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Lincoln Electric SP-125 PLUS, Operator'S Manual

The Lincoln Electric SP-125 PLUS welding system offers exceptional versatility and power for all your welding needs. To ensure optimal operation and safety, download the free Operator's Manual from manualshive.com today. This comprehensive manual provides step-by-step instructions and valuable insights to help you get the most out of your SP-125 PLUS.

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vi

SP-125 PLUS

TABLE OF CONTENTS

Page

Installation .......................................................................................................Section A

Technical Specifications ........................................................................................A-1
Identify and Locate Components ...........................................................................A-2
Select Suitable Location ........................................................................................A-3
Output Connections ...............................................................................................A-3
Input Connections..................................................................................................A-5
Code Requirements ..............................................................................................A-6

Operation .........................................................................................................Section B

Safety Precautions ................................................................................................B-1
General Description ...............................................................................................B-2

Design Features and Advantages...................................................................B-2
Welding Capability ..........................................................................................B-2
Limitations .......................................................................................................B-2
Controls and Settings ......................................................................................B-2

Welding Operations ...............................................................................................B-3
Overload Protection ...............................................................................................B-7
Learning to Weld....................................................................................................B-8
Application Chart .................................................................................................B-19

Accessories .....................................................................................................Section C

Accessories ...........................................................................................................C-1
Replacement Parts ................................................................................................C-2

Maintenance ....................................................................................................Section D

Safety Precautions ................................................................................................D-1
Items Requiring No Maintenance ..........................................................................D-1
Routine and Periodic Maintenance........................................................................D-1
Gun and Cable Maintenance.................................................................................D-2
Configuration of Components in Wire Feeding System.........................................D-2
Component Replacement Procedures ..................................................................D-3

Troubleshooting ..............................................................................................Section E

Safety Precautions.................................................................................................E-1
How To Use Troubleshooting Guide......................................................................E-1
Troubleshooting Guide ..........................................................................................E-2

Wiring Diagrams ..............................................................................................Section F

SP-125 Plus Wiring Diagram .................................................................................F-1

Parts Lists....................................................................................P263 Series & P202-E

Summary of Contents for SP-125 PLUS

Page 1: ...st importantly think before you act and be careful For use with machine Code Numbers 10260 10481 10685 10689 10690 10740 ISO 9001 CERTIFICATE NUMBER 30273 Designed and Manufactured Under a Quality Program Certified by ABS Quality Evaluations Inc to ISO 9001 Requirements QMS ANSI RAB Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 F...

Page 2: ...CEMAKER 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 ...

Page 3: ... electrical 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 we...

Page 4: ... to prevent 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 ...

Page 5: ...ropriés et 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 ...

Page 6: ...where the 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 ...

Page 7: ...Welding Operations B 3 Overload Protection B 7 Learning to Weld B 8 Application Chart B 19 Accessories Section C Accessories C 1 Replacement Parts C 2 Maintenance Section D Safety Precautions D 1 Items Requiring No Maintenance D 1 Routine and Periodic Maintenance D 1 Gun and Cable Maintenance D 2 Configuration of Components in Wire Feeding System D 2 Component Replacement Procedures D 3 Troublesho...

Page 8: ...vii SP 125 PLUS ...

Page 9: ...UT OUTPUT RECOMMENDED INPUT CABLE AND FUSE SIZES Height Width Depth Weight 12 0 in 9 75 in 16 5 in 54 Ibs 305 mm 248 mm 419 mm 24 3 kg PHYSICAL DIMENSIONS Standard Voltage Frequency Input Current 115V 60Hz 20 Amps Rated Output 115V 60Hz 25 Amps Maximum Output 115V 60Hz 15 Amps CSA Rated output Duty Cycle Amps Volts at Rated Amperes 20 Duty Cycle Rated DC Output 90 18 20 Duty Cycle CSA Rated Output...

Page 10: ...justable mixed Gas Regulator Hose For available options and accessories refer to the accessories section later in this manual 1 As shipped from the factory the SP 125 Plus gun is ready to feed 023 or 025 0 6 mm wire ELECTRIC SHOCK can kill Only qualified personnel should perform this installation Only personnel that have read and under stood the SP 125 Plus Operating Manual should install and oper...

Page 11: ...er Lead Connectors 5 Positive and negative output terminals 6 Wire Feed Gearbox and Gun Connector Block 7 Cable Clamp 8 Thumbscrew Secures gun and cable assembly 9 Optional Spot Stitch Timer Kit see Accessories Work Clamp Installation Attach the work clamp per the following 1 Unplug the machine or turn the power switch to the OFF position 2 Insert the work cable terminal lug with the larger hole t...

Page 12: ...itch being used is other than that supplied with the SP 125 Plus the switch must be a normally open momentary switch The terminals of the switch must be insulated from the welding circuit Malfunction of the SP 125 Plus will result if this switch shorts to the SP 125 Plus welding output circuit or is common to any electri cal circuit other than the SP 125 Plus trigger circuit GAS CONNECTION Refer t...

Page 13: ...e located on the rear of the machine FIGURE A 6 BUILDUP OF SHIELDING GAS may harm health or kill Shut off shielding gas supply when not in use SEE AMERICAN NATIONAL STANDARD Z 49 1 SAFETY IN WELDING AND CUTTING PUB LISHED BY THE AMERICAN WELDING SOCIETY 1 Chain the cylinder to a wall or other stationary sup port to prevent the cylinder from falling over Insulate the cylinder from the work circuit ...

Page 14: ...Hertz AC only The rated output with this installation is 90 amps 18 Volts 20 duty cycle 2 minutes of every 10 minutes used for welding Do not connect the SP 125 Plus to an input power supply with a rated voltage that is greater than 125 volts Do not remove the power cord ground prong Requirements For Maximum Output In order to utilize the maximum output capability of the machine a branch circuit c...

Page 15: ...om work and ground Always wear dry insulating gloves FUMES AND GASES can be dangerous Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone WELDING SPARKS can cause fire or explosion Keep flammable material away Do not weld on closed contain ers ARC RAYS can burn eyes and skin Wear eye ear and body protec tion Observe all safety information throughout this manu...

Page 16: ... stat and a circuit breaker Quality wire drive with electronic overload protec tion Easy to set continuous range controls for precise setting of arc voltage and wire speed Continuous voltage control Quick Release idle roll pressure arm is easily adjusted Reversible dual groove drive roll Drive roll will feed 023 035 0 6 0 9 mm diameter wire Accommodates both 8 200 mm diameter and 4 100 mm diameter...

Page 17: ...ch should be turned to the OFF O position before working inside the wire feed enclosure The machine is shipped from the factory ready to feed 4 100 mm diameter spools A 4 100 mm diameter spool is mounted directly on the 5 8 16 mm diame ter spindle that has a built in adjustable friction brake to prevent overrun of the spool and excess slack in the wire The wing nut at the end of the shaft is used ...

Page 18: ...roll pressure adjustment wing nut is nor mally set for mid position on the pressure arm threads 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 drive roll slips while feeding wire the pressure should be increased until ...

Page 19: ...and for range of metal thicknesses that can be welded 2 See the Application Chart on the inside of wire feed section door for information on setting the SP 125 Plus controls 3 Set the Voltage V and Wire Speed olo con trols to the settings suggested for the welding wire and base metal thickness being used FIGURE B 6 FIGURE B 5 Gun Handle Gas Diffuser Contact Tip Gas Nozzle 4 Check that the polarity...

Page 20: ...ble B 1 for Recommended Procedure Settings Aluminum wire requires K663 1 Aluminum Welding kit See ACCES SORIES section It is important when changing between welding with steel wire and aluminum to exchange feeding components due to the lubricant applied to steel wire Failure to do so may result in contaminated welds when welding aluminum TABLE B 1 SP 125 Plus Welding Procedures CHANGING MACHINE OV...

Page 21: ... until the machine cools to a nor mal operating temperature This is an automatic func tion and is self resetting Wire Feed Overload Protection If the SP 125 Plus has an automatic electronic protec tion circuit to protect the wire feed motor If excessive motor overload occurs due to excessive feeding force jammed drive rolls or shorted motor leads the circuit will shut down the wire feed motor and ...

Page 22: ...This helps 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 Fumes and slag generated from Innershield type electrodes recom mended for use with this welding machine can be toxic Avoid contact...

Page 23: ... 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 9mm NR 211 MP Innershield elec trode is recommended for Self Shielded Flux Cored Ar...

Page 24: ...u 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 25: ...al 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 Verti...

Page 26: ...o 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 chan...

Page 27: ...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 FIGURE B 20 FIGURE B 18 WARNING FIGURE B 19 3 8 1 2 10 12 mm Electrical Stickout ESO Contact Tip Wire Electrode Solidifying ridge Molten puddle The...

Page 28: ...orrect welding speed is to perform the following exercise Refer to Figure B 22 1 Learn to strike an arc by positioning the gun over the joint and touching the wire to 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 corre...

Page 29: ...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 30: ... 1 6 mm Electrode Lincolnweld 0 025 L 56 electrode CO2 Voltage Setting V G Wire Feed Speed o o 5 For the SP 125 Plus use the following FIGURE B 24 3 The Correct Electrical Stickout ESO The electrical stickout ESO is the distance from the end of the contact tip to the end of the wire See Figure B 24 Once the arc has been established maintaining the correct ESO becomes extremely important The ESO sh...

Page 31: ... free from moisture oil rust paint or other contaminants To Eliminate a Ropy Convex Bead in order of importance 1 Increase voltage 2 Decrease stickout 3 Decrease WFS wire feed speed 4 Decrease travel speed 5 Decrease drag angle 6 Check for correct gas if used To Reduce Spatter in order of importance 1 Increase voltage 2 Increase drag angle 3 Decrease stickout 4 Increase WFS wire feed speed 5 Decre...

Page 32: ...kink or 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 ...

Page 33: ...B 19 APPLICATION CHART SP 125 PLUS ...

Page 34: ...d large rear wheels Handle height is easily adjustable Bottom tray provided for tools and accessories Easy assembly required takes less than 15 minutes 2 K1800 1 CO2 Adjustable Regulator and Hose Kit Includes an adjustable pressure flow regulator for use on CO2 cylinders Weld shielding gas may be obtained from a weld ing supply distributor Also included is a gas hose which connects to the rear of ...

Page 35: ...tenance section for details 4 Remove gas nozzle if installed and install gasless nozzle To remove simply unscrew 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 045 1 2 mm S19726 4 Contact Tip Tapered 025 0 6 mm S20278 1 Contact Tip Tapered 030 0 8 mm S20278 2 Contact Tip Ta...

Page 36: ... with short piece of wire Clean cable liner when rough and erratic wire feed ing occur MAINTENANCE D 1 WARNING AFTER FEEDING 50 OF FLUX CORED WIRE OR 300 OF SOLID WIRE Unplug machine or turn power switch to OFF O position Remove gun and cable from machine Remove gas nozzle and contact tip from gun Lay cable out straight blow out gently into gun end with compressed air Bend cable back and forth blo...

Page 37: ...e 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 gun tube screw the locking nut on the gun tube as far as possible Then screw the gun tube into the cable connector until it b...

Page 38: ... electrode As shipped the drive roll is installed in the 023 025 0 6 mm position If 030 035 0 8 0 9 mm wire is to be used the drive roll must be reversed as follows 1 Turn the power switch to OFF marked O 2 Release the spring loaded idle arm tensioner Figure D 1 Item 2 and lift the idle roll arm Figure D 1 Item 3 away from the drive roll 3 Loosen the Phillips Head screw holding the drive roll onto...

Page 39: ...le 6 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 7 Fully seat the liner bushing into the connector 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 8 With the gas nozzle and diffuser removed from the gun tube be ...

Page 40: ...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 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 Counter clockwise ...

Page 41: ...nly be performed by Lincoln Electric Factory Trained Personnel Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty For your safety and to avoid Electrical Shock please observe all safety notes and precautions detailed throughout this manual ____________________________________________________________...

Page 42: ...certain that power switch is in the ON position Contact your LOCAL LINCOLN AUTHORIZED FIELD SERVICE FACILITY 1 Arc voltage may be set too low 2 Gun tip may be worn Replace 3 Check for correct input voltage to machine 4 Gun or work cable may be faulty 1 Check the circuit breaker locat ed in the machine s wire drive compartment Reset if tripped 2 The thermostat may be tripped due to overheating Let ...

Page 43: ...logged cable liner or feeding problems 1 Make sure that the wire speed control is not set at maximum RECOMMENDED COURSE OF ACTION Contact your local Lincoln Authorized Field Service Facility FEEDING PROBLEMS PROBLEMS SYMPTOMS Low or no gas flow when gun trigger is pulled Wire feed weld output and fan operate normally POSSIBLE AREAS OF MISADJUSTMENT S 1 Check gas supply flow regulator and gas hoses...

Page 44: ... 3 Check gun tip for wear or dam age Replace 4 Check for proper gas and flow rate for process 5 Check work cable for loose or faulty connections 6 Check gun for damage or breaks RECOMMENDED COURSE OF ACTION Contact your local Lincoln Authorized Field Service Facility WELDING PROBLEMS If for any reason you do not understand the test procedures or are unable to Perform the tests repairs safely conta...

Page 45: ... 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 H I G H V O L T A G E c a n k i l l N B DIODES D2 D4 ARE MOUNTED ON THE INSIDE HEATSINK WHICH IS CLOSEST TO THE CENTER PANEL LEAD COLOR CODE B BLACK W WHITE N B N D COMPONENT SIDE OF BOARD N D BOLTED ALUMINUM CONNECTIONS REQUIRE T12837 JOINT COMPOUND DOW CORNING 340 WHEN REA...

Page 46: ...SP 125 PLUS F 2 NOTES ...

Page 47: ...SP 125 PLUS NOTES ...

Page 48: ...6 383 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 4 th Class Book Rate...

Page 49: ...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 50: ...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 51: ...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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