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Lincoln Electric IM788 manual

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Table of contents for the manual

  • Page 1

    SP- 135 PLUS OPERA TOR’S MANUAL IM788 July, 2005 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 A[...]

  • Page 2

    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. ________________________________________________[...]

  • Page 3

    SP-135 PLUS 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 prote[...]

  • Page 4

    SP-135 PLUS 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 [...]

  • Page 5

    SP-135 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 contre la secousse électrique: a. Le[...]

  • Page 6

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

  • Page 7

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

  • Page 8

    A-1 A-1 INST ALLA TION SP-135 PLUS Fuse or Output Mode Input Voltage Breaker Size Input Amps Extension Cord Three Conductor #14 AWG RATED 115V/60Hz 20 Amp 20 (2.1 mm 2 ) or Larger for up to 25 feet (7.6m) Three Conductor #12 AWG MAXIMUM 115V/60Hz 25 Amp 25 (3.3 mm 2 ) or Larger for up to 50 feet (15.2 m) TECHNICAL SPECIFICA TIONS – SP-135 PLUS IN[...]

  • Page 9

    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-135 PLUS from its carton and remove all packing material around the SP-135 PLUS. Remove the following loose items from the carton (see Figure A.1): 1. SP-135 PLUS 2. [...]

  • Page 10

    A-3 A-3 INST ALLA TION SP-135 PLUS SELECT SUIT ABLE LOCA TION 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 accumulation that can block air passa[...]

  • Page 11

    A-4 A-4 INST ALLA TION 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-135 PLUS is wired for positive polari- ty. This is the appropriate configuration for the Gas Metal Arc Welding (GMAW) process. To complete installation, use the provided wing nut to connect [...]

  • Page 12

    A-5 A-5 INST ALLA TION SP-135 PLUS 2 . With the cylinder securely installed, remove the cylinder cap. Stand to one side away from the out- 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 “CRACKIN[...]

  • Page 13

    A-6 A-6 INST ALLA TION SP-135 PLUS CODE REQUIREMENTS FOR INPUT CONNECTIONS This welding machine must be connected to power source in accordance with applicable elec- trical codes. The National Electrical Code provides standards for amperage handling capability of supply con- ductors based on duty cycle of the welding source. If there is any questio[...]

  • Page 14

    SP-135 PLUS B-1 B-1 OPERA TION Read entire Operation section before operating the SP-135 PLUS. 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. •[...]

  • Page 15

    B-2 B-2 OPERA TION GENERAL DESCRIPTION The SP-135 PLUS is a complete semiautomatic con- stant voltage DC arc welding machine. Included is a solid state controlled, single phase constant voltage transformer/ rectifier power source and a wire feeder for feeding solid steel electrode and cored electrode. The SP-135 PLUS is ideally suited for individua[...]

  • Page 16

    B-3 B-3 OPERA TION FIGURE B.1a 4. Circuit Breaker – Protects machine from damage if maximum output is exceeded. Button will extend out when tripped (Manual reset). 5. Gun Trigger - Activates welding output, wire feed, and gas solenoid operation. Releasing the trigger deactivates welding and simultaneously activates the “burnback” function so [...]

  • Page 17

    B-4 B-4 OPERA TION FIGURE B.3 Friction Brake Adjustment With wire spool installed on the spindle shaft and the wing nut loose, turn the spool by hand while slowly tightening the wing nut until a light drag is felt. Tighten the wing nut an additional 1/4 turn. Note: When properly adjusted, the brake should pro- vide only enough drag to prevent overr[...]

  • Page 18

    SP-135 PLUS B-5 B-5 OPERA TION Shielding Gas When using the GMAW process, a cylinder of shield- ing gas, must be obtained. Refer to the ACCES- SORIES section for more information about selecting gas cylinders for use with the SP-135 PLUS. 1. For CO 2 , open the cylinder very slowly. For argon- mixed gas, open cylinder valve slowly a fraction of a t[...]

  • Page 19

    B-6 B-6 OPERA TION 9. To stop welding, release the gun trigger and then pull the gun away from the work after the arc goes out. 10. When no more welding is to be done, close valve on gas cylinder (if used), momentarily operate gun trigger to release gas pressure, and turn off the SP-135 PLUS. Cleaning Tip And Nozzle Clean the contact tip and nozzle[...]

  • Page 20

    B-7 B-7 OPERA TION OVERLOAD PROTECTION Output Overload The SP-135 PLUS is equipped with a circuit breaker which protects the machine from potential damage from excessive output current. The circuit breaker but- ton will extend out when tripped. The circuit breaker must be manually reset. Thermal Protection The SP-135 PLUS duty cycle is exceeded a t[...]

  • Page 21

    B-8 B-8 APPLICA TION CHART SP-135 PLUS[...]

  • Page 22

    C-1 C-1 ACCESSORIES 4 . KP666-035C Knurled Drive Roll (optional) — Reversible Drive Roll with double knurled grooves for .035 (0.9 mm) cored electrode. 5. K549-1 .035 (0.9 mm) Innershield Welding Kit Includes a contact tip, a gasless nozzle and a cable liner to permit the Magnum™ 100L gun and cable to use .030-.035” (0.8-0.9 mm) diameter flux[...]

  • Page 23

    C-2 C-2 ACCESSORIES INNERSHIELD (FCA W) CONVERSION Several changes are needed to convert the unit for operation with the Innershield (FCAW) process. The K549-1 Innershield Kit includes all the necessary accessories for this conversion and are provided for this purpose. The following conversions should be made using the contents of this kit: 1. Chan[...]

  • Page 24

    MAINTENANCE SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Disconnect input power by removing plug from receptacle before working inside SP-135 PLUS. Use only grounded recep- tacle. Do not touch electrically “hot” parts inside SP-135 PLUS. • Have qualified personnel do the maintenance and trouble shoot- ing work. ITEMS REQUIRING NO MAINTENAN[...]

  • Page 25

    SP-135 PLUS D-2 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-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, [...]

  • Page 26

    SP-135 PLUS D-3 D-3 MAINTENANCE COMPONENT REPLACEMENT PROCEDURES CHANGING THE CONT ACT 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-clockwise. 4. Insert and hand tighten des[...]

  • Page 27

    D-4 GUN HANDLE P ARTS The gun handle consists of two halves that are held together with a collar on each end. To open up the handle, turn the collars approximately 60 degrees counter-clockwise until the collar reaches a stop. Then pull the collar off the gun handle. If the collars are diffi- cult to turn, position the gun handle against a corner, p[...]

  • Page 28

    SP-135 PLUS If machine case sides and top are removed, the case front must be supported. Failure to do this could result in mechanical or electrical damage to the SP-135 PLUS. ___________________________________________________________________ CAUTION E-1 TROUBLESHOOTING E-1 If for any reason you do not understand the test procedures or are unable [...]

  • Page 29

    E-2 SP-135 PLUS E-2 TROUBLESHOOTING Observe Safety Guidelines detailed in the beginning of this manual. TROUBLESHOOTING GUIDE 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 weld output or wire feed when gun trigger is pulled. Fan runs and[...]

  • Page 30

    SP-135 PLUS E-3 E-3 TROUBLESHOOTING Observe Safety Guidelines detailed in the beginning of this manual. TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) No wire feed when gun trigger is pulled. Fan runs, gas flows and machine has correct open circuit voltage (28 vdc maximum) – weld output. Wire feed speed motor runs very fast. Weld output, gas flow and [...]

  • Page 31

    E-4 E-4 TROUBLESHOOTING Observe Safety Guidelines detailed in the beginning of this manual. TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) Arc is unstable – Poor starting POSSIBLE AREAS OF MISADJUSTMENT(S) 1. Check for correct input voltage to machine – 115 vac. 2. Check for proper electrode polarity for process. 3. Check gun tip for wear or dam- ag[...]

  • Page 32

    F-1 F-1 WIRING DIAGRAMS W ARNI NG HIGH VOLTAGE can kill Only qualified persons should install, use or ser vice this machine. Do not operate with covers remove d. Disconnect input power by unplugging power cord befor e servicing. Do not touch electrically live parts L1 L2 31 32 531 TO GROUND PER NATIONAL ELECTRICAL CODE S1 SW ITCH 202 201 D1 D3 D2 D[...]

  • Page 33

    W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TENÇÃO 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 P ARA EL [...]

  • Page 34

    W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA 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 fr[...]

  • Page 35

    • 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 •[...]