Output Polarity Connection

Work Cable Installation

1.Open the wire feed section door on the right side of the SP-100.

2.Pass the end of the work cable that has the termi- nal lug with the smaller hole through the hole (hole D) next to the louvers in the case front.

3.Route the cable under and around the back of the wire feed unit.

4.Using wing nut provided, connect the terminal lug to the negative (–) output terminal located above the wire feed unit; item M (make certain that both wing nuts are tight).

NOTE: This connection gives the correct electrode polarity for the GMAW process. If using Innershield, see Output Polarity Connection Section below for negative electrode polarity connection.

The SP-100, as shipped, is connected for positive electrode polarity.

To connect for negative electrode polarity (required for the Innershield process), connect the short cable attached to the gun connector block to the negative

(–) output terminal and the work cable to the positive

(+)terminal using the provided wing nuts (make cer- tain that both wing nuts are tight).

GUN INSTALLATION

As shipped from the factory, the SP-100 gun is ready to feed .023, .024 or .025" (0.6 mm) wire. If .030" (0.8

mm)wire is to be used, install the .030" (0.8 mm) con- tact tip. .023 – .025" contact tip is stenciled .025 and/or 0.6 mm and .030" contact tip is stenciled .030 and/or 0.8 mm. See Maintenance Section for instruc- tions to change contact tip.

If .035" (0.9 mm) Innershield flux cored wire is to be used, see Maintenance Section for instructions to change contact tip, cable liner, and gas nozzle.

Connect the gun cable to the SP-100 per the follow- ing:

1.Unplug the machine or turn power switch to the off “O” position.

2.Pass the insulated terminals of the gun trigger con- trol leads, one at a time, through the rectangular “keyhole” opening (item F) in the case front. The leads are to be routed under the wire feed unit and through the cable hanger on the inner panel.

3.Insert the connector on the gun conductor cable through the large hole in the SP-100 case front. Make sure the connector is all the way in the metal connector block to obtain proper gas flow. Rotate the connector so control leads are on the underside and tighten the thumbscrew in the connector block.

4.Connect the insulated control lead terminals to the two insulated 1/4" (6.4 mm) tab connector bushings located above the “Gun Trigger Connection” decal in the wire feed section. Either lead can go to either connector. Form the leads so that they are as close as possible to the inside panel.

CAUTION

The gun trigger switch must be a normally open, momentary switch. The terminals of the switch must be insulated from the welding circuit. Malfunction of the SP-100 will result if this switch shorts to the SP- 100 welding output circuit or is common to any elec- trical circuit other than the SP-100 trigger circuit.

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Gun trigger connectors

Thumbscrew

Gun connector block	{
	{
Case front

Brass connector

Gun trigger control lead terminals

WIRE FEED DRIVE ROLL

The SP-100 drive roll has two grooves; one for .023 –

.025" (0.6 mm) solid steel electrode and the other for

.030" (0.8 mm) solid and .035" (0.9 mm) flux-cored steel electrode. As shipped, the drive roll is installed in the .023/.025" (0.6 mm) position (as indicated by the stenciling on the exposed side of the drive roll).

If .030 – .035" (0.8 – 0.9 mm) wire is to be used, the drive roll must be reversed as follows:

1.Make certain the SP-100 power switch is “off”.

2.Open the quick release arm; lift up the idle roll arm.

3.Remove the drive roll retaining screw and washer with a screwdriver.

4.Remove the drive roll, flip over and install with the

.030/.035" (0.8/0.9 mm) stencil visible (away from gearbox). Make certain the small key is in place in the keyway.

5.Replace the washer and retaining screw.

Idle roll arm

Spring loaded pressure arm

Drive roll

Retaining Screw

WELDING WIRE LOADING

WARNING

The machine power switch should be turned to the OFF (“O”) position before working inside the wirefeed enclosure.

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The machine is shipped from the factory ready to feed 8" (200 mm) diameter spools [2.2" (56 mm) max. width]. These spools fit on a 2" (50 mm) diameter spindle that has a built-in, adjustable* friction brake to prevent overrun of the spool and excess slack in the

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