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Lincoln Electric SP-100 service manual Table of Contents

Models: SP-100

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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 burnWelding 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 InstallationIdentify and Locate Components Safety PrecautionsRead entire installation section before starting InstallationTilting Work Clamp InstallationSelect Suitable Location Output ConnectionsGUN Installation Connecting GUN Cable to the SP-100GAS Connection Input PowerInput Connections Gas Solenoid Inlet FittingRequirements for Rated Output Code Requirements for Input ConnectionsRequirements for Maximum Output Requirements for CSA Rated OutputSP-100 Table of Contents Wear eye, ear and body protec- tion OperationOff Operational Features and ControlsDesign Features Advantages General DescriptionSequence of Operation Wire LoadingWelding Operations Process GuidelinesRefer to Figure B-4 Friction Brake AdjustmentsMaking a Weld Shielding GASOverload Protection SP-100 Accessories Section Innershield Welding Kits 1ACCESSORIESReplacement Parts Lincoln GAS Regulator Kits K467 Input Line CordMaintenance 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 Code 9794 and Above Problems SymptomsPossible Areas of Misadjustments Recommended Course of ActionFeeding Problems Troubleshooting Guide Codes 9794 and above 6J1 10J2 1J1 1J2 Codes below SP-100 PC Board Connector LocationsNormal Open Circuit Voltage Waveform 9TROUBLESHOOTING & RepairScope Settings Volts Volts/DivTypical Output Voltage Waveform Machine Loaded VoltsAbnormal Open Circuit Voltage Waveform Tools Required Procedure DescriptionProcedure FAN Blade and Motor Removal1B. for Codes below Wire Drive Assembly RemovalMotor Removal Procedure 1A. for Codes AboveInput Amps AT Rated Output Input Amps AC @ Output DC Wire Speed RangeRetest After Repair Main Transformer Secondary Voltages Test PointsSP-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