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Lincoln Electric SP-100 manual

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Table of contents for the manual

  • Page 1

    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 [...]

  • Page 2

    i SAFETY SP-100 PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. 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- chase a copy of “Safety in Welding & Cuttin[...]

  • Page 3

    ii SP-100 SAFETY FOR ELECTRICALL Y powered equipment. 6.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 6.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations. 6.c. Ground the equipment in accordance with the U.S. Nati[...]

  • Page 4

    iii SAFETY SP-100 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Mar. ‘93 ELECTRIC AND MAGNETIC FIELDS may be dangerous 8.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines 8.b. EMF[...]

  • Page 5

    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 dans ce manuel aussi bien que les précautions de sûreté générales suivantes: Sûreté P[...]

  • Page 6

    MASTER T ABLE OF CONTENTS FOR ALL SECTIONS Page Installation .......................................................................................................Section A Technical Specifications ........................................................................................A-1 Identify and Locate Components ............................[...]

  • Page 7

    Installation ......................................................................................................Section A Technical Specifications ........................................................................................A-1 Input and Output Specifications ......................................................................A-1 Ca[...]

  • Page 8

    A-1 INST ALLA TION 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 Amp 20 15 Amp, 125V, Three Conductor Three Prong [...]

  • Page 9

    A-2 INST ALLA TION 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 starting installation. SAFETY PRECAUTIONS IDENTIFY AND LOCA TE COMPONENTS If you have not already done so, unpac[...]

  • Page 10

    A-3 INST ALLA TION 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 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 fro[...]

  • Page 11

    A-4 INST ALLA TION 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 Figure A.2. As deliv- ered, the SP-100 is wired fo[...]

  • Page 12

    3. Attach the flow regulator to the cylinder valve and tighten the union nut securely with a wrench. The flow regulator for carbon dioxide must have a plas- tic washer seated in the fitting that attaches to the cylinder to prevent leakage. 4. Refer to Figure A.6. Attach one end of inlet gas hose to the outlet fitting of the flow regulator and tight[...]

  • Page 13

    A-6 INST ALLA TION 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 to power source in accordance with applicable elec- trical codes. The Uni[...]

  • Page 14

    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

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SP-100 T ABLE OF CONTENTS – OPERA TION SECTION – Operation ...........................................................................................................Section B Safety Precautions ...................................................................[...]

  • Page 16

    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 OPERA TION Read entire operation section before operating the SP-100. ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrode with skin or wet c[...]

  • Page 17

    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 OPERA TION GENERAL DESCRIPTION The SP-100, Type K462, is a complete semiautomatic constant voltage DC arc welding machine. Included is a solid state controlled, single[...]

  • Page 18

    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 OPERA TION FIGURE B.1a Refer to Figure B-1b. 4. Circuit Breaker - Protects machine from damage if maximum output is exceeded. Button will extend out when tripped (Manu[...]

  • Page 19

    B-4 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 OPERA TION tightened fully clockwise. Also make certain the start end of the wire, which may protrude through the side of the spool does not contact any metallic case [...]

  • Page 20

    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 OPERA TION When inching the welding wire, the drive rolls, the gun connector block and the gun contact tip are always energized relative to work and ground and remain [...]

  • Page 21

    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 OPERA TION 6. Refer to Figure B.7. Connect work clamp to metal to be welded. Work clamp must make good elec- trical contact to the workpiece. The workpiece must also b[...]

  • Page 22

    B-7 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 NOTES[...]

  • Page 23

    SP-100 Section C T ABLE OF CONTENTS – ACCESSORIES SECTION – Accessories .....................................................................................................Section C Accessories ...........................................................................................................C-1 Replacement Parts ......................[...]

  • Page 24

    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 as the line cord supplied with the SP-100, but has a NEMA type 5-20P plug for use on 25 amp branc[...]

  • Page 25

    SP-100 Section D T ABLE OF CONTENTS – MAINTENANCE SECTION – Maintenance ...................................................................................................Section D Safety Precautions ...............................................................................................D-1 Items Requiring No Maintenance ................[...]

  • Page 26

    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 AFTER EACH SPOOL OF WIRE FEED • Remove contact tip and clean inside diam- eter with short piece of wire • Clean cable liner – when rough and erratic wire feeding occ[...]

  • Page 27

    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 the Idle Roll Arm (3). 3. Remove the drive roll[...]

  • Page 28

    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 P ARTS AS NECESSAR Y The gun handle consists of two halves that are held together with a collar on each end. To open up the han[...]

  • Page 29

    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 Assembly 4 Case Side Assembly 5 Rectifier & [...]

  • Page 30

    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-5 NOTES[...]

  • Page 31

    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 ...........................................E-1 Output Control, Rectification and Voltage F[...]

  • Page 32

    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 THEOR Y OF OPERA TION NOTE: Unshaded areas of block logic diagram are the subject of discussion. INPUT LINE VOL T AGE, F AN MOTOR AND MAIN TRANSFORMER The 115 vac inpu[...]

  • Page 33

    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 THEOR Y OF OPERA TION NOTE: Unshaded areas of block logic diagram are the subject of discussion. OUTPUT CONTROL, RECTIFICA- TION AND VOL T AGE FEEDBACK The AC voltage [...]

  • Page 34

    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 THEOR Y OF OPERA TION NOTE: Unshaded areas of block logic diagram are the subject of discussion. TRIGGER, GAS SOLENOID AND WIRE DRIVE Closure of the trigger circuit (p[...]

  • Page 35

    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 THEOR Y OF OPERA TION An SCR is fired by a short burst of current into the gate. This gate pules must be more positive than the cathode voltage. Since there is a stand[...]

  • Page 36

    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 THEOR Y OF OPERA TION THERMAL PROTECTION A thermostat protects the machine from excessive operating temperatures. Excessive operating temperatures may be caused by lac[...]

  • Page 37

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SP-100 Section F T ABLE OF CONTENTS – TROUBLESHOOTING SECTION – Troubleshooting .............................................................................................Section F Safety Precautions ............................................................[...]

  • Page 38

    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 & REP AIR Step 1. LOCATE PROBLEM (SYMPTOM). Look under the column labeled “PROBLEM (SYMPTOMS)”. This column describes pos- sible symptoms that [...]

  • Page 39

    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 & REP AIR 4. Test the machine to determine if the fail- ure symptom has been corrected by the replacement PC board. NOTE: Allow the machine to heat[...]

  • Page 40

    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 & REP AIR Observe Safety Guidelines detailed in the beginning of this manual. TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) Major physical or electrica[...]

  • Page 41

    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-4 TROUBLESHOOTING & REP AIR Observe Safety Guidelines detailed in the beginning of this manual. TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) No weld output when gun tri[...]

  • Page 42

    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 & REP AIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) CODE 9794 and ABOVE No Wire[...]

  • Page 43

    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 & REP AIR Observe Safety Guidelines detailed in the beginning of this manual. TROUBLESHOOTING GUIDE If for any reason you do not understand the tes[...]

  • Page 44

    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 & REP AIR Observe Safety Guidelines detailed in the beginning of this manual. TROUBLESHOOTING GUIDE If for any reason you do not understand the tes[...]

  • Page 45

    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 & REP AIR PC BOARD CONNECTOR LOCA TIONS FIGURE F.1 Codes 9794 and above Codes below 9794 6J1 10J2 1J1 1J2 6J1 10J2 1J1 1J2[...]

  • Page 46

    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 & REP AIR SCOPE SETTINGS This is the typical output voltage waveform generated from a properly operating machine. Note that each vertical division [...]

  • Page 47

    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-10 TROUBLESHOOTING & REP AIR SCOPE SETTINGS This is the typical output voltage waveform generated from a properly operating machine. Note that each vertical division[...]

  • Page 48

    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 1 TROUBLESHOOTING & REP AIR SCOPE SETTINGS This is NOT the typical output voltage waveform. The output capacitor was disconnected from the circuit. Note the increa[...]

  • Page 49

    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 & REP AIR FIGURE F.2 FIGURE F.3 FIGURE F.4 F AN BLADE AND MOTOR REMOV AL PROCEDURE DESCRIPTION The following procedure will aid in the removal and[...]

  • Page 50

    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 & REP AIR FIGURE F.5 Two plastic fastener buttons attach the Connector Block to the Front Panel at these points. To remove the Connector Block, cu[...]

  • Page 51

    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 & REP AIR RETEST AFTER REP AIR Should a machine under test be rejected for any reason requiring the removal of any mechani- cal part that could af[...]

  • Page 52

    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-15 NOTES:[...]

  • Page 53

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SP-100 Section G T ABLE OF CONTENTS – ELECTRICAL DIAGRAMS SECTION – Electrical Diagrams ........................................................................................Section G SP-100 Wiring Diagram (codes 9794 and above) ...............................[...]

  • Page 54

    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 TO GROUND PER NATIONAL ELECTRICAL CODE S1 SWITCH 20[...]

  • Page 55

    G-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 WIRING DIAGRAMS L1 L2 31 32 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 mf 40V 203 204 - + OUTPUT CHO[...]

  • Page 56

    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 troubleshooting. PC Board repairs will invalidate your [...]

  • Page 57

    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-5 ELECTRICAL DIAGRAMS SP-100 NOTE: Lincoln Electric assumes no responsibility for liabilities resulting from board level troubleshooting. PC Board repairs will invalidate your [...]

  • Page 58

    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-6 ELECTRICAL DIAGRAMS SP-100 NOTE: Lincoln Electric assumes no responsibility for liabilities resulting from board level troubleshooting. PC Board repairs will invalidate your [...]

  • Page 59

    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-7 ELECTRICAL DIAGRAMS SP-100 NOTE: Lincoln Electric assumes no responsibility for liabilities resulting from board level troubleshooting. PC Board repairs will invalidate your [...]

  • Page 60

    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-8 ELECTRICAL DIAGRAMS SP-100 MACHINE SCHEMA TIC: Codes 9794 and Above GND IN OUT X4 4.7 35V C6 MC7815CTDS REGULATOR D8 30A 125VAC CIRCUIT BREAKER +15V D7 +15V SUPPLY +15V 150 5[...]

  • Page 61

    G-9 ELECTRICAL DIAGRAMS SP-100 MACHINE SCHEMA TIC: 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 HAVING A COMMON CODE NUMBER. GENERAL INFORMATION f VO[...]

  • Page 62

    SVM ERR OR REPORTING FORM W e need to know if there are errors in our manuals. W e also v alue any suggestions as to additional tests or procedures that would mak e this SVM a better tool f or you. If you disco ver ne w or diff erent “Problems or Symptoms” that are not co v ered in the three col- umn troubleshooting chart, please share this inf[...]