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IM366-B
November 1993
SP- 1 00
OPERATOR'S MANUAL
For use with machines having Code Number 9284 and above.
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 importantly, think before you
act and be caref
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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. A Free c
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4.f. Sparks and spatter are thrown from the welding arc. Wear oil 7.c.Do not add the fuel near an open flame weld- free protective garments such as leather gloves, heavy shirt, ing arc or when the engine is running. Stop cuffless trousers, high shoes and a cap over your hair. Wear the engine and allow it to cool before refuel- ear plugs when welding out of position or in confined places. ing to prevent spilled fuel from vaporizing on Always wear safety glasses with side shields when in a weld- c
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zones où l’on pique le laitier. PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de Pour votre propre protection lire et observer toutes les instructions prévenir tout risque d’incendie dû aux étincelles. et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- 7. Quand on ne soude pas, poser la pince à une endroit isolé de antes: la masse. Un court-circuit accidental peut provoquer un échau
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TABLE OF CONTENTS Page Safety Precautions .............................................................................................................2-4 Introductory Information .......................................................................................................6 Product Description..............................................................................................................7 Recommended Processes and Equipment.................................................
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for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Thank You Electric Company product ��� as much pride as we have in bringing this product to you! 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
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The recommended gas and electrode for GMAW is PRODUCT DESCRIPTION welding grade CO gas and .025" (0.6 mm) diameter 2 The SP-100, Type K462, is a complete semiautomatic Lincoln L-56 mild-steel welding wire [supplied on 12 constant voltage DC arc welding machine. Included is 1/2 lb (6 kg) spools]. For 14 gauge (2.0 mm) and thin- a solid state controlled, single phase constant voltage ner, CO gas is recommended because it gives equal 2 transformer/ rectifier power source and a wire feeder or better
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SPECIFICATIONS Type K462 Rated DC Output (For use on 20 ampere 90 amps @ 18 volts branch circuit) 20% duty cycle Maximum DC Output (For use on 25 ampere branch circuit with optional 100 amps @ 17 volts K467 input line cord installed) 30% duty cycle CSA Rated DC Output 63 amps @ 20 volts (For use on 15 ampere branch circuit) 20% duty cycle Input Power @ CSA rated Output 115 volts AC only 60 hertz 15 amps Maximum Open Circuit Voltage 28 volts 115 volts Input Power @ Rated Output, AC only 60 hertz
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M. Wire feed gearbox and gun connector block. DESCRIPTION OF CONTROLS N. Wire feed section door — With application chart Become familiar with the SP-100 controls and compo- for machine setting procedures. nents before attempting to weld. Refer to illustrations O. Gun cable and control lead access hole. and lettered items below for brief descriptions. P. Work cable access hole. A. Wire speed — Controls the wire speed from 50 – 400 in./min (1.3 – 10 m/min). The control can be LOCATION preset on th
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Work Cable Installation CAUTION 1. Open the wire feed section door on the right side of the SP-100. The gun trigger switch must be a normally open, momentary switch. The terminals of the switch must 2. Pass the end of the work cable that has the termi- be insulated from the welding circuit. Malfunction of nal lug with the smaller hole through the hole (hole the SP-100 will result if this switch shorts to the SP- D) next to the louvers in the case front. 100 welding output circuit or is common to
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wire. The thumb screw at the end of the shaft is not ELECTRICAL INPUT CONNECTION intended to be loosened; it should be tightened full clockwise. WARNING *Earlier spindle shafts did not include a set screw to ELECTRIC SHOCK can kill. adjust brake friction. If set screw is desired, order � Disconnect input power by removing Lincoln part number T12932-2. plug from receptacle before working CAUTION inside SP-100. � Use only grounded receptacle. If full tightening of the spindle thumbscrew causes � D
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Extension Cord WARNING If an extension cord is required, use one that is rated for the application and is 3 conductor #14 AWG (2.1 BE SURE TO KEEP YOUR FACE AWAY FROM THE 2 mm ) or larger. The recommended maximum lengths VALVE OUTLET WHEN “CRACKING” THE VALVE. 2 are 25 ft (7.5 m) if #14 AWG (2.1 mm ) is used and 50 Never stand directly in front of or behind the flow 2 ft (15 m) if #12 AWG* (3.3 mm ) is used. regulator when opening the cylinder valve. Always stand to one side. *AMERICAN WIRE GAUG
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K499 Argon-Mixed Gas Regulator and Hose Kit The K464 Kit is for use with the earlier “Lincoln ® Electric ” gun (with black trigger). The end of the brass Install the pressure-flow regulator and gauge to a fitting on the end of the liner for .035 (0.9 mm) wire is cylinder according to the instructions in Section 1.10. color coded green. The .023-.030 (0.6-0.8 mm) factory Connect one end of the 10 foot (3.0 m) hose to the installed liner is color coded orange. SP-100 gas inlet fitting and the othe
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4. Depress the gun trigger switch and feed welding If the machine shuts down due to an output overload, wire through the gun and cable (Point gun away first check the circuit breaker which is located on the from yourself and others while feeding wire.) inside panel of the wire feed section. If the button is Release gun trigger after wire appears at end of extended, reset after several minutes of cooling, by gun. depressing the button. 5. Replace contact tip and gas nozzle. 6. Cut the wire off 1/
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LEARNING TO WELD No one can learn to weld simply by reading about it. WARNING Skill comes only with practice. The following pages will help the inexperienced operator to understand Fume and slag generated from Innershield type welding and develop this skill. For more detailed infor- electrodes recommended for use with this welding mation, order a copy of “New Lessons in Arc Welding” machine can be toxic. listed inside the back cover of this manual. � Avoid contact with eyes and skin. � Do not ta
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WELDING TECHNIQUES FOR THE SELF- SHIELDED FCAW PROCESS Four simple manipulations are of prime importance. With complete mastery of the four, welding will be Burning of core materials Cored wire easy. inside wire electrode results in shield of gas. The Correct Welding Position. Protective slag Arc stream Illustrated below is the correct welding position for right-handed people. (For left-handed, it is opposite.) Weld metal Base metal Hold the gun (of the gun and cable assembly) in your Molten poo
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The Correct Electrical Stickout First weld from A to B; then from C to A; then from D to C; B C D E A then from E to D, and so on. 2-3” (50-75mm) BACKSTEPPING Contact tip Practice. The best way of getting practice in the four skills that Wire electrode enable you to maintain: 3/8 - 1/2” Electrical Stickout 1. Correct welding position 2. Correct way to strike an arc 3. Correct electrical stickout 4. Correct welding speed The electrical stickout (ESO) is the distance from the end of the contact ti
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steel can usually be easily welded without special pre- cautions. Some steels, however, contain higher car- bon levels or other alloys and are more difficult to weld. Basically, if a magnet sticks to the metal and if you can easily cut the metal with a file, chances are good that you will be able to weld the material with the SP-100. For further information on identifying various types of steels and other metals, and for proper proce- dures for welding them, we again suggest you pur- Penetratio
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Vertical-Up and Overhead Welding protect the molten weld metal. For this reason, a con- tinuous even flow of shielding gas is needed to protect The problem, when welding vertical-up, is to put the the molten weld metal from atmospheric contaminan- molten metal where it is wanted and make it stay t's such as oxygen and nitrogen. Shielding gas is sup- there. If too much molten metal is deposited, gravity plied through the gun and cable assembly through the will pull it downwards and make it “drip.
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operate gun trigger to release gas pressure, then turn off MACHINE SETUP FOR THE GMAW (MIG) the machine. PROCESS 1. See “Recommended Processes and Equipment” for The Correct Electrical Stickout selection of welding wire and shielding gas and for The electrical stickout (ESO) for GMAW (MIG) weld- range of metal thicknesses that can be welded. ing is 3/8 to 1/2 inch (10 to 12 mm). The same rules 2. See the “Welding ” chart on the inside of wire feed apply as when welding with .035" (0.9 mm) NR-211
