Lincoln Electric SP-100

SP-100

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F-8

TROUBLESHOOTING & REPAIR

PC BOARD CONNECTOR LOCATIONS

FIGURE F.1

Codes 9794 and above

Codes below 9794

6J1 10J2

1J1 1J2

6J1 10J2

1J1 1J2

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