Safety Precautions, Installation | Lincoln Electric SP-100 guide

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INSTALLATION	A-2
Read entire installation section before starting	FIGURE A.1
installation.
SAFETY PRECAUTIONS	1

WARNING

ELECTRIC SHOCK can kill.

• Only qualified personnel should perform this installation.

• Only personnel that have read and under- stood the SP-100 Operating Manual should install and operate this equipment.

• Machine must be plugged into a receptacle which is grounded per any national, local or other applicable electrical codes.

• The SP-100 power switch is to be in the

OFF (“O”) position when installing work2 cable and gun and when connecting power

cord to input power.

IDENTIFY AND LOCATE		3a
COMPONENTS
If you have not already done so, unpack the SP-100
from its carton and remove all packing material
around the SP-100. Remove the following loose items		3b
from the carton (see Figure A.1):
1.	SP-100
2.	Gun and cable assembly(1)
3.	Literature envelope which contains:	4
	a) This operating manual

b) A contact tip for .030” (0,8 mm) diameter wire.

4. 10 ft (3,0 m) work cable.

5. Work clamp.	5

(1) Gun is ready to feed .025" (0.6 mm) diameter wire (also .023 and .024 diameter wire).

SP-100

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Lincoln Electric SP-100 Safety Precautions, Identify and Locate Components, Installation, Electric Shock can kill

Contents

SP-100 Electric Shock can kill SafetyARC Rays can burn Fumes and Gases can be dangerous 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 Read entire installation section before starting Safety PrecautionsInstallation Identify and Locate Components Select Suitable Location Work Clamp InstallationOutput Connections Tilting GUN Installation Connecting GUN Cable to the SP-100GAS Connection Input Connections PowerGas Solenoid Inlet Fitting Input Requirements for Maximum Output Code Requirements for Input ConnectionsRequirements for CSA Rated Output Requirements for Rated Output SP-100 Table of Contents Wear eye, ear and body protec- tion Operation Design Features Advantages Operational Features and ControlsGeneral Description Off Welding Operations Wire LoadingProcess Guidelines Sequence of Operation Refer to Figure B-4 Friction Brake Adjustments Making a Weld Shielding GAS Overload Protection SP-100 Accessories Section Replacement Parts 1ACCESSORIESLincoln GAS Regulator Kits K467 Input Line Cord Innershield Welding Kits 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 Possible Areas of Misadjustments Problems SymptomsRecommended Course of Action Code 9794 and Above Feeding Problems Troubleshooting Guide Codes 9794 and above 6J1 10J2 1J1 1J2 Codes below SP-100 PC Board Connector Locations Scope Settings 9TROUBLESHOOTING & RepairVolts Volts/Div Normal Open Circuit Voltage Waveform Typical Output Voltage Waveform Machine Loaded Volts Abnormal Open Circuit Voltage Waveform Procedure Procedure DescriptionFAN Blade and Motor Removal Tools Required Motor Removal Procedure Wire Drive Assembly Removal1A. for Codes Above 1B. for Codes below Retest After Repair Wire Speed RangeMain Transformer Secondary Voltages Test Points Input Amps AT Rated Output Input Amps AC @ Output DC 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