Lincoln Electric SP 170-I Operator'S Manual Download

Page: 33 / 48

C-2

ACCESSORIES

INNERSHIELD (FCAW)
CONVERSION

Several changes are needed to convert the unit for
operation with the Innershield (FCAW) process. The
following conversions should be reviewed before
welding with (FCAW):

1. Change the output polarity to DC(

–

). See

“

Work

Cable Installation

”

in Installation section for details.

2. Install proper drive roll for the wire size selected.

See

“

Changing Drive Roll

”

in Maintenance section

for details.

3. Install the proper gun liner and tip for the wire size

selected. See

“

Component Replacement

”

Maintenance section for details.

4. Remove gas nozzle (if installed) and install gasless

nozzle.

5. Load wire into machine and thread into gun and

cable per

“

Welding Wire Loading

”

section.

REPLACEMENT PARTS

Complete Gun and Cable Assembly (Code 10488
and 10489 only)
L10738

Complete Gun and Cable Assembly (Code 10490
and above only)
L10744

Contact Tip .025

”

(0.6 mm)

S18704-1

Contact Tip .030

”

(0.8 mm)

S18704-2

Contact Tip .035

”

(0.9 mm)

S18704-3

Contact Tip .045

”

(1.2 mm)

S18704-13

Liner .023 - .030

”

(0.6 - 0.8 mm)

S18704-4 (Color coded Orange)

Liner .035/.045

”

(0.9/1.2 mm)

S18704-5 (Color coded Green)

Liner for Aluminum .040 (1.0 mm)
S18704-17 (Color coded Black)

Gas Diffuser
S18704-6

Gas Nozzle
S18704-7

Gasless Nozzle (Innershield Only)
S18704-14

SP 170-I

Summary of Contents for SP 170-I

Page 1: ...T And most importantly think before you act and be careful For use with machine Code Numbers 10488 thru 10634 10693 10694 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 I...

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: ...ical 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 3...

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 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 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: ...ding B 4 Making a Weld B 5 Process Guidelines B 5 Chaning Over to Feed Other Wire Sizes B 6 Welding with GMAW B 6 Welding with FCAW B 6 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 Routine Maintenance D 1 Gun and Cable Maintenance D 2 Configuration of Components in Wire F...

Page 8: ... 419 mm 25 9 kg PHYSICAL DIMENSIONS The SP170 I UWW 170 is designed for industrial and professional use in accordance with the standard EN 60974 1 IEC 974 1 Standard Voltage Frequency Input Current 230V 50 60Hz 20 Amps Rated Output Duty Cycle Amps Volts at Rated Amperes 25 120 20 60 100 19 100 75 18 Welding Current Range Maximum Open Circuit Voltage Wire Speed Range Rated DC Output 30 170 amps 32 ...

Page 9: ...ored or solid wire c 5 64 2 0 mm Hex key wrench for removal of drive roll 4 10 ft 3 0 m work cable 5 Work clamp 6 14 0 ft 4 3 m 19 4 8 mm dia gas hose 7 2 Hose clamps 1 The gun is ready to feed 030 0 8mm diameter wire ELECTRIC SHOCK can kill Only qualified personnel should perform this installation Only personnel that have read and under stood the SP 170 I Operating Manual should install and opera...

Page 10: ...flux cored arc welding are the only processes supported by the SP 170 I The handle can not be used for transport by crane OUTPUT CONNECTIONS Refer to Figure A 2 1 Work Cable Access Hole 2 Gun Cable and Control Lead Access Hole 3 Connector Block 4 Gun Trigger Lead Connectors 5 Positive and negative output terminals 6 Wire Feed Gearbox Feedplate 7 Cable Hanger 8 Thumbscrew 9 Circuit Breaker Manual R...

Page 11: ... Control Lead Access Slot A 2 2 in the case front The leads are to be routed up the inside of the case front behind the gas line 3 Insert the connector on the gun conductor cable through the Gun Cable Access Hole A 2 2 in the SP 170 I case front Make sure the connector is all the way in the brass connector block to obtain proper gas flow If the gun connector will not fully insert unscrew the thumb...

Page 12: ...he gas hose is not kinked or twisted Tighten the gas line hose clamp INPUT CONNECTIONS Refer to Figure A 6 FIGURE A 6 CYLINDER may explode if dam aged Keep cylinder upright and chained to support Keep cylinder away from areas where it may be damaged Never lift welder with cylinder attached Never allow welding electrode to touch cylinder Keep cylinder away from welding or other live electrical circ...

Page 13: ...E WIRE SINGLE PHASE SYSTEM OR TO ONE PHASE OF A TWO OR THREE PHASE SYSTEM This welding machine must be connected to a power source in accordance with applicable elec trical codes The United States National Electrical Code Article 630 B 1990 Edition provides standards for amperage handling capability of supply conduc tors based on duty cycle of the welding source If there is any question about the ...

Page 14: ...dependability of both gas metal arc welding or GMAW also known as MIG welding and the Innershield process self shielded flux cored or FCAW A convenient chart is mounted inside the wire feed section door for setting welding procedures for 24 gauge 60 mm through 5 16 8 0 mm mild steel The machine is rugged and reliable and is designed for dependable service and long life RECOMMENDED PROCESSES The SP...

Page 15: ...e Light Indicates thermostat has cut the output The fan will be running Thermostat resets automatically FIGURE B 1a 5 Circuit Breaker Protects machine from damage if maxi mum output is exceeded Button will extend out when tripped Manual reset OFF ON ARC VOLTS WIRE SPEED 6 Optional K695 1 Spot Stitch Timer Kit Controls see ACCESSORIES section If present replaces Blank Panel Assembly located on the ...

Page 16: ... 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 shaft and held in place with the previously removed hardware Also make certain the start end of the wire which may pro trude through the side of the spool does not contact any metallic case parts FIGURE B 3 Friction Brake Ad...

Page 17: ...oximately five full turns from where the wing nut first engages the threads of the pressure arm 1 If feeding problems occur because the wire is flattened excessively turn the pressure adjust ment 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 unt...

Page 18: ... gun trigger and then pull the gun away from the work after the arc goes out FIGURE B 6 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 170 I Cleaning Tip And Nozzle Clean the contact tip and nozzle to avoid arc bridging between the nozzle and contact tip which can result in a shorted nozzle poor ...

Page 19: ...t of position or in a drafty location 3 Keep the cylinder valve closed except when using the SP 170 I 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 170 I WELDING WITH FCAW Innershield When using the FCAW process the correct drive roll and electrode polarity must be used See Work Cable In...

Page 20: ...his 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 21: ...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 and 0 045 0 9 and 1 2 mm NR 211 MP Innershield electrode is recommended for Self Shielded Flu...

Page 22: ...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 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: ...tickout 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 Th...

Page 26: ...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 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 h...

Page 28: ...25 L 56 electrode CO2 Voltage Setting V C Wire Feed Speed o o 4 For the SP 170 I use the following B 15 SP 170 I B 15 LEARNING TO WELD 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 29: ...s 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 Decr...

Page 30: ... 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 31: ...1 6 mm 075 in 2 0 mm 105 in 2 5 mm 3 16 in 5 0 mm 1 4 in 6 0 mm B 2 B 2 B 2 C 3 C 3 D 5 A 2 A 2 B 3 B 4 C 5 B 2 C 3 C 3 D 4 B 3 B 3 C 3 D 5 A 1 A 1 B 2 B 2 C 2 5 D 2 E 2 Multiple passes required OUTPUT POLARITY DRIVE ROLL ORIENTATION MIG DC ALIGN GROOVE WITH CENTER OF GUIDE TUBES SECURE DRIVE ROLL WITH SET SCREW CENTERED ON FLAT MIG DC 025 0 6 mm DIA SOLID STEEL WIRE 030 0 8 mm DIA SOLID STEEL WIR...

Page 32: ...use 035 0 9 mm diameter flux cored electrode The fitting on the end of the liner is stenciled with the maximum rated wire size 045 1 2 mm Also included is a 10 lb 4 5 kg spool of 035 0 9 mm Innershield NR 211 MP For use with Lincoln Electric gun with black trigger The end of the brass fitting on the end of the 035 045 0 9 1 2mm liner is color coded green The 023 030 0 6 0 8mm liner is color coded ...

Page 33: ...t in Maintenance section for details 4 Remove gas nozzle if installed and install gasless nozzle 5 Load wire into machine and thread into gun and cable per Welding Wire Loading section REPLACEMENT PARTS Complete Gun and Cable Assembly Code 10488 and 10489 only L10738 Complete Gun and Cable Assembly Code 10490 and above only L10744 Contact Tip 025 0 6 mm S18704 1 Contact Tip 030 0 8 mm S18704 2 Con...

Page 34: ...passages causing the welder to run hot Blow dirt out of the welder with low pressure air at regular intervals to eliminate excessive dirt and dust build up on interval parts WIRE FEED COMPARTMENT 1 When necessary vacuum accumulated dirt from gearbox and wire feed section 2 Occasionally inspect the incoming guide tube and clean inside diameter if necessary 3 Motor and gearbox have lifetime lubricat...

Page 35: ...hield process the gasless nozzle should be screwed 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 gun tube s...

Page 36: ...he machine to its rated input power per instructions in Installation section 2 Release 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 an...

Page 37: ...ully seat the liner bushing into the con nector Tighten the set screw on the brass cable connector At this time the gas dif fuser should not be installed onto the end of the gun tube 7 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 Figure D 2a or D 2b Remove any burrs from the end of the liner 8 Screw the ...

Page 38: ...e GUN HANDLE PARTS red trigger The gun handle consists of two halves that are held together with a collar on each end To open up the handle turn the collars 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...

Page 39: ... Authorized Field Service Facility If you do not understand or are unable to perform the Recommended Course of Action safely contact your local Lincoln 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 to the technician and...

Page 40: ...on section Electrical Connections 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 tripped due to overheating Let machine cool Weld at lower duty cycle 2 Check for obstructions in air flow 3 Check Gun Trigger connections See Installation section 4 Gun trigger may be faulty RECOMMENDED COURSE OF ACTION ...

Page 41: ...ld Service Facility FEEDING PROBLEMS If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your LOCAL AUTHORIZED LINCOLN ELECTRIC FIELD SERVICE FACILITY for assistance before you proceed CAUTION PROBLEMS SYMPTOMS Low or no gas flow when gun trigger is pulled Wire feed weld output and fan operate normally POSSIBLE AREAS OF MISADJUSTMEN...

Page 42: ...chine See Installation sec tion Electrical Input Connections 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 s...

Page 43: ... persons should install use or service this machine Do not operate with covers removed Disconnect input power before servicing Do not touch electrically live parts N A N D N D CR1 221 220 CR1 M18931 SP 170 I WIRING DIAGRAM TAB TERMINAL TINNED BRASS TAB TERMINAL H1 N D BOLTED ALUMINUM CONNECTIONS REQUIRE N B DIODES D2 D4 D6 D8 ARE MOUNTED ON TO THE CENTER PANEL THE INSIDE HEATSINK WHICH IS CLOSEST ...

Page 44: ...NOTES SP 170 I ...

Page 45: ...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 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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