Lincoln Electric SP-100 service manual 1TROUBLESHOOTING & Repair, HOW to USE Troubleshooting Guide

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F-1TROUBLESHOOTING & REPAIR

HOW TO USE TROUBLESHOOTING GUIDE

WARNING

Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this

manual.

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This Troubleshooting Guide is provided to help you locate and correct possible machine malfunctions or misadjustments. Simply follow the three-step procedure listed below.

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Step 1. LOCATE PROBLEM (SYMPTOM).

Look under the column labeled “PROBLEM (SYMPTOMS)”. This column describes pos- sible symptoms that the machine may exhibit. Find the listing that best describes the symptom that the machine is exhibiting.

Symptoms are grouped into the following categories: Output Problems; Feeding Problems; Gas Flow Problems; and Welding Problems.

Step 2. PERFORM EXTERNAL TESTS. The second column labeled “POSSIBLE AREAS OF MISADJUSTMENT(S)” lists the obvious external possibilities that may con- tribute to the machine symptom. Perform these tests/checks in the order listed. In general, these tests can be conducted with- out removing the case wrap-around cover.

Step 3. PERFORM COMPONENT TESTS.

The last column labeled “Recommended Course of Action” lists the most likely com- ponents that may have failed in your machine. It also specifies the appropriate test procedure to verify that the subject component is either good or bad. If there are a number of possible components check the components in the order listed to eliminate one possibility at a time until you locate the cause of you problem.

All the needed test specifications and repair procedures are described in detail on the referenced pages. All the needed electrical test points, terminal strips, junctions, etc., can be found on the referenced electrical wiring diagrams and schematics. See Electrical Diagram Section.

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CAUTION

If for any reason you do not understand the test procedures or are unable to Perform the tests/repairs safely, contact your LOCAL AUTHORIZED LINCOLN ELECTRIC FIELD SERVICE FACILITY for assistance before you proceed. Call 216-383-3531 or 1-800-833-9353

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SP-100

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Contents SP-100 ARC Rays can burn SafetyElectric Shock can kill 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-100Installation Safety PrecautionsRead entire installation section before starting Identify and Locate ComponentsOutput Connections Work Clamp InstallationSelect Suitable Location TiltingGAS Connection GUN InstallationConnecting GUN Cable to the SP-100 Gas Solenoid Inlet Fitting PowerInput Connections InputRequirements for CSA Rated Output Code Requirements for Input ConnectionsRequirements for Maximum Output Requirements for Rated OutputSP-100 Table of Contents Operation Wear eye, ear and body protec- tionGeneral Description Operational Features and ControlsDesign Features Advantages OffProcess Guidelines Wire LoadingWelding Operations Sequence of OperationFriction Brake Adjustments Refer to Figure B-4Shielding GAS Making a WeldOverload Protection SP-100 Accessories Section Lincoln GAS Regulator Kits K467 Input Line Cord 1ACCESSORIESReplacement Parts 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 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 ProceduresFacility Troubleshooting GuideAuthorized Field Service Below Code 9794 only Recommended Course of Action Problems SymptomsPossible Areas of Misadjustments Code 9794 and AboveFeeding Problems Troubleshooting Guide PC Board Connector Locations Codes 9794 and above 6J1 10J2 1J1 1J2 Codes below SP-100Volts Volts/Div 9TROUBLESHOOTING & RepairScope Settings Normal Open Circuit Voltage WaveformVolts Typical Output Voltage Waveform Machine LoadedAbnormal Open Circuit Voltage Waveform FAN Blade and Motor Removal Procedure DescriptionProcedure Tools Required1A. for Codes Above Wire Drive Assembly RemovalMotor Removal Procedure 1B. for Codes belowMain Transformer Secondary Voltages Test Points Wire Speed RangeRetest After Repair Input Amps AT Rated Output Input Amps AC @ Output DCSP-100 Electrical Diagrams Section Diagram Wiring DiagramsWiring 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
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