Lincoln Electric SP-100 IM366-B manual

SP- 1 00 OPERA TOR'S MANU AL For use with machines having Code Number 9284 and above . Sales and Service through Subsidiaries and Distributors Worldwide 22801 St. Clair Ave. Cleveland, Ohio 44117-1199 U.S.A. Tel. (216) 481-8100 World's Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors IM366-B November 1993 S[...]

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 & Cutting - ANSI Standard[...]

FOR ENGINE powered equipment. 7.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. --------------------------------------------------------------------------------------- 7.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes out- doors. -----------[...]

-4- 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. Les circuits à l’él[...]

T ABLE OF CONTENTS Page Safety Precautions .............................................................................................................2-4 Introductory Information ....................................................................................................... 6 Product Description ...........................................[...]

EXPLANA TION OF SYMBOLS THA T APPEAR ON THIS EQUIPMENT Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment i[...]

PRODUCT DESCRIPTION The SP-100, Type K462, is a complete semiautomatic constant 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 .023 – .030" (0.6 – 0.8 mm) solid steel electrode and .035" (0.9 mm) cored electrode. The [...]

Type K462 Rated DC Output (For use on 20 ampere 90 amps @ 18 volts branch circuit) 20% duty cycle Maximum DC Output (For use on 25 ampere branch circuit with optional 100 amps @ 17 volts K467 input line cord installed) 30% duty cycle CSA Rated DC Output 63 amps @ 20 volts (For use on 15 ampere branch circuit) 20% duty cycle Input Power @ CSA rated [...]

DESCRIPTION OF CONTROLS Become familiar with the SP-100 controls and compo- nents before attempting to weld. Refer to illustrations and lettered items below for brief descriptions. A. Wire speed — Controls the wire speed from 50 – 400 in./min (1.3 – 10 m/min). The control can be preset on the dial to the setting specified on the SP-100 Applic[...]

Work Cable Installation 1. Open the wire feed section door on the right side of the SP-100. 2. Pass the end of the work cable that has the termi- nal lug with the smaller hole through the hole (hole D) next to the louvers in the case front. 3. Route the cable under and around the back of the wire feed unit. 4. Using wing nut provided, connect the t[...]

ELECTRICAL INPUT CONNECTION Code Requirements This welding machine must be connected to power source in accordance with applicable electrical codes. The United States National Electrical Code (Article 630-B, 1990 Edition) provides standards for amper- age handling capability of supply conductors based on duty cycle of the welding power source. If t[...]

Extension Cord If an extension cord is required, use one that is rated for the application and is 3 conductor #14 AWG (2.1 mm 2 ) or larger. The recommended maximum lengths are 25 ft (7.5 m) if #14 AWG (2.1 mm 2 ) is used and 50 ft (15 m) if #12 AWG* (3.3 mm 2 ) is used. *AMERICAN WIRE GAUGE SHIELDING GAS When using the GMAW process, a cylinder of [...]

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 danger- ous. • Keep your head out of fumes. • Use ventilation[...]

– 14 – 4. Depress the gun trigger switch and feed welding wire through the gun and cable (Point gun away from yourself and others while feeding wire.) Release gun trigger after wire appears at end of gun. 5. Replace contact tip and gas nozzle. 6. Cut the wire off 1/4 – 3/8" (6 – 10 mm) from the end of the tip. The SP-100 is now ready t[...]

No one can learn to weld simply by reading about it. Skill comes only with practice. The following pages will help the inexperienced operator to understand welding and develop this skill. For more detailed infor- mation, order a copy of “New Lessons in Arc Welding” listed inside the back cover of this manual. THE ARC-WELDING CIRCUIT The operato[...]

– 16 – The cored wire melts in the arc and tiny droplets of molten metal shoot across the arc into the molten pool. The wire sheath provides additional filler metal for the joint to fill the groove or gap between the two pieces of the base metal. The core materials also melt or burn in the arc and perform several functions. They make the arc st[...]

– 17 – Practice. The best way of getting practice in the four skills that enable you to maintain: 1. Correct welding position 2. Correct way to strike an arc 3. Correct electrical stickout 4. Correct welding speed is to spend a little more time on the following exercise. Use the following: Mild Steel 16 gauge or 1/16 inch (1.6 mm) Electrode .03[...]

– 18 – steel can usually be easily welded without special pre- cautions. Some steels, however, contain higher car- bon levels or other alloys and are more difficult to weld. Basically, if a magnet sticks to the metal and if you can easily cut the metal with a file, chances are good that you will be able to weld the material with the SP-100. For[...]

– 19 – Vertical-Up and Overhead Welding The problem, when welding vertical-up, is to put the molten metal where it is wanted and make it stay there. If too much molten metal is deposited, gravity will pull it downwards and make it “drip.” Therefore, a certain technique has to be followed. When welding out-of-position, run stringer beads. Do[...]

MACHINE SETUP FOR THE GMA W (MIG) PROCESS 1. See “Recommended Processes and Equipment” for selection of welding wire and shielding gas and for range of metal thicknesses that can be welded. 2. See the “Welding ” chart on the inside of wire feed section door or in this manual for information on setting the controls. 3. Set the “Voltage” [...]

– 21 – TROUBLESHOOTING WELDS Good welds have excellent appearance. To Eliminate Porosity (in order of importance) — Turn on gas supply, if used 1. Decrease voltage 2. Increase stickout 3. Increase WFS (wire feed speed) 4. Decrease drag angle 5. Decrease travel speed. NOTE: Always be sure the joint is free from mois- ture, oil, rust, paint or [...]

ROUTINE MAINTENANCE Requires NO Maintenance • Drive Motor and Gearbox - Lifetime lubrication • Fan Motor - Lifetime lubrication. • Wire Reel Spindle - Do NOT lubricate shaft. Before Each Use • Check over machine and accessories for any obvious condition that may prevent safe performance or operation, repair or replace items as necessary to [...]

– 23 – • Replace Liner - when wire feeding problems occur and other items have been checked. NOTICE: The variation in cable lengths prevents 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 requirement. Remove gun and cable as[...]

– 24 – GENERAL TROUBLESHOOTING GUIDE Problems Problem Possible Cause What To Do No Wire Feed, Weld Welder not ON (“I”) Turn welder power ON (“I”) Output or Gas Flow Welder not plugged in Plug in - check both ends of input cable Gun Cable Damaged Inspect or Replace Trigger Switch Problem Repair or Replace Circuit breaker or Thermostat Tr[...]

– 25 – Low or no gas flow Cylinder valve closed Open cylinder valve Gas flow not set correctly Set proper flow rate Cylinder out of gas Get new cylinder of gas Leak in gas line Inspect and replace Clog or Leak in gun Check for obstruction or defective seals Arc unstable Wrong welding polarity Check polarity - Refer to proper section Erratic or [...]

     11-12-93K M 16576 L1 L2 31 32 531 TO GROUND PER NATIO NAL ELECTRICAL CODE S1 SW ITCH 202 201 D1 D3 D2 D4 204 204 204 203 203 203 C1 59,000 f 40V 203 204 - + OUTP UT CHOKE GUN CAB LE CONDU CTOR BLOC K TO WO RK E L E CT RI CA L S Y M B OL S P ER E 1537 CIRCUIT BREAKER 31A 12 3 456 LATCH FAN MO TO R 1 234 LATCH 5 6789 1 0 J1 J2 CAV[...]

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– 41 – Now A vailable...12th Edition The 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. This printing will go fast so don’t delay. Place your order now using the coupon below. The hardbound boo[...]

– 42 – 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 ABRICANT[...]

– 43 – 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 PAR TES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust to remo[...]

ST A TEMENT OF W ARRANTY : The Lincoln Electric Company (Lincoln) warrants to the original purchaser (end-user) of new equipment that it will be free of defects in workmanship and material. This warranty is void if Lincoln finds that the equipment has been subjected to improper care or abnormal operation. W ARRANTY PERIOD: All warranty periods date[...]