Lincoln Electric SP-100 service manual Cylinder may explode if damaged

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SAFETY

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WELDING SPARKS can cause fire or explosion.

4.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot

materials from welding can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily available.

4.b. Where compressed gases are to be used at the job site, special precautions should be used to prevent hazardous situations. Refer to “Safety in Welding and Cutting” (ANSI Standard Z49.1) and the operating information for the equipment being used.

4.c. When not welding, make certain no part of the electrode circuit is touching the work or ground. Accidental contact can cause overheating and create a fire hazard.

4.d. Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside. They can cause an explosion even though they have been “cleaned”. For information, purchase “Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances”, AWS F4.1 from the American Welding Society (see address above).

4.e. Vent hollow castings or containers before heating, cutting or welding. They may explode.

4.f. Sparks and spatter are thrown from the welding arc. Wear oil free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes and a cap over your hair. Wear ear plugs when welding out of position or in confined places. Always wear safety glasses with side shields when in a welding area.

4.g. Connect the work cable to the work as close to the welding area as practical. Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains, crane cables or other alternate cir- cuits. This can create fire hazards or overheat lifting chains or cables until they fail.

4.h. Also see item 7c.

CYLINDER may explode if damaged.

5.a. Use only compressed gas cylinders

containing the correct shielding gas for the process used and properly operating regulators designed for the gas and

pressure used. All hoses, fittings, etc. should be suitable for the application and maintained in good condition.

5.b. Always keep cylinders in an upright position securely chained to an undercarriage or fixed support.

5.c. Cylinders should be located:

Away from areas where they may be struck or subjected to physical damage.

A safe distance from arc welding or cutting operations and any other source of heat, sparks, or flame.

5.d. Never allow the electrode, electrode holder or any other electrically “hot” parts to touch a cylinder.

5.e. Keep your head and face away from the cylinder valve outlet when opening the cylinder valve.

5.f. Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use.

5.g. Read and follow the instructions on compressed gas cylinders, associated equipment, and CGA publication P-l, “Precautions for Safe Handling of Compressed Gases in Cylinders,” available from the Compressed Gas Association 1235 Jefferson Davis Highway, Arlington, VA 22202.

FOR ELECTRICALLY powered equipment.

6.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment.

6.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations.

6.c. Ground the equipment in accordance with the U.S. National Electrical Code and the manufacturer’s recommendations.

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Mar. ‘93

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 ConnectionsGUN Installation Connecting GUN Cable to the SP-100GAS Connection 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 Maintenance Items Requiring no MaintenanceRoutine and Periodic Maintenance Changing the Contact TIP Changing Drive RollLiner 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 & RepairTroubleshooting Guide Authorized Field ServiceFacility 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 Wiring Diagrams WiringDiagram 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