Lincoln Electric SP-100 service manual Operation, Wear eye, ear and body protec- tion

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B-1

SP-100

OPERATION

Read entire operation section before operating the SP-100.

WARNING

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or electrode with skin or wet clothing. Insulate yourself from work and ground.

•Always wear dry insulating gloves.

FUMES AND GASES can be dangerous.

• Keep your head out of fumes.

•Use ventilation or exhaust to remove fumes from breathing zone.

WELDING SPARKS can cause fire or explosion.

• Keep flammable material away.

•Do not weld on closed contain- ers.

ARC RAYS can burn eyes and skin.

• Wear eye, ear and body protec- tion.

Observe all safety information throughout this manual.

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Contents SP-100 Safety Electric Shock can killARC Rays can burn 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-100Safety Precautions Read entire installation section before startingInstallation Identify and Locate ComponentsWork Clamp Installation Select Suitable LocationOutput Connections TiltingConnecting GUN Cable to the SP-100 GUN InstallationGAS Connection Power Input ConnectionsGas Solenoid Inlet Fitting InputCode Requirements for Input Connections Requirements for Maximum OutputRequirements for CSA Rated Output Requirements for Rated OutputSP-100 Table of Contents Operation Wear eye, ear and body protec- tionOperational Features and Controls Design Features AdvantagesGeneral Description OffWire Loading Welding OperationsProcess Guidelines Sequence of OperationFriction Brake Adjustments Refer to Figure B-4Shielding GAS Making a WeldOverload Protection SP-100 Accessories Section 1ACCESSORIES Replacement PartsLincoln 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 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 Problems Symptoms Possible Areas of MisadjustmentsRecommended Course of Action Code 9794 and AboveFeeding Problems Troubleshooting Guide PC Board Connector Locations Codes 9794 and above 6J1 10J2 1J1 1J2 Codes below SP-1009TROUBLESHOOTING & Repair Scope SettingsVolts Volts/Div Normal Open Circuit Voltage WaveformVolts Typical Output Voltage Waveform Machine LoadedAbnormal Open Circuit Voltage Waveform Procedure Description ProcedureFAN Blade and Motor Removal Tools RequiredWire Drive Assembly Removal Motor Removal Procedure1A. for Codes Above 1B. for Codes belowWire Speed Range Retest After RepairMain Transformer Secondary Voltages Test Points 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