Lincoln Electric SP-100T Operator'S Manual Download Page 42

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TROUBLESHOOTING

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SP-100T

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local  Lincoln Authorized Field Service Facility

for technical troubleshooting assistance before you proceed.

CAUTION

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 

 115vac.

2. Check for proper electrode

polarity for process.

3. Check gun tip for wear or dam-

age and proper size 

 Replace.

4. Check for proper gas and flow

rate for process. (For MIG only.)

5. Check work cable for loose or

faulty connections.

6. Check gun for damage or

breaks.

7. Check for proper drive roll orien-

tation and alignment.

8. Check liner for proper size.

RECOMMENDED
COURSE OF ACTION

Contact your local Lincoln
Authorized Field Service Facility.

WELDING PROBLEMS

Summary of Contents for SP-100T

Page 1: ...mportantly think before you act and be careful For use with machine Code Number 10262 10271 10480 10484 10739 10879 SP 100T 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 Date of Purchase Serial Number Code Number Model Where Purchased...

Page 2: ...R 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 purchase a copy of Safety in Welding Cutting ANSI Standard Z49 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is availa...

Page 3: ...rical earth ground 3 f Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation 3 g Never dip the electrode in water for cooling 3 h Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders ...

Page 4: ...event the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available 6 b Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Weldin...

Page 5: ...s et non inflamma bles 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 pantalons 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 Eloign...

Page 6: ...he information must be followed to avoid minor personal injury or damage to this equipment CAUTION 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 is receive...

Page 7: ... B 2 Controls and Settings B 2 Welding Operations B 3 Overload Protection B 6 Learning to Weld B 7 Application Chart B 18 Accessories Section C Accessories C 1 Replacement Parts C 2 Maintenance Section D Safety Precautions D 1 Items Requiring No Maintenance D 1 Routine Maintenance D 1 Gun and Cable Maintenance D 2 Component Replacement Procedures D 2 Troubleshooting Section E Safety Precautions E ...

Page 8: ...HNICAL SPECIFICATIONS SP 100T INPUT SINGLE PHASE ONLY RATED OUTPUT OUTPUT RECOMMENDED INPUT CABLE AND FUSE SIZES Height Width Depth Weight 12 0 in 9 75 in 16 5 in 48 Ibs 305 mm 248 mm 419 mm 21 8 kg PHYSICAL DIMENSIONS Standard Voltage Frequency Input Current 115V 60Hz 20 Amps Rated Output 115V 60Hz 15 Amps CSA Rated output Duty Cycle Amps Volts at Rated Amperes 20 Duty Cycle 88 18 20 Duty Cycle C...

Page 9: ...e and lens 8 Instructional video 9 Adjustable mixed Gas Regulator Hose For available options and accessories refer to the Accessories Section of this manual 1 As shipped from the factory the SP 100T gun liner is ready to feed 023 0 6 mm 035 0 9 mm wire The contact tip is sized for 023 025 0 6 mm wire feeding ELECTRIC SHOCK can kill Only qualified personnel should perform this installation Only per...

Page 10: ...an 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 passages and cause overheating STACKING SP 100T s cannot be stacked TILTING Each machine must be placed on a secure level sur face either directly or on either recommended cart The machine may...

Page 11: ... the gun conductor cable through the Gun Cable Access Hole 2 in the SP 100T case front Make sure the connector is all the way in the brass connector block Unscrew thumb screw on the connector block a few turns if gun connector will not insert fully Rotate the connector so control leads are on the underside and tighten the Thumbscrew 8 in the connector block 4 Connect the gun trigger control lead t...

Page 12: ...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 CRACKING THE VALVE Never stand directly in front of or behind the flow regulator when opening the cylind...

Page 13: ...factory installed on the SP 100T Connect this plug to a mating grounded receptacle which is connected to a 20 amp branch cir cuit with a nominal voltage rating of 115 to 125 volts 60 Hertz AC only The rated output with this installation is 88 amps 18 Volts 20 duty cycle 2 minutes of every 10 minutes used for welding Do not connect the SP 100T to an input power supply with a rated voltage that is g...

Page 14: ...suited for individuals having access to 115 volt AC input power and wanting the ease of use quality and dependability of both gas metal arc welding or GMAW also known as MIG welding and the Innershield electrode process self shielded flux cored or FCAW The SP 100T is a rugged and reliable machine that has been designed for dependable service and long life RECOMMENDED PROCESSES The SP 100T can be u...

Page 15: ...e SP 100T The SP 100T is not recommended for pipe thawing or TIG welding CONTROLS AND SETTINGS Refer to Figure B 1a 1 Control Power ON OFF Switch When the power is on the fan motor will run and air will be exhausted out the louvers in the front of the machine The weld ing output and wire feeder remain off until the gun trigger is pressed 2 Wire Speed Control Controls the wire feed speed from 50 30...

Page 16: ...d an 8 200 mm diameter spool on the wire spool spindle shown in Figure B 2 To use 4 100 mm diameter spools the 2 50 mm diameter spindle must be removed See Figure B 3 Remove the wing nut and spacer at the end of the shaft and remove the outside plastic wire spool spin dle The spindle can be stored in the wire feed com partment A 4 100 mm diameter spool is mounted directly on the 5 8 16 mm diameter...

Page 17: ...ire 6 The idle roll pressure adjustment wing nut is facto ry set to approximately five full turns from where the wing nut first engages the threads of the pres sure arm 1 If feeding problems occur because the wire is flattened excessively turn the pressure adjustment counter clockwise to reduce distortion of the wire Slightly less pressure may be required when using 0 023 0 025 0 6 mm wire If the ...

Page 18: ...3 8 inch 10 mm 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 100T Cleaning Tip And Nozzle Clean the contact tip and nozzle to avoid arc bridging between the nozzle and contact tip which can ...

Page 19: ...3 Keep the cylinder valve closed except when using the SP 100T When finished welding a Close the cylinder valve to stop gas flow b Depress the gun trigger briefly to release the pressure in the gas hose c Turn off the SP 100T WELDING WITH FCAW Innershield When using the FCAW process the correct drive roll and electrode polarity must be used See Work Cable Installation in INSTALLATION section for c...

Page 20: ... pre vent current from going through an unwanted path Avoid allowing the welding circuit to pass through hinges bearings electronic components or similar devices that can be damaged See Figure B 8 Always disconnect electrical devices before welding upon them FIGURE B 8 Fumes and slag generated from Innershield type electrodes recom mended for use with this welding machine can be toxic Avoid contac...

Page 21: ...g on top of the weld during cooling After running a weld bead the slag may be removed with a chipping hammer and wire brush This improves appearance and allows for inspection of the finished weld Since machine size and output characteristics limit the size and type of wire electrode which can be used Lincoln 0 035 0 9 mm NR 211 MP Innershield elec trode is recommended for Self Shielded Flux Cored ...

Page 22: ... will be able to weld the material In addition aluminum and stainless steel can be welded using the K664 1 Aluminum Welding Kit For further information on identifying various types of steels and other metals and for proper procedures for welding them we again suggest you purchase a copy of New Lessons in Arc Welding Regardless of the type of metal being welded in order to get a quality weld it is ...

Page 23: ...cal up or vertical down Vertical up is used whenever a larger stronger weld is desired Vertical down is used primarily on sheet metal 5 32 3 9 mm and under for fast low penetrating welds Use of this unit on thicker materials than recom mended 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 Vert...

Page 24: ...to the settings suggested on the Application Guide for the welding wire and base metal thickness being used The voltage control is marked V and the wire feed speed is marked olo 4 Check that the polarity is correct for the welding wire being used Set the polarity for DC when welding with NR 211 MP Innershield electrode See Work Cable Installation in the INSTALLATION section for instructions on cha...

Page 25: ...ickout ESO is the distance from the end of the contact tip to the end of the wire See Figure B 19 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 cor rect length is by listening to its sound The correct ESO has a distinctive crackling sound very ...

Page 26: ...the work 2 Position face shield to protect face and eyes 3 Depress gun trigger hold gun so contact tip to work distance is about 3 8 to 1 2 inch 10 to 12 mm and the gun is at proper angle 4 After you strike the arc practice the correct electri cal stickout Learn to distinguish it by its sound 5 When you are sure that you can hold the correct electrical stickout with a smooth crackling arc start mo...

Page 27: ...of the four welding will be easy They are as follows 1 The Correct Welding Position Figure B 23 illustrates the correct welding position for right handed people For left handed people it is the opposite When GMAW MIG welding on sheet metal it is important to use the forehand push technique Hold the gun of the gun and cable assembly in your right hand and hold the shield with your left hand Left ha...

Page 28: ...g the molten metal FIGURE B 25 Helpful Hints 1 For general welding it is not necessary to weave the arc neither forward or backward nor sideways Weld along at a steady pace You will find it easier 2 When welding on thin plate you will find that you will have to increase the welding speed whereas when welding on heavy plate it is necessary to go more slowly in order to get good penetration 3 When w...

Page 29: ...tage 2 Increase drag angle 3 Decrease stickout 4 Increase WFS wire feed speed 5 Decrease travel speed 6 Check for correct gas if used To Correct Poor Penetration in order of impor tance 1 Decrease stickout 2 Increase WFS wire feed speed 3 Increase voltage 4 Decrease speed 5 Decrease drag angle 6 Check for correct gas if used If Arc Blow Occurs in order of importance NOTE Try different ground conne...

Page 30: ... pull the gun around sharp corners 2 Keep the gun cable as straight as practical when welding 3 Do not allow dolly wheels or trucks to run over the cables 4 Keep the cable clean 5 Innershield electrode has proper surface lubrica tion Use only clean rust free electrode 6 Replace contact tip when it becomes worn or the end is fused or deformed SP 100T ...

Page 31: ...B 18 APPLICATION CHART B 18 SP 100T ...

Page 32: ...rled drive roll for feeding 035 0 9 mm diameter flux cored electrode 4 K520 Utility Cart Designed to transport the Lincoln family of small welders Has provisions for mounting a single gas cylinder Has front casters and large rear wheels Handle height is easily adjustable Bottom tray provided for tools and accessories Easy assembly required takes less than 15 minutes 5 K1800 1 CO2 Adjustable Regula...

Page 33: ...enance section for details 4 Remove gas nozzle if installed and install gasless nozzle To remove simply unscrew 5 Load wire into machine and thread into gun and cable per Welding Wire Loading section REPLACEMENT PARTS Complete Gun and Cable Assembly L8311 6 K530 4 Contact Tip 025 0 6 mm S19726 1 Contact Tip 030 0 8 mm S19726 2 Contact Tip 035 0 9 mm S19726 3 Contact Tip Tapered 025 0 6 mm S20278 1...

Page 34: ...blems NO maintenance is required In extremely dusty locations dirt may clog the air passages causing the welder to run hot with premature tripping of ther mal protection If so blow dirt out of the welder with low pres sure air at regular intervals to eliminate excessive dirt and dust build up on internal parts WIRE FEED COMPARTMENT 1 When necessary vacuum accumulated dirt from gearbox and wire fee...

Page 35: ...r the Innershield process the gasless nozzle should be screws onto the diffuser 5 To remove gun tube from gun remove gas nozzle or gasless nozzle and remove diffuser from gun tube Remove both collars from each end of the gun handle and separate the handle halves Loosen the locking nut holding the gun tube in place against the gun end cable connector Unscrew gun tube from cable connector To install...

Page 36: ...e the spring loaded pressure arm and lift the idle roll arm away from the drive roll 3 Turn the power switch to ON marked I 4 Set the wire speed to minimum and jog the drive unit with the trigger switch until the drive roll set screw is facing up When inching the welding wire the drive rolls gun connector block and gun contact tip are energized relative to work and ground and remain energized for ...

Page 37: ...the cable 5 Insert a new untrimmed liner into the connector end of the cable Be sure the liner bushing is stenciled appropriately for the wire size being used 6 Fully seat the liner bushing into the con nector Tighten the set screw on the brass cable connector At this time the gas diffuser should not be installed onto the end of the gun tube 7 With the gas nozzle and diffuser removed from the gun ...

Page 38: ...ately 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 place a screwdriver against the tab on the collar and give the screwdriver a sharp blow to turn the collar past an internal locking rib See Figure D 3 FIGURE D 3 SP 100T Counter clockwise ...

Page 39: ...n be conducted with out removing the case wrap around cover Step 3 PERFORM COMPONENT TESTS If you have exhausted all of the recom mended tests in Step 2 Consult your Local Authorized Field Service Facility HOW TO USE TROUBLESHOOTING GUIDE Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel Unauthorized repairs performed on this equipment may result in danger t...

Page 40: ...oes NOT operate No wire feed weld output or gas flow when gun trigger is pulled Fan operates normally POSSIBLE AREAS OF MISADJUSTMENT S None Contact your local Authorized Field Service Facility 1 Make sure correct voltage is applied to the machine 115vac 2 Make certain that power switch is in the ON position 3 Make sure circuit breaker inside wire drive compartment is reset 1 The thermostat may be...

Page 41: ...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 clogged cable liner or contact tip 3 Check for proper size cable liner and contact tip RECOMMENDED COURSE OF ACTION Contact your local Lincoln Authorized Field Service Facility FEEDING PROBLEMS PROBLEMS SYMPTOMS Low or no gas flow when gun trigger i...

Page 42: ...MPTOMS Arc is unstable Poor starting POSSIBLE AREAS OF MISADJUSTMENT S 1 Check for correct input voltage to machine 115vac 2 Check for proper electrode polarity for process 3 Check gun tip for wear or dam age and proper size Replace 4 Check for proper gas and flow rate for process For MIG only 5 Check work cable for loose or faulty connections 6 Check gun for damage or breaks 7 Check for proper dr...

Page 43: ...J3 9 6 96C S1 SWITCH D1 D3 D2 D4 204 204 204 203 203 203 C1 59 000 f 40V 203 204 GUN CABLE CONDUCTOR BLOCK TO WORK ELECTRICAL SYMBOLS PER E1537 CAVITY NUMBERING SEQUENCE COMPONENT SIDE OF BOARD 539 541 T1 GUN TRIGGER THERMOSTAT 208 5K WIRE SPEED R2 W B N C N C COMPONENT VIEWED FROM REAR ON OFF N C 209 WINDING 24V AUXILIARY FAN MOTOR X1 202 X2 S2 SELECTOR SWITCH CIRCUIT BREAKER 115V 60HZ 115V 60HZ ...

Page 44: ...NOTES SP 100T ...

Page 45: ...16 383 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 Rate ...

Page 46: ...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 Elektrode...

Page 47: ...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 co...

Page 48: ...s 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 ...

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