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E-4

TROUBLESHOOTING

E-4

SP-100T

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility

for technical troubleshooting assistance before you proceed.

CAUTION

Observe Safety Guidelines

detailed in the beginning of this manual.

TROUBLESHOOTING GUIDE

PROBLEMS
(SYMPTOMS)

Arc is unstable

–

Poor starting

POSSIBLE AREAS OF
MISADJUSTMENT(S)

1. Check for correct input voltage

to machine

–

115vac.

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 size.

RECOMMENDED
COURSE OF ACTION

Contact your local Lincoln
Authorized Field Service Facility.

WELDING PROBLEMS

Содержание SP-100T

Страница 1: ... INSTALL OPERATE OR REPAIR THIS 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 Number 11028 SP 100T 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 Leade...

Страница 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...

Страница 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...

Страница 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...

Страница 5: ...propriés 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...

Страница 6: ...tion below for future reference This information can be found on your machine nameplate Product _________________________________________________________________________________ Model Number ___________________________________________________________________________ Code Number or Date Code_________________________________________________________________ Serial Number______________________________...

Страница 7: ... B 2 Limitations B 2 Controls and Settings B 2 Welding Operations B 3 Overload Protection B 6 Application Chart B 7 Accessories Section C Accessories C 1 Replacement Parts C 2 Maintenance Section D Safety Precautions D 1 Items Requiring No Maintenance D 1 Routine Maintenance D 1 Gun and Cable Maintenance D 2 Component Replacement Procedures D 2 Troubleshooting Section E Safety Precautions E 1 How ...

Страница 8: ...2 mm INSTALLATION TECHNICAL SPECIFICATIONS SP 100T 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 47 Ibs 305 mm 248 mm 419 mm 21 4 kg PHYSICAL DIMENSIONS Standard Voltage Frequency Input Current 115V 60Hz 20 Amps Rated Output 15 Amps CSA Rated output Duty Cycle Current Voltage 20 Duty Cycle 88Amps 18V 20 Duty Cyc...

Страница 9: ...filter plate and lens 8 Instructional video 9 Adjustable mixed Gas Regulator Hose For available options and accessories refer to the Accessories Section of this manual 1 As shipped from the factory the SP 100T gun liner is ready to feed 023 0 6 mm 035 0 9 mm wire The contact tip is sized for 023 025 0 6 mm wire ELECTRIC SHOCK can kill Only qualified personnel should perform this installation Only ...

Страница 10: ...he louvers in the back and out the front of the unit A location that minimizes the amount of smoke and dirt drawn into the rear louvers reduces the chance of dirt accumulation that can block air passages and cause overheating STACKING SP 100T s cannot be stacked TILTING Each machine must be placed on a secure level sur face either directly or on either recommended cart The machine may topple over ...

Страница 11: ... the gun conductor cable through the Gun Cable Access Hole 2 in the SP 100T case front Make sure the connector is all the way in the brass connector block Unscrew thumb screw on the connector block a few turns if gun connector will not insert fully Rotate the connector so control leads are on the underside and tighten the Thumbscrew 8 in the connector block 4 Connect the gun trigger control lead t...

Страница 12: ...With the cylinder securely installed remove the cylinder cap Stand to one side away from the out let and open the cylinder valve very slightly for an instant This blows away any dust or dirt which may have accumulated in the valve outlet BE SURE TO KEEP YOUR FACE AWAY FROM THE VALVE OUTLET WHEN CRACKING THE VALVE Never stand directly in front of or behind the flow regulator when opening the cylind...

Страница 13: ...the SP 100T Connect this plug to a mating grounded receptacle which is connected to a 20 amp branch cir cuit with a nominal voltage rating of 115 to 125 volts 60 Hertz AC only The rated output with this installation is 88 amps 18 Volts 20 duty cycle 2 minutes of every 10 minutes used for welding Do not connect the SP 100T to an input power supply with a rated voltage that is greater than 125 volts...

Страница 14: ...suited for individuals having access to 115 volt AC input power and wanting the ease of use quality and dependability of both gas metal arc welding or GMAW also known as MIG welding and the Innershield electrode process self shielded flux cored or FCAW The SP 100T is a rugged and reliable machine that has been designed for dependable service and long life RECOMMENDED PROCESSES The SP 100T can be u...

Страница 15: ...The SP 100T is not recommended for pipe thawing or TIG welding CONTROLS AND SETTINGS Refer to Figure B 1a 1 Control Power ON OFF Switch When the power is on the fan motor will run and air will be exhausted out the louvers in the front of the machine The weld ing output and wire feeder remain off until the gun trigger is pressed 2 Wire Speed Control Controls the wire feed speed from 50 300 in min 1...

Страница 16: ...URE B 2 Load an 8 200 mm diameter spool on the wire spool spindle shown in Figure B 2 To use 4 100 mm diameter spools the 2 50 mm diameter spindle must be removed See Figure B 3 Remove the wing nut and spacer at the end of the shaft and 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 ...

Страница 17: ...re 6 The idle roll pressure adjustment wing nut is facto ry set to approximately five full turns from where the wing nut first engages the threads of the pres sure arm 1 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 d...

Страница 18: ...tance is about 3 8 inch 10 mm 9 To stop welding release the gun trigger and then pull the gun away from the work after the arc goes out 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 100T Cleaning Tip And Nozzle Clean the contact tip and nozzle to avoid arc bridging between the nozzle and contact...

Страница 19: ... 30 CFH 12 14 I min 3 Keep the cylinder valve closed except when using the SP 100T 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 100T WELDING WITH FCAW Innershield When using the FCAW process the correct drive roll and electrode polarity must be used See Work Cable Installation in INSTAL...

Страница 20: ...B 7 APPLICATION CHART B 7 SP 100T ...

Страница 21: ...luminum wire This kit may also be used for feeding 035 stainless wire Included with this kit are a drive roll liner and contact tip It is important when changing between welding with steel wire and aluminum to exchange these components due to the lubricant applied to steel wire Failure to do so may result in contaminated welds when weld ing aluminum 3 KP1884 1 Drive Roll Optional Knurled drive rol...

Страница 22: ...ponent Replacement in Maintenance section for details 4 Remove gas nozzle if installed and install gasless nozzle To remove simply unscrew 5 Load wire into machine and thread into gun and cable per Welding Wire Loading section REPLACEMENT PARTS Complete Gun and Cable Assembly K530 5 Contact Tip 025 0 6 mm KP2039 1 Contact Tip 030 0 8 mm KP2039 2 Contact Tip 035 0 9 mm KP2039 3 Contact Tip Tapered ...

Страница 23: ...blems NO maintenance is required In extremely dusty locations dirt may clog the air passages causing the welder to run hot with premature tripping of ther mal protection If so blow dirt out of the welder with low pres sure air at regular intervals to eliminate excessive dirt and dust build up on internal parts WIRE FEED COMPARTMENT 1 When necessary vacuum accumulated dirt from gearbox and wire fee...

Страница 24: ...hield process the gasless nozzle should be screws 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 sc...

Страница 25: ...e 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 and gun contact tip are energized relative to work and ground and remain energized for ...

Страница 26: ...the cable 5 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 6 Fully seat the liner bushing into the con nector 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 7 With the gas nozzle and diffuser removed from the gun ...

Страница 27: ...ately 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 SP 100T Counter clockwise ...

Страница 28: ...n be conducted with out removing the case wrap around cover Step 3 PERFORM COMPONENT TESTS If you have exhausted all of the recom mended tests in Step 2 Consult your Local 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 t...

Страница 29: ...is pulled Fan does NOT operate No wire feed weld output or gas flow when gun trigger is pulled Fan operates normally POSSIBLE AREAS OF MISADJUSTMENT S None Contact your local Authorized Field Service Facility 1 Make sure correct voltage is applied to the machine 115vac 2 Make certain that power switch is in the ON position 3 Make sure circuit breaker is reset 1 The thermostat may be tripped due to...

Страница 30: ...POSSIBLE AREAS OF MISADJUSTMENT S 1 If the wire drive motor is running make sure that the correct drive rolls are installed in the machine 2 Check for clogged cable liner or contact tip 3 Check for proper size cable liner and contact tip RECOMMENDED COURSE OF ACTION Contact your local Lincoln Authorized Field Service Facility FEEDING PROBLEMS PROBLEMS SYMPTOMS Low or no gas flow when gun trigger i...

Страница 31: ...MPTOMS Arc is unstable Poor starting POSSIBLE AREAS OF MISADJUSTMENT S 1 Check for correct input voltage to machine 115vac 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 dr...

Страница 32: ...V 60HZ 115V 60HZ OUTPUT CHOKE X3 X4 X5 H1 H1 H2 F1 541 204 203 209 208 539 213 214 1 2 3 4 LATCH 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 GAS SOLENOID CONTROL P C BOARD J1 J1 CR1 H1 H2 LS1 H2 H2 N O 214 N B N D N A N D TO EARTH GROUND PER NATIONAL LOCAL OR OTHER APPLICABLE ELECTRICAL CODES MOUNTED TO SEC COIL WIRE FEED MOTOR CASE GROUNDING STUD N A DIODES D2 D4 ARE MOUNTED ON THE OUTSIDE HEATSINK N B DIO...

Страница 33: ...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...

Страница 34: ...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...

Страница 35: ...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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