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Lincoln Electric SP-100, Operator'S Manual, Page: 10 / 31

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Lincoln Electric SP-100 Operator'S Manual Download Page 10

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 terminal lug

to the negative (–) output terminal located above
the wire feed unit; item M (make certain that 

both

wing nuts are tight). 

NOTE: This connection gives the correct electrode
polarity for the GMAW process. If using Innershield,
see Output Polarity Connection Section below for
negative electrode polarity connection.

OUTPUT POLARITY CONNECTION

The SP-100, as shipped, is connected for positive
electrode polarity.

To connect for negative electrode polarity (required for
the Innershield process), connect the short cable
attached to the gun connector block to the negative
(–) output terminal and the work cable to the positive
(+) terminal using the provided wing nuts (make cer-
tain that 

both

wing nuts are 

tight).

GUN INSTALLATION

As shipped from the factory, the SP-100 gun is ready
to feed .023, .024 or .025" (0.6 mm) wire. If .030" (0.8
mm) wire is to be used, install the .030" (0.8 mm) con-
tact tip. .023 – .025" contact tip is stenciled .025
and/or 0.6 mm and .030" contact tip is stenciled .030
and/or 0.8 mm. See Maintenance Section for instruc-
tions to change contact tip.

If .035" (0.9 mm) Innershield flux cored wire is to be
used, see Maintenance Section for instructions to
change contact tip, cable liner, and gas nozzle.

Connect the gun cable to the SP-100 per the follow-
ing:

1. Unplug the machine or turn power switch to the off

“O” position.

2. Pass the insulated terminals of the gun trigger con-

trol leads, one at a time, through the rectangular
“keyhole” opening (item F) in the case front. The
leads are to be routed under the wire feed unit and
through the cable hanger on the inner panel.

3. Insert the connector on the gun conductor cable

through the large hole in the SP-100 case front.
Make sure the connector is all the way in the metal
connector block to obtain proper gas flow. Rotate
the connector so control leads are on the underside
and tighten the thumbscrew in the connector block.

4. Connect the insulated control lead terminals to the

two insulated 1/4" (6.4 mm) tab connector bushings
located above the “Gun Trigger Connection” decal
in the wire feed section. Either lead can go to either
connector. Form the leads so that they are as close
as possible to the inside panel.

–

10

–

The gun trigger switch must be a normally open,
momentary switch. The terminals of the switch must
be insulated from the welding circuit. Malfunction of
the SP-100 will result if this switch shorts to the SP-
100 welding output circuit or is common to any elec-
trical circuit other than the SP-100 trigger circuit.

-----------------------------------------------------------------------

WIRE FEED DRIVE ROLL

The SP-100 drive roll has two grooves; one for .023 –
.025" (0.6 mm) solid steel electrode and the other for
.030" (0.8 mm) solid and .035" (0.9 mm) flux-cored
steel electrode. As shipped, the drive roll is installed in
the .023/.025" (0.6 mm) position (as indicated by the
stenciling on the exposed side of the drive roll).

If .030 – .035" (0.8 – 0.9 mm) wire is to be used, the
drive roll must be reversed as follows:

1. Make certain the SP-100 power switch is “off”.

2. Open the quick release arm; lift up the idle roll arm.

3. Remove the drive roll retaining screw and washer

with a screwdriver.

4. Remove the drive roll, flip over and install with the

.030/.035" (0.8/0.9 mm) stencil visible (away from
gearbox). Make certain the small key is in place in
the keyway.

5. Replace the washer and retaining screw.

Gun trigger
connectors

Thumbscrew

Case front

Gun connector block

{

Brass connector

Gun trigger
control lead
terminals

Idle roll arm

Retaining Screw

Drive roll

Spring loaded
pressure arm

CAUTION

WELDING WIRE LOADING

The machine power switch should be turned to
the OFF (“O”) position before working inside the
wirefeed enclosure.

------------------------------------------------------------------------

The machine is shipped from the factory ready to feed
8" (200 mm) diameter spools [2.2" (56 mm) max.
width]. These spools fit on a 2" (50 mm) diameter
spindle that has a built-in, adjustable* friction brake to
prevent overrun of the spool and excess slack in the

WARNING

Summary of Contents for SP-100

Page 1: ...remier Manufacturer of Industrial Motors IM366 B November 1993 Safety Depends on You Lincoln arc welding equipment is designed and built with safety in mind However your overall safety can be increased by proper instal lation and thoughtful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READ ING THIS MANUAL AND THE SAFETY PRECAUTIONS CON TAINED THROUGHOUT And most i...

Page 2: ... Make certain the insulation is large enough to cover your full area of physical contact with work and ground In addition to the normal safety precautions if welding must be performed under electrically hazardous condi tions in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaf folds when in cramped positions such as sitting kneel ing or lying if there...

Page 3: ...ans and all other mov ing parts when starting operating or repair ing equipment 7 e In some cases it may be necessary to remove safety guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts 7 f Do not put your hands near the engine fan Do not attem...

Page 4: ... non inflammables 4 Des gouttes de laitier en fusion sont émises de l arc de soudage Se protéger avec des vêtements de protection libres de l huile tels que les gants en cuir chemise épaisse pan talons sans revers et chaussures montantes 5 Toujours porter des lunettes de sécurité dans la zone de soudage Utiliser des lunettes avec écrans lateraux dans les zones où l on pique le laitier 6 Eloigner l...

Page 5: ...g Wire 13 Making a Weld 14 Overload Protection Shutdown 14 Wire Feed Overload Protection 14 Learning to Weld 15 The Arc Welding Circuit 15 The Self Shielded FCAW Welding Arc 15 Machine Setup for the Self Shielded FCAW Process 16 Welding Techniques for the Self Shielded FCAW Process 16 Common Metals 17 Types of Welds 18 Welding Procedures 18 Welding in the Vertical Position 18 The GMAW MIG Welding ...

Page 6: ...acement parts for or information on this equipment always supply the information you have recorded above 6 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 an...

Page 7: ...with the SP 100 on thicker materials than recommended may result in poor welds The welds may look good but may just be sitting on top of the plate This is called cold casting and will result in weld failure 035 0 9 mm Dia NR 211 MP Electrode Wire 025 0 6 mm Dia L 56 GMAW Innershield FCAW Shielding Gas CO2 or blended None Self Shielded Electrode Polarity Positive Negative Minimum Gauge 24 ga 0 6 mm...

Page 8: ...ECIFICATIONS 1 Requires optional Innershield Welding Kit INSTALLATION 8 SAFETY PRECAUTIONS Read the safety precautions at the beginning of this Operator s Manual before proceeding Only personnel that have read and under stood the SP 100 Operating Manual should install and operate this equipment Machine must be plugged into a receptacle which is grounded per any national local or other applic able ...

Page 9: ...ne to gun connector block G Gun trigger lead connectors H Circuit breaker Protects machine from damage if maximum output is exceeded Button will extend out when tripped Manual reset I Wire spool spindle J Gas solenoid inlet fitting K Power cord L Spring loaded pressure arm adjusts pressure of idle roll on wire M Wire feed gearbox and gun connector block N Wire feed section door With application ch...

Page 10: ...00 case front Make sure the connector is all the way in the metal connector block to obtain proper gas flow Rotate the connector so control leads are on the underside and tighten the thumbscrew in the connector block 4 Connect the insulated control lead terminals to the two insulated 1 4 6 4 mm tab connector bushings located above the Gun Trigger Connection decal in the wire feed section Either le...

Page 11: ...e C Fully reinstall the thumbscrew and check for proper brake force to prevent spool overrun but allow smooth and easy wire feeding If not repeat Load an 8 200 mm diameter spool on the wire spool spindle shown above To use 4 100 mm diameter spools the 2 50 mm diameter spindle must be removed Remove the thumb screw at the end of the shaft and remove the spindle It can be stored in the wire feed com...

Page 12: ...isted 5 For CO2 open the cylinder valve slowly For argon mixed gas open cylinder valve slowly a fraction of a turn When the cylinder pressure gauge pointer stops moving open the valve fully 6 If using a regulator with an adjustable flowmeter close the gun trigger and adjust the flow to give 15 20 cubic ft per hour CFH 7 10 L min use 20 25 CFH 10 12 L min when welding out of posi tion or in a draft...

Page 13: ...mm factory installed liner is color coded orange See Maintenance and Troubleshooting Section for instructions on installing liner and contact tip in gun K467 Input Line Cord Same as line cord supplied with the SP 100 but has a NEMA type 5 20P plug for use on a 25 amp branch circuit with a nominal voltage rating of 115 volts to 125 volts 60 hertz Install per the following 1 Turn the SP 100 Power Sw...

Page 14: ...machine The SP 100 has both a thermostat and a circuit break er to protect the machine from damage if the maxi mum output is exceeded If either device is tripped there will be no wire feed or output voltage when the gun trigger is depressed The fan will continue to run CAUTION If the machine shuts down due to an output overload first check the circuit breaker which is located on the inside panel o...

Page 15: ...duce vomiting Never give anything by mouth to an unconscious person Call a physi cian The gun and cable assembly is held by the operator who guides the automatically fed wire along the joint maintaining a contact tip to work distance of about 3 8 to 1 2 inch 10 12 mm this is called electrical stick out This electrical stickout ESO must be properly maintained by the operator The electric arc is mad...

Page 16: ... nozzle to give improved visibility 6 Connect work clamp to metal to be welded Work clamp must make good electrical contact to the workpiece The workpiece must also be grounded as stated in Arc Welding Safety Precautions sec tion of this manual WELDING TECHNIQUES FOR THE SELF SHIELDED FCAW PROCESS Four simple manipulations are of prime importance With complete mastery of the four welding will be e...

Page 17: ...ctrical stickout ESO is the distance from the end of the contact tip to the end of the wire Once the arc has been established maintaining the correct ESO becomes extremely important The ESO should be approximately 3 8 to 1 2 inch 10 to 12 mm long The easiest way to tell whether the ESO is the correct length is by listening to its sound The correct ESO has a distinctive crackling sound very much li...

Page 18: ...wo plates keeping the gun slightly tilted in the direction of travel Watch the molten metal to be sure it distributes itself evenly on both edges and in between the plates Penetration Unless a weld penetrates close to 100 of the metal thickness a butt weld will be weaker than the material welded together In this example the total weld is only half the thickness of the material thus the weld is onl...

Page 19: ...he molten weld metal from atmospheric contaminan t s such as oxygen and nitrogen Shielding gas is sup plied through the gun and cable assembly through the gas nozzle and into the welding zone The shielding gas has several other functions besides protecting the molten weld metal It helps shape the cross section of the weld deposit may increase or decrease arc temperature stabilizes the arc and reg ...

Page 20: ...on light gauge mater ial weld from right to left if right handed pushing the electrode ahead of the arc see figure following This technique results in a colder weld and has less ten dency for burnthrough You may weld in the opposite direction as long as you are obtaining desirable results The Correct Way to Strike an Arc 1 The arc is struck the same as for self shielded FCAW welding However for ea...

Page 21: ...e drag angle 6 Check for correct gas if used If Arc Blow Occurs in order of importance NOTE Try different ground connection locations before adjusting procedures 1 Decrease drag angle 2 Increase stickout 3 Decrease voltage V 4 Decrease WFS wire feed speed oIo and voltage V 5 Decrease travel speed To Eliminate Stubbing in order of importance 1 Increase voltage V 2 Decrease WFS wire feed speed oIo 3...

Page 22: ...emove gun and cable from machine Remove gas nozzle and contact tip from gun Lay cable out straight blow out gently with compressed air Bend cable back and forth blow out again Repeat until clean CAUTION Excessive pressure at start may cause the dirt to form a plug Perodically As Required Blow dirt out of the welder with low pressure air to eliminate excessive dirt and dust buildup that could cause...

Page 23: ...t be installed onto the end of the gun tube With the gas nozzle and diffuser removed from the gun tube be sure the cable is straight and then trim the liner to the length shown in the diagram below Remove any burrs from the end of the liner Screw the gas diffuser onto the end of the gun tube and securely tighten Replace the contact tip and nozzle Replace internal gun handle parts as necessary The ...

Page 24: ...ol or reel empty Install new spool or reel Drive Roll size incorrect Change Drive Roll Refer to proper section Drive Roll worn Replace Wire Drive release open Close wire drive release Wire welded to tip Peel wire off or use new tip Kink or bend in Wire Remove wire cut out kink reload wire Tip or cable liner to small for wire Insert correct tip or liner Trigger circuit connections loose Check conne...

Page 25: ...defective seals Arc unstable Wrong welding polarity Check polarity Refer to proper section Erratic or Intermittent Wrong size worn and or Replace tip remove any spatter on end of tip Arc Poor Starting melted contact tip Hunting Arc Worn work cable or poor connections Inspect repair or replace as necessary Loose electrode connections Be sure electrode lead is tight gun cable tight in wire feeder co...

Page 26: ... HEATSINK 208 209 203 5K WIRE SPEED 205 206 207 5K 32 J1 J2 C ONNECTOR CAVITY NUMBER ARC VOLTAGE R1 R2 W B 7 32A N A N C ON OFF N C N D N D 24 VAC AUX WDG NOTES N A DIODES D1 D3 ARE MOUNTED ON THE OUTSIDE HEATSINK N C COMPONENT VIEWED FROM REAR HIGH VOLTAGE can kill Only qualified persons should install use or service this machine Do not operate with covers removed Do not touch electrically live p...

Page 27: ......

Page 28: ... 216 383 2259 and ask for the Welding School Registrar Lincoln Welding School BASIC COURSE 700 00 5 weeks of fundamentals There is a 10 discount on all orders of 50 00 or more for shipment at one time to one location Orders of 50 or less before discount or orders outside of North America must be prepaid with charge check or money order in U S Funds Only Prices include shipment by 4thClass Book Rat...

Page 29: ...h electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja da Aislese del trabajo y de la tierra Ne laissez ni la peau ni des vête ments mouillés entrer en contact avec des pièces sous tension Isolez vous du travail et de la terre Berühren Sie keine stromführenden Teile oder Elektro...

Page 30: ...r gute Be und Entlüftung des Arbeitsplatzes Mantenha seu rosto da fumaça Use ventilação e exhaustão para remover fumo da zona respiratória Turn power off before servicing Desconectar el cable de ali mentación de poder de la máquina antes de iniciar cualquier servicio Débranchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom völlig öff nen Maschine anhalten Não opere ...

Page 31: ...n the warranty period Written notification is recommended WARRANTY REPAIR If Lincoln s inspection of the equipment confirms the exis tence of a defect covered by this warranty the defect will be corrected by repair or replacement at Lincoln s option WARRANTY COSTS You must bear the cost of shipping the equipment to a Lincoln Service Center or Field Service Shop as well as return shipment to you fr...

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