Lincoln Electric SP-100 service manual General Description, Off, Recommended Processes

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OPERATION

B-2

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GENERAL DESCRIPTION

The SP-100, Type K462, is a complete semiautomatic constant voltage DC arc welding machine. Included is a solid state controlled, single phase constant voltage transformer/ rectifier power source and a wire feeder for feeding solid steel electrode and cored electrode.

The SP-100 is ideally suited for individuals having access to 115 volt AC input power, and wanting the ease of use, quality and dependability of both gas metal arc welding or GMAW (also known as MIG welding) and the Innershield electrode process (self shielded flux cored or FCAW). The SP-100 is a rugged and reliable machine that has been designed for dependable service and long life.

Reversible, dual groove drive roll. Drive roll will feed .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 used with 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% duty cycle on a ten minute basis. It is capable of higher duty cycles at lower output currents.

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RECOMMENDED PROCESSES

The SP-100 can be used for welding mild steel using the GMAW, single pass, process which requires a supply of shielding gas or it can be used for the self shielded, Innershield electrode process (FCAW). The SP-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 Speed Control, and a Circuit Breaker.

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 —

I

On

When the power is on the

fan motor will run and air will

be exhausted out the louvers

O Off

in the front of the machine.

The welding output and wire

feeder remain off until the gun trigger is pressed.

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DESIGN FEATURES AND

ADVANTAGES

Operates on 115 volt input — no special wiring required.

Solid state output control.

“Cold electrode” until gun trigger is pressed for an added 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 precise setting of arc voltage and wire speed.

Continuous voltage control.

“Quick Release” idle roll pressure arm is easily adjusted.

2.Voltage Control — A contin- uous control that gives full range adjustment of power source output voltage. Voltage can be adjusted while welding.

3.Wire Speed Control — Controls the wire feed speed from 50 – 400 in /min (1.3 – 10 m/min). The control can be preset on the dial to the setting specified on the SP- 100 Application Guide locat- ed on the inside of the wire feed section door. Wire speed is not affected when changes are made in the voltage control.

V

Arc Volts

oo

Wire Speed

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 TiltingGAS Connection GUN InstallationConnecting GUN Cable to the SP-100 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 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 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 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