Lincoln Electric SP-100 Select Suitable Location, Output Connections, Work Clamp Installation

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A-3

INSTALLATION

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SELECT SUITABLE LOCATION

Locate the welder in a dry location where there is free circulation of clean air into the louvers in the back and out the front of the unit. A location that minimizes the amount of smoke and dirt drawn into the rear louvers reduces the chance of dirt accumulation that can block air passages and cause overheating.

WORK CLAMP INSTALLATION

Attach the work clamp per the following:

1.Unplug the machine or turn the power switch to the “OFF” position.

2.Insert the work cable terminal lug with the larger hole through the strain relief hole in the work clamp as shown in Figure A-3.

STACKING

3. Fasten securely with the bolt and nut provided.

SP-100’s cannot be stacked.

FIGURE A.3

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TILTING

Each machine must be placed on a secure, level sur- face, either directly or on a recommended undercar- riage. The machine may topple over if this procedure is not followed.

OUTPUT CONNECTIONS

Refer to Figure A.2.

1.Work Cable Access Hole.

2.Gun Cable and Control Lead Access Hole.

3.Connector Block.

4.Gun Trigger Lead Connectors.

5.Positive (+) and negative (–) output terminals.

Strain Relief Hole

Work Cable

Nut & Bolt

Work Clamp

WORK CABLE INSTALLATION

Refer to Figure A.2.

1.Open the wire feed section door on the right side of the SP-100.

2.Pass the end of the work cable that has the termi- nal lug with the smaller hole through the Work Cable Access Hole (1) in the case front.

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FIGURE A.2

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8

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1

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SP-100

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Contents SP-100 ARC Rays can burn SafetyElectric Shock can kill Fumes and Gases can be dangerousCylinder may explode if damaged Welding Sparks can cause fire or explosionElectric and Magnetic Fields May be dangerousPrécautions DE Sûreté Sûreté Pour Soudage a L’ArcMaster Table of Contents for ALL Sections Table of Contents Installation SectionInstallation Technical Specifications SP-100Installation Safety PrecautionsRead entire installation section before starting Identify and Locate ComponentsOutput Connections Work Clamp InstallationSelect Suitable Location TiltingConnecting GUN Cable to the SP-100 GUN InstallationGAS Connection Gas Solenoid Inlet Fitting PowerInput Connections InputRequirements for CSA Rated Output Code Requirements for Input ConnectionsRequirements for Maximum Output Requirements for Rated OutputSP-100 Table of Contents Operation Wear eye, ear and body protec- tionGeneral Description Operational Features and ControlsDesign Features Advantages OffProcess Guidelines Wire LoadingWelding Operations Sequence of OperationFriction Brake Adjustments Refer to Figure B-4Shielding GAS Making a WeldOverload Protection SP-100 Accessories Section Lincoln GAS Regulator Kits K467 Input Line Cord 1ACCESSORIESReplacement Parts Innershield Welding KitsMaintenance Section Items Requiring no Maintenance MaintenanceRoutine and Periodic Maintenance Changing Drive Roll Changing the Contact TIPLiner trim length for the Magnum 100L gun red trigger Figure D.3 SP-100 SUB Assemblies SP-100 Theory of Operation Figure E.1 Input Power Circuits Input Line VOLTAGE, FAN Motor and Main TransformerOutput CONTROL, RECTIFICA- Tion and Voltage Feedback Figure E.2 Output CircuitsTRIGGER, GAS Solenoid and Wire Drive 3THEORY of OperationSCR Operation Figure E.4 SCR OperationThermostat protects the machine from Troubleshooting Section Oscilloscope Waveforms1TROUBLESHOOTING & Repair HOW to USE Troubleshooting GuideTroubleshooting & Repair PC Board Troubleshooting ProceduresAuthorized Field Service Troubleshooting GuideFacility Below Code 9794 only Recommended Course of Action Problems SymptomsPossible Areas of Misadjustments Code 9794 and AboveFeeding Problems Troubleshooting Guide PC Board Connector Locations Codes 9794 and above 6J1 10J2 1J1 1J2 Codes below SP-100Volts Volts/Div 9TROUBLESHOOTING & RepairScope Settings Normal Open Circuit Voltage WaveformVolts Typical Output Voltage Waveform Machine LoadedAbnormal Open Circuit Voltage Waveform FAN Blade and Motor Removal Procedure DescriptionProcedure Tools Required1A. for Codes Above Wire Drive Assembly RemovalMotor Removal Procedure 1B. for Codes belowMain Transformer Secondary Voltages Test Points Wire Speed RangeRetest After Repair Input Amps AT Rated Output Input Amps AC @ Output DCSP-100 Electrical Diagrams Section Wiring Wiring DiagramsDiagram SP-100 Wiring Diagram Codes Below 4 5 1 MElectrical Diagrams Electrical Diagrams Control P.C. Board G1842Control P.C. Board G2314 Control P.C. Board G2314 SCR1, SCR2 SCR 81 Heatsink AsblyMachine Schematic Codes 9794 and Above ErrorMachine Schematic Codes Below 86R R63R64 1 5 KSVM Error Reporting Form