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IM536-D
March, 2001
SP- 125 PLUS
For use with machine Code Numbers 10260, 10481,10685,10689,10690,10740
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 i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can- chemicals known to the State of California to cause cer, birth defects, and other reproductive harm. cancer, birth defects, or other reproductive harm. The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY
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ii ii SAFETY ELECTRIC SHOCK can ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover kill. plates to protect your eyes from sparks and 3.a. The electrode and work (or ground) circuits the rays of the arc when welding or observing are electrically “hot” when the welder is on. open arc welding. Headshield and filter lens Do not touch these “hot” parts with your bare should conform to ANSI Z87. I standards. skin or wet clothing. Wear dry, hole-free gloves to insulate hands. 4.b. Us
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iii iii SAFETY WELDING SPARKS can CYLINDER may explode cause fire or explosion. if damaged. 6.a. Remove fire hazards from the welding area. 7.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 hos
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iv iv SAFETY 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 provo
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v v for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product Thank You ••• 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
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vi TABLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications ........................................................................................A-1 Identify and Locate Components...........................................................................A-2 Select Suitable Location ........................................................................................A-3 Outpu
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vii SP-125 PLUS
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A-1 INSTALLATION TECHNICAL SPECIFICATIONS – SP-125 Plus INPUT – SINGLE PHASE ONLY Standard Voltage/Frequency Input Current 115V/60Hz 20 Amps - Rated Output 115V/60Hz 25 Amps - Maximum Output 115V/60Hz 15 Amps - CSA Rated output RATED OUTPUT Duty Cycle Amps Volts at Rated Amperes 20% Duty Cycle – Rated DC Output 90 18 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 CSA Rated DC Out
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W WEL ELD DIIN NG G AM AMP P R RAN ANG GE E 2 25-1 5-12 25 5 A-2 INSTALLATION FIGURE A.1 Read entire installation section before starting installation. 1 2 SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill. • Only qualified personnel should perform this installation. • Only personnel that have read and under- stood the SP-125 Plus Operating Manual should install and operate this equipment. • Machine must be plugged into a receptacle 4 which is grounded per any national, local 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 with
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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). through the Gun Cable Access Hole (2) in the SP- 125 Plus case front. Make sure the connector is all 4. For GMAW Only: Refer to Figure A.2. As deliv- the way in the metal connector block to obtain ered, the SP-125 Plus is wired for positive polarity. proper gas flow. Rotate the connector so control This is the appropriate configuration for the Gas leads
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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. Refer to K1800-1 in • Shut off shielding gas supply the accessories section. when not in use. 4. Refer to Figure A.6. Attach one end of inlet gas • SEE AMERICAN NATIONAL hose to the ou
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A-6 INSTALLATION Requirements For CSA Rated Output CODE REQUIREMENTS FOR INPUT CONNECTIONS A line cord with a 15 amp, 125 volt, three-prong plug (NEMA Type 5-15P) is factory installed. Connect this plug to a mating grounded receptacle which is con- WARNING nected to a 15 amp branch circuit with a nominal volt- age rating of 115 volts to 125 volts, 60 hertz, AC only. This welding machine must be connected to power source in accordance with applicable elec- With this installation, the SP-125 Plus
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B-1 OPERATION Read entire Operation section before operating the SP-125 Plus. 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 c
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B-2 OPERATION ● Reversible, dual groove drive roll. Drive roll will GENERAL DESCRIPTION feed .023-.035” (0.6- 0.9 mm) diameter wire. The SP-125 Plus is a complete semiautomatic con- ● Accommodates both 8” (200 mm) diameter and 4” stant voltage DC arc welding machine. Included is a (100 mm) diameter spools of wire. solid state controlled, single phase constant voltage ● No external shielding gas is required when used transformer/ rectifier power source and a wire feeder with Lincoln Innershield
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B-3 OPERATION WELDING OPERATIONS 1 1 2 SEQUENCE OF OPERATION WELDING AMP RANGE 25-125 Wire Loading 3 Refer to Figure B.2 AND B3. SP-125 Plus The machine power switch should be turned to the OFF (“O”) position before working inside the wire feed enclosure. FIGURE B.1a The machine is shipped from the factory ready to feed 4” (100 mm) diameter spools. A 4" (100 mm) diameter Refer to Figure B.1b spool is mounted directly on the 5/8" (16 mm) diame- ter spindle that has a built-in adjustabl
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B-4 OPERATION FIGURE B.3 FIGURE B.4 Wire Spindle Shaft 4" Wire Spool 2 1 Wing Nut 4 5 and Spacer To wire drive The Wire Drive Feed Roll can 3 accommodate two wire sizes by flipping the wire drive feed roll Note: The brake should be adjusted with a spool of over. The sizes are stenciled on the drive roll. wire installed. When properly adjusted it should move freely but not coast. Friction Brake Adjustments 6. The idle roll pressure adjustment wing nut is nor- 1. With wire spool installed, check
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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 Shielding Gas 4. Check that the polarity is correct for the welding When using the GMAW process, a cylinder of shield- wire being used and that the gas supply, if ing gas, must be obtained. Refer to the ACCES- required, is turned on. SORIES section for more information about selecting gas cylinders for use with the SP-125 Plus. 5. When using Innershield e
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B-6 OPERATION 9. To stop welding, release the gun trigger and then CAUTION pull the gun away from the work after the arc goes It is important when changing between welding out. with steel wire and aluminum to exchange feeding components due to the lubricant applied to steel 10. When no more welding is to be done, close valve wire. Failure to do so may result in contaminated on gas cylinder (if used), momentarily operate gun welds when welding aluminum. trigger to release gas pressure, and turn
