 0.1,100V, 10%C22 CAPACITOR-PEF, 0.22, 100V, 10%C1, C25 CAPACITOR-CD, .0047/.005, 1400V,
20%C2, C3, C27 CAPACITOR-PEF, 0.1, 400V, 1o%DZ3 ZENER DIODE-1W, 16V, 5%, 1N4745ADZ1 ZENER DIODE-1W, 10V, 5%, 1N4740ADZ4 ZENER DIODE-1W, 43V, 5%, 1N4755ADZ2 ZENER DIODE-1W, 5.1V, 5%, 1N4733AQ2, Q3, Q4, Q5 TRANSISTOR-N, T226, 0.5A, 40V,
2N4401D15, D16 DIODE-AXLDS, 3A, 200V, 1N54o2D10 DIODE-AXLDS, 0.15A, 75W, 1N914B31A, B531 CONNECTOR, TAB, QC, VERTICAL, 1/4B7, B32 CONNECTOR, TAB, QC, VERTICAL,
3/16R69, R72 RESISTOR-WW, 5W, 0.5, 5%, SQR5 RESISTOR-MF, 1/4W, 100, 1%
R2, R4, R8, R26, R27, RESISTOR-MF, 1/4W, 1.00K, 1%R41, R48, R51, R55,R58, R70
R50, R57, R53, R54, RESISTOR-MF, 1/4W, 10.0K, 1%R71, R73, R74
R42, R52, R53, R54, RESISTOR-MF, 1/4W,10.0K, 1%R59
R43 RESISTOR-MF, 1/4W, 1.00M, %R15, R16, R18 RESISTOR-MF, 1/4W, 1.30K, 1%R3 RESISTOR-MF, 1/4W, 150, 1%R36, R63, R64, R67 RESISTOR-MF, 1/4W, 15.0K, 1%
R45 RESISTOR-MF, 1/4W, 18.2K, 1%R28, R31, R47, R49 RESISTOR-MF, 1/4W, 2.21K, 1%R12, R38, R39, R60, RESISTOR-MF, 1/4W, 22.1K, 1%
R61R75 RESISTOR-MF, 1/4W, 267, 1%R22 RESISTOR-MF, 1/4W, 267K, 1%R46, R78, R79, R80 RESISTOR-MF, 1/4W, 3.32K, 1%R21, R35 RESISTOR-MF, 1/4W, 33.2K, 1%R44 RESISTOR-MF, 1/4W, 392K, 1%R11 RESISTOR-MF, 1/4W, 4.75K, 1%R10, R62 RESISTOR-MF, 1/4W, 47.5K, 1%R23, R24 RESISTOR-MF, 1/4W, 562, 1%R17, R25, R29, R30 RESISTOR-MF, 1/4W, 56.2K, 1%R76 RESISTOR-MF, 1/4W, 681, 1%R19, R65 RESISTOR-MF, 1/4W, 6.81K, 1%R14, R20 RESISTOR-MF, 1/4W, 68.1K, 1%R13 RESISTOR-MF, 1/4W, 82.5K, 1%Q7 TRANSISTOR-PMF, T220, 6A, 100V,
IRF9520X1, X2, X3 C-OP-AMP, QUAD, GEN-PURPOSE,
224NQ1, Q6 TRANSISTOR-N, T226, 0.5A, 300V,
MPS-A42R37, R83 RESISTOR-MF, 1/4W, 2.00K, 1%R34, R81, R82 RESISTOR-MF, 1/4W, 3.01K, 1%R56 TRIMMER-ST, 1/2W, 10K, 10%, LINEARR6 RESISTOR-WW, 5W, 25, 5%, SQR1 RESISTOR-WW, 5W, 150, 5%, SQ
Ret
urn
to S
ectio
n T
OC
Ret
urn
to S
ectio
n T
OC
Ret
urn
to S
ectio
n T
OC
Ret
urn
to S
ectio
n T
OC
Ret
urn
to M
aste
r T
OC
Ret
urn
to M
aste
r T
OC
Ret
urn
to M
aste
r T
OC
Ret
urn
to M
aste
r T
OC
G-6 ELECTRICAL DIAGRAMS
SP-100
NOTE: Lincoln Electric assumes no responsibility for liabilities resulting from board level troubleshooting. PC Boardrepairs will invalidate your factory warranty. This Printed Circuit Board schematic is provided for referenceonly. It may not be totally applicable to your machine’s specific PC board version. This diagram is intendedto provide general information regarding PC board function. Lincoln Electric discourages board level trou-bleshooting and repair since it may compromise the quality of the design and may result in Danger to theMachine Operator or Technician. Improper PC board repairs could result in damage to the machine.
CONTROL P.C. BOARD G2314
A A
A
C1
6
Ret
urn
to S
ectio
n T
OC
Ret
urn
to S
ectio
n T
OC
Ret
urn
to S
ectio
n T
OC
Ret
urn
to S
ectio
n T
OC
Ret
urn
to M
aste
r T
OC
Ret
urn
to M
aste
r T
OC
Ret
urn
to M
aste
r T
OC
Ret
urn
to M
aste
r T
OC
G-7 ELECTRICAL DIAGRAMS
SP-100
NOTE: Lincoln Electric assumes no responsibility for liabilities resulting from board level troubleshooting. PC Boardrepairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not avail-able from Lincoln Electric. This information is provided for reference only. Lincoln Electric discouragesboard level troubleshooting and repair since it may compromise the quality of the design and may result indanger to the Machine Operator or Technician. Improper PC board repairs could result in damage to themachine.
Item IdentificationItem Identification
CONTROL P.C. BOARD G2314
SCR1, SCR2 SCR 81 HEATSINK ASBLYX4 C-VOLT REG, FIXED, 3-T, (+),1A, 15VC4, C9, C11, C12, C13, CAPACITOR-CEMO, .022, 50V, 20%
C14, C16, C20, C21,C24, C26
J1 CONNECTOR, MOLEX, MINI, PCB,6-PIN
C5 CAPACITOR-ALEL, 150, 50V, +150/ –10%
D1, D2, D3, D4, D5, D6, DIODE-AXLDS, 1A, 400VD7, D8, D9, D11 , D12,D13, D14, D17, D18,D19, D20, D21
R32, R33 RESISTOR-WW, 15W, 80,5%, SQC19 CAPACITOR-TAEL, 1.8, 20V, 10%C6, C17 CAPACITOR-TAEL, 4.7, 35V, 10%C15 CAPACITOR-TAEL, 18,15V, 10%C8, C10, C18 CAPACITOR-TAEL, 1.0, 35V, 10%C23 CAPACITOR-ALEL, 3300, 50V, +30/-10%OCI1 OCI2 OPTOCOUPLER-TRIAC DRIVER, 3023TRI1 TRIAC-T220, 6A, 400V, 2500DJ2 CONNECTOR, MOLEX, MINI, PCB,
10-PINC7 CAPACITOR-PEF, 0.1,100V, 10%C22 CAPACITOR-PEF, 0.22, 100V, 10%C1, C25 CAPACITOR-CD, .0047/.005, 1400V,
20%C2 C3 C27 CAPACITOR-PEF, 0.1, 400V, 10%DZ3 ZENER DIODE-1W, 16V, 5%,1N4745ADZ1 ZENER DIODE-1W, 10V, 5%,1N4740ADZ4 ZENER DIODE-1W, 43V, 5%,1N4755ADZ2 ZENER DIODE-1W, 5.1V, 5%,1N4733AQ2, Q3, Q4, Q5 TRANSISTOR-N, T226, 0.5A, 40V,
2N4401D15, D16 DIODE-AXLDS, 3A, 200V, 1N5402D10 DIODE-AXLDS, 0.15A, 75V, 1N914B31 A, B531 CONNECTOR, TAB, QC, VERTICAL,
1/4B7, B32 CONNECTOR, TAB, QC, VERTICAL,
3/16R69, R72 RESISTOR-WW, 5W, 0.5,5%, SQR5 RESISTOR-MF, 1/4W, 100, 1%R2, R4, R8, R26, R27, RESISTOR-MF, 1/4W, 1.00K, 1%
R41, R48, R51, R55,R58, R70
R50, R57, R66, R68, RESISTOR-MF, 1/4W, 10.0K, 1%R71, R73, R74
R42, R52, R53, R54, RESISTOR-MF, 1/4W, 100K, 1%R55
R43 RESISTOR-MF, 1/4W, 1.00M, %R15, R16, R18 RESISTOR-MF, 1/4W, 1.30K, 1%R3 RESISTOR-MF, 1/4W, 150,1%R36, R63, R64, R67 RESISTOR-MF, 1/4W, 15.0K, 1%
R45 RESISTOR-MF, 1/4W, 18.2K, 1%R28, R31, R47, R49 RESISTOR-MF, 1/4W, 2.21 K, 1%R12, R38, R39, R60, RESISTOR-MF, 1/4W, 22.1K, 1%
R61R75 RESISTOR-MF, 1/4W, 267,1 %R22 RESISTOR-MF, 1/4W, 267K, 1%R46, R78, R79, R80 RESISTOR-MF, 1/4W, 3.32K, 1%R21 RESISTOR-MF, 1/4W, 33.2K, 1%R35 RESISTOR-MF, 1/4W, 39.2K, 1%R44 RESISTOR-MF, 1/4W, 392K, 1%R11 RESISTOR-MF, 1/4W, 4.75K, 1%R10 RESISTOR-MF, 1/4W, 47.5K, 1%R62 RESISTOR-MF, 1/4W, 47.5,1%R23, R24 RESISTOR-MF, 1/4W, 562,1%R17, R25, R29, R30 RESISTOR-MF, 1/4W, 56.2K, 1%R76 RESISTOR-MF, 1 /4W, 681 ,1 %R19, R65 RESISTOR-MF, 1/4W, 6.81K, 1%R14, R20 RESISTOR-MF, 1/4W, 68.1K, 1%R13 RESISTOR-MF, 1/4W, 82.5K, 1%Q7 TRANSISTOR-PMF, T220, 6A, 100V,
IRF9520X1 , X2, X3 C-OP-AMP, OUAD, GEN-PURPOSE,
224NQ1, Q6 TRANSISTOR-N, T226, 0.5A, 300V,
MPS-A42R37, R83 RESISTOR-MF, 1/4W, 2.00K, 1%R34, R81, R82 RESISTOR-MF, 1/4W, 3.01K, 1%R56 TRIMMER-ST, 1/2W, 10K, 10%,
LINEARR6 RESISTOR-WW, 5W, 25, 5%, SQR1 RESISTOR-WW, 5W, 150, 5%, SQ
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urn
to S
ectio
n T
OC
Ret
urn
to S
ectio
n T
OC
Ret
urn
to S
ectio
n T
OC
Ret
urn
to S
ectio
n T
OC
Ret
urn
to M
aste
r T
OC
Ret
urn
to M
aste
r T
OC
Ret
urn
to M
aste
r T
OC
Ret
urn
to M
aste
r T
OC
G-8ELECTRICAL DIAGRAMS
SP-100
MACHINE SCHEMATIC: Codes 9794 and Above
GND
IN OUTX4
4.735V
C6
MC7815CTDSREGULATOR
D8
30A
125VAC
CIRCUITBREAKER
+15V
D7
+15V SUPPLY
+15V
15050V
C5
39 .2K
R35
VOLTAGE
X11
3
2
1 .3K
R16
OCI1
1
2
1 .035V
C10X1
14
13
12
56 .2K
R292.21K
R28
56 .2K R30
1N914
D10
1 .00K
R26
4 . 75K
R11
8 2 .5K
R13
56 .2K
R25
1.00K
R27
R1
1W10VDZ1
5K
ARC
562R23
2 05
J1
4
22 .1K
R12
206 J15
562R24
D5
68 .1K
R14
2W
ARC VOLTAGEFEEDBACK
C9
VOLTS
.15A75V
SAWTOOTH
CONTROLSOLENOIDGAS
47 .5KR10
+15V
204
+15V
1.3K
R15
D6
207
J1
1
LM224
X2
4
11
L8552
X 2
6
7
5
BURNBACK
WELD
ARC VOLTAGEERROR AMPL IF IER
SCR
PWM
OCI2
1
2
+15V
C24
100V.1
C7
X18
10
9
1 .3K
R18
C11
1W5.1VDZ2
56 .2K
R17
D11
D9
X17
6
5
2 .21K
R31
F IR ING
LM224
X1
4
11
267K
R22
68 .1KR20
+15V
C12 C13
LM224
X3
4
11
33 .2K
R21
6 . 81K
R19
1.035V
C8
+15V
H IGH
SETTR IM
WIRESPEED
2W5K
D12
100K
R42
100K
R52
392K
R44
1815V
C15
1 .00M R43
100K
R53
10K
R57
1 00K
R54
C16
209 J27
208
J2
10
X2
9
8
10
18 .2K
R45
2.21K
R47
6 81R76
1 . 00K
R55
2 . 21K
R49
203
J2
6
X214
12
13
100K
R59
1.820V
C191 .00K
R58
TR IMSET
LOW
SET
MOTOR
FEEDBACKCURRENT
SPEED
FEEDBACKVOLTAGE
R2
MOTOR
D14
10KCW
R56
X3
5
7
6
400V.1C27
G
MT2
MT12500DTRI1
100
R5
C4
5W25
R6
3 .32K
R78
OC I14
6
1400V.0047C1
1 .00K
R8
400V.1
C3
P1
J1
2
3 .32K
R79
SCR23
1 2
D1
3 .32K
R80
OC I26
4
1 .00K
R2
150
R3
600V55A
SCR1
3
2 1
400V.1
C2
P1
J1
6
GAS
120VAC
32
CONTROLGAS SOLENOID
7
SOLENOID
WDG
31A
125VAC
24VW/115VACAUX
31A31
5W.5
R69
1 5 .0K
R63
2 2 .1K
R39
1.00K
R41 D13
6 .81K
R65C20
X21
3
2
15 .0K
R64
D17
10K
R68 1 0K
R66
22 .1K
R61
6A100V
Q7
13
2
1W16VDZ3
203
+15V
ERRORAMP
OSCILLATORSHUTDOWN
203
PWM
1.00K
R70
X314
12
13
22 .1K
R38
C26
X38
9
10
40V600mAQ2
500mA300V
Q1
C14
X31
2
3
22 .1K
R60
3 30050V
C23
3A200V
D16
10K
R71
2K
R37 2K
R83
D19
204
+15V
+15V
+15V
+15V
SU
PP
LY
10
J2
5
LEA
D C
OLO
R C
OD
E
B -
BLA
CK
MFD
1A, 4
00V
31
8 015W
R32
D2
211
J2
9
P2 J23
3 .01K
R34 3 . 01K
R81
1 . 00K
R4
3.01K
R82
C21
40V600mAQ3
15.0K
R67
5W150
R1
213
J2
8
40V600mAQ4
D18
83 27
4 7 .5
R62
4 . 735V
C17
3 .32K
R46
1 0K
R50
40V600mAQ5
1.035V
C18 1 .00K
R51
1 .00K
R48
1 0K
R73
D20
B
MOTOR
W
32L2
S1SWITCHON-OFF
FEEDWIRE
D4D3
24VAC
GND
60 HZ
115VAC
L1
FAN
300V500mAQ6
D21
539
J2
2
541
J2
1
5W.5
R72
8 5A300V
85A300V
D1 D2
C-
D-
21
1W43VDZ4
R-
3A200V
D15
FRA
ME
CO
NN
EC
TIO
N
DZ-
4
LATC
H
L
4
J1
LAS
T N
O.
US
ED
PO
WE
R S
UP
PLY
SO
UR
CE
PO
INT
6
SC
HE
MA
TIC
SP
100
CO
NTR
OL
(UN
LES
S O
THER
WIS
E S
PEC
IFIE
D)
UN
LES
S O
THER
WIS
E S
PEC
IFIE
D)
UN
LES
S O
THER
WIS
E S
PEC
IFIE
D)
POWER
DIO
DES
=
CA
PA
CIT
OR
S =
RES
ISTO
RS
= O
hms
(.0
22/5
0V1/
4W(
GE
NE
RA
L IN
FOR
MA
TIO
N
ELE
CTR
ICA
L S
YM
BO
LS P
ER
E15
37
LAB
ELS
WELD ING
OUTPUT
61
W -
WH
ITE
P 1
J1
3
1400VDC.0047
C25MOTOR
203
EA
RTH
GR
OU
ND
CO
NN
EC
TIO
N
8552
CO
MM
ON
CO
NN
EC
TIO
N
VO
LTA
GE
NE
T
NO
T S
HO
W T
HE
EX
AC
T C
OM
PO
NE
NTS
OR
CIR
CU
ITR
Y O
F C
ON
TRO
LS H
AV
ING
A C
OM
MO
N C
OD
EW
ITH
OU
T A
FFEC
TIN
G T
HE
INTE
RC
HA
NG
EAB
ILIT
Y O
F A
CO
MP
LETE
BO
AR
D,
THIS
DIA
GR
AM
MA
YN
.A.
S
INC
E C
OM
PO
NEN
TS O
R C
IRC
UIT
RY
ON
A P
RIN
TED
CIR
CU
IT B
OA
RD
MA
Y C
HA
NG
E
NU
MB
ER.
NO
TES
:
2 67
R75
OUTPUT
8015W
R33
TR IGGER212
SWITCHMOTOR
STOP
203
T1
P2 J24
10K
R74
CHOKE
531
OVERCURRENT
SCR
S2
THERMOSTAT
D3
300V85A
300V
D485A
+ C1
40V59K
32
F IR ING
100V.22C22
15 .0K
R36
2 03
10-2
2-93
L
NOTE: This machine schedmatic is provided for reference only and may not be totally applicable to every code coveredin this manual.
G-9ELECTRICAL DIAGRAMS
SP-100
MACHINE SCHEMATIC: Codes Below 9794
LAS
T N
O.
US
ED
L
DCR
N.A
.
SIN
CE
CO
MP
ON
EN
TS O
R C
IRC
UIT
RY
ON
A P
RIN
TED
CIR
CU
IT B
OA
RD
MA
Y C
HA
NG
EW
ITH
OU
T A
FFE
CTI
NG
TH
E I
NTE
RC
HA
NG
EA
BIL
ITY
OF
A C
OM
PLE
TE B
OA
RD
, TH
IS D
IAG
RA
M M
AY
NO
T S
HO
W T
HE
EX
AC
T C
OM
PO
NE
NTS
OR
CIR
CU
ITR
Y O
F C
ON
TRO
LS H
AV
ING
A C
OM
MO
N C
OD
EN
UM
BE
R.
GE
NE
RA
L IN
FOR
MA
TIO
N
f
VO
LTA
GE
NE
TS
UP
PLY
(con
nect
or c
avit
y re
pre
sent
atio
ns)
NO
TES
:
DIO
DE
S =
1A
, 40
0V (
UN
LES
S O
THE
RW
ISE
SP
EC
IFIE
D)
RE
SIS
TOR
S =
Ohm
s (1
/4W
UN
LES
S O
THE
RW
ISE
SP
EC
IFIE
D)
CA
PA
CIT
OR
S =
d
(.0
22/5
0V U
NLE
SS
OTH
ER
WIS
E S
PE
CIF
IED
)E
LEC
TRIC
AL
SY
MB
OLS
PE
R E
-153
7
LAB
ELS
FRA
ME
CO
NN
EC
TIO
NP
OW
ER
SU
PP
LY S
OU
RC
E P
OIN
T
EA
RTH
GR
OU
ND
CO
NN
EC
TIO
N
CO
MM
ON
CO
NN
EC
TIO
N
1%
W
7619
SC
HE
MA
TIC
2 03
203 203
B
6A100V
Q7
13
2
WIREFEEDMOTOR
47 .5
R62
GENERAL INFORMAT ION
.55W
R72
1W16VDZ3
330050V
C2310K
R71
5 39
J2
2
541
J2
1
1W43VDZ4
3A200V
D15
1 .035V
C8
208
J2
10
+15V
203
J2
6
X21
3
2
100K
R53
SPEED
22 .1K
R39
5K
R22W
LM224
X3
4
11
100K
R54
LM224
X2
4
11
CW
2KR40
D13
D20
C13
1 .00K
R41
1 815V
C15
15 .0KR36
1 0K
CW
R56
2
3
1
+15V
SHUTDOWN
X214
12
13
100K
R52
+15V
392K
R44
209 J27
203
2 .21K
R49
1 .00M R43
C16
39 .2KR35
1 00K
R42
D12
LATCH J1
1 3
6
1 .00K
R55
C26
C14
30V200mAQ2
1
3
2
22 .1K
R38
1 0K
R57
OUTPUT
1 .820V
C19
32
1 .00K
R58
X38
9
10
SWITCH
115VAC
60 HZ
32
TO GND.
D14
S1
L2
L1
B531
OVERCURRENT
P2 J24
T1 300V85AD1 D2
85A300V
D385A300V
D485A300V
40V
C1
59K
P2 J23
500mA300VQ1
24V
T1
3
5
4
62
1
1N914D10
68 .1KR20
OC I2
1
2
33 .2K
R21
5 6 .2K R30
5 62R23
1 00V.1C7
1
6
1 .3K
R18
7619
CONNECTOR CAV ITY NUMBERING SEQUENCE
(V IEWED FROM COMPONENT S IDE OF BOARD)
205
J1
4
X17
6
5
D9
1 .3K
R15
+15V
+15V
L
206 J15
LM224
X1
4
11
C11X1
14
13
12
OC I1
1
2
56 .2K
R25
VOLTS
BURNBACK
PWM
FIR INGSCR
ARC
5K
ARC VOLTAGE
CONTROLSOLENOID
FEEDBACK
ERROR AMPL IF IER
D11
GAS
C24
56 .2K
R17
X18
10
9
ARC VOLTAGE
2WC9
68 .1K
R14
SAWTOOTH
MOTOR
2.21K
R31
2 . 21K
R47
5 6 .2K
R29
500mW5.1VDZ2
267K
R22
5 62R24
2 . 21K
R28
500mW10VDZ1
2
1
22 .1K
R12
1 .00K
R26
2 07
J1
1
1 .035V
C10C12
1 .00K
R27
X3
5
7
6
82 .5K
R13
ON-OFF
+15V
X2
6
7
5
5%
GASSOLENOID
MOTOR
1.3K
R16
FEEDBACK
SPEED
120VAC
SET
LOAD CURRENT
.55W
R69
FEEDBACKVOLTAGE
MOTORSTOP
5
10
J2
ELECTR ICAL SYMBOLS PER E1537CAPACITORS = MFD/VOLT ( . 022 /50V ,UNLESS OTHERWISE SPEC IF IED )RES ISTORS = OHMS (1 /4WATT ,UNLESS OTHERWISE SPEC IF IED )D IODES = 1A/400V (UNLESS OTHERWISE SPEC IF IED )
= COMMON CONNECT ION
= SOURCE PO INT C IRCUIT LOCAT ION
2N4123Q5
4 .75K
R11
+15V
1 .00K
R70
R1
+ 15V
22 .1K
R61
100K
R59
X11
3
2
6 .81K
R19
22 .1K
R60
X314
12
13
2N4123Q4
300V500mAQ6
1 .00K
R51
10K
R50
D8
D71/2W27
R9
D5
D4
D6
D3
47 .5KR10 GND
IN OUTX4
2W27
R6
1 /2W1000
R2
D1
1/2W150
R3
.00471400V
C1
1400V.0047C25
.1400V
C3
B31A
2W10K
R7
400V.1C2
1/2W1K
R8
150V45J
TP2
F IR ING
REGULATORVOLTAGE
C4
1/2W100
R5
GAS SOLENOID
B7
CONTROL
31
31A
115ACMOTORFAN
BREAKERCIRCUIT30A
+15V SUPPLY
24VAC
+15V
15050V
C5
D18
4 .735V
C6
2500DTR I1
2W120
R1
600V55ASCR1
3
2 1
OCI14
6
600V55A
SCR23
1 2
OCI26
4
MC7815CTDS
P1
J1
3
D19
SCR
D2
1/2W1000
R4
B32A
OSCILLATOR
PWMERRORAMP
CHOKE
213
J2
8
D17
10K
R74
WELD INGPOWER
OUTPUT
3A200V
D16
8015W R
32
203
10K
R66
204
10K
R68
SW ITCHS2
THERMOSTAT
TR IGGER
+15V
15 .0K
R67
2 11
J2
9
100V.22C22
+15V
X31
2
3
C21
2N4123Q3
15 .0KR63
1 . 00K
R34
1 . 00K
R37
1 5 .0KR64
+15V
C20
8015WR
33
6 . 81K
R65
WIRE
LEAD COLOR CODE
X2
9
8
10
204 3 .32K
R46
2 67
R75
B - BLACK
W - WHITE
D21
4
10K
R73
1 .00K
R48
4 . 735V
C17
1 .035V
C18
18 .2K
R45
1/2W
1/2W
75 21
DZ
4
SP
100
WE
LDE
RS
7-27
-90J
NOTE: This machine schedmatic is provided for reference only and may not be totally applicable to every code coveredin this manual.R
etur
n to
Sec
tion
TO
CR
etur
n to
Sec
tion
TO
CR
etur
n to
Sec
tion
TO
CR
etur
n to
Sec
tion
TO
C
Ret
urn
to M
aste
r T
OC
Ret
urn
to M
aste
r T
OC
Ret
urn
to M
aste
r T
OC
Ret
urn
to M
aste
r T
OC
SVM ERROR REPORTING FORM
We need to know if there are errors in our manuals. We also value any suggestions as toadditional tests or procedures that would make this SVM a better tool for you.
If you discover new or different “Problems or Symptoms” that are not covered in the three col-umn troubleshooting chart, please share this information with us. Please include themachine’s code number and how the problem was resolved.
Thank You,Technical Services GroupLincoln Electric Co.22801 ST. Clair Ave.Cleveland, Ohio 44117-1199
FAX 216-481-2309
SVM Number ___________________________
Page Number if necessary__________________
Your Company__________________________
Your Name_____________________________
Please give detailed description below:
_______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
SD287 01/99
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urn
to S
ectio
n T
OC
Ret
urn
to S
ectio
n T
OC
Ret
urn
to S
ectio
n T
OC
Ret
urn
to S
ectio
n T
OC
Ret
urn
to M
aste
r T
OC
Ret
urn
to M
aste
r T
OC
Ret
urn
to M
aste
r T
OC
Ret
urn
to M
aste
r T
OC