Lincoln Electric SP-100 Safety Precautions, Identify and Locate Components, Installation

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INSTALLATION	A-2
Read entire installation section before starting	FIGURE A.1
installation.
SAFETY PRECAUTIONS	1

WARNING

ELECTRIC SHOCK can kill.

• Only qualified personnel should perform this installation.

• Only personnel that have read and under- stood the SP-100 Operating Manual should install and operate this equipment.

• Machine must be plugged into a receptacle which is grounded per any national, local or other applicable electrical codes.

• The SP-100 power switch is to be in the

OFF (“O”) position when installing work2 cable and gun and when connecting power

cord to input power.

IDENTIFY AND LOCATE		3a
COMPONENTS
If you have not already done so, unpack the SP-100
from its carton and remove all packing material
around the SP-100. Remove the following loose items		3b
from the carton (see Figure A.1):
1.	SP-100
2.	Gun and cable assembly(1)
3.	Literature envelope which contains:	4
	a) This operating manual

b) A contact tip for .030” (0,8 mm) diameter wire.

4. 10 ft (3,0 m) work cable.

5. Work clamp.	5

(1) Gun is ready to feed .025" (0.6 mm) diameter wire (also .023 and .024 diameter wire).

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 TiltingGUN Installation Connecting GUN Cable to the SP-100GAS Connection 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 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 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 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