Lincoln Electric IM795 manual

SP 170-I OPERA TOR’S MANUAL IM795 March, 2004 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 [...]

FOR ENGINE powered 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 fumes outdoors. ________________________________________________[...]

ii SAFETY ii ARC RA YS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable flame-resistant material to protect your skin[...]

FOR ELECTRICALL Y powered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer ’ s recommendations. 8.c. Ground the equipment in accordance with the U.S. National Electrical[...]

iv SAFETY iv PR É CAUTIONS DE S Û RET É Pour votre propre protection lire et observer toutes les instructions et les pr é cautions de s û ret é specifiques qui parraissent dans ce manuel aussi bien que les pr é cautions de s û ret é g é n é rales suiv- antes: S û ret é Pour Soudage A L ’ Arc 1. Protegez-vous contre la secousse é lec[...]

v SAFETY v[...]

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vii vii 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 this manual and keep it handy for quick reference.[...]

viii viii T ABLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications ........................................................................................A-1 Identify and Locate Components ..........................................[...]

SP-170-I Duty Cycle Amps Volts at Rated Amperes 25% 125 20.25 60% 85 18.25 100% 70 17.50 Welding Current Range Maximum Open Circuit Voltage Wire Speed Range Rated DC Output: 30 – 175 amps 33 50-400IPM (1.3-10.2m/min) A-1 A-1 INST ALLA TION Fuse or Output Mode Input Voltage Breaker Size Input Amps Power Cord RATED 230V/50/60Hz 30 Super Lag 20 16 A[...]

A-2 A-2 INST ALLA TION Read entire installation section before starting installation. SAFETY PRECAUTIONS IDENTIFY AND LOCA TE COMPONENTS If you have not already done so, unpack the SP 170-I from its carton and remove all packing material around the SP 170-I. Remove the following loose items from the carton (see Figure A.1): 1. SP 170-I 2. Gun and c[...]

A-3 A-3 INST ALLA TION SP 170-I SELECT SUIT ABLE LOCA TION The SP 170-I has an IP21S rating. Locate the welder in a dry location where there is free circulation of clean air into the louvers in the back and out the front of the unit. A location that minimizes the amount of smoke and dirt drawn into the rear louvers reduces the chance of dirt accumu[...]

A-4 A-4 INST ALLA TION Work Cable Installation Refer to Figure A.2. 1. Open the wire feed section door on the right side of the SP 170-I. 2. Pass the end of the work cable that has the termi- nal lug with the smaller hole through the Work Cable Access Hole (1) in the case front. 3. Route the cable under the feedplate (6) and in front of the Wire Fe[...]

A-5 A-5 INST ALLA TION SP 170-I let and open the cylinder valve very slightly for an instant. This blows away any dust or dirt which may have accumulated in the valve outlet. BE SURE TO KEEP YOUR FACE AWAY FROM THE VALVE OUTLET WHEN “ CRACKING ” THE VALVE. Never stand directly in front of or behind the flow regulator when opening the cylinder v[...]

A-6 A-6 INST ALLA TION Line Cord Connection A 3 conductor international cordset with a 16 amp, 230 volt, two-prong plug is factory installed. Connect this plug to a mating grounded receptacle which is connected to an appropriate power supply per any applicable local codes. CONNECT TO A SYSTEM GROUNDING WIRE. SEE THE UNITED STATES NATIONAL ELECTRICA[...]

SP-170-I B-1 B-1 OPERA TION Read entire operation section before operating the SP 170-I. ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrode with skin or wet clothing. Insulate yourself from work and ground. • Always wear dry insulating gloves. FUMES AND GASES can be dangerous. • Keep your head out of fumes. • Use v[...]

B-2 B-2 OPERA TION ● No external shielding gas is required when used with Lincoln Innershield .035 ” (0,9 mm) NR ® -211- MP electrode. ● Spindle accommodates both 8 in. (200 mm) diame- ter and 4 in. (100 mm) diameter spools of wire. WELDING CAP ABILITY The SP 170-I is rated at 125 amps, 20.25 volts, at 25% duty cycle on a ten minute basis. I[...]

B-3 B-3 OPERA TION WELDING OPERA TIONS SEQUENCE OF OPERA TION Wire Loading Refer to Figures B.2 and B.3. The machine power switch should be turned to the OFF ( “ O ” ) position before working inside the wire feed enclosure. The welder is shipped from the factory ready to feed 8" (200 mm) diameter spools with 2.2" (56 mm) maxi- mum wid[...]

B-4 B-4 OPERA TION Refer to Figure B.4 1 . Release the Spring Loaded Pressure Arm (1) rotate the Idle Roll Arm (2) away from the Wire Feed Drive Roll (3). Ensure that the groove size in the feeding position on the drive roll match - es the wire size being used. This occurs when the desired groove is located on the inside, toward the feedplate. See [...]

B-5 B-5 OPERA TION Making A Weld 1. See “ Process Guidelines ” in this section for selec- tion of welding wire and shielding gas and for range of metal thicknesses that can be welded. 2. See the Application chart on the inside of the wire feed compartment door for information on setting the SP 170-I controls. Refer to Table B.1 for alu- minum a[...]

B-6 SP 170-I B-6 OPERA TION The SP 170-I is suitable for .035" (0.9 mm) aluminum wire and .023" – .035" (0.6 - 0.9 mm) stainless wire. Refer to Table B.1 for Recommended Procedure Settings. Aluminum wire requires an Aluminum Welding kit. See ACCESSORIES section. It is important when changing between welding with steel wire and alum[...]

Be sure to read and understand the warnings on this welding machine and the section on ARC WELDING SAFETY PRECAUTIONS in the Operating Manual. Because design, fabrication, assembly and welding variables affect the results obtained in applying this type of information, the serviceability of a product or assembly is the responsibility of the builder/[...]

C-1 C-1 ACCESSORIES OPTIONAL ACCESSORIES See Maintenance section for instructions on installing drive roll, cable liner, contact tip and their proper configuration. 1. KP665-045C Drive Roll – Optional — Knurled drive roll for feeding .035 - .045 ” (0.9 - 1.2 mm) diameter flux-cored electrode. 2. K520 Utility Cart — Designed to transport the[...]

C-2 C-2 ACCESSORIES MIG (GMA W) CONVERSION Several changes are needed to convert the unit for operation with the MIG (GMAW) process. The follow- ing conversions should be reviewed before welding with (GMAW): 1. Change the output polarity to DC(+). See “ Work Cable Installation ” in Installation section for details. 2. Install proper drive roll [...]

MAINTENANCE SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Disconnect input power by removing plug from receptacle before working inside SP170-I. Use only grounded receptacle. Do not touch electrically “ hot ” parts inside SP 170-I. • Have qualified personnel do the mainte- nance and trouble shooting work. ROUTINE MAINTENANCE POWER SOURCE CO[...]

D-2 SP-170-I D-2 MAINTENANCE GUN AND CABLE MAINTENANCE Gun Cable Cleaning Clean cable liner after using approximately 300 lbs (136 kg) of solid wire or 50 lbs (23 kg) of flux-cored wire. Remove the cable from the wire feeder and lay it out straight on the floor. Remove the contact tip from the gun. Using low pressure air, gently blow out the cable [...]

D-3 D-3 MAINTENANCE SP 170-I COMPONENT REPLACEMENT PROCEDURES CHANGING THE CONT ACT TIP (These instructions pertain to the Lincoln Electric ® gun. The instructions for the Magnum ™ 100L gun, are similar except that the gas nozzle is threaded.) 1. Refer to Figure D.2a or D.2b. Remove the gas noz- zle from the gun by pulling and rotating it clockw[...]

D-4 D-4 MAINTENANCE SP 170-I CHANGING LINER NOTICE: The variation in cable lengths pre- vents the interchangeability of liners. Once a liner has been cut for a particular gun, it should not be installed in another gun unless it can meet the liner cutoff length require- ment. Refer to Figure D.2a or D.2b. 1 . Remove the gas nozzle from the gun (thre[...]

D-5 D-5 MAINTENANCE SP 170-I GUN HANDLE P ARTS (Lincoln Electric) The gun handle consists of two halves that are held together with four screws. To open up the gun handle assembly, remove the four screws and pry down the trigger handle half with a screwdriver. See Figure D.3. FIGURE D.3 Screwdriver Cable GUN HANDLE P ARTS (Magnum 100L) The gun hand[...]

E-1 E-1 TROUBLESHOOTING SP 170-I This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three-step procedure listed below. Step 1. LOCATE PROBLEM (SYMPTOM). Look under the column labeled “ PROBLEM (SYMP- TOMS) ” . This column describes possible symptoms that the machine may exhibit.[...]

E-2 E-2 TROUBLESHOOTING SP 170-I Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) Major physical or electrical damage is evident. No wire feed, weld output or gas flow when gun trigger is pulled. Fan does NOT operate. No wire feed, weld output or gas flow when gun trigger is pulled Fan operates normally. POSSI[...]

E-3 E-3 TROUBLESHOOTING SP 170-I PROBLEMS (SYMPTOMS) No wire feed when gun trigger is pulled. Fan runs, gas flows and machine has correct open circuit voltage (33 VDC maximum) – weld output. POSSIBLE AREAS OF MISADJUSTMENT(S) 1. If the wire drive motor is running make sure that the correct drive rolls are installed in the machine. 2. Check for cl[...]

E-4 SP-170-I E-4 TROUBLESHOOTING If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your LOCAL AUTHORIZED LINCOLN ELECTRIC FIELD SERVICE FACILITY for assistance before you proceed. CAUTION PROBLEMS (SYMPTOMS) Arc is unstable – Poor starting POSSIBLE AREAS OF MISADJUSTMENT(S) 1. C[...]

SP-170-I F-1 F-1 WIRING DIAGRAMS NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels.[...]

NOTES SP 170-I[...]

NOTES SP 170-I[...]

W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL F ABRICANTE PARA EL[...]

W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE PARA ESTE EQUIP AMENTO E AS P ARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust to remove fumes f[...]

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