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Lincoln Electric SP-100 User Manual

Lincoln Electric SP-100
62 pages
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SP-100
SERVICE MANUAL
SVM102-A
March, 1999
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However, your
overall safety can be increased by
proper installation ... and thought-
ful operation on your part. DO
NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT READING THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and be careful.
For use with machines
having Code Numbers
9284-10050
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• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
World's Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors

Table of Contents

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Lincoln Electric SP-100 Specifications

General IconGeneral
Input Voltage120 V
Input PhaseSingle Phase
Input Frequency60 Hz
Output Amperage Range30 - 100 A
Welding ProcessMIG (GMAW)
Wire Size Range.030 - .035 in
Wire Feed Speed Range50-700 IPM

Summary

Safety Precautions

Electric Shock Hazards

Details potential dangers and necessary precautions related to electric shock during welding operations.

Arc Ray Hazards

Explains the risks associated with arc rays and the required protective measures.

Fumes and Gases Hazards

Covers the dangers of welding fumes and gases, emphasizing ventilation and health precautions.

Safety Precautions

Welding Spark Fire and Explosion Risks

Addresses the hazards of welding sparks causing fires or explosions and preventative measures.

Cylinder Explosion Hazards

Highlights the risks associated with compressed gas cylinders and safe handling practices.

Safety Precautions

Electrical Safety Precautions

Provides safety guidelines for powered equipment, including EMF and engine-specific precautions.

Installation Guide

Technical Specifications and Requirements

Details input voltage, current, output ratings, cable sizes, and physical dimensions for the SP-100.

Installation Safety and Component Identification

Lists safety instructions and guides on unpacking and identifying SP-100 parts.

Installation Guide

Location, Output, and Cable Connections

Explains choosing a location and connecting output components like the work clamp and cable.

Gun, Gas, and Input Connections

Details gun installation, gas connection, and input power connections with safety notes.

Installation Guide

Code Requirements and Extension Cords

Outlines electrical code compliance and provides recommendations for using extension cords.

Operation of the SP-100

General Description and Controls

Provides an overview of the SP-100, its features, and controls like Power, Voltage, and Wire Speed.

Welding Processes and Capabilities

Identifies suitable welding processes (GMAW, Innershield) and outlines the machine's capabilities and limitations.

Operation of the SP-100

Wire Threading and Brake Adjustments

Details the process for threading welding wire and adjusting the wire spool friction brake.

Shielding Gas and Making a Weld

Guides on setting up shielding gas and performing a weld, including polarity and gas checks.

Operation of the SP-100

Cleaning, Welding with Innershield, and Overload Protection

Covers gun cleaning, Innershield welding, and the machine's overload protection systems.

Accessories and Replacement Parts

Gas Regulator and Welding Kits

Details available regulator kits for shielding gases and kits for Innershield welding.

Drive Rolls and Replacement Parts List

Lists options for drive rolls and common replacement parts for the SP-100 welder.

Maintenance Procedures

Safety and Routine Maintenance Checks

Highlights safety precautions and covers routine checks required before and after use.

Component Replacement: Tips and Rolls

Provides instructions for replacing the gun's contact tip and changing the drive roll for different wire sizes.

Maintenance Procedures

Component Replacement: Liner and Gun Handle

Details procedures for replacing the gun cable liner and accessing internal gun handle parts.

Location of Components Diagram

Illustrates and identifies the locations of various subassemblies and components within the SP-100.

Theory of Operation

Input Power Circuits and Transformer Theory

Explains how input voltage, fan motor, and the main transformer function in the SP-100.

Output Control and Voltage Feedback

Details how output voltage is controlled, rectified, and regulated using SCRs and feedback mechanisms.

Theory of Operation

Trigger, Gas Solenoid, and Wire Drive Operation

Describes the functional interaction between the trigger, gas solenoid, and wire drive motor.

SCR Operation Principles

Explains the fundamental working principles of Silicon Controlled Rectifiers (SCRs) in controlling welding output.

Theory of Operation

Thermal Protection Mechanism

Details the thermal protection system that prevents overheating by controlling output and fan operation.

Troubleshooting and Repair Guide

How to Use the Troubleshooting Guide

Provides a step-by-step guide on how to effectively use the troubleshooting chart to diagnose and resolve issues.

PC Board Troubleshooting Procedures

Offers specific steps and precautions for troubleshooting and replacing printed circuit boards.

Troubleshooting and Repair Guide

Troubleshooting Output Problems

Lists common output problems, potential causes, and recommended actions for diagnosis and repair.

Troubleshooting Feeding, Gas, and Welding Issues

Covers problems related to wire feed, gas flow, unstable arcs, and poor starting.

Troubleshooting and Repair Guide

Waveform Analysis and Component Removal

Explains waveform analysis for diagnosing faults and procedures for removing fan and wire drive components.

Retest After Repair Procedures

Specifies retesting procedures required after mechanical or electrical component repair or replacement.

Wiring Diagrams

SP-100 Wiring Diagram (Codes 9794+)

Presents the electrical wiring diagram for SP-100 models with code numbers 9794 and higher.

SP-100 Wiring Diagram (Codes Below 9794)

Shows the electrical wiring diagram for SP-100 models with code numbers below 9794.

Electrical Diagrams: PC Board Layouts

Control PC Board G1842 Component Layout

Diagram illustrating component placement on the G1842 control PC board.

Control PC Board G2314 Component Layout

Diagram showing the layout of components on the G2314 control PC board.

Electrical Diagrams: Machine Schematics

Machine Schematic (Codes 9794+)

Provides the overall machine schematic for SP-100 models with code numbers 9794 and higher.

Machine Schematic (Codes Below 9794)

Presents the overall machine schematic for SP-100 models with code numbers below 9794.

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