Lincoln Electric SP-175 PLUS IM790 Operator'S Manual Download Page 42

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E-3

SP-175 PLUS

E-3

TROUBLESHOOTING

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)

No wire feed when gun trigger is
pulled. Fan runs, gas flows and
machine has correct open circuit
voltage (33 VDC maximum) – weld
output.

Wire feed speed motor runs very
fast. Weld output, gas flow and fan
operate normally.

POSSIBLE AREAS OF
MISADJUSTMENT(S)

1. If the wire drive motor is running

check to see if the correct wire
is in the machine.

2. If the wire drive motor is running

make sure that the correct drive
rolls are installed in the
machine.

3. Check for clogged cable liner or

feeding problems.

4. Check brake adjustment (could

be too tight).

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.

2. Check gun connection to

machine for obstruction or leaky
seals.

RECOMMENDED
COURSE OF ACTION

Contact your local Lincoln
Authorized Field Service Facility.

GAS FLOW PROBLEMS

Observe Safety Guidelines detailed in the beginning of this manual.

Summary of Contents for SP-175 PLUS IM790

Page 1: ...EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT And most importantly think before you act and be careful For use with machine Code Numbers 10542 10743 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...

Page 2: ...EMAKER 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 a...

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 wel...

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: ...opriés et non inflammables 4 Des gouttes de laitier en fusion sont émises de lʼarc de soudage Se protéger avec des vêtements de protection libres de lʼhuile 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 lʼon pique le laitier 6 E...

Page 6: ...here 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 r...

Page 7: ...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 Troubles...

Page 8: ...T RECOMMENDED INPUT CABLE AND FUSE SIZES Height Width Depth Weight 12 0 in 9 75 in 16 5 in 60 Ibs 305 mm 248 mm 419 mm 27 3 kg PHYSICAL DIMENSIONS Standard Voltage Frequency Input Current 230V 60Hz 21 Amps Rated Output 208V 60Hz 23 Amps Rated Output Duty Cycle Amps Volts at Rated Amperes 30 Duty Cycle 230V 60Hz 130 20 30 Duty Cycle 208V 60Hz 130 20 Welding Current Range Maximum Open Circuit Voltag...

Page 9: ...d 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 175 Plus gun liner is ready to feed 023 0 6 mm 035 0 9 mm wire The contact tip is sized for 025 0 6 mm wire feeding ELECTRIC SHOCK can kill Only qualified personnel should perform this installation Only personnel that have read and under stood the SP...

Page 10: ...nnectors 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 through the...

Page 11: ...that supplied with the SP 175 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 175 Plus will result if this switch shorts to the SP 175 Plus welding output circuit or is common to any electri cal circuit other than the SP 175 Plus trigger circuit GAS CONNECTION Refer to Figure A 5 When using the GM...

Page 12: ...tions are 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 ...

Page 13: ... SP 175 Plus Use only grounded receptacle Do not touch electrically hot parts inside SP 175 Plus Have qualified personnel do the main tenance and troubleshooting work 230 Volt Input Connection The SP 175 Plus is shipped from the factory connect ed for 230 volt input power If the welder has been reconnected for 208 volt input power and 230 volt input is desired perform the following reconnection in...

Page 14: ...from 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 ma...

Page 15: ...e output control Cold electrode until gun trigger is pressed for an added measure of safety Overload protection incorporates both a thermostat and a circuit breaker Quality wire drive with electronic overload protection Easy to set continuous range controls for precise setting of arc voltage and wire speed Quick Release idle roll pressure arm is easily adjusted Reversible dual groove drive roll Dr...

Page 16: ...e parts FIGURE B 2 B 3 SP 175 PLUS B 3 OPERATION FIGURE B 1a Refer to Figure B 1b 4 Circuit Breaker Protects machine from damage if maximum output is exceeded Button will extend out when tripped Manual reset 5 Optional K695 2 Spot Stitch Controls see ACCES SORIES section If present replaces Blank Panel Assembly located on the center panel inside the case door Mode Switch Selects between Spot Stitc...

Page 17: ...essure 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 the wir...

Page 18: ...re and shielding gas 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 175 Plus controls 3 Set the Voltage V and Wire Speed oloʼ 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 C...

Page 19: ...um 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 175 Plus Welding Procedures CHANGING MACHINE OVER TO FEED OTHER WIRE SIZES The SP 175 Plus is shipped from the factory with a ...

Page 20: ...ntil 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 175 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 th...

Page 21: ... 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 with eyes...

Page 22: ... 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 Fl...

Page 23: ...hat you will be able to weld the material In addition aluminum and stainless steel can be welded using an aluminum welding kit For further information on identifying vari ous 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 24: ...tical 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 Ve...

Page 25: ...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 ʻʼolo ʼʼ 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...

Page 26: ...stickout 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 T...

Page 27: ... Correct 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 cor...

Page 28: ...tery 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 Le...

Page 29: ...mm Electrode Lincolnweld 0 030 L 56 electrode CO2 or 75 25 Ag CO2 Voltage Setting V E Wire Feed Speed o o 5 For the SP 175 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...

Page 30: ...m 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 Decrease trave...

Page 31: ...ot 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 32: ...B 19 B 19 APPLICATION CHART SP 175 PLUS ...

Page 33: ...red 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 the welder See Gas Connection in Installation section for installation instructions 3 K1799 1 Argon Mixed Gas Adjustable ...

Page 34: ...and install gasless nozzle To remove simply unscrew REPLACEMENT PARTS Complete Gun and Cable Assembly L8311 6 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 Tapered 035 0 9 mm S20278 3 Contact Tip Tapered 045 1 2mm S20278 4 Con...

Page 35: ...ece of wire Clean cable liner when rough and erratic wire feed ing occur MAINTENANCE D 1 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 blow out agai...

Page 36: ...r 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 bottoms Then unscrew no more than one t...

Page 37: ...5 0 6mm solid steel electrode and a larg er groove for 030 0 8mm solid and 035 0 9mm flux cored steel electrode As shipped the drive roll is installed in the 023 025 0 6mm position If 030 035 0 9mm 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...

Page 38: ...he cable Pull the liner out of the cable 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 con nector At this time the gas diffuser should not be installed onto the end of the gun tube 8 With the gas nozzle and...

Page 39: ...s 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 40: ...y exhibit Find the listing that best describes the symptom that the machine is exhibiting Step 2 POSSIBLE CAUSE The second column labeled POSSIBLE CAUSE lists the obvious external possibilities that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause generally it states to contact your local Lincoln Authorized Fie...

Page 41: ...D 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 machineʼs wire drive compartment Reset if tripped 2 The thermostat may be tripped due to overheating Let machine cool Weld within the duty cycle or remove any air obstruction to machine 3 Wire fe...

Page 42: ...chine 2 If the wire drive motor is running make sure that the correct drive rolls are installed in the machine 3 Check for clogged cable liner or feeding problems 4 Check brake adjustment could be too tight 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...

Page 43: ...YMPTOMS Arc is unstable Poor starting POSSIBLE AREAS OF MISADJUSTMENT S 1 Check for correct input voltage to machine 208 or 230 VAC 2 Check for proper electrode polarity for process 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 7 Check wire feed to assure smooth wire f...

Page 44: ...MPERED PLUG STANDARD SPOT STITCH TIMER OPTIONAL 215 215 213 J3 203 203 D4 D6 D1 204 204 C1 N D THERMOSTAT MOUNTED TO SEC COIL 31A 32 H1 H1 230V 208 230 60Hz GAS SOLENOID H1 H3 G CASE GROUNDING STUD TO EARTH GROUND PER NATIONAL LOCAL OR OTHER APPLICABLE ELECTRICAL CODES H3 208V N A DIODES D1 D3 D5 D7 ARE MOUNTED ON THE OUTSIDE HEATSINK N B DIODES D2 D4 D6 D8 ARE MOUNTED ON THE INSIDE HEATSINK CUSTO...

Page 45: ...NOTES ...

Page 46: ...letin ED 80 or call 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 b...

Page 47: ...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 48: ... 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 entretien Strom vor Wartungsarbeiten abschalten Netzstrom völlig öff nen Maschine anhalten Não opere co...

Page 49: ...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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