Table of Contents | Lincoln Electric SP-100 manual

Return to Master TOC

Return to Master TOC

Return to Master TOC

Return to Master TOC

TABLE OF CONTENTS	Section B
– OPERATION SECTION –
Operation	Section B
Safety Precautions	B-1
General Description	B-2
Recommended Processes	B-2
Operational Features and Controls	B-2
Design Features and Advantages	B-2
Welding Capability	B-2
Limitations	B-2
Controls and Settings	B-2
Welding Operations	B-3
Process Guidelines	B-3
Sequence of Operations	B-3
Wire Loading	B-3
Friction Brake Adjustments	B-4
Wire Threading	B-4
Shielding Gas	B-5
Making a Weld	B-5
Cleaning Tip and Nozzle	B-6
Changing Machine Over To Feed Other Wire Sizes	B-6
Welding With Innershield	B-6
Overload Protection	B-6
Output Overload	B-6
Thermal Protection	B-6
Wire Feed Overload Protection	B-6

SP-100

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Lincoln Electric SP-100 service manual Table of Contents

Contents

SP-100 Fumes and Gases can be dangerous SafetyElectric Shock can kill ARC Rays can burn Welding Sparks can cause fire or explosion Cylinder may explode if damaged May be dangerous Electric and Magnetic Fields Sûreté Pour Soudage a L’Arc Précautions DE Sûreté Master Table of Contents for ALL Sections Installation Section Table of Contents Technical Specifications SP-100 Installation Identify and Locate Components Safety PrecautionsRead entire installation section before starting Installation Tilting Work Clamp InstallationSelect Suitable Location Output Connections GUN Installation Connecting GUN Cable to the SP-100GAS Connection Input PowerInput Connections Gas Solenoid Inlet Fitting Requirements for Rated Output Code Requirements for Input ConnectionsRequirements for Maximum Output Requirements for CSA Rated Output SP-100 Table of Contents Wear eye, ear and body protec- tion Operation Off Operational Features and ControlsDesign Features Advantages General Description Sequence of Operation Wire LoadingWelding Operations Process Guidelines Refer to Figure B-4 Friction Brake Adjustments Making a Weld Shielding GAS Overload Protection SP-100 Accessories Section Innershield Welding Kits 1ACCESSORIESReplacement Parts Lincoln GAS Regulator Kits K467 Input Line Cord Maintenance 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 Circuits Figure E.2 Output Circuits Output CONTROL, RECTIFICA- Tion and Voltage Feedback 3THEORY of Operation TRIGGER, GAS Solenoid and Wire Drive Figure E.4 SCR Operation SCR Operation Thermostat protects the machine from Oscilloscope Waveforms Troubleshooting Section HOW to USE Troubleshooting Guide 1TROUBLESHOOTING & Repair PC Board Troubleshooting Procedures Troubleshooting & Repair Troubleshooting Guide Authorized Field ServiceFacility Below Code 9794 only Code 9794 and Above Problems SymptomsPossible Areas of Misadjustments Recommended Course of Action Feeding Problems Troubleshooting Guide Codes 9794 and above 6J1 10J2 1J1 1J2 Codes below SP-100 PC Board Connector Locations Normal Open Circuit Voltage Waveform 9TROUBLESHOOTING & RepairScope Settings Volts Volts/Div Typical Output Voltage Waveform Machine Loaded Volts Abnormal Open Circuit Voltage Waveform Tools Required Procedure DescriptionProcedure FAN Blade and Motor Removal 1B. for Codes below Wire Drive Assembly RemovalMotor Removal Procedure 1A. for Codes Above Input Amps AT Rated Output Input Amps AC @ Output DC Wire Speed RangeRetest After Repair Main Transformer Secondary Voltages Test Points SP-100 Electrical Diagrams Section Wiring Diagrams WiringDiagram 4 5 1 M SP-100 Wiring Diagram Codes Below Electrical Diagrams Control P.C. Board G1842 Electrical Diagrams Control P.C. Board G2314 SCR1, SCR2 SCR 81 Heatsink Asbly Control P.C. Board G2314 Error Machine Schematic Codes 9794 and Above 86R R63R64 1 5 K Machine Schematic Codes Below SVM Error Reporting Form