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G-9

ELECTRICAL DIAGRAMS

SP-100

MACHINE SCHEMATIC: Codes Below 9794

LAST NO. USED

L

D

C

R

N.A.   SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE

WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY

NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE

NUMBER.

GENERAL INFORMATION

f

VOLTAGE NET

SUPPLY

(connector cavity representations)

NOTES :

DIODES = 1A, 400V (UNLESS OTHERWISE SPECIFIED)

RESISTORS = Ohms (1/4W UNLESS OTHERWISE SPECIFIED)

CAPACITORS =   d (.022/50V UNLESS OTHERWISE SPECIFIED)

ELECTRICAL SYMBOLS PER E-1537

LABELS

FRAME CONNECTION

POWER SUPPLY SOURCE POINT

EARTH GROUND CONNECTION

COMMON CONNECTION

1 %

W

7619

SCHEMATIC

2 0 3

2 0 3

2 0 3

B

6 A

1 0 0 V

Q 7

1

3

2

W I R E
F E E D
M O T O R

4 7 . 5

R62

G E N E R A L   I N F O R M A T I O N

. 5
5 W

R 7 2

1 W

1 6 V

D Z 3

3 3 0 0
5 0 V

C 2 3

1 0 K

R71

5 3 9

J 2

2

5 4 1

J 2

1

1 W

4 3 V

D Z 4

3 A
2 0 0 V

D 1 5

1 . 0
3 5 V

C 8

2 0 8

J 2

1 0

+ 1 5 V

2 0 3

J 2

6

X 2

1

3

2

1 0 0 K

R 5 3

S P E E D

2 2 . 1 K

R 3 9

5 K

R2

2 W

L M 2 2 4

X 3

4

1 1

1 0 0 K

R54

L M 2 2 4

X 2

4

1 1

C W

2 K

R40

D 1 3

D 2 0

C 1 3

1 . 0 0 K

R41

1 8
1 5 V

C 1 5

1 5 . 0 K

R36

1 0 K

C W

R56

2

3

1

+ 1 5 V

S H U T D O W N

X 2

1 4

1 2

1 3

1 0 0 K

R 5 2

+ 1 5 V

3 9 2 K

R 4 4

2 0 9

J 2

7

2 0 3

2 . 2 1 K

R 4 9

1 . 0 0 M

R43

C 1 6

3 9 . 2 K

R35

1 0 0 K

R 4 2

D 1 2

L A T C H

J 1

1

3

6

1 . 0 0 K

R55

C 2 6

C 1 4

3 0 V

2 0 0 m A

Q 2

1

3

2

2 2 . 1 K

R38

1 0 K

R57

O U T P U T

1 . 8
2 0 V

C 1 9

3 2

1 . 0 0 K

R58

X 3

8

9

1 0

S W I T C H

1 1 5 V A C

6 0   H Z

3 2

T O   G N D .

D 1 4

S 1

L 2

L 1

B 5 3 1

O V E R C U R R E N T

P 2

J 2

4

T 1

3 0 0 V

8 5 A

D 1

D 2
8 5 A
3 0 0 V

D 3
8 5 A
3 0 0 V

D 4
8 5 A
3 0 0 V

4 0 V

C 1

5 9 K

P 2

J 2

3

5 0 0 m A

3 0 0 V

Q 1

2 4 V

T 1

3

5

4

6

2

1

1 N 9 1 4

D 1 0

6 8 . 1 K

R20

O C I 2

1

2

3 3 . 2 K

R21

5 6 . 2 K

R30

5 6 2

R23

1 0 0 V

. 1

C 7

1

6

1 . 3 K

R18

7619

C O N N E C T O R   C A V I T Y   N U M B E R I N G   S E Q U E N C E

( V I E W E D   F R O M   C O M P O N E N T   S I D E   O F   B O A R D )

2 0 5

J 1

4

X 1

7

6

5

D 9

1 . 3 K

R 1 5

+ 1 5 V

+ 1 5 V

L

2 0 6

J 1

5

L M 2 2 4

X 1

4

1 1

C 1 1

X 1

1 4

1 3

1 2

O C I 1

1

2

5 6 . 2 K

R 2 5

V O L T S

B U R N B A C K

P W M

F I R I N G

S C R

A R C

5 K

A R C   V O L T A G E

C O N T R O L

S O L E N O I D

F E E D B A C K

E R R O R   A M P L I F I E R

D 1 1

G A S

C 2 4

5 6 . 2 K

R 1 7

X 1

8

1 0

9

A R C   V O L T A G E

2 W

C 9

6 8 . 1 K

R 1 4

S A W T O O T H

M O T O R

2 . 2 1 K

R31

2 . 2 1 K

R47

5 6 . 2 K

R 2 9

5 0 0 m W

5 . 1 V

D Z 2

2 6 7 K

R22

5 6 2

R24

2 . 2 1 K

R 2 8

5 0 0 m W

1 0 V

D Z 1

2

1

2 2 . 1 K

R 1 2

1 . 0 0 K

R26

2 0 7

J 1

1

1 . 0
3 5 V

C 1 0

C 1 2

1 . 0 0 K

R27

X 3

5

7

6

8 2 . 5 K

R 1 3

O N - O F F

+ 1 5 V

X 2

6

7

5

5 %

G A S
S O L E N O I D

M O T O R

1 . 3 K

R 1 6

F E E D B A C K

S P E E D

1 2 0 V A C

S E T

L O A D   C U R R E N T

. 5
5 W

R 6 9

F E E D B A C K

V O L T A G E

M O T O R
S T O P

5

1 0

J 2

E L E C T R I C A L   S Y M B O L S   P E R   E 1 5 3 7
C A P A C I T O R S   =   M F D / V O L T   ( . 0 2 2 / 5 0 V , U N L E S S   O T H E R W I S E   S P E C I F I E D )
R E S I S T O R S   =   O H M S   ( 1 / 4 W A T T , U N L E S S   O T H E R W I S E   S P E C I F I E D )
D I O D E S   =   1 A / 4 0 0 V   ( U N L E S S   O T H E R W I S E   S P E C I F I E D )

=   C O M M O N   C O N N E C T I O N

=   S O U R C E   P O I N T   C I R C U I T   L O C A T I O N

2 N 4 1 2 3

Q 5

4 . 7 5 K

R11

+ 1 5 V

1 . 0 0 K

R70

R1

+ 1 5 V

2 2 . 1 K

R 6 1

1 0 0 K

R 5 9

X 1

1

3

2

6 . 8 1 K

R 1 9

2 2 . 1 K

R60

X 3

1 4

1 2

1 3

2 N 4 1 2 3

Q 4

3 0 0 V

5 0 0 m A

Q 6

1 . 0 0 K

R 5 1

1 0 K

R 5 0

D 8

D 7

1 / 2 W

2 7

R 9

D 5

D 4

D 6

D 3

4 7 . 5 K

R10

G N D

I N

O U T

X 4

2 W

2 7

R6

1 / 2 W

1 0 0 0

R 2

D 1

1 / 2 W

1 5 0

R 3

. 0 0 4 7
1 4 0 0 V

C 1

1 4 0 0 V

. 0 0 4 7

C 2 5

. 1
4 0 0 V

C 3

B 3 1 A

2 W

1 0 K

R7

4 0 0 V

. 1

C 2

1 / 2 W

1 K

R8

1 5 0 V
4 5 J

T P 2

F I R I N G

R E G U L A T O R

V O L T A G E

C 4

1 / 2 W

1 0 0

R 5

G A S   S O L E N O I D

B 7

C O N T R O L

3 1

3 1 A

1 1 5 A C

M O T O R

F A N

B R E A K E R

C I R C U I T

3 0 A

+ 1 5 V   S U P P L Y

2 4 V A C

+ 1 5 V

1 5 0
5 0 V

C 5

D 1 8

4 . 7
3 5 V

C 6

2 5 0 0 D

T R I 1

2 W

1 2 0

R 1

6 0 0 V

5 5 A

S C R 1

3

2

1

O C I 1

4

6

6 0 0 V

5 5 A

S C R 2

3

1

2

O C I 2

6

4

M C 7 8 1 5 C T D S

P 1

J 1

3

D 1 9

S C R

D 2

1 / 2 W

1 0 0 0

R 4

B 3 2 A

O S C I L L A T O R

P W M

E R R O R
A M P

C H O K E

2 1 3

J 2

8

D 1 7

1 0 K

R 7 4

W E L D I N G
P O W E R

O U T P U T

3 A
2 0 0 V

D 1 6

8 0

1 5 W

R32

2 0 3

1 0 K

R 6 6

2 0 4

1 0 K

R68

S W I T C H

S 2

T H E R M O S T A T

T R I G G E R

+ 1 5 V

1 5 . 0 K

R67

2 1 1

J 2

9

1 0 0 V

. 2 2

C 2 2

+ 1 5 V

X 3

1

2

3

C 2 1

2 N 4 1 2 3

Q 3

1 5 . 0 K

R63

1 . 0 0 K

R34

1 . 0 0 K

R37

1 5 . 0 K

R64

+ 1 5 V

C 2 0

8 0
1 5 W

R33

6 . 8 1 K

R 6 5

W I R E

L E A D   C O L O R   C O D E

X 2

9

8

1 0

2 0 4

3 . 3 2 K

R46

2 6 7

R 7 5

B   -   B L A C K

W   -   W H I T E

D 2 1

4

1 0 K

R 7 3

1 . 0 0 K

R48

4 . 7
3 5 V

C 1 7

1 . 0
3 5 V

C 1 8

1 8 . 2 K

R 4 5

1 / 2 W

1 / 2 W

75

21

DZ4

SP 100 WELDERS

7-27-90J

NOTE:  This machine schedmatic is provided for reference only and may not be totally applicable to every code covered

in this manual.

Retur

n to Section TOC

Retur

n to Section TOC

Retur

n to Section TOC

Retur

n to Section TOC

Retur

n to Master TOC

Retur

n to Master TOC

Retur

n to Master TOC

Retur

n to Master TOC

Содержание SP-100

Страница 1: ... CONTAINED THROUGHOUT And most importantly think before you act and be careful For use with machines having Code Numbers 9284 10050 RETURN TO MAIN INDEX Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC View Safety Info View Safety Info View Safety Info View Safety Info Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S...

Страница 2: ...ead nozzle or semiautomatic welding gun are also electrically hot 1 d Always be sure the work cable makes a good electrical connection with the metal being welded The connection should be as close as possible to the area being welded 1 e Ground the work or metal to be welded to a good electrical earth ground 1 f Maintain the electrode holder work clamp welding cable and welding machine in good saf...

Страница 3: ...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 4 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 Welding and Cutting ANSI Standard Z49 1 and the...

Страница 4: ...ntilated areas or vent the engine exhaust fumes outdoors ____________________________________________________ 7 c Do not add the fuel near an open flame welding arc or when the engine is running Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting Do not spill fuel when filling tank If fuel is spilled wipe it up...

Страница 5: ...imité au soudage à l aide d écrans appropriés 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...

Страница 6: ...Maintenance Section D Safety Precautions D 1 Items Requiring No Maintenance D 1 Routine and Periodic Maintenance D 1 Component Replacement Procedures D 2 Location of Components D 4 Theory of Operation Section E Input Line Voltage Fan Motor and Main Transformer E 1 Output Control Rectification and Voltage Feedback E 2 Trigger Gas Solenoid and Wire Drive E 3 SCR Operation E 4 Thermal Protection E 5 ...

Страница 7: ...Installation A 3 Work Cable Installation A 3 Gun Installation A 4 Connecting Gun Cable to the SP 100 A 4 Gas Connection A 4 Input Connections A 5 Code Requirements For Input Connections A 6 Requirements For Rated Output A 6 Requirements For Maximum Output A 6 Requirements For CSA Rated Output A 6 Extension Cord Usage A 6 Section A TABLE OF CONTENTS INSTALLATION SECTION SP 100 Return to Master TOC ...

Страница 8: ...Amp 12 15 Amp 125V 3 3 mm2 Three Prong Plug For lengths up to NEMA Type 5 15P 50 Ft 15 m TECHNICAL SPECIFICATIONS SP 100 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 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 ...

Страница 9: ...embly 1 3 Literature envelope which contains a This operating manual b A contact tip for 030 0 8 mm diameter wire 4 10 ft 3 0 m work cable 5 Work clamp 1 Gun is ready to feed 025 0 6 mm diameter wire also 023 and 024 diameter wire ELECTRIC SHOCK can kill Only qualified personnel should perform this installation Only personnel that have read and under stood the SP 100 Operating Manual should instal...

Страница 10: ...hine may topple over if this procedure is not followed 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 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 cab...

Страница 11: ...as possible to the inside panel If the gun trigger switch being used is other than that supplied with the SP 100 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 100 may result if this switch shorts to the SP 100 welding output circuit or is common to any electrical circuit other than the SP 100 trigger...

Страница 12: ...ot 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 and earth ground FIGURE A 5 2 With the cylinder securely installed remove the cylinder cap Stand to one side away from the out let an...

Страница 13: ...inal voltage rating of 115 to 125 volts 60 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 REQUIREMENTS FOR MAXIMUM OUTPUT An optional power cord K467 Input Line Cord is available to permit the SP 100 to be connected to a 25 amp branch circuit with a nominal voltage rating of 115 to 125 volts 60 Hertz AC only Wi...

Страница 14: ...A7 NOTES SP 100 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Страница 15: ...nd Advantages B 2 Welding Capability B 2 Limitations B 2 Controls and Settings B 2 Welding Operations B 3 Process Guidelines B 3 Sequence of Operations B 3 Wire Loading B 3 Friction Brake Adjustments B 4 Wire Threading B 4 Shielding Gas B 5 Making a Weld B 5 Cleaning Tip and Nozzle B 6 Changing Machine Over To Feed Other Wire Sizes B 6 Welding With Innershield B 6 Overload Protection B 6 Output Ov...

Страница 16: ...ectrically 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 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...

Страница 17: ...ntil gun trigger is pressed for an added measure of safety Overload protection incorporates both a thermo 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 ...

Страница 18: ...n welding of 20 gauge through 5 16 1 0 8 0 mm thick steel multi ple passes are required for 1 4 and 5 16 6 0 and 8 0 mm SEQUENCE OF OPERATION WIRE LOADING Refer to Figure B 2 and B 3 The machine power switch 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 8 200 mm diameter spools 2 2 56 mm max width These sp...

Страница 19: ...lease the wire until after step 5 3 Cut the bent portion of wire off and straighten the first 4 100 mm 4 Thread the wire through the In going guide tube 4 over the drive roll 3 and into the out going guide tube 5 5 Close the idle roll arm and latch the spring loaded pressure arm 2 in place now you may release the welding wire 6 The idle roll pressure adjustment wing nut is nor mally set for mid po...

Страница 20: ...er stops moving open the valve fully FIGURE B 6 FIGURE B 5 Gun Handle Gas Diffuser Contact Tip Gas Nozzle WARNING 2 If using a regulator with an adjustable flow meter close the gun trigger and adjust the flow to give 15 20 cubic ft per hour CFH 7 10 I min use 20 25 CFH 10 12 I min when welding out of position or in a drafty location for CO2 For argon mixed gas trigger to release gas pressure and t...

Страница 21: ...over to other sizes Refer to Changing the Contact Tip and Changing the Drive Roll in the MAINTENANCE sec tion for specific information on these procedures WELDING WITH INNERSHIELD Welding with Innershield requires an Innershield Welding Kit A gasless nozzle is provided in the Innershield Welding Kit When using Innershield elec trode installing the gasless nozzle will improve visibili ty of the arc...

Страница 22: ...B 7 SP 100 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTES ...

Страница 23: ...SP 100 Section C TABLE OF CONTENTS ACCESSORIES SECTION Accessories Section C Accessories C 1 Replacement Parts C 1 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Страница 24: ...0 K463 CO2 Regulator The K463 kit includes a preset non adjustable pressure flow regulator for use on CO2 cylinders The K463 CO2 pressure flow regulator is preset at the factory to pro vide a flow rate of 20 cubic feet per hour 10 l min This setting cannot be changed Also included is a 10 foot 3 0 m gas hose which connects to the rear of the SP 100 The K463 CO2 pressure flow regulator can be used ...

Страница 25: ...nance D 1 Before Each Use D 1 After 5 Minutes of Welding D 1 After Each Spool of Wire Feed D 1 Component Replacement Procedures D 2 Changing The Contact Tip D 2 Changing Drive Roll D 2 Replace Liner D 3 Replace Internal Gun Handle Parts As Necessary D 3 Location of Components D 4 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Страница 26: ...accumulated dirt from gear box and wire feed section Refer to Figure D 4 Inspect the incoming guide tube and clean inside diameter if necessary Replace when excessively worn Replace Contact Tip when hole is enlarged or elongated refer to Changing Contact Tip below D 1 MAINTENANCE SAFETY PRECAUTIONS ELECTRIC SHOCK can kill Disconnect input power by removing plug from receptacle before work ing insi...

Страница 27: ...e the gas nozzle from the gun by unscrewing counter clockwise 2 Remove the existing contact tip from the gun by unscrewing counter clockwise 3 Insert and hand tighten desired contact tip 4 Replace gas nozzle CHANGING DRIVE ROLL The SP 100 Wire Feed Drive Roll 1 has two grooves one for 0 023 0 025 0 6 mm solid steel electrode and the other for 0 030 0 8 mm solid and 0 035 O 9 mm flux cored steel el...

Страница 28: ... can meet the liner cutoff length requirement Refer to Figure D 2 1 Remove gun and cable assembly from machine 2 Remove the gas nozzle from the gun by unscrewing counter clockwise 3 Remove the existing contact tip from the gun by unscrewing counter clockwise 4 Remove the gas diffuser from the gun tube by unscrewing counter clockwise 5 Lay the gun and cable out straight on a flat surface Loosen the...

Страница 29: ...aster TOC Return to Master TOC Return to Master TOC Return to Master TOC D 4 MAINTENANCE FIGURE D 4 LOCATION OF COMPONENTS 1 Case Back and Bottom Assembly 2 Center Panel Assembly 3 Case Front Assembly 4 Case Side Assembly 5 Rectifier Fan Motor Assembly 6 Wire Drive Assembly SP 100 SUB ASSEMBLIES 1 2 3 4 5 6 ...

Страница 30: ...SP 100 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC D 5 NOTES ...

Страница 31: ...r TOC SP 100 Theory of Operation Section E Input Line Voltage Fan Motor and Main Transformer E 1 Output Control Rectification and Voltage Feedback E 2 Trigger Gas Solenoid and Wire Drive E 3 SCR Operation E 4 Thermal Protection E 5 Section E TABLE OF CONTENTS THEORY OF OPERATION ...

Страница 32: ...t power is applied to the SP 100 through a receptacle located on the rear panel The input power is connected to the fan motor control board and main transformer through a line switch located on the front panel A circuit breaker is incorpo rated in the 115 vac circuit to protect the unit from current overloads The fan motor employs a 24 vac auxiliary winding which powers the control board The main ...

Страница 33: ...icon Controlled Rectifiers The SCR s are controlled by a pulse signal developed on the control board The control board compares the commands of the arc voltage control with the voltage feedback signal The board circuitry then sends a pulse to turn on the SCR s In this manner the voltage applied to the primary of the transformer is varied and controlled This variable and controlled voltage is FIGUR...

Страница 34: ...ed to the main transformer Output volt age is developed at the output terminals and fed back to the control board This welding output voltage is also used to power the wire drive motor FIGURE E 3 Trigger Gas Solenoid and Wire Drive The welding output voltage that powers the wire drive motor is varied and controlled on the control board The control board moni tors the drive motor armature current a...

Страница 35: ...me is longer resulting in greater SCR output If the gate firing occurs later in the cycle the conduction time is less resulting in lower SCR output SCR OPERATION A silicon controlled rectifier SCR is a three terminal device used to control large cur rents to a load An SCR acts very much like a switch When it is turned on there is cur rent flow from anode to cathode In the ON state the SCR acts lik...

Страница 36: ...the duty cycle and output rating If excessive operating temperature should occur the thermostat will prevent voltage and wire drive The fan will remain on during this period The thermostat is self resetting once the machine cools sufficient ly If the thermostat shutdown is caused by excessive output or duty cycle and the fan is running normally the power switch may be left on and the reset should ...

Страница 37: ...bleshooting Procedures F 2 Troubleshooting Guide F 3 Output Problems F 3 Feeding Problems F 6 Gas Flow Problems F 7 Welding Problems F 7 PC Board Connector Locations F 8 Oscilloscope Waveforms Normal Open Circuit Voltage Waveform F 9 Typical Output Voltage Waveform Machine Loaded F 10 Abnormal Open Circuit Voltage Waveform F 11 Replacement Procedures Fan Blade and Motor Removal F 12 Wire Drive Ass...

Страница 38: ...nts check the components in the order listed to eliminate one possibility at a time until you locate the cause of you problem All the needed test specifications and repair procedures are described in detail on the referenced pages All the needed electrical test points terminal strips junctions etc can be found on the referenced electrical wiring diagrams and schematics See Electrical Diagram Secti...

Страница 39: ... reports are to be submitted NOTE Following this procedure and writing on the warranty report INSTALLED AND Switched PC BOARDS TO VERIFY PROB LEM will help avoid denial of legitimate PC board warranty claims ELECTRIC SHOCK can kill Have an electrician install and service this equip ment Turn the input power OFF and unplug the machine before work ing on equipment Do not touch electrically hot parts...

Страница 40: ...otor See wiring dia gram 2 If 115 vac is not present at leads 31 to 32 then check the power switch and input line cord SI 1 Check voltage from leads 202 to 201 at the output diode heat sinks Normal voltage is from 2 vac to 20 VAC depending on arc voltage control setting If the cor rect AC voltage is present check the output diodes and connec tions Also check the output ca pacitor C1 See wiring dia...

Страница 41: ... drive compartment Normal OCV is from 10 vdc to 28 vdc depending on arc voltage control setting If correct OCV is present check gun and work cable 2 If correct OCV is not present at the output terminals then check for broken leads at the output choke or at the positive output terminal 1 Remove main power supply to SP 100 With gun trigger pulled check for continuity zero ohms from 8J2 lead 213 to 9...

Страница 42: ...ger may be faulty RECOMMENDED COURSE OF ACTION 1 Check for 24 vac at plug 2J1 to 6J1 on the control board If volt age is not present check conti nuity of leads to fan motor If leads are OK replace fan motor See Figure F 1 2 Remove main power supply to SP 100 With gun trigger pulled check for continuity zero ohms from 8J2 lead 213 to 9J2 lead 211 at harness plug If zero ohms is indicated then trig ...

Страница 43: ...ged cable liner or feeding problems 1 Make sure that the wire speed control is not set at maximum RECOMMENDED COURSE OF ACTION 1 Check for a DC voltage at wire drive motor armature leads 539 to 541 The voltage should be between 2 vdc and 10 vdc This voltage will vary with the wire speed control setting If the correct voltage is present the drive motor may be faulty Replace See wiring diagram 2 If ...

Страница 44: ...voltage is present but the solenoid does not activate replace solenoid See wiring dia gram 2 If voltage is not present at leads 7 to 32A remove main supply power to machine Test leads 7 and 32A for continuity zero ohms to the control board 3 Control board may be faulty Replace GAS FLOW PROBLEMS PROBLEMS SYMPTOMS Arc is unstable Poor starting POSSIBLE AREAS OF MISADJUSTMENT S 1 Check for correct in...

Страница 45: ...to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F 8 TROUBLESHOOTING REPAIR PC BOARD CONNECTOR LOCATIONS FIGURE F 1 Codes 9794 and above Codes below 9794 6J1 10J2 1J1 1J2 6J1 10J2 1J1 1J2 ...

Страница 46: ...utput voltage waveform generated from a properly operating machine Note that each vertical division represents 10 volts and that each hor izontal division represents 20 milliseconds in time Note Scope probes connected at machine output ter minals Positive probe to terminal negative probe to terminal NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM 0 volts 10 volts Div 20 ms Div C1 Volts Div 10 Div Horizontal ...

Страница 47: ...ting machine Note that each vertical division represents 10 volts and that each hor izontal division represents 20 milliseconds in time The machine was loaded with a resistance grid bank The ammeter read 90 amps and the voltmeter read 19 vdc Note Scope probes connected at machine output ter minals Positive probe to terminal negative probe to terminal TYPICAL OUTPUT VOLTAGE WAVEFORM MACHINE LOADED ...

Страница 48: ... disconnected from the circuit Note the increased ripple in the waveform This condi tion simulates the faulty output filter capacitor Each vertical division represents 10 volts and that each hor izontal division represents 20 milliseconds in time Note Scope probes connected at machine output ter minals Positive probe to terminal negative probe to terminal ABNORMAL OPEN CIRCUIT VOLTAGE WAVEFORM 0 v...

Страница 49: ...ads and one small blue lead from the large choke lead 4 Remove leads 211 and 212 from the thermostat located on the diode heat sink 5 Remove the four leads from the fan motor noting their positions TWO LEADS ON CODES BELOW 9794 6 Remove the three wires connected to the input receptacle Note lead placement and connections L1 L2 and green ground lead 7 Remove the four self tapping screws holding the...

Страница 50: ...OCEDURE Refer to Figure F 5 1A FOR CODES ABOVE 10000 Cut heads off of two plastic fastener buttons locat ed on the front panel Order new fastener buttons Part No T14659 3 1B FOR CODES BELOW 10000 Remove two flat head screws holding conductor block to front panel 2 Remove gas hose from Connector block 3 Remove cable running from output terminal to Connector block 1 4 With 5116 nutdriver remove moun...

Страница 51: ...cal characteristics or if any electrical components are repaired or replaced the machine must be retested MAIN TRANSFORMER SECONDARY VOLTAGES INPUT AMPS AT RATED OUTPUT OPEN CIRCUIT VOLTAGES WIRE SPEED RANGE TEST POINTS VOLTAGES LEADS 201 202 2 20 vac Dependent on arc voltage control Located on Output Diode Heat Sinks setting min to max TEST POINTS VOLTAGES OUTPUT TERMINALS 10 to 27 vdc Dependent ...

Страница 52: ...SP 100 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F 15 NOTES ...

Страница 53: ...ONTENTS ELECTRICAL DIAGRAMS SECTION Electrical Diagrams Section G SP 100 Wiring Diagram codes 9794 and above G 2 SP 100 Wiring Diagram codes below 9794 G 3 Control PC Board G1842 Components G 4 Control PC Board G2314 Components G 6 Machine Schematic codes 9794 and above G 8 Machine Schematic below code 9794 G 9 ...

Страница 54: ... I R E S P E E D 2 0 5 2 0 6 2 0 7 5 K 3 2 J 1 J 2 C O N N E C T O R C A V I T Y N U M B E R A R C V O L T A G E R 1 R 2 W B 7 3 2 A N A N C O N O F F N C N D N D 2 4 V A C A U X W D G N O T E S N A D I O D E S D 1 D 3 A R E M O U N T E D O N T H E O U T S I D E H E A T S I N K N C C O M P O N E N T V I E W E D F R O M R E A R HIGH VOLTAGE can kill O n l y q u a l i f i e d p e r s o n s s h o u l...

Страница 55: ...2 0 3 2 0 9 2 1 3 2 0 8 2 1 1 5 3 1 3 1 A T 1 W I R E F E E D M O T O R 2 1 2 2 1 3 2 1 1 G U N T R I G G E R T H E R M O S T A T M O U N T E D T O D I O D E H E A T S I N K 2 0 8 2 0 9 2 0 3 5 K W I R E S P E E D 2 0 5 2 0 6 2 0 7 5 K 3 2 J 1 J 2 C O N N E C T O R C A V I T Y N U M B E R A R C V O L T A G E R 1 R 2 W B 7 3 2 A H I L O N B N A N C N C N C C O M P O N E N T V I E W E D F R O M R E ...

Страница 56: ...invalidate your factory warranty This Printed Circuit Board schematic is provided for reference only It may not be totally applicable to your machine s specific PC board version This diagram is intended to provide general information regarding PC board function Lincoln Electric discourages board level trou bleshooting and repair since it may compromise the quality of the design and may result in D...

Страница 57: ...F 0 1 100V 10 C22 CAPACITOR PEF 0 22 100V 10 C1 C25 CAPACITOR CD 0047 005 1400V 20 C2 C3 C27 CAPACITOR PEF 0 1 400V 1o DZ3 ZENER DIODE 1W 16V 5 1N4745A DZ1 ZENER DIODE 1W 10V 5 1N4740A DZ4 ZENER DIODE 1W 43V 5 1N4755A DZ2 ZENER DIODE 1W 5 1V 5 1N4733A Q2 Q3 Q4 Q5 TRANSISTOR N T226 0 5A 40V 2N4401 D15 D16 DIODE AXLDS 3A 200V 1N54o2 D10 DIODE AXLDS 0 15A 75W 1N914 B31A B531 CONNECTOR TAB QC VERTICAL...

Страница 58: ...lidate your factory warranty This Printed Circuit Board schematic is provided for reference only It may not be totally applicable to your machine s specific PC board version This diagram is intended to provide general information regarding PC board function Lincoln Electric discourages board level trou bleshooting and repair since it may compromise the quality of the design and may result in Dange...

Страница 59: ...ITOR PEF 0 22 100V 10 C1 C25 CAPACITOR CD 0047 005 1400V 20 C2 C3 C27 CAPACITOR PEF 0 1 400V 10 DZ3 ZENER DIODE 1W 16V 5 1N4745A DZ1 ZENER DIODE 1W 10V 5 1N4740A DZ4 ZENER DIODE 1W 43V 5 1N4755A DZ2 ZENER DIODE 1W 5 1V 5 1N4733A Q2 Q3 Q4 Q5 TRANSISTOR N T226 0 5A 40V 2N4401 D15 D16 DIODE AXLDS 3A 200V 1N5402 D10 DIODE AXLDS 0 15A 75V 1N914 B31 A B531 CONNECTOR TAB QC VERTICAL 1 4 B7 B32 CONNECTOR ...

Страница 60: ...C I L L A T O R S H U T D O W N 2 0 3 P W M 1 00K R 7 0 X 3 14 12 13 22 1K R 3 8 C 2 6 X 3 8 9 10 4 0 V 6 0 0 m A Q 2 5 0 0 m A 3 0 0 V Q1 C14 X 3 1 2 3 22 1K R 6 0 3 3 0 0 5 0 V C 2 3 3 A 2 0 0 V D16 10K R 7 1 2 K R 3 7 2 K R 8 3 D19 2 0 4 15V 15V 15V 15V S U P P L Y 1 0 J 2 5 L E A D C O L O R C O D E B B L A C K M F D 1 A 4 0 0 V 3 1 8 0 15W R 3 2 D 2 211 J 2 9 P 2 J 2 3 3 01K R 3 4 3 01K R 8 1...

Страница 61: ... D F E E D B A C K E R R O R A M P L I F I E R D 1 1 G A S C 2 4 5 6 2 K R 1 7 X 1 8 1 0 9 A R C V O L T A G E 2 W C 9 6 8 1 K R 1 4 S A W T O O T H M O T O R 2 2 1 K R 3 1 2 2 1 K R 4 7 5 6 2 K R 2 9 5 0 0 m W 5 1 V D Z 2 2 6 7 K R 2 2 5 6 2 R 2 4 2 2 1 K R 2 8 5 0 0 m W 1 0 V D Z 1 2 1 2 2 1 K R 1 2 1 0 0 K R 2 6 2 0 7 J 1 1 1 0 3 5 V C 1 0 C 1 2 1 0 0 K R 2 7 X 3 5 7 6 8 2 5 K R 1 3 O N O F F 1...

Страница 62: ...__________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ _____________________________________________________________...

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