Lincoln Electric IM536-D - Manuals

Page 2 - SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines

SP-125 PLUS FOR ENGINEpowered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fum...

Page 3 - ii

SP-125 PLUS ii SAFETY ii ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards. 4.b. Use suitable clothing made ...

Page 4 - iii

SP-125 PLUS FOR ELECTRICALLYpowered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working onthe equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’srecommendations. 8.c. Ground the equ...

Page 5 - iv; PRÉCAUTIONS DE SÛRETÉ

SP-125 PLUS iv SAFETY iv PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous co...

Page 6 - Thank You; Please Examine Carton and Equipment For Damage Immediately

SP-125 PLUS v Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save t...

Page 7 - TABLE OF CONTENTS; Page

vi SP-125 PLUS TABLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications ........................................................................................A-1Identify and Locate ...

Page 8 - vii

Page 9 - INSTALLATION; TECHNICAL SPECIFICATIONS – SP-125 Plus; INPUT – SINGLE PHASE ONLY

A-1 INSTALLATION SP-125 PLUS Fuse or Output Mode Input Voltage Breaker Size Input Amps Extension Cord RATED 115V/60Hz 20 Amp 20 Three Conductor #14 AWG (2.1 mm 2 ) or Larger for up to MAXIMUM 115V/60Hz 25 Amp 25 25 feet (7.6m) Three Conductor #12 AWG CSA 115V/60Hz 15 Amp 15 (3.3 mm 2 ) or Larger for...

Page 10 - SAFETY PRECAUTIONS; Gun and cable assembly; ELECTRIC SHOCK can kill.

A-2 INSTALLATION SP-125 PLUS Read entire installation section before startinginstallation. SAFETY PRECAUTIONS IDENTIFY AND LOCATE COMPONENTS If you have not already done so, unpack the SP-125Plus from its carton and remove all packing materialaround the SP-125 Plus. Remove the following looseitems f...

Page 11 - SELECT SUITABLE LOCATION; OUTPUT CONNECTIONS; Accessories; Work Clamp Installation; Work Cable Installation

A-3 INSTALLATION SP-125 PLUS SELECT SUITABLE LOCATION Locate the welder in a dry location where there is freecirculation of clean air into the louvers in the back andout the front of the unit. A location that minimizes theamount of smoke and dirt drawn into the rear louversreduces the chance of dirt...

Page 12 - Route the cable under and around the back of the; GAS CONNECTION; Connecting Gun Cable to the SP-125 Plus; power switch to the off “O” position.; CAUTION

SP-125 PLUS A-4 INSTALLATION 3. Route the cable under and around the back of the Wire Feed Gearbox (6). 4. For GMAW Only: Refer to Figure A.2. As deliv- ered, the SP-125 Plus is wired for positive polarity.This is the appropriate configuration for the GasMetal Arc Welding (GMAW) process. To complete...

Page 13 - Attach the flow regulator to the cylinder valve and; INPUT CONNECTIONS; Chain the cylinder to a wall or other stationary sup-

A-5 INSTALLATION SP-125 PLUS 3. Attach the flow regulator to the cylinder valve and tighten the union nut securely with a wrench. Theflow regulator for carbon dioxide must have a plas- tic washer seated in the fitting that attaches to thecylinder to prevent leakage. Refer to K1800-1 inthe accessorie...

Page 14 - Requirements For Rated Output; Do not remove the power cord ground prong.; Requirements For Maximum Output

A-6 INSTALLATION SP-125 PLUS CODE REQUIREMENTS FOR INPUTCONNECTIONS This welding machine must be connected topower source in accordance with applicable elec-trical codes. The United States National Electrical Code (Article630-B, 1990 Edition) provides standards for amperagehandling capability of sup...

Page 15 - OPERATION

SP-125 PLUS B-1 OPERATION Read entire Operation section beforeoperating the SP-125 Plus. ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrode with skin orwet clothing. Insulate yourselffrom work and ground. • Always wear dry insulating gloves. FUMES AND GASES can bedangerous....

Page 16 - GENERAL DESCRIPTION; RECOMMENDED PROCESSES; Solid state output control.; WELDING CAPABILITY; P o w e r O N / O F F S w i t c h —

SP-125 PLUS SP-125 PLUS B-2 OPERATION GENERAL DESCRIPTION The SP-125 Plus is a complete semiautomatic con-stant voltage DC arc welding machine. Included is asolid state controlled, single phase constant voltagetransformer/ rectifier power source and a wire feederfor feeding solid steel electrode and...

Page 17 - Circuit Breaker – Protects machine from damage if; WELDING OPERATIONS; SEQUENCE OF OPERATION; Wire Loading; When loading and removing the 8” Spools make

SP-125 PLUS B-3 OPERATION FIGURE B.1a Refer to Figure B.1b 4. Circuit Breaker – Protects machine from damage if maximum output is exceeded. Button will extendout when tripped (Manual reset). 5. Optional K695-2 Spot/Stitch Controls (see ACCES- SORIES section) - If present, replaces Blank PanelAssembl...

Page 18 - Friction Brake Adjustments

SP-125 PLUS B-4 OPERATION FIGURE B.3 Note: The brake should be adjusted with a spool ofwire installed. When properly adjusted it shouldmove freely but not coast. Friction Brake Adjustments 1. With wire spool installed, check free movement and coast of the spool. 2. To tighten the brake turn the wing...

Page 19 - Shielding Gas

SP-125 PLUS B-5 OPERATION Shielding Gas When using the GMAW process, a cylinder of shield-i n g g a s , m u s t b e o b t a i n e d . R e f e r t o t h e A C C E S -SORIES section for more information about selectinggas cylinders for use with the SP-125 Plus. 1. For CO 2 , open the cylinder very slo...

Page 20 - To stop welding, release the gun trigger and then; Cleaning Tip And Nozzle; PROCESS GUIDELINES; is recommended for weld-; TABLE B.1 — SP-125 Plus Welding Procedures

SP-125 PLUS B-6 OPERATION 9. To stop welding, release the gun trigger and then pull the gun away from the work after the arc goesout. 10. When no more welding is to be done, close valve on gas cylinder (if used), momentarily operate guntrigger to release gas pressure, and turn off theSP-125 Plus. Cl...

Page 21 - OVERLOAD PROTECTION; Output Overload

SP-125 PLUS B-7 OPERATION OVERLOAD PROTECTION Output Overload The SP-125 Plus is equipped with a circuit breakerwhich protects the machine from potential damagefrom excessive output current. The circuit breaker but-ton will extend out when tripped. The circuit breakermust be manually reset. Thermal ...

Page 22 - LEARNING TO WELD; THE ARC-WELDING CIRCUIT; • Avoid contact with eyes and skin.

SP-125 PLUS B-8 LEARNING TO WELD LEARNING TO WELD No one can learn to weld simply by reading about it.Skill comes only with practice. The following pages willhelp the inexperienced operator to understand weld-ing and develop this skill. For more detailed informa-tion, order a copy of “New Lessons in...

Page 23 - PROCESS SELECTION; Is most of my welding performed on 16 gauge and

SP-125 PLUS B-9 LEARNING TO WELD The “arc stream” is seen in the middle of the picture.This is the electric arc created by the electric currentflowing through the space between the end of the wireelectrode and the base metal. The temperature of thisarc is about 6000°F, which is more than enough tome...

Page 24 - Will welding be performed outdoors or under windy; COMMON METALS; Butt Welds

SP-125 PLUS B-10 LEARNING TO WELD 2. Can I afford the extra expense, space, and lack of portability required for gas cylinders and gas sup-ply? 3. Do I require clean, finished-looking welds? If you have answered yes to all the above questionsG M A W m a y b e t h e p r o c e s s f o r y o u . I f y ...

Page 25 - Penetration; Welding In The Vertical Position; Vertical-up And Overhead Welding

SP-125 PLUS B-11 LEARNING TO WELD FIGURE B.12 Penetration Unless a weld penetrates close to 100% of the metalthickness, a butt weld will be weaker than the materialwelded together. In the example shown in FigureB.13, the total weld is only half the thickness of thematerial thus the weld is only appr...

Page 26 - Vertical-down Welding; See PROCESS GUIDELINES in the OPERATION; The Correct Welding Position

SP-125 PLUS B-12 LEARNING TO WELD FIGURE B.16 Vertical-down Welding Refer to Figure B.17 Vertical-down welds are appliedat a fast pace. These welds are therefore shallow andnarrow and, as such, are excellent for sheet metal.Vertical-down welds may be applied to 5/32” (3.9 mm)and lighter material. Us...

Page 27 - ARC RAYS can burn eyes and skin.; The Correct Welding Speed

SP-125 PLUS B-13 LEARNING TO WELD ARC RAYS can burn eyes and skin. When using an open arc process, itIs necessary to use correct eye,head and body protection. Protect yourself and others, read“ARC RAYS can burn” at the frontof this manual. 2. The Correct Way To Strike An Arc 1. Be sure the work clam...

Page 28 - Mild Steel; Helpful Hints

SP-125 PLUS B-14 LEARNING TO WELD Mild Steel 16 gauge or 1/16 inch (1.6 mm) Electrode 0.035" (0.9 mm) NR-211-MP Innershield Wire Voltage Setting “V” E Wire Feed Speed “o|o” 2 For the SP-125 Plus, use the following: Helpful Hints 1. For general welding, it is not necessary to weave the arc, neith...

Page 31 - TROUBLESHOOTING WELDS; To Eliminate Porosity

SP-125 PLUS B-17 LEARNING TO WELD 4. After you strike the arc, practice the correct electri- cal stickout. Learn to distinguish it by its sound. 5. When you are sure that you can hold the correct electrical stickout, with a smooth “crackling” arc,start moving. Look at the molten puddle constantly. 6...

Page 32 - Proper Gun Handling

SP-125 PLUS B-18 LEARNING TO WELD Proper Gun Handling Most feeding problems are caused by improper han-dling of the gun cable or electrodes. 1. Do not kink or pull the gun around sharp corners 2. Keep the gun cable as straight as practical when welding. 3. Do not allow dolly wheels or trucks to run ...

Page 33 - APPLICATION CHART

Page 34 - ACCESSORIES; Includes spot; OPTIONAL ACCESSORIES; Designed to transport the; Adjustable Regulator and Hose Kit —; Accommodates CO; K 6 6 3 - 2 A l u m i n u m W e l d i n g K i t; — T h i s k i t; It is important when changing between

C-1 SP-125 PLUS ACCESSORIES 6. KP666-035C Knurled Drive Roll (optional) — Reversible Drive Roll with double knurled groovesfor .035 (0.9 mm) cored electrode. 7. K695-2 Spot / Stitch Timer Kit — Includes spot timer to control the spot welding arc time, and astitch timer to control the on/off cycle ti...

Page 35 - Cable Installation” section for details.; REPLACEMENT PARTS; Complete Gun and Cable Assembly

C-2 SP-125 PLUS ACCESSORIES INNERSHIELD (FCAW)CONVERSION Several changes are needed to convert the unit foroperation with the Innershield (FCAW) process. TheK549-1 Innershield Kit includes all the necessaryaccessories for this conversion and are provided forthis purpose. The following conversions sh...

Page 36 - BEFORE EACH USE; MAINTENANCE; PERIODICALLY AS REQUIRED

SP-125 PLUS MAINTENANCE SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Disconnect input power by remov- ing plug from receptacle beforeworking inside SP-125 PLUS. Useonly grounded receptacle. Do nottouch electrically “hot” partsinside SP-125 PLUS. • Have qualified personnel do the maintenance and tro...

Page 37 - Gun Cable Cleaning

SP-125 PLUS D-2 MAINTENANCE GUN AND CABLE MAINTENANCE FOR MAGNUM™ 100L GUN Gun Cable Cleaning Clean cable liner after using approximately 300 lbs(136 kg) of solid wire or 50 lbs (23 kg) of flux-coredwire. Remove the cable from the wire feeder and lay itout straight on the floor. Remove the contact t...

Page 38 - CHANGING THE CONTACT TIP

SP-125 PLUS D-3 MAINTENANCE COMPONENT REPLACEMENT PROCEDURES CHANGING THE CONTACT TIP 1. Unplug or turn power switch to Off “O” position. 2. Refer to Figure D.2. Remove the gas nozzle from the gun by unscrewing counter-clockwise. 3. Remove the existing contact tip from the gun by unscrewing counter-...

Page 39 - CHANGING LINER; Liner trim length for gun with red trigger (MagnumTM 100L)

SP-125 PLUS D-4 MAINTENANCE CHANGING LINER NOTICE: The variation in cable lengths pre-vents the interchangeability of liners. Oncea liner has been cut for a particular gun, its h o u l d n o t b e i n s t a l l e d i n a n o t h e r g u nunless it can meet the liner cutoff lengthrequirement. Refer t...

Page 40 - GUN HANDLE PARTS

SP-125 PLUS D-5 MAINTENANCE GUN HANDLE PARTS The gun handle consists of two halves that are heldtogether with a collar on each end. To open up thehandle, turn the collars approximately 60 degreescounter-clockwise until the collar reaches a stop. Thenpull the collar off the gun handle. If the collars...

Page 41 - TROUBLESHOOTING; HOW TO USE TROUBLESHOOTING GUIDE; LOCAL AUTHORIZED LINCOLN ELECTRIC; for assistance before you proceed.

SP-125 PLUS E-1 TROUBLESHOOTING Step 1. LOCATE PROBLEM (SYMPTOM). Look under the column labeled “PROBLEM(SYMPTOMS)”. This column describes pos-sible symptoms that the machine mayexhibit. Find the listing that best describesthe symptom that the machine is exhibiting. Symptoms are grouped into the fol...

Page 42 - TROUBLESHOOTING GUIDE; OUTPUT PROBLEMS; LOCAL AUTHORIZED LINCOLN ELECTRIC FIELD SERVICE FACILITY

SP-125 PLUS E-2 TROUBLESHOOTING Observe Safety Guidelines detailed in the beginning of this manual. TROUBLESHOOTING GUIDE PROBLEMS(SYMPTOMS) Major physical or electrical damageis evident. No wire feed, weld output or gasflow when gun trigger is pulled. Fandoes NOT operate. No weld output or wire fee...

Page 43 - FEEDING PROBLEMS

SP-125 PLUS E-3 TROUBLESHOOTING Observe Safety Guidelinesdetailed in the beginning of this manual. TROUBLESHOOTING GUIDE PROBLEMS(SYMPTOMS) No wire feed when gun trigger ispulled. Fan runs, gas flows andmachine has correct open circuitvoltage (28 vdc maximum) – weldoutput. Wire feed speed motor runs...

Page 44 - WELDING PROBLEMS

SP-125 PLUS E-4 TROUBLESHOOTING Observe Safety Guidelinesdetailed in the beginning of this manual. TROUBLESHOOTING GUIDE PROBLEMS(SYMPTOMS) Arc is unstable – Poor starting POSSIBLE AREAS OFMISADJUSTMENT(S) 1. Check for correct input voltage to machine – 115 vac. 2. Check for proper electrode polarit...

Page 45 - WIRING DIAGRAMS

SP-125 PLUS F-1 WIRING DIAGRAMS SP-125 PLUS WIRING DIAGRAM: CODE 10260, 10481 M18196 L1 L2 31 32 531 TO GROUND PER NATIONAL ELECTRICAL CODE S1 SWITCH 202 201 D1 D3 D2 D4 204 204 204 203 203 203 C1 59,000 f 40V 203 204 - + OUTPUT CHOKE GUN CABLE CONDUCTOR BLOCK TO WORK ELECTRICAL SYMBOLS PER E1537 CI...

Page 46 - NOTES

Page 48 - Lincoln Welding School; BASIC COURSE; weeks of fundamentals

Now Available...12th EditionThe Procedure Handbook of Arc Welding With over 500,000 copies of previous editions published since 1933, the Procedure Handbook is considered by many to be the “Bible” of the arc welding industry. T h i s p r i n t i n g w i l l g o f a s t s o d o n ’ t d e l a y . P l ...