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SVM102-A
RETURN TO MAIN INDEX
March, 1999
SP- 100
For use with machines
having Code Numbers 9284-10050
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However, your
overall safety can be increased by
proper installation ... and thought-
ful operation on your part. DO
NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT READING THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and b
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i SAFETY ARC WELDING can be hazardous. WARNING PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER 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 pur- chase 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
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ii SAFETY WELDING SPARKS can CYLINDER may explode cause fire or explosion. if damaged. 4.a. Remove fire hazards from the welding area. 5.a.Use only compressed gas cylinders If this is not possible, cover them to prevent containing the correct shielding gas for the the welding sparks from starting a fire. process used and properly operating Remember that welding sparks and hot regulators designed for the gas and materials from welding can easily go through small cracks pressure used. All hoses, f
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iii SAFETY ELECTRIC AND MAGNETIC FOR ENGINE powered equipment. FIELDS 7.a. Turn the engine off before troubleshooting and maintenance may be dangerous work unless the maintenance work requires it to be running. ____________________________________________________ 8.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and 7.b. Operate engines in open, well-ventilated welding machines area
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iv SAFETY 5. Toujours porter des lunettes de sécurité dans la zone de PRÉCAUTIONS DE SÛRETÉ soudage. Utiliser des lunettes avec écrans lateraux dans les zones où l’on pique le laitier. Pour votre propre protection lire et observer toutes les instruc- tions et les précautions de sûreté specifiques qui parraissent 6. Eloigner les matériaux inflammables ou les recouvrir afin de dans ce manuel aussi bien que les précautions de sûreté prévenir tout risque d’incendie dû aux étincelles. générales suiva
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RETURN TO MAIN INDEX v MASTER TABLE OF CONTENTS FOR ALL SECTIONS Page Installation .......................................................................................................Section A Technical Specifications ........................................................................................A-1 Identify and Locate Components...........................................................................A-2 Select Suitable Location .....................................................
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Section A TABLE OF CONTENTS – INSTALLATION SECTION – Installation ......................................................................................................Section A Technical Specifications ........................................................................................A-1 Input and Output Specifications ......................................................................A-1 Cable and Fuse Sizes ..............................................................................
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A-1 INSTALLATION TECHNICAL SPECIFICATIONS – SP-100 INPUT – SINGLE PHASE ONLY Standard Voltage/Frequency Input Current 115V/60Hz 20 Amps - Rated Output 115V/60Hz 25 Amps - Maximum Output 115V/60Hz 12 Amps - CSA Rated output RATED OUTPUT Duty Cycle Amps Volts at Rated Amperes 20% Duty Cycle 90 18 30% Duty Cycle 100 17 20% Duty Cycle - CSA Rated Output 63 20 OUTPUT Welding Current Range (Continuous) Maximum Open Circuit Voltage Auxiliary Power Rated DC Output: 0 - 90 amps 28 N/A Maximum DC Output:
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A-2 INSTALLATION FIGURE A.1 Read entire installation section before starting installation. 1 SAFETY PRECAUTIONS WARNING 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 install and operate this equipment. • Machine must be plugged into a receptacle which is grounded per any national, local or other applicable electrical codes. • The SP-100 power switch is to be in the OFF (“O”
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A-3 INSTALLATION WORK CLAMP INSTALLATION SELECT SUITABLE LOCATION Attach the work clamp per the following: Locate the welder in a dry location where there is free circulation of clean air into the louvers in the back and 1. Unplug the machine or turn the power switch to the out the front of the unit. A location that minimizes the “OFF” position. amount of smoke and dirt drawn into the rear louvers reduces the chance of dirt accumulation that can block 2. Insert the work cable terminal lug wit
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A-4 INSTALLATION 3. Route the cable under and around the back of the 3. Insert the connector on the gun conductor cable Wire Feed Gearbox (6). into the Gun Cable Access Hole (2) in the SP-100 case front. Make sure the connector is all the way 4. For GMAW Only: Refer to Figure A.2. As deliv- in the metal connector block to obtain proper gas ered, the SP-100 is wired for positive polarity. This flow. Rotate the connector so control leads are on is the appropriate configuration for the Gas Metal
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A-5 INSTALLATION 3. Attach the flow regulator to the cylinder valve and WARNING tighten the union nut securely with a wrench. The flow regulator for carbon dioxide must have a plas- BUILDUP OF SHIELDING GAS may tic washer seated in the fitting that attaches to the harm health or kill. cylinder to prevent leakage. • Shut off shielding gas supply when not in use. 4. Refer to Figure A.6. Attach one end of inlet gas hose to the outlet fitting of the flow regulator and • SEE AMERICAN NATIONAL tighte
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A-6 INSTALLATION REQUIREMENTS FOR MAXIMUM OUTPUT CODE REQUIREMENTS FOR INPUT CONNECTIONS 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 WARNING 115 to 125 volts, 60 Hertz, AC only. With this installa- tion the SP-100 can be used at an output of 100 This welding machine must be connected to amps, 17 volts, 30% duty cycle. power source in accordance with applicable elec- trical codes. Ref
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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
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Section B TABLE OF CONTENTS – OPERATION SECTION – Operation ...........................................................................................................Section B Safety Precautions ......................................................................................................B-1 General Description ....................................................................................................B-2 Recommended Processes....................................................
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B-1 OPERATION Read entire operation section before operating the SP-100. WARNING 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 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
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B-2 OPERATION l Reversible, dual groove drive roll. Drive roll will GENERAL DESCRIPTION feed .023-.025” (0,6- 0,9 mm) diameter wire. The SP-100, Type K462, is a complete semiautomatic l Accommodates both 8” (200 mm) diameter and 4” constant voltage DC arc welding machine. Included is (100 mm) diameter spools of wire. a solid state controlled, single phase constant voltage l No external shielding gas is required when used transformer/ rectifier power source and a wire feeder with Lincoln Innersh
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B-3 OPERATION FIGURE B.1a The recommended gas and electrode for GMAW is welding grade CO gas and 0.025” (0 6 mm) diameter 2 Lincoln L-56 mild-steel welding wire [supplied on 121/2 Ib (6 kg) spools]. For 14 gauge (2,0 mm) and thinner, CO gas is recommended because it gives 2 equal or better performance than a blended gas at a lower cost. A mixed gas consisting of 75 to 80% Argon 2 1 and 20 to 25% CO is recommended for welding on 2 heavier gauge [12 gauge (2,5 mm) for example] steel. The recommen
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B-4 OPERATION FIGURE B.2 WIRE THREADING Refer to Figure B-4 8” Wire Spool Wire Spool Spindle FIGURE B.4 2 Be sure that this stud engages the hole in the wire spool. 1 To Wire Drive 4 5 Wire Spool must be pushed all the way on the spindle so that the The Wire Drive Feed Roll can spindle’s tab will hold it in place. The Wire Spool will rotate clock- 3 accommodate two wire sizes by wise when wire is dereeled. flipping the wire drive feed roll over. The sizes are stenciled on the drive roll. tighte
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B-5 OPERATION FIGURE B.5 FIGURE B.6 Gun Handle Contact Tip Gas Diffuser/ Contact Tip Wire Electrode Gas Nozzle 3/8" – 1/2" Electrical Stickout WARNING 2. If using a regulator with an adjustable flow meter, close the gun trigger and adjust the flow to give 15 When inching the welding wire, the drive rolls, the – 20 cubic ft per hour (CFH) (7 – 10 I/min) [use 20 gun connector block and the gun contact tip are -– 25 CFH (10 – 12 I/min) when welding out of always energized relative to work and grou
