Lincoln Electric Troubleshooting for SP-100, SP 100, and SP100 Welders

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F-5	TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE		Observe Safety Guidelines
		detailed in the beginning of this manual.

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PROBLEMS (SYMPTOMS)

CODE 9794 and ABOVE

No Wire feed, weld output or gas flow when the gun trigger is pulled - Fan operates normally.

POSSIBLE AREAS OF MISADJUSTMENT(S)

OUTPUT PROBLEMS

1.Check the circuit breaker in the machine – Located in the wire drive compartment. Reset if tripped.

2.The thermostat may be tripped due to overheating. Let machine cool. Weld within the duty cycle or remove any air obstruction to machine.

3.Wire feed motor may be over- loaded – correct feeding prob- lem.

4.Gun trigger may be faulty.

RECOMMENDED COURSE OF ACTION

1.Check for 24 vac at plug 2J1 to 6J1 on the control board. If volt- age is not present, check conti- nuity of leads to fan motor. If leads are OK, replace fan motor. See Figure F.1

2.Remove main power supply to SP-100. With gun trigger pulled check for continuity (zero ohms) from 8J2 (lead #213) to 9J2 (lead #211) at harness plug. If zero ohms is indicated then trig- ger circuit is OK. See Figure F.1.

3.If an open circuit or high resis- tance is indicated in Step 2, then check leads #211, #212 and #213 for loose or broken con- nections. Also check the normal- ly closed thermostat mounted on the diode heat sink assembly.

4.The control board may be faulty

– Replace.

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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 the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed call 216-383-2531 or 1-800-833-9353.

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 TiltingGUN Installation Connecting GUN Cable to the SP-100GAS Connection 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 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 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 ProceduresTroubleshooting Guide Authorized Field ServiceFacility 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 Wiring Diagrams WiringDiagram 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