Page 2 - SAFETY; WARNING; ARC WELDING can be hazardous.; Return to Master TOC
i SAFETY SP-100 PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDRENAWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING. Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you pur-c...
Page 3 - ii
ii SP-100 SAFETY FOR ELECTRICALLYpowered equipment. 6.a. Turn off input power using the disconnect switch at the fuse box before working onthe equipment. 6.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’srecommendations. 6.c. Ground th...
Page 4 - iii
iii SAFETY SP-100 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Mar. ‘93 ELECTRIC AND MAGNETICFIELDSmay be dangerous 8 . a . E l e c t r i c c u r r e n t f l o w i n g t h r o u g h a n y c o n d u c t o r c a u s e s localized Electric and Magnetic Fields (EMF...
Page 5 - iv; PRÉCAUTIONS DE SÛRETÉ
iv SAFETY SP-100 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instruc- tions et les précautions de sûreté specifiques qui parraissent d a n s c e m a n u e l a u s s i b i e n q u e ...
Page 6 - MASTER TABLE OF CONTENTS FOR ALL SECTIONS; Page
MASTER TABLE OF CONTENTS FOR ALL SECTIONS Page Installation .......................................................................................................Section A Technical Specifications ........................................................................................A-1Identify an...
Page 7 - Section A; TABLE OF CONTENTS
Installation ......................................................................................................Section A Technical Specifications ........................................................................................A-1 Input and Output Specifications .............................
Page 8 - INSTALLATION; Return to Section TOC; TECHNICAL SPECIFICATIONS – SP-100; INPUT – SINGLE PHASE ONLY
A-1 INSTALLATION SP-100 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Fuse or Output Mode Input Voltage Breaker Size Input Amps Power Cord Extension Cord RATED 115V/60Hz 20 A...
Page 9 - SAFETY PRECAUTIONS; Gun and cable assembly; ELECTRIC SHOCK can kill.
A-2 INSTALLATION SP-100 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Read entire installation section before startinginstallation. SAFETY PRECAUTIONS IDENTIFY AND LOCATE COM...
Page 10 - SELECT SUITABLE LOCATION; STACKING; OUTPUT CONNECTIONS; WORK CLAMP INSTALLATION
A-3 INSTALLATION SP-100 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SELECT SUITABLE LOCATION Locate the welder in a dry location where there is freecirculation of clean air...
Page 11 - GAS CONNECTION; CAUTION
A-4 INSTALLATION SP-100 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 3. Route the cable under and around the back of the Wire Feed Gearbox (6). 4. For GMAW Only: Refer to Fi...
Page 12 - Attach the flow regulator to the cylinder valve and; INPUT CONNECTIONS; Chain the cylinder to a wall or other stationary sup-
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. 4. Refer to Figure A.6. Attach one end of inlet gas hose to the...
Page 13 - Do not remove the power cord ground prong.; ) or larger. The recommended maximum lengths
A-6 INSTALLATION SP-100 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC CODE REQUIREMENTS FOR INPUT CONNECTIONS This welding machine must be connected topower source in accorda...
Page 14 - NOTES
A7 NOTES SP-100 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
Page 15 - Section B
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SP-100 TABLE OF CONTENTS – OPERATION SECTION – Operation ...........................................................................................................Section B Safety Precautions ..........................
Page 16 - OPERATION
B-1 SP-100 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC OPERATION R e a d e n t i r e o p e r a t i o n s e c t i o n b e f o r eoperating the SP-100. ELECTRIC SHOCK can kil...
Page 17 - RECOMMENDED PROCESSES; Solid state output control.; WELDING CAPABILITY; P o w e r O N / O F F S w i t c h —
B-2 SP-100 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC OPERATION GENERAL DESCRIPTION The SP-100, Type K462, is a complete semiautomaticconstant voltage DC arc welding machi...
Page 18 - Circuit Breaker - Protects machine from damage if; WELDING OPERATIONS; PROCESS GUIDELINES; gas is recommended because it gives; SEQUENCE OF OPERATION; *Earlier spindle shafts did not include a set screw to
B-3 SP-100 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC OPERATION FIGURE B.1a Refer to Figure B-1b. 4. Circuit Breaker - Protects machine from damage if maximum output is ex...
Page 20 - MAKING A WELD
B-5 SP-100 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC OPERATION When inching the welding wire, the drive rolls, thegun connector block and the gun contact tip arealways en...
Page 21 - Position gun over joint. End of wire may be lightly; WELDING WITH INNERSHIELD; OVERLOAD PROTECTION; OUTPUT OVERLOAD
B-6 SP-100 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC OPERATION 6. Refer to Figure B.7. Connect work clamp to metal to be welded. Work clamp must make good elec-trical con...
Page 23 - Section C
SP-100 Section C TABLE OF CONTENTS – ACCESSORIES SECTION – Accessories .....................................................................................................Section C Accessories .............................................................................................................
Page 24 - ACCESSORIES; REPLACEMENT PARTS; LINCOLN GAS REGULATOR KITS; Regulator; cylinders. The K463 CO; INNERSHIELD WELDING KITS; Two kits are available:; DRIVE ROLL
SP-100 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC C-1 ACCESSORIES K467 INPUT LINE CORD The K467 Input Line Cord is the same asthe line cord supplied with the SP-100, butha...
Page 25 - Section D
SP-100 Section D TABLE OF CONTENTS – MAINTENANCE SECTION – Maintenance ...................................................................................................Section D Safety Precautions ...............................................................................................D-1Ite...
Page 26 - PERIODICALLY AS REQUIRED; MAINTENANCE; • Disconnect input power; BEFORE EACH USE
SP-100 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC A F T E R E A C H S P O O L O F W I R EFEED • Remove contact tip and clean inside diam- eter with short piece of wire • C...
Page 27 - CHANGING THE CONTACT TIP; Liner trim length for the Magnum 100L gun (red trigger)
SP-100 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC D-2 MAINTENANCE 1. Make certain the SP-100 power switch is off “O”. 2. Open the Spring Loaded Pressure Arm (2); Lift up t...
Page 28 - CHANGING LINER
SP-100 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC D-3 MAINTENANCE REPLACE INTERNAL GUN HANDLE PARTS AS NECESSARY The gun handle consists of two halves thatare held togethe...
Page 29 - FIGURE D.4 – LOCATION OF COMPONENTS; SP-100 SUB ASSEMBLIES
SP-100 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC D-4 MAINTENANCE FIGURE D.4 – LOCATION OF COMPONENTS 1 Case Back and Bottom Assembly 2 Center Panel Assembly 3 Case Front ...
Page 31 - Section E
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SP-100 Theory of Operation ........................................................................................Section E Input Line Voltage, Fan Motor and Main Transformer ...........................................
Page 32 - THEORY OF OPERATION; FIGURE E.1 – Input Power Circuits
SP-100 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC E-1 THEORY OF OPERATION NOTE: Unshaded areas of block logic diagram are the subject of discussion. INPUT LINE VOLTAGE, FA...
Page 33 - FIGURE E.2 – Output Circuits
SP-100 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC E-2 THEORY OF OPERATION NOTE: Unshaded areas of block logic diagram are the subject of discussion. OUTPUT CONTROL, RECTIF...
Page 34 - FIGURE E.3 – Trigger, Gas Solenoid and Wire Drive
SP-100 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC E-3 THEORY OF OPERATION NOTE: Unshaded areas of block logic diagram are the subject of discussion. TRIGGER, GAS SOLENOID ...
Page 35 - SCR OPERATION; FIGURE E.4 SCR OPERATION
SP-100 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC E-4 THEORY OF OPERATION An SCR is fired by a short burst of currentinto the gate. This gate pules must be morepositive th...
Page 36 - THERMAL PROTECTION
SP-100 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC E-5 THEORY OF OPERATION THERMAL PROTECTION A thermostat protects the machine frome x c e s s i v e o p e r a t i n g t e ...
Page 37 - Section F; Replacement Procedures
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SP-100 Section F TABLE OF CONTENTS – TROUBLESHOOTING SECTION – Troubleshooting .............................................................................................Section F Safety Precautions ..................
Page 38 - TROUBLESHOOTING & REPAIR; in the order listed to; HOW TO USE TROUBLESHOOTING GUIDE
SP-100 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-1 TROUBLESHOOTING & REPAIR Step 1. LOCATE PROBLEM (SYMPTOM).Look under the column labeled “PROBLEM(SYMPTOMS)”. This...
Page 39 - PC BOARD TROUBLESHOOTING PROCEDURES
SP-100 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-2 TROUBLESHOOTING & REPAIR 4. Test the machine to determine if the fail- ure symptom has been corrected by therepla...
Page 40 - TROUBLESHOOTING GUIDE; OUTPUT PROBLEMS
SP-100 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-3 TROUBLESHOOTING & REPAIR Observe Safety Guidelines detailed in the beginning of this manual. TROUBLESHOOTING GUID...
Page 42 - Check the circuit breaker in the
SP-100 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-5 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual...
Page 43 - FEEDING PROBLEMS
SP-100 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-6 TROUBLESHOOTING & REPAIR Observe Safety Guidelinesdetailed in the beginning of this manual. TROUBLESHOOTING GUIDE...
Page 44 - GAS FLOW PROBLEMS
SP-100 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-7 TROUBLESHOOTING & REPAIR Observe Safety Guidelinesdetailed in the beginning of this manual. TROUBLESHOOTING GUIDE...
Page 45 - PC BOARD CONNECTOR LOCATIONS
SP-100 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-8 TROUBLESHOOTING & REPAIR PC BOARD CONNECTOR LOCATIONS FIGURE F.1 Codes 9794 and above Codes below 9794 6J1 10J2 1...
Page 46 - SCOPE SETTINGS
SP-100 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-9 TROUBLESHOOTING & REPAIR SCOPE SETTINGS This is the typical output voltage waveform generatedfrom a properly oper...
Page 49 - FA N B L A D E A N D M O T O R; PROCEDURE DESCRIPTION; TOOLS REQUIRED
SP-100 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-12 TROUBLESHOOTING & REPAIR FIGURE F.2 FIGURE F.3 FIGURE F.4 FA N B L A D E A N D M O T O R REMOVAL PROCEDURE DESCR...
Page 50 - WIRE DRIVE ASSEMBLY REMOVAL
SP-100 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-13 TROUBLESHOOTING & REPAIR FIGURE F.5 Two plastic fastener buttons attach the Connector Block to theFront Panel at...
Page 51 - RETEST AFTER REPAIR; -20 vac Dependent on arc voltage control
SP-100 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-14 TROUBLESHOOTING & REPAIR RETEST AFTER REPAIR Should a machine under test be rejected for any reason requiring th...
Page 53 - Section G
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SP-100 Section G TABLE OF CONTENTS – ELECTRICAL DIAGRAMS SECTION – Electrical Diagrams ........................................................................................Section G SP-100 Wiring Diagram (codes 97...
Page 54 - WIRING DIAGRAMS; pasted inside the machine on one of the enclosure panels.
SP-100 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC G-2 WIRING DIAGRAMS SP-100 WIRING DIAGRAM: CODES 9794 and Above CLEVELAND, OHIO U.S.A. 11-12-93K M16576 L1 L2 31 32 531 T...
Page 56 - ELECTRICAL DIAGRAMS
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC G-4 ELECTRICAL DIAGRAMS SP-100 NOTE: Lincoln Electric assumes no responsibility for liabilities resulting from board level troub...
Page 60 - MACHINE SCHEMATIC: Codes 9794 and Above
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC G-8 ELECTRICAL DIAGRAMS SP-100 MACHINE SCHEMATIC: Codes 9794 and Above G N D I N O U T X 4 4 . 73 5 V C 6 M C 7 8 1 5 C ...
Page 61 - MACHINE SCHEMATIC: Codes Below 9794
G-9 ELECTRICAL DIAGRAMS SP-100 MACHINE SCHEMATIC: Codes Below 9794 LAST NO. USED L D C R N.A. SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVI...
Page 62 - SVM ERROR REPORTING FORM; Please give detailed description below:
SVM ERROR REPORTING FORM We need to know if there are errors in our manuals. We also value any suggestions as toadditional tests or procedures that would make this SVM a better tool for you. If you discover new or different “Problems or Symptoms” that are not covered in the three col-umn troubleshoo...
