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ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or

electrode with skin or wet clothing.

• Insulate yourself from work and

ground.

• Always wear dry insulating gloves.

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

FUMES AND GASES can be danger-

ous.

• 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 containers.

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

ARC RAYS can burn eyes and skin.
• Wear eye, ear and body 

protection.

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

See additional warning information at

front of this owners manual.

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

K499 Argon-Mixed Gas Regulator and Hose Kit

Install the pressure-flow regulator and gauge to a
cylinder according to the instructions in Section 1.10.
Connect one end of the 10 foot (3.0 m) hose to the
SP-100 gas inlet fitting and the other end to the regu-
lator fitting.

The K499 argon-mixed gas pressure-flow regulator is
preset by the manufacturer to deliver a nominal flow of
30 cubic feet per hour (14 1/min) of argon or argon-
mixed gas. This setting cannot be changed.

.035" (0.9 mm) Innershield Welding Kit

Includes a contact tip, gasless nozzle, and a cable
liner to permit the SP-100 gun and cable to use .035
(0.9 mm) diameter flux-cored electrode. Also included
is a spool of .035 (0.9 mm) Innershield

®

NR-211-MP.

The

K549-1 Kit

is for use with the Magnum™ 100L

gun (with red trigger). The fitting on the end of the
liner is stenciled with the maximum rated wire size
(.045"/1.2 mm).

The

K464 Kit

is for use with the earlier “Lincoln

Electric

®

” gun (with black trigger). The end of the brass

fitting on the end of the liner for .035 (0.9 mm) wire is
color coded green. The .023-.030 (0.6-0.8 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 Switch to OFF (“O”).

2. If connected, remove the line cord plug from power

supply receptacle.

3. Remove the two screws that hold the line cord

receptacle in the SP-100 flanged inlet connector
and disconnect the line cord from the SP-100.

4. Connect the S18410 input line cord receptacle to

the SP-100 and replace the retaining screws.

OPERATING INSTRUCTIONS

DUTY CYCLE

The SP-100 is rated at the following duty cycles.

(1)

Based upon 10 minute time period. (i.e. for 20% duty cycle it is 2
minutes on and 8 minutes off.)

(2)

Using Optional K467 Input line cord on a 25 amp branch circuit.

SELECTING A WIRE SPOOL SIZE

Select a spool size so that the wire is used up within a
six month period. This eliminates needless waste of
wire due to oxidation and rusting. Dirty, oxidized, or
rusty wire results in poor wire feeding and poor weld-
ing performance. This wire should be discarded.

FEEDING WELDING WIRE

When inching the welding wire, the drive rolls, the
gun connector block and the gun contact tip are
always energized relative to work and ground and
remain energized several seconds after the gun
trigger is released.

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

1. Remove gas nozzle and contact tip from end of gun

according to instructions in the maintenance sec-
tion of this manual.

2. Turn the SP-100 ON (“I”).
3. Straighten the gun cable assembly.

–

13

–

Duty

Condition

Cycle

(1)

Amps

Volts

Rated Output

20%

90

18

Maximum

Output

(2)

30%

100

17

CSA Rated Output

20%

63

20

WARNING

WARNING

Содержание SP-100

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 27: ......

Страница 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...

Страница 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...

Страница 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 ...

Страница 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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