Operation | Lincoln Electric SP-100 instruction

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B-1

SP-100

OPERATION

Read entire operation section before operating the SP-100.

WARNING

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or electrode with skin or wet clothing. Insulate yourself from work and ground.

•Always wear dry insulating gloves.

FUMES AND GASES can be dangerous.

• Keep your head out of fumes.

•Use ventilation or exhaust to remove fumes from breathing zone.

WELDING SPARKS can cause fire or explosion.

• Keep flammable material away.

•Do not weld on closed contain- ers.

ARC RAYS can burn eyes and skin.

• Wear eye, ear and body protec- tion.

Observe all safety information throughout this manual.

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Lincoln Electric SP-100 service manual Operation, Wear eye, ear and body protec- tion

Contents

SP-100 Safety Electric Shock can killARC Rays can burn Fumes and Gases can be dangerous Cylinder may explode if damaged Welding Sparks can cause fire or explosion Electric and Magnetic Fields May be dangerous Précautions DE Sûreté Sûreté Pour Soudage a L’Arc Master Table of Contents for ALL Sections Table of Contents Installation Section Installation Technical Specifications SP-100 Safety Precautions Read entire installation section before startingInstallation Identify and Locate Components Work Clamp Installation Select Suitable LocationOutput Connections Tilting Connecting GUN Cable to the SP-100 GUN InstallationGAS Connection Power Input ConnectionsGas Solenoid Inlet Fitting Input Code Requirements for Input Connections Requirements for Maximum OutputRequirements for CSA Rated Output Requirements for Rated Output SP-100 Table of Contents Operation Wear eye, ear and body protec- tion Operational Features and Controls Design Features AdvantagesGeneral Description Off Wire Loading Welding OperationsProcess Guidelines Sequence of Operation Friction Brake Adjustments Refer to Figure B-4 Shielding GAS Making a Weld Overload Protection SP-100 Accessories Section 1ACCESSORIES Replacement PartsLincoln GAS Regulator Kits K467 Input Line Cord Innershield Welding Kits Maintenance Section Items Requiring no Maintenance MaintenanceRoutine and Periodic Maintenance Changing Drive Roll Changing the Contact TIPLiner 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 Transformer Output CONTROL, RECTIFICA- Tion and Voltage Feedback Figure E.2 Output Circuits TRIGGER, GAS Solenoid and Wire Drive 3THEORY of Operation SCR Operation Figure E.4 SCR Operation Thermostat protects the machine from Troubleshooting Section Oscilloscope Waveforms 1TROUBLESHOOTING & Repair HOW to USE Troubleshooting Guide Troubleshooting & Repair PC Board Troubleshooting Procedures Authorized Field Service Troubleshooting GuideFacility Below Code 9794 only Problems Symptoms Possible Areas of MisadjustmentsRecommended Course of Action Code 9794 and Above Feeding Problems Troubleshooting Guide PC Board Connector Locations Codes 9794 and above 6J1 10J2 1J1 1J2 Codes below SP-100 9TROUBLESHOOTING & Repair Scope SettingsVolts Volts/Div Normal Open Circuit Voltage Waveform Volts Typical Output Voltage Waveform Machine Loaded Abnormal Open Circuit Voltage Waveform Procedure Description ProcedureFAN Blade and Motor Removal Tools Required Wire Drive Assembly Removal Motor Removal Procedure1A. for Codes Above 1B. for Codes below Wire Speed Range Retest After RepairMain Transformer Secondary Voltages Test Points Input Amps AT Rated Output Input Amps AC @ Output DC SP-100 Electrical Diagrams Section Wiring Wiring DiagramsDiagram SP-100 Wiring Diagram Codes Below 4 5 1 M Electrical Diagrams Electrical Diagrams Control P.C. Board G1842 Control P.C. Board G2314 Control P.C. Board G2314 SCR1, SCR2 SCR 81 Heatsink Asbly Machine Schematic Codes 9794 and Above Error Machine Schematic Codes Below 86R R63R64 1 5 K SVM Error Reporting Form