Lincoln Electric SP-100 Code Requirements for Input Connections, Requirements for Maximum Output

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INSTALLATION

A-6

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CODE REQUIREMENTS FOR INPUT CONNECTIONS

WARNING

This welding machine must be connected to power source in accordance with applicable elec- trical codes.

The United States National Electrical Code (Article 630-B, 1990 Edition) provides standards for amperage handling capability of supply conductors based on duty cycle of the welding source.

If there is any question about the installation meeting applicable electrical code requirements, consult a qualified electrician.

REQUIREMENTS FOR MAXIMUM OUTPUT

An optional power cord (K467 Input Line Cord) is available to permit the SP-100 to be connected to a 25 amp branch circuit with a nominal voltage rating of 115 to 125 volts, 60 Hertz, AC only. With this installa- tion the SP-100 can be used at an output of 100 amps, 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 this plug 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 an output of 63 amps, 20 volts, 20% duty cycle.

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CAUTION

Do not connect the SP-100 to an input power sup- ply with a rated voltage that is greater than 125 volts.

Do not remove the power cord ground prong.

REQUIREMENTS FOR RATED OUTPUT

A power cord with a 15 amp, 125 volt, three prong plug (NEMA Type 5-15P) is factory installed on the SP-100. Connect this plug to a mating grounded receptacle 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, 18 Volts, 20% duty cycle (2 minutes of every 10 minutes used for welding).

EXTENTION CORD USAGE

If an extension cord is required, use one that is rated for the application and is 3 conductor #14 AWG (2.1 mm2) or larger. The recommended maximum lengths are 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.

SP-100

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Contents SP-100 Electric Shock can kill SafetyARC Rays can burn Fumes and Gases can be dangerousWelding 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 InstallationRead entire installation section before starting Safety PrecautionsInstallation Identify and Locate ComponentsSelect Suitable Location Work Clamp InstallationOutput Connections TiltingConnecting GUN Cable to the SP-100 GUN InstallationGAS Connection Input Connections PowerGas Solenoid Inlet Fitting InputRequirements for Maximum Output Code Requirements for Input ConnectionsRequirements for CSA Rated Output Requirements for Rated OutputSP-100 Table of Contents Wear eye, ear and body protec- tion OperationDesign Features Advantages Operational Features and ControlsGeneral Description OffWelding Operations Wire LoadingProcess Guidelines Sequence of OperationRefer to Figure B-4 Friction Brake AdjustmentsMaking a Weld Shielding GASOverload Protection SP-100 Accessories Section Replacement Parts 1ACCESSORIESLincoln GAS Regulator Kits K467 Input Line Cord 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 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 & RepairAuthorized Field Service Troubleshooting GuideFacility Below Code 9794 only Possible Areas of Misadjustments Problems SymptomsRecommended Course of Action Code 9794 and AboveFeeding Problems Troubleshooting Guide Codes 9794 and above 6J1 10J2 1J1 1J2 Codes below SP-100 PC Board Connector LocationsScope Settings 9TROUBLESHOOTING & RepairVolts Volts/Div Normal Open Circuit Voltage WaveformTypical Output Voltage Waveform Machine Loaded VoltsAbnormal Open Circuit Voltage Waveform Procedure Procedure DescriptionFAN Blade and Motor Removal Tools RequiredMotor Removal Procedure Wire Drive Assembly Removal1A. for Codes Above 1B. for Codes belowRetest After Repair Wire Speed RangeMain Transformer Secondary Voltages Test Points Input Amps AT Rated Output Input Amps AC @ Output DCSP-100 Electrical Diagrams Section Wiring Wiring DiagramsDiagram 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