Lincoln Electric GUN Installation, GAS Connection, Connecting GUN Cable to the SP-100

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INSTALLATION

A-4

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3.Route the cable under and around the back of the Wire Feed Gearbox (6).

4.For GMAW Only: Refer to Figure A.2. As deliv- ered, the SP-100 is wired for positive polarity. This is the appropriate configuration for the Gas Metal Arc Welding (GMAW) process. To complete instal- lation, use the provided wing nut to connect the work cable’s terminal lug to the negative (–) output terminal (5) located above the Wire Feed Gearbox

(6). Make sure that both wing nuts are tight.

5.For Innershield Only: Refer to Figure A.4. To wire for negative polarity, connect the short cable attached to the connector block (1) to the negative

(–) output terminal (2) and the work cable (3) to the positive (+) terminal (4).

 

FIGURE A.4

4

3

2

1

GUN INSTALLATION

As shipped from the factory, the SP-100 gun is ready to feed 0.023 - 0.025” (0,6 mm) wire. If 0.030” (0,8

mm)wire is to be used install the 0.030” (0.8 mm) contact tip. Refer to the MAINTENANCE section for contact tip installation details.

CONNECTING GUN CABLE TO THE SP-100

1.Refer to Figure A.2. Unplug the machine or turn power switch to the off “O” position.

2.Pass the insulated terminals of the gun trigger con- trol leads, one at a time, through the Gun Cable and Control Lead Access Slot (2) in the case front. The leads are to be routed under the Wire Feed Gearbox (6) and through the Cable Hanger (7) on the inner panel.

3.Insert the connector on the gun conductor cable into the Gun Cable Access Hole (2) in the SP-100 case front. Make sure the connector is all the way in the metal connector block to obtain proper gas flow. Rotate the connector so control leads are on the underside and tighten the Thumbscrew (8) in the connector block.

4.Connect the gun trigger control lead terminals to the two insulated 1/4" (6,4 mm) tab connector bushings located above the “Gun Trigger Connection” decal in the wire feed section (4). Either lead can go to either connector. Form the leads so that they are as close as possible to the inside panel.

CAUTION

If the gun trigger switch being used is other than that supplied with the SP-100, the switch must be a normally open, momentary switch. The terminals of the switch must be insulated from the welding circuit. Malfunction of the SP-100 may result if this switch shorts to the SP-100 welding output circuit or is common to any electrical circuit other than the SP-100 trigger circuit.

GAS CONNECTION

Refer to Figure A.5

When using the GMAW process, a cylinder of carbon dioxide (CO2) or argon-carbon dioxide mixed shielding gas, flow regulator, and an inlet gas hose must be obtained. For more information about selecting gas cylinders for use with the SP-100, refer to the ACCES- SORIES section.

WARNING

CYLINDER may explode if dam- aged. Keep cylinder upright and chained to support

• Keep cylinder away from areas where it may be damaged.

•Never lift welder with cylinder attached.

•Never allow welding electrode to touch cylinder.

•Keep cylinder away from welding or other live electrical circuits.

SP-100

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Contents SP-100 Fumes and Gases can be dangerous SafetyElectric Shock can kill ARC Rays can burnWelding Sparks can cause fire or explosion Cylinder may explode if damagedMay be dangerous Electric and Magnetic FieldsSûreté Pour Soudage a L’Arc Précautions DE SûretéMaster Table of Contents for ALL Sections Installation Section Table of ContentsTechnical Specifications SP-100 InstallationIdentify and Locate Components Safety PrecautionsRead entire installation section before starting InstallationTilting Work Clamp InstallationSelect Suitable Location Output ConnectionsGAS Connection GUN InstallationConnecting GUN Cable to the SP-100 Input PowerInput Connections Gas Solenoid Inlet FittingRequirements for Rated Output Code Requirements for Input ConnectionsRequirements for Maximum Output Requirements for CSA Rated OutputSP-100 Table of Contents Wear eye, ear and body protec- tion OperationOff Operational Features and ControlsDesign Features Advantages General DescriptionSequence of Operation Wire LoadingWelding Operations Process GuidelinesRefer to Figure B-4 Friction Brake AdjustmentsMaking a Weld Shielding GASOverload Protection SP-100 Accessories Section Innershield Welding Kits 1ACCESSORIESReplacement Parts Lincoln GAS Regulator Kits K467 Input Line CordMaintenance Section Routine and Periodic Maintenance MaintenanceItems Requiring no Maintenance Liner trim length for the Magnum 100L gun red trigger Changing the Contact TIPChanging Drive Roll Figure D.3 SP-100 SUB Assemblies SP-100 Theory of Operation Input Line VOLTAGE, FAN Motor and Main Transformer Figure E.1 Input Power CircuitsFigure E.2 Output Circuits Output CONTROL, RECTIFICA- Tion and Voltage Feedback3THEORY of Operation TRIGGER, GAS Solenoid and Wire DriveFigure E.4 SCR Operation SCR OperationThermostat protects the machine from Oscilloscope Waveforms Troubleshooting SectionHOW to USE Troubleshooting Guide 1TROUBLESHOOTING & RepairPC Board Troubleshooting Procedures Troubleshooting & RepairFacility Troubleshooting GuideAuthorized Field Service Below Code 9794 only Code 9794 and Above Problems SymptomsPossible Areas of Misadjustments Recommended Course of ActionFeeding Problems Troubleshooting Guide Codes 9794 and above 6J1 10J2 1J1 1J2 Codes below SP-100 PC Board Connector LocationsNormal Open Circuit Voltage Waveform 9TROUBLESHOOTING & RepairScope Settings Volts Volts/DivTypical Output Voltage Waveform Machine Loaded VoltsAbnormal Open Circuit Voltage Waveform Tools Required Procedure DescriptionProcedure FAN Blade and Motor Removal1B. for Codes below Wire Drive Assembly RemovalMotor Removal Procedure 1A. for Codes AboveInput Amps AT Rated Output Input Amps AC @ Output DC Wire Speed RangeRetest After Repair Main Transformer Secondary Voltages Test PointsSP-100 Electrical Diagrams Section Diagram Wiring DiagramsWiring 4 5 1 M SP-100 Wiring Diagram Codes BelowElectrical Diagrams Control P.C. Board G1842 Electrical DiagramsControl P.C. Board G2314 SCR1, SCR2 SCR 81 Heatsink Asbly Control P.C. Board G2314Error Machine Schematic Codes 9794 and Above86R R63R64 1 5 K Machine Schematic Codes BelowSVM Error Reporting Form
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