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SP-100
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SP-100
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D-5
NOTES
Contents
Main
SP-100
SERVICE MANUAL
SVM102-A
iSAFETY
Apr. 93
WARNING
FUMES AND GASES can be dangerous.
ii
FOR ELECTRICALLY powered equipment.
Mar. 93
CYLINDER may explode if damaged.
WELDING SPARKS can cause fire or explosion.
iii SAFETY
ELECTRIC AND MAGNETIC FIELDS may be dangerous
FOR ENGINE powered equipment.
iv
PRCAUTIONS DE SRET
Mar. 93
PRCAUTIONS DE SRET POUR LES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR
MASTER TABLE OF CONTENTS FOR ALL SECTIONS
v
Section A
TABLE OF CONTENTS INSTALLATION SECTION
A-1 INSTALLATION
TECHNICAL SPECIFICATIONS SP-100
PHYSICAL DIMENSIONS
INPUT SINGLE PHASE ONLY RATED OUTPUT OUTPUT RECOMMENDED INPUT CABLE AND FUSE SIZES
A-2
SAFETY PRECAUTIONS
3a 3b
A-3 INSTALLATION
SELECT SUITABLE LOCATION
STACKING
TILTING
OUTPUT CONNECTIONS
WORK CLAMP INSTALLATION
A-4
GAS CONNECTION
GUN INSTALLATION
INPUT CONNECTIONS
A-5 INSTALLATION
A-6
CODE REQUIREMENTS FOR INPUT CONNECTIONS
Page
TABLE OF CONTENTS OPERATION SECTION
Section B
Page
B-2
GENERAL DESCRIPTION
RECOMMENDED PROCESSES
Wire Speed
I O V
Arc Volts
o|o
B-3
WELDING OPERATIONS
PROCESS GUIDELINES
SEQUENCE OF OPERATION
B-4
B-5
WARNING
B-6
CHANGING MACHINE OVER TO FEED OTHER WIRE SIZES
WELDING WITH INNERSHIELD
OVERLOAD PROTECTION
OUTPUT OVERLOAD
THERMAL PROTECTION
WIRE FEED OVERLOAD PROTECTION
Page
Page
C-1 ACCESSORIES K467 INPUT LINE CORD
REPLACEMENT PARTS
LINCOLN GAS REGULATOR KITS
INNERSHIELD WELDING KITS
DRIVE ROLL
Section D
TABLE OF CONTENTS MAINTENANCE SECTION
AFTER EACH SPOOL OF WIRE FEED
AFTER FEEDING 50# OF FLUX CORED WIRE OR 300# OF SOLID WIRE
PERIODICALLY AS REQUIRED
D-1 MAINTENANCE
SAFETY PRECAUTIONS
ITEMS REQUIRING NO MAINTENANCE
ROUTINE AND PERIODIC MAINTENANCE
BEFORE EACH USE
AFTER 5 MINUTES OF WELDING or when spatter accumulates in nozzle
COMPONENT REPLACE- MENT PROCEDURES
CHANGING THE CONTACT TIP
CHANGING DRIVE ROLL
D-3 MAINTENANCE REPLACE INTERNAL GUN HANDLE PARTS AS NECESSARY
CHANGING LINER
Page
Page
Page
Page
E-2
OUTPUT CONTROL, RECTIFICA- TION AND VOLTAGE FEEDBACK
E-3 THEORY OF OPERATION
TRIGGER, GAS SOLENOID AND WIRE DRIVE
E-4
SCR OPERATION
E-5 THEORY OF OPERATION THERMAL PROTECTION
Section F
TABLE OF CONTENTS TROUBLESHOOTING SECTION
F-1 TROUBLESHOOTING & REPAIR
Step 1. LOCATE PROBLEM (SYMPTOM).
in the order listed
Step 2. PERFORM EXTERNAL TESTS.
HOW TO USE TROUBLESHOOTING GUIDE
F-2
F-3 TROUBLESHOOTING & REPAIR
F-4
F-5 TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
F-6
FEEDING PROBLEMS
Page
Page
Page
F-10
SCOPE SETTINGS
TYPICAL OUTPUT VOLTAGE WAVEFORM MACHINE LOADED
0 volts
10 volts 20 ms
C1
Page
F-12
FAN BLADE AND MOTOR REMOVAL
PROCEDURE DESCRIPTION
taking note of blade placement on motor shaft.
F-13 TROUBLESHOOTING & REPAIR
WIRE DRIVE ASSEMBLY REMOVAL
PROCEDURE DESCRIPTION
F-14
RETEST AFTER REPAIR
12/95
Page
Page
G-2 WIRING DIAGRAMS
-
pasted inside the machine on one of the enclosure panels.
WHICH IS CLOSEST TO THE CENTER PANEL.
N.D. BOLTED ALUMINUM CONNECTIONS REQUIRE JOINT COMPOUND.
can kill
-
+
GUN CABLE CONDUCTOR
TO WORK ELECTRICAL SYMBOLS PER E1537
W-WHITE
Page
G-5
CONTROL P.C. BOARD G1842
G-6 ELECTRICAL DIAGRAMS
CONTROL P.C. BOARD G2314
G-7
CONTROL P.C. BOARD G2314
G-8
MACHINE SCHEMATIC: Codes 9794 and Above
W - WHITE
LABELS
GENERAL INFORMATION
R72
MACHINE SCHEMATIC: Codes Below 9794
SP 100 WELDERS
R64
R37
R63
SVM ERROR REPORTING FORM