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SP-100OPERATOR'S MANUALFor use with machines having Code Number 9284 and above.
Sales and Service through Subsidiaries and Distributors Worldwide22801 St. Clair Ave. Cleveland, Ohio 44117-1199 U.S.A. Tel. (216) 481-8100
World's Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors
IM366-BNovember 1993
Safety Depends on YouLincoln arc welding equipment isdesigned and built with safety inmind. However, your overall safetycan be increased by proper instal-lation ... and thoughtful operationon your part. DO NOT INSTALLOPERATE OR REPAIR THISEQUIPMENT WITHOUT READ-ING THIS MANUAL AND THESAFETY PRECAUTIONS CON-TAINED THROUGHOUT. And,most importantly, think before youact and be careful.
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LISTED
170G
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PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDRENAWAY. 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 copy of “Arc Welding Safety” booklet E205 is available from theLincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR PROCEDURES AREPERFORMED ONLY BY QUALIFIED INDIVIDUALS.
WELDING SPARKS cancause fire or explosion.4.a..Remove fire hazards from the welding area.
If this is not possible, cover them to preventthe welding sparks from starting a fire.Remember that welding sparks and hot
materials from welding can easily go through small cracksand openings to adjacent areas. Avoid welding nearhydraulic lines. Have a fire extinguisher readily available.
4.b. Where compressed gases are to be used at the job site, spe-cial precautions should be used to prevent hazardous situa-tions. Refer to “Safety in Welding and Cutting” (ANSIStandard Z49.1) and the operating information for the equip-ment being used.
4.c. When not welding, make certain no part of the electrode cir-cuit is touching the work or ground. Accidental contact cancause overheating and create a fire hazard.
4.d. Do not heat, cut or weld tanks, drums or containers until theproper steps have been taken to insure that such procedureswill not cause flammable or toxic vapors from substancesinside. They can cause an explosion even though they havebeen “cleaned.” For information purchase “RecommendedSafe Practices for the Preparation for Welding and Cutting ofContainers and Piping That Have Held HazardousSubstances”, AWS F4.1 from the American Welding Society(see address above).
4.e. Vent hollow castings or containers before heating, cutting orwelding. They may explode.
ARC RAYS can burn.2.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards.
2.b. Use suitable clothing made from durable flame-resistantmaterial to protect your skin and that of your helpers fromthe arc rays.
2.c. Protect other nearby personnel with suitable non-flammablescreening and/or warn them not to watch the arc nor exposethemselves to the arc rays or to hot spatter or metal.
ELECTRIC SHOCK cankill.1.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.Do not touch these “hot” parts with your bareskin or wet clothing. Wear dry, hole-freegloves to insulate hands.
1.b. Insulate yourself from work and ground using dry insulation.Make certain the insulation is large enough to cover your fullarea of physical contact with work and ground.
In addition to the normal safety precautions, if weldingmust be performed under electrically hazardous condi-tions (in damp locations or while wearing wet clothing;on metal structures such as floors, gratings or scaf-folds; when in cramped positions such as sitting, kneel-ing or lying, if there is a high risk of unavoidable or acci-dental contact with the workpiece or ground) use the fol-lowing equipment:
• Semiautomatic DC Constant Voltage (Wire)Welder.
• DC Manual (Stick) Welder.• AC Welder with Reduced Voltage Control.
1.c. In semiautomatic or automatic wire welding, the electrode,electrode reel, welding head, nozzle or semiautomatic weld-ing gun are also electrically“hot”.
1.d. Always be sure the work cable makes a good electrical con-nection with the metal being welded. The connection shouldbe 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 andwelding machine in good, safe operating condition. Replacedamaged insulation.
1.g. Never dip the electrode in water for cooling.
1.h. Never simultaneously touch electrically “hot” parts of elec-trode holders connected to two welders because voltagebetween the two can be the total of the open circuit voltageof both welders.
1.i. When working above floor level, use a safety belt to protectyourself from a fall should you get a shock.
1.j. Also see Items 4.c. and 6.
WARNING ARC WELDING can be hazardous.
FUMES AND GASEScan be dangerous.3.a. Welding may produce fumes and gases haz-
ardous to health. Avoid breathing thesefumes and gases.When welding, keep yourhead out of the fume. Use enough ventila-tion and/or exhaust at the arc to keep fumes
and gases away from the breathing zone. When weldingwith electrodes which require special ventilation suchas stainless or hard facing (see instructions on contain-er or MSDS) or on lead or cadmium plated steel andother metals or coatings which produce highly toxicfumes, keep exposure as low as possible and belowThreshold Limit Values (TLV) using local exhaust ormechanical ventilation. In confined spaces or in somecircumstances, outdoors, a respirator may be required.Additional precautions are also required when weldingon galvanized steel.
3.b. Do not weld in locations near chlorinated hydrocarbon vaporscoming from degreasing, cleaning or spraying operations.The heat and rays of the arc can react with solvent vapors toform phosgene, a highly toxic gas, and other irritating prod-ucts.
3.c. Shielding gases used for arc welding can displace air andcause injury or death. Always use enough ventilation, espe-cially in confined areas, to insure breathing air is safe.
3.d. Read and understand the manufacturer’s instructions for thisequipment and the consumables to be used, including thematerial safety data sheet (MSDS) and follow your employ-er’s safety practices. MSDS forms are available from yourwelding distributor or from the manufacturer.
3.e. Also see item 7b.
Apr. ‘93 -2-
FOR ENGINEpowered equipment.
7.a. Turn the engine off before troubleshooting and maintenancework unless the maintenance work requires it to be running.
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7.b. Operate engines in open, well-ventilatedareas or vent the engine exhaust fumes out-doors.
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FOR ELECTRICALLYpowered equipment.6.a. Turn off input power using the disconnect
switch at the fuse box before working onthe equipment.
6.b. Install equipment in accordance with the U.S. NationalElectrical Code, all local codes and the manufacturer’s rec-ommendations.
6.c. Ground the equipment in accordance with the U.S. NationalElectrical Code and the manufacturer’s recommendations.
CYLINDER may explodeif damaged.5.a. Use only compressed gas cylinders contain-
ing the correct shielding gas for the processused and properly operating regulatorsdesigned for the gas and pressure used. All
hoses, fittings, etc. should be suitable for the application andmaintained in good condition.
5.b. Always keep cylinders in an upright position securelychained to an undercarriage or fixed support.
5.c. Cylinders should be located: • Away from areas where they may be struck or subjected to
physical damage. • A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
5.d. Never allow the electrode, electrode holder or any otherelectrically “hot” parts to touch a cylinder.
5.e. Keep your head and face away from the cylinder valve outletwhen opening the cylinder valve.
5.f. Valve protection caps should always be in place and handtight except when the cylinder is in use or connected foruse.
5.g. Read and follow the instructions on compressed gas cylin-ders, associated equipment, and CGA publication P-l,“Precautions for Safe Handling of Compressed Gases inCylinders,”available from the Compressed Gas Association1235 Jefferson Davis Highway, Arlington, VA 22202.
7.c.Do not add the fuel near an open flame weld-ing arc or when the engine is running. Stopthe engine and allow it to cool before refuel-ing to prevent spilled fuel from vaporizing oncontact with hot engine parts and igniting.Do not spill fuel when filling tank. If fuel isspilled, wipe it up and do not start engineuntil fumes have been eliminated.
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7.d. Keep all equipment safety guards, coversand devices in position and in good repair.Keep hands, hair, clothing and tools awayfrom V-belts, gears, fans and all other mov-ing parts when starting, operating or repair-ing equipment.
7.e. In some cases it may be necessary to remove safetyguards to perform required maintenance. Removeguards only when necessary and replace them when themaintenance requiring their removal is complete.Always use the greatest care when working near movingparts.
7.f. Do not put your hands near the engine fan. Do notattempt to override the governor or idler by pushing onthe throttle control rods while the engine is running.
7.g. To prevent accidentally starting gasoline engines while turn-ing the engine or welding generator during maintenancework, disconnect the spark plug wires, distributor cap ormagneto wire as appropriate.
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7.h. To avoid scalding, do not remove the radia-tor pressure cap when the engine is hot.
-3- Mar. ‘93
ELECTRIC AND MAGNETIC FIELDSmay be dangerous8.a. Electric current flowing through any con-
ductor causes localized Electric andMagnetic Fields (EMF). Welding currentcreates EMF fields around welding cablesand welding machines.
8.b. EMF fields may interfere with some pacemakers, andwelders having a pacemaker should consult their physicianbefore welding.
8.c. Exposure to EMF fields in welding may have other healtheffects which are now not known.
8d. All welders should use the following procedures in order tominimize exposure to EMF fields from the welding circuit:
8.d.1. Route the electrode and work cables together - Securethem with tape when possible.
8.d.2. Never coil the electrode lead around your body.
8.d.3. Do not place your body between the electrode andwork cables. If the electrode cable is on your right side,the work cable should also be on your right side.
8.d.4. Connect the work cable to the workpiece as close aspossible to the area being welded.
8.d.5. Do not work next to welding power source.
4.f. Sparks and spatter are thrown from the welding arc. Wear oilfree protective garments such as leather gloves, heavy shirt,cuffless trousers, high shoes and a cap over your hair. Wearear plugs when welding out of position or in confined places.Always wear safety glasses with side shields when in a weld-ing area.
4.g. Connect the work cable to the work as close to the weldingarea as practical. Work cables connected to the buildingframework or other locations away from the welding areaincrease the possibility of the welding current passing throughlifting chains, crane cables or other alternate circuits. This cancreate fire hazards or overheat lifting chains or cables untilthey fail.
4.h. Also see item 7c.
-4-
PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les instructionset les précautions de sûreté specifiques qui parraissent dans cemanuel aussi bien que les précautions de sûreté générales suiv-antes:
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous tensionquand la machine à souder est en marche. Eviter toujourstout contact entre les parties sous tension et la peau nue oules vétements mouillés. Porter des gants secs et sans trouspour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand onsoude dans des endroits humides, ou sur un plancher met-allique ou des grilles metalliques, principalement dans les positions assis ou couché pour lesquelles une grande partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble desoudage et la machine à souder en bon et sûr état defonc-tionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour lerefroidir.
e. Ne jamais toucher simultanément les parties sous tensiondes porte-électrodes connectés à deux machines à souder parce que la tension entre les deux pinces peut être le total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source decourant pour soudage semi-automatique, ces precautionspour le porte-électrode s’applicuent aussi au pistolet desoudage.
2. Dans le cas de travail au dessus du niveau du sol, se protégercontre les chutes dans le cas ou on recoit un choc. Ne jamaisenrouler le câble-électrode autour de n’importe quelle partie ducorps.
3. Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:
a. Utiliser un bon masque avec un verre filtrant approprié ainsiqu’un verre blanc afin de se protéger les yeux du rayon-nement de l’arc et des projections quand on soude ouquand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la peaude soudeur et des aides contre le rayonnement de l‘arc.
c. Protéger l’autre personnel travaillant à proximité ausoudage à l’aide d’écrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de l’arc desoudage. Se protéger avec des vêtements de protection libresde 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 desoudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.
6. Eloigner les matériaux inflammables ou les recouvrir afin deprévenir tout risque d’incendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé dela masse. Un court-circuit accidental peut provoquer un échauf-fement et un risque d’incendie.
8. S’assurer que la masse est connectée le plus prés possible dela zone de travail qu’il est pratique de le faire. Si on place lamasse sur la charpente de la construction ou d’autres endroitséloignés de la zone de travail, on augmente le risque de voirpasser le courant de soudage par les chaines de levage,câbles de grue, ou autres circuits. Cela peut provoquer desrisques d’incendie ou d’echauffement des chaines et descâbles jusqu’à ce qu’ils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.Ceci est particuliérement important pour le soudage de tôlesgalvanisées plombées, ou cadmiées ou tout autre métal quiproduit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenantd’opérations de dégraissage, nettoyage ou pistolage. Lachaleur ou les rayons de l’arc peuvent réagir avec les vapeursdu solvant pour produire du phosgéne (gas fortement toxique)ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté, voirle code “Code for safety in welding and cutting” CSA StandardW 117.2-1974.
PRÉCAUTIONS DE SÛRETÉ POURLES MACHINES À SOUDER ÀTRANSFORMATEUR ET ÀREDRESSEUR
1. Relier à la terre le chassis du poste conformement au code del’électricité et aux recommendations du fabricant. Le dispositifde montage ou la piece à souder doit être branché à unebonne mise à la terre.
2. Autant que possible, I’installation et l’entretien du poste seronteffectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la debrancherà l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur place.
Mar. ‘93
TABLE OF CONTENTSPage
Safety Precautions .............................................................................................................2-4Introductory Information .......................................................................................................6Product Description..............................................................................................................7Recommended Processes and Equipment..........................................................................7Optional Accessories ...........................................................................................................7Specifications.......................................................................................................................8Installation .........................................................................................................................8-12
Safety Precautions ........................................................................................................8Unpacking the SP-100...................................................................................................8Description of Controls ..................................................................................................9Location of Equipment...................................................................................................9Work Cable and Clamp .................................................................................................9Output Polarity Connection...........................................................................................10Gun...............................................................................................................................10Wire Feed Drive Roll ....................................................................................................10Welding Wire Loading ..................................................................................................10Electrical Input Connection...........................................................................................11Shielding Gas Connection ............................................................................................12Optional Accessories....................................................................................................12
Operating Instructions.........................................................................................................13Safety Precautions .......................................................................................................13Duty Cycle ....................................................................................................................13Selecting a Wire Spool Size .........................................................................................13Feeding Welding Wire ..................................................................................................13Making a Weld..............................................................................................................14
Overload Protection Shutdown ...........................................................................................14Wire Feed Overload Protection ....................................................................................14
Learning to Weld.................................................................................................................15The Arc-Welding Circuit................................................................................................15The Self-Shielded FCAW Welding Arc .........................................................................15Machine Setup for the Self-Shielded FCAW Process ..................................................16Welding Techniques for the Self-Shielded FCAW Process..........................................16Common Metals ...........................................................................................................17Types of Welds.............................................................................................................18Welding Procedures .....................................................................................................18Welding in the Vertical Position ....................................................................................18The GMAW (MIG) Welding Arc ....................................................................................19Process Selection.........................................................................................................19Machine Setup for the GMAW (MIG) Process..............................................................20Welding Techniques for GMAW (MIG) Process ...........................................................20Welding Procedures .....................................................................................................20Troubleshooting Welds.................................................................................................21Proper Gun Handling....................................................................................................21
Routine Maintenance ......................................................................................................22 - 23Troubleshooting Guide ....................................................................................................24 - 25Wiring Diagram ...................................................................................................................26Procedures Chart................................................................................................................27Parts Lists........................................................................................................................28 - 39Book Order Form ................................................................................................................41Nine Language Warning Information...............................................................................42 - 43Waranty Information ....................................................................................................Back Cover
-5-
EXPLANATION OF SYMBOLS THAT APPEAR ON THIS EQUIPMENT
Please Examine Carton and Equipment For Damage ImmediatelyWhen this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claimsfor material damaged in shipment must be made by the purchaser against the transportation company at the timethe shipment is received.
Please record your equipment identification information below for future reference. This information can be foundon your machine nameplate.
Model Number ____________________________________
Serial or Product Number ____________________________
Date of Purchase __________________________________
Whenever you request replacement parts for or information on this equipment always supply the information youhave recorded above.
-6-
Thank Youfor selecting a QUALITY product by Lincoln Electric.We want you to take pride in operating this LincolnElectric Company product ••• as much pride as wehave in bringing this product to you!
Read this Operators Manual completely before attempting to use this equipment. Save thismanual and keep it handy for quick reference. Pay particular attention to the safety instructionswe have provided for your protection. The level of seriousness to be applied to each isexplained below:
WARNING
This statement appears where the information must be followed exactly to avoid serious per-sonal injury or loss of life.
This statement appears where the information must be followed to avoid minor personalinjury or damage to this equipment.
CAUTION
OFF
ON
ARC VOLTS
WIRE SPEED
O
PRODUCT DESCRIPTIONThe SP-100, Type K462, is a complete semiautomaticconstant voltage DC arc welding machine. Included isa solid state controlled, single phase constant voltagetransformer/ rectifier power source and a wire feederfor feeding .023 – .030" (0.6 – 0.8 mm) solid steelelectrode and .035" (0.9 mm) cored electrode.
The SP-100 is ideally suited for individuals havingaccess to 115 volt AC input power, and wanting theease of use, quality and dependability of both gasmetal arc welding or GMAW (also known as MIGwelding) and the Innershield® electrode process (self-shielded flux-cored or FCAW). A convenient chart ismounted inside the wire feed section door for settingwelding procedures for 24 gauge through 12 gauge(0.6 – 2.5 mm) mild steel (Chart also may be found inthis manual). The SP-100 is a rugged and reliablemachine that has been designed for dependable ser-vice and long life.
RECOMMENDED PROCESSES ANDEQUIPMENTThe SP-100 can be used for welding mild steel usingthe GMAW, single pass, process which requires asupply of shielding gas or it can be used for the self-shielded, Innershield electrode process.
The recommended gas and electrode for GMAW iswelding grade CO2 gas and .025" (0.6 mm) diameterLincoln L-56 mild-steel welding wire [supplied on 121/2 lb (6 kg) spools]. For 14 gauge (2.0 mm) and thin-ner, CO2 gas is recommended because it gives equalor better performance than a blended gas at a lowercost. A mixed gas consisting of 75 to 80% Argon and20 to 25% CO2 is recommended for welding on heav-ier gauge [12 gauge (2.5 mm) for example] steel.
The recommended electrode for the self-shieldedprocess is .035" (0.9 mm) diameter LincolnInnershield NR-211-MP on 10 lb (4.5 kg) spools. Thiselectrode can be used for all position welding of 20gauge through 5/16" (1.0 – 8.0 mm) thick steel [multi-ple passes are required for 1/4" and 5/16" (6.0 and 8.0mm)].
Use of the GMAW process with the SP-100 onthicker materials than recommended may result inpoor welds. The welds may “look” good, but mayjust be “sitting” on top of the plate. This is called“cold casting” and will result in weld failure.---------------------------------------------------------------------
.035" (0.9 mm) Dia. NR-211-MPElectrode Wire .025" (0.6 mm) Dia. L-56 (GMAW) Innershield (FCAW)
Shielding Gas CO2 or blended None (Self Shielded)Electrode Polarity Positive Negative
Minimum Gauge 24 ga (0.6 mm) 20 ga (1.0 mm)NOTE: Requires more skill to use on 20 and
18 gauge (1.0 and 1.2 mm) than isrequired with .025" (0.6 mm) L-56.
Maximum Gauge 14 gauge (2.0 mm) Can be used to weld 1/4" and 5/16" (6.3 mmNOTE: Can be used for 12 gauge (2.5 mm) and 8.0 mm) thick steel with multiple passes.
with Argon-CO2 gas.(1)
Penetration into Good ExcellentBase Metal
Smoke Level Low HighAmount of Slag Low, little or no cleaning required Slag must be removed
Comparison of the GMAW (MIG) and FCAW (Innershield) Processes
OPTIONAL ACCESSORIES1. K463 CO2 Gas Regulator and Hose Kit —
Includes a preset, nonadjustable pressure andflow regulator for use on CO2 cylinders. Alsoincluded is a 10 foot (3.0 m) gas hose which con-nects to the rear of the SP-100.
2. K499 Ar-Mixed Gas Regulator and Hose Kit —Includes a preset, nonadjustable pressure andflow regulator for use on argon-mixed gas cylin-ders. Also included is a 10 foot (3.0 m) gas hosewhich connects to the rear of the SP-100.
3. .035 (0.9 mm) Innershield® Welding Kit —Includes a contact tip, a gasless nozzle and acable liner to permit the SP-100 gun and cable touse a .035" (0.9 mm) diameter flux-cored elec-
trode. Also included is a spool of .035 (0.9 mm)Innershield® NR-211-MP.Two kits are available:K549-1 kit is for use with the Magnum™ 100L gun(with red trigger).K464 kit is for use with the original LincolnElectric® gun (with black trigger).
4. M15448-1 Reversible Drive Roll with doubleknurled grooves for .035 cored electrode.
5. K467 Input Line Cord — Same as line cord sup-plied with the SP-100 but has a NEMA type 5-20Pplug for use on 25 amp branch circuits.To install optional features refer to instructionsincluded with the kit, and/or in this manual.
– 7 –
WARNING
Type K462
Rated DC Output (For use on 20 ampere 90 amps @ 18 voltsbranch circuit) 20% duty cycle
Maximum DC Output (For use on 25ampere branch circuit with optional 100 amps @ 17 voltsK467 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 voltsAC only 60 hertz
15 amps
Maximum Open Circuit Voltage 28 volts
115 voltsInput Power @ Rated Output, AC only 60 hertz
20 amps
115 voltsInput Power @ 60 hertzMaximum Output, AC only 25 amps
Wire Speed Range 50 to 400 in./min(1.3 to 10.2 m/min)
Wire Sizes .023 – .030" (0.6 – 0.8 mm) Solid Steel.035" (0.9 mm) Flux-Cored(1)
Spool Sizes 8" OD x 2" ID x 2.2" wide(200 mm x 50 mm x 56 mm)4" OD x 5/8" ID x 1.7" wide
(100 mm x 16 mm x 43 mm)
Weight 54 lbs (24.3 kg)
Dimensions (H x W x D) (Less Handle) 12" x 9 3/4" x 16 1/2"(305 mm x 248 mm x 419 mm)
SPECIFICATIONS
1) Requires optional Innershield Welding Kit
INSTALLATION
– 8 –
SAFETY PRECAUTIONS● Read the safety precautions at the beginning of
this Operator's Manual before proceeding.● Only personnel that have read and under-
stood the SP-100 Operating Manual shouldinstall and operate this equipment.
● Machine must be plugged into a receptacle whichis grounded per any national, local or other applic-able electrical codes.
● The SP-100 power switch is to be in the OFF(“O”) position when installing work cable and gunand when connecting power cord to input power.
UNPACKING THE SP-100 (K462)Unpack the SP-100 from its carton and remove allpacking material around the SP-100. Remove the fol-lowing loose items from the carton:
1.SP-100.2.Gun and cable assembly(1) — ready to feed .025"
(0.6 mm) diameter wire (also .023 and .024 diam-eter wire).
3.Literature envelope which contains:a) This operating manual, andb) A contact tip for .030" (0.8 mm) diameter wire.
4.10 ft (3.0 m) work cable.5.Work clamp.(1) K474 model gun is ready to feed .035 (0.9 mm) Innershield
with conversion parts for .030 (0.8) wire.
DESCRIPTION OF CONTROLSBecome familiar with the SP-100 controls and compo-nents before attempting to weld. Refer to illustrationsand lettered items below for brief descriptions.A. Wire speed — Controls the wire speed from 50 –
400 in./min (1.3 – 10 m/min). The control can bepreset on the dial to the setting specified on theSP-100 Application Chart located on the inside ofthe wire feed section door. Wire speed is notaffected when changes are made in the voltagecontrol. The control is marked (“olo”)
B. Power ON/OFF switch — When the power is on,the fan motor will run and air will be exhaustedout the louvers in the front of the machine. Thewelding output and wire feeder remain off until thegun trigger is pressed.
C. Voltage control — A continuous control that givesfull range adjustment of power source output volt-age. Can be adjusted while welding.
D. Thumbscrew — secures gun and cable assembly.E. Positive (+) and negative (–) output terminals.F. Shielding gas hose (factory installed, not shown)
— routed from gas solenoid inside rear ofmachine to gun connector block.
G. Gun trigger lead connectors.H. Circuit breaker — Protects machine from damage
if maximum output is exceeded. Button will extendout when tripped. (Manual reset.)
I. Wire spool spindle.J. Gas solenoid inlet fitting.K. Power cord.L. Spring loaded pressure arm — adjusts pressure
of idle roll on wire.
M. Wire feed gearbox and gun connector block.N. Wire feed section door — With application chart
for machine setting procedures.O. Gun cable and control lead access hole.P. Work cable access hole.
LOCATIONLocate the welder in a dry location where there is freecirculation of clean air into the louvers in the back andout the front. A location that minimizes the amount ofsmoke and dirt drawn into the rear louvers reducesthe chance of dirt accumulation that can block air pas-sages and cause overheating.
WORK CABLE AND CLAMP INSTALLATIONWork Clamp Installation
Attach the work clamp to the work cable per the fol-lowing:1. Unplug the machine or turn the power switch to the
“Off” position.2. Insert the work cable terminal lug with the larger
hole through the strain relief hole in the work clampas shown below.
3. Fasten securely with the bolt and nut provided.
– 9 –
A
B
C
DE
F
G H
I
J
K
L
M
N
O
P
Work cable
Work clamp
Work Cable Installation1. Open the wire feed section door on the right side of
the SP-100.2. Pass the end of the work cable that has the termi-
nal lug with the smaller hole through the hole (holeD) next to the louvers in the case front.
3. Route the cable under and around the back of thewire feed unit.
4. Using wing nut provided, connect the terminal lugto the negative (–) output terminal located abovethe wire feed unit; item M (make certain that bothwing nuts are tight).
NOTE: This connection gives the correct electrodepolarity for the GMAW process. If using Innershield,see Output Polarity Connection Section below fornegative electrode polarity connection.
OUTPUT POLARITY CONNECTIONThe SP-100, as shipped, is connected for positiveelectrode polarity.
To connect for negative electrode polarity (required forthe Innershield process), connect the short cableattached to the gun connector block to the negative(–) output terminal and the work cable to the positive(+) terminal using the provided wing nuts (make cer-tain that both wing nuts are tight).
GUN INSTALLATIONAs shipped from the factory, the SP-100 gun is readyto feed .023, .024 or .025" (0.6 mm) wire. If .030" (0.8mm) wire is to be used, install the .030" (0.8 mm) con-tact tip. .023 – .025" contact tip is stenciled .025and/or 0.6 mm and .030" contact tip is stenciled .030and/or 0.8 mm. See Maintenance Section for instruc-tions to change contact tip.
If .035" (0.9 mm) Innershield flux cored wire is to beused, see Maintenance Section for instructions tochange contact tip, cable liner, and gas nozzle.
Connect the gun cable to the SP-100 per the follow-ing:1. Unplug the machine or turn power switch to the off
“O” position.2. Pass the insulated terminals of the gun trigger con-
trol leads, one at a time, through the rectangular“keyhole” opening (item F) in the case front. Theleads are to be routed under the wire feed unit andthrough the cable hanger on the inner panel.
3. Insert the connector on the gun conductor cablethrough the large hole in the SP-100 case front.Make sure the connector is all the way in the metalconnector block to obtain proper gas flow. Rotatethe connector so control leads are on the undersideand tighten the thumbscrew in the connector block.
4. Connect the insulated control lead terminals to thetwo insulated 1/4" (6.4 mm) tab connector bushingslocated above the “Gun Trigger Connection” decalin the wire feed section. Either lead can go to eitherconnector. Form the leads so that they are as closeas possible to the inside panel.
– 10 –
The gun trigger switch must be a normally open,momentary switch. The terminals of the switch mustbe insulated from the welding circuit. Malfunction ofthe SP-100 will result if this switch shorts to the SP-100 welding output circuit or is common to any elec-trical circuit other than the SP-100 trigger circuit.-----------------------------------------------------------------------
WIRE FEED DRIVE ROLLThe SP-100 drive roll has two grooves; one for .023 –.025" (0.6 mm) solid steel electrode and the other for.030" (0.8 mm) solid and .035" (0.9 mm) flux-coredsteel electrode. As shipped, the drive roll is installed inthe .023/.025" (0.6 mm) position (as indicated by thestenciling on the exposed side of the drive roll).
If .030 – .035" (0.8 – 0.9 mm) wire is to be used, thedrive roll must be reversed as follows:1. Make certain the SP-100 power switch is “off”.2. Open the quick release arm; lift up the idle roll arm.3. Remove the drive roll retaining screw and washer
with a screwdriver.4. Remove the drive roll, flip over and install with the
.030/.035" (0.8/0.9 mm) stencil visible (away fromgearbox). Make certain the small key is in place inthe keyway.
5. Replace the washer and retaining screw.
Gun triggerconnectors
Thumbscrew
Case front
Gun connector block {
Brass connector
Gun triggercontrol leadterminals
Idle roll arm
Retaining Screw
Drive roll
Spring loadedpressure arm
CAUTION
WELDING WIRE LOADING
The machine power switch should be turned tothe OFF (“O”) position before working inside thewirefeed enclosure.------------------------------------------------------------------------The machine is shipped from the factory ready to feed8" (200 mm) diameter spools [2.2" (56 mm) max.width]. These spools fit on a 2" (50 mm) diameterspindle that has a built-in, adjustable* friction brake toprevent overrun of the spool and excess slack in the
WARNING
ELECTRICAL INPUT CONNECTION
Code Requirements
This welding machine must be connected to powersource in accordance with applicable electricalcodes.
The United States National Electrical Code (Article630-B, 1990 Edition) provides standards for amper-age handling capability of supply conductors basedon duty cycle of the welding power source.
If there is any question about the installation meetingapplicable electrical code requirements, consult aqualified electrician.------------------------------------------------------------------------Requirements for Rated OutputA power cord with a 15 amp, 125 volt, three prongplug (NEMA Type 5-15P) is factory installed on theSP-100. Connect this plug to a mating groundedreceptacle 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 90 amps, 18volts, 20% duty cycle (2 minutes of every 10 minutesused for welding).
Do not connect the SP-100 to an input power supplywith a rated voltage that is greater than 125 volts.-------------------------------------------------------------------------------------------------------
Requirements for Maximum OutputAn optional power cord is available to permit the SP-100 to be connected to a 25 amp branch circuit with anominal voltage rating of 115 to 125 volts, 60 Hertz,AC only. With this installation the SP-100 can be usedat an output of 100 amps, 17 volts, 30% duty cycle.See Optional Accessories Section.
Requirements for CSA Rated OutputA line cord with a 15 amp, 125 volt, three-prong plug(NEMA Type 5-15P) is factory installed. Connect thisplug to a mating grounded receptacle which is con-nected to a 15 amp branch circuit with a nominal volt-age rating of 115 volts to 125 volts, 60 hertz, AC only.With this installation, the SP-100 can be used at anoutput of 63 amps, 20 volts, 20% duty cycle.
– 11 –
wire. The thumb screw at the end of the shaft is notintended to be loosened; it should be tightened fullclockwise.
*Earlier spindle shafts did not include a set screw toadjust brake friction. If set screw is desired, orderLincoln part number T12932-2.
If full tightening of the spindle thumbscrew causestoo much feed force to rotate the wire spool, thethumbscrew stop point can be adjusted as follows:
A. Remove the thumbscrew.B. Using a 3/16”(4.8mm) hex wrench, turn the set
screw, located inside the tapped hole in the spindleshaft, one or two turns counterclockwise.
C. Fully reinstall the thumbscrew and check forproper brake force to prevent spool overrun, butallow smooth and easy wire feeding. If not, repeat.------------------------------------------------------------------------
Load an 8" (200 mm) diameter spool on the wire spoolspindle shown above.
To use 4" (100 mm) diameter spools, the 2" (50 mm)diameter spindle must be removed. Remove thethumb screw at the end of the shaft and remove thespindle. It can be stored in the wire feed compartment.A 4" (100 mm) diameter spool is mounted directly onthe 5/8" (16 mm) diameter shaft and held in place withthe previously removed thumb screw. Make certainthat the thumbscrew is tightened fully clockwise. Alsomake certain the start end of the wire which may pro-trude through the side of the spool does not contactany metallic case parts.
Thread the welding wire through the wire feeder guidetubes per the following instructions:1. Release the idle roll pressure arm and rotate the
idle roll arm away from the drive roll. (Check thatvisible, stenciled size on drive roll matches wiresize being used — See Wire Drive Roll Section.)
2. Carefully detach the end of the wire from the spool.To prevent the spool from unwinding, do notrelease the wire until after step 5.
3. Cut the bent portion of wire off and straighten thefirst 4" (100 mm).
4. Thread the wire through the ingoing guide tube,over the drive roll, and into the outgoing guide tube.
5. Close the idle roll arm and latch the pressure arm inplace (now you may release the welding wire).
6. The idle roll pressure adjustment wing nut is normal-ly set for mid-position on the pressure arm threads.If feeding problems occur because the wire is flat-tened excessively, turn the pressure adjustmentcounterclockwise to reduce distortion of thewire.Slightly less pressure may be required whenusing .023–.025 (0.6 mm) wire. If the drive roll slipswhile feeding wire, the pressure should be increaseduntil the wire feeds properly. NOTE: See operatinginstructions for feeding welding wire on page 12.
Be sure this stud engagesthe hole in the wire spool
Wire spool must be pushed allthe way on spindle so the tabsprings out to hold it in place.
Spool to rotate clockwisewhen wire is dereeled.
Thumbscrew
ELECTRIC SHOCK can kill.• Disconnect input power by removing
plug from receptacle before workinginside SP-100.
• Use only grounded receptacle.• Do not remove the power cord ground prong.• Do not touch electrically “hot” parts inside SP-100.• Have qualified personnel do the maintenance and
troubleshooting work.---------------------------------------------------------------------
WARNING
WARNING
CAUTION
CAUTION
Extension CordIf an extension cord is required, use one that is ratedfor the application and is 3 conductor #14 AWG (2.1mm2) or larger. The recommended maximum lengthsare 25 ft (7.5 m) if #14 AWG (2.1 mm2) is used and 50ft (15 m) if #12 AWG* (3.3 mm2) is used.*AMERICAN WIRE GAUGE
SHIELDING GASWhen using the GMAW process, a cylinder of carbondioxide (CO2) or argon-carbon dioxide mixed shieldinggas, flow regulator, and an inlet gas hose must beobtained.The Lincoln K463 CO2 or K499 Ar-mixed gas regula-tor and hose kit is recommended for use with the SP-100.
Weld shielding gas may be obtained from a weldingsupply distributor.
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 earthground.
2. With the cylinder securely installed, remove thecylinder cap. Stand to one side away from the out-let and open the cylinder valve very slightly for aninstant. This blows away any dust or dirt whichmay have accumulated in the valve outlet.
– 12 –
Flow regulator
Gas hose
Cylinder valve
BE SURE TO KEEP YOUR FACE AWAY FROM THEVALVE OUTLET WHEN “CRACKING” THE VALVE.Never stand directly in front of or behind the flowregulator when opening the cylinder valve. Alwaysstand to one side.
------------------------------------------------------------------------
3. Attach the flow regulator to the cylinder valve andtighten the union nut securely with a wrench. Flowregulator for carbon dioxide must have plasticwasher seated in the fitting that attaches to thecylinder.
4. Attach one end of inlet gas hose to the outlet fittingof the flow regulator and tighten the union nutsecurely with a wrench. Connect the other end tothe SP-100 inlet gas fitting (5/8 – 18 female threads— for CGA – 032 fitting). Make certain the gashose is not kinked or twisted.
5. For CO2, open the cylinder valve slowly. For argon-mixed gas, open cylinder valve slowly a fraction ofa turn. When the cylinder pressure gauge pointerstops moving, open the valve fully.
6. If using a regulator with an adjustable flowmeter,close the gun trigger and adjust the flow to give 15–20 cubic ft per hour (CFH) (7 – 10 L/min) [use 20– 25 CFH (10 – 12 L/min) when welding out of posi-tion or in a drafty location for C02]. For argon mixedgas, adjust the flow to give 25-30 CFH (12-14L/min).
7. Keep the cylinder valve closed, except when usingthe SP-100. When finished welding:a)First close the cylinder valve to stop gas flow,b) then depress the gun trigger briefly to release the
pressure in the gas hose.c) turn off the SP-100.
OPTIONAL ACCESSORIES INSTALLATIONK463 C02 Gas Regulator and Hose Kit
Install the pressure-flow regulator to a cylinder accord-ing to the instructions in Section 1.10. Make certainthe plastic washer is seated in the fitting that attachesto the C02 cylinder. Connect one end of the 10 foot(3.0 m) hose to the SP-100 gas inlet fitting and theother end to the regulator outlet fitting.
The K463 C02 pressure-flow regulator is preset at thefactory to give a flow rate of 20 cubic feet per hour (10l/min). This setting cannot be changed.
The K463 C02 pressure-flow regulator can be used ona cylinder of argon-mixed gas if a CGA-580-320(Western Enterprises No. 810) adapter is usedbetween the cylinder and the regulator.
CYLINDER may explode if damaged.• Keep cylinder upright and chained to
support.• Keep cylinder away from areas where
it may be damaged.• Never lift welder with cylinder attached.• Never allow welding electrode to touch cylinder.• Keep cylinder away from welding or other live elec-
trical circuits.BUILDUP OF SHIELDING GAS may
harm health or kill.• Shut off shielding gas supply when not
in use.
SEE AMERICAN NATIONAL STANDARD Z-49.1,“SAFETY IN WELDING AND CUTTING” PUBLISHEDBY THE AMERICAN WELDING SOCIETY.------------------------------------------------------------------------
WARNING
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 danger-
ous.• Keep your head out of fumes.• Use ventilation or exhaust to remove
fumes from breathing zone.------------------------------------------------------------------------
WELDING SPARKS can cause fire orexplosion.
• Keep flammable material away.• Do not weld on closed containers.
------------------------------------------------------------------------ARC RAYS can burn eyes and skin.• Wear eye, ear and body protection.
------------------------------------------------------------
See additional warning information atfront of this owners manual.
-----------------------------------------------------------
K499 Argon-Mixed Gas Regulator and Hose Kit
Install the pressure-flow regulator and gauge to acylinder according to the instructions in Section 1.10.Connect one end of the 10 foot (3.0 m) hose to theSP-100 gas inlet fitting and the other end to the regu-lator fitting.
The K499 argon-mixed gas pressure-flow regulator ispreset by the manufacturer to deliver a nominal flow of30 cubic feet per hour (14 1/min) of argon or argon-mixed gas. This setting cannot be changed.
.035" (0.9 mm) Innershield Welding Kit
Includes a contact tip, gasless nozzle, and a cableliner to permit the SP-100 gun and cable to use .035(0.9 mm) diameter flux-cored electrode. Also includedis a spool of .035 (0.9 mm) Innershield® NR-211-MP.
The K549-1 Kit is for use with the Magnum™ 100Lgun (with red trigger). The fitting on the end of theliner is stenciled with the maximum rated wire size(.045"/1.2 mm).
The K464 Kit is for use with the earlier “LincolnElectric®” gun (with black trigger). The end of the brassfitting on the end of the liner for .035 (0.9 mm) wire iscolor coded green. The .023-.030 (0.6-0.8 mm) factoryinstalled liner is color coded orange.
See Maintenance and Troubleshooting Section forinstructions on installing liner and contact tip in gun.
K467 Input Line Cord
Same as line cord supplied with the SP-100 but has aNEMA type 5-20P plug for use on a 25 amp branchcircuit with a nominal voltage rating of 115 volts to 125volts, 60 hertz. Install per the following:1. Turn the SP-100 Power Switch to OFF (“O”).2. If connected, remove the line cord plug from power
supply receptacle.3. Remove the two screws that hold the line cord
receptacle in the SP-100 flanged inlet connectorand disconnect the line cord from the SP-100.
4. Connect the S18410 input line cord receptacle tothe SP-100 and replace the retaining screws.
OPERATING INSTRUCTIONSDUTY CYCLEThe SP-100 is rated at the following duty cycles.
(1) Based upon 10 minute time period. (i.e. for 20% duty cycle it is 2minutes on and 8 minutes off.)
(2) Using Optional K467 Input line cord on a 25 amp branch circuit.
SELECTING A WIRE SPOOL SIZESelect a spool size so that the wire is used up within asix month period. This eliminates needless waste ofwire due to oxidation and rusting. Dirty, oxidized, orrusty wire results in poor wire feeding and poor weld-ing performance. This wire should be discarded.
FEEDING WELDING WIRE
When inching the welding wire, the drive rolls, thegun connector block and the gun contact tip arealways energized relative to work and ground andremain energized several seconds after the guntrigger is released.------------------------------------------------------------------------1. Remove gas nozzle and contact tip from end of gun
according to instructions in the maintenance sec-tion of this manual.
2. Turn the SP-100 ON (“I”).3. Straighten the gun cable assembly.
– 13 –
DutyCondition Cycle(1) Amps Volts
Rated Output 20% 90 18MaximumOutput(2)
30% 100 17
CSA Rated Output 20% 63 20
WARNING
WARNING
– 14 –
4. Depress the gun trigger switch and feed weldingwire through the gun and cable (Point gun awayfrom yourself and others while feeding wire.)Release gun trigger after wire appears at end ofgun.
5. Replace contact tip and gas nozzle.6. Cut the wire off 1/4 – 3/8" (6 – 10 mm) from the end
of the tip. The SP-100 is now ready to weld.
Making A Weld1. See “Recommended Processes and Equipment”
section for selection of welding wire and shieldinggas and for range of metal thicknesses that can bewelded.
2. See the Applications chart on the inside of wirefeed section door for information on setting theSP-100 controls.
3. Set the Voltage (“V”) and Wire Speed (“oIo”) con-trols to the settings suggested for the welding wireand base metal thickness being used.
4. Check that the polarity is correct for the weldingwire being used and that the gas supply, ifrequired, is turned on.
5. When using Innershield® electrode, remove thegas nozzle and install the gasless nozzle. This willimprove visibility of the arc and protect the gas dif-fuser from weld spatter.
6. Connect work clamp to metal to be welded. Workclamp must make good electrical contact to theworkpiece. The workpiece must also be groundedas stated in “Arc Welding Safety Precautions”.
7. Position gun over joint. End of wire may be lightlytouching the work.
8. Lower welding helmet, close gun trigger, andbegin welding. Hold the gun so the contact tip towork distance is about 3/8 inch (10 mm).
9. To stop welding, release the gun trigger and thenpull the gun away from the work after the arc goesout.
10. When no more welding is to be done, close valveon gas cylinder (if used), momentarily operate guntrigger to release gas pressure, and turn off SP-100.
OVERLOAD PROTECTION SHUTDOWNWelding Power Overload Protection
Exceeding the maximum rating of the SP-100 canreduce the life of the machine.------------------------------------------------------------------------The SP-100 has both a thermostat and a circuit break-er to protect the machine from damage if the maxi-mum output is exceeded. If either device is tripped,there will be no wire feed or output voltage when thegun trigger is depressed. (The fan will continue torun.)
CAUTION
If the machine shuts down due to an output overload,first check the circuit breaker which is located on theinside panel of the wire feed section. If the button isextended, reset after several minutes of cooling, bydepressing the button.
If there is no output and the circuit breaker is nottripped, the internal thermostat has probably tripped.This device will automatically reset after several min-utes of cooling. Leaving the machine on with the fanmotor running will cool the machine at a faster rate,allowing the thermostat to reset sooner.
If the SP-100 does not operate and the fan does notrun with the machine ON (“I”), the power supplybranch circuit protection (circuit breaker or fuse) hastripped.
Wire Feed Overload Protection
The SP-100 has an automatic electronic protectioncircuit to protect the wire feed motor. If excessivemotor overload occurs (due to prolonged excessivefeeding force, jammed drive rolls or shorted motorleads), the circuit will shutdown the wire feed motorand the welding power output.
The wire feed shutdown will reset automatically whenthe gun trigger is released, but will reoccur if the over-load situation is not corrected. The two most commoncauses of wire feed overload are an excessively bentgun cable and a plugged contact t ip. (SeeMaintenance and Troubleshooting Section.)
The serviceability of a product or structure utilizingthis type of information is and must be the soleresponsibility of the builder/user. Many variablesbeyond the control of The Lincoln Electric Companyaffect the results obtained in applying this type ofinformation. These variables include, but are notlimited to, welding procedure, plate chemistry andtemperature, weldment design, fabrication methodsand service requirements.
No one can learn to weld simply by reading about it.Skill comes only with practice. The following pageswill help the inexperienced operator to understandwelding and develop this skill. For more detailed infor-mation, order a copy of “New Lessons in Arc Welding”listed inside the back cover of this manual.
THE ARC-WELDING CIRCUITThe operator’s knowledge of arc welding must gobeyond the arc itself. The operator must know how tocontrol the arc, and this requires a knowledge of thewelding circuit and the equipment that provides theelectric current used in the arc. Following is a drawingof the welding circuit for the SP-100. The circuitbegins where the gun cable is attached to the weldingmachine. Current flows through the gun cable, gun,and contact tip, to the wire and across the arc. On thework side of the arc, current flows through the basemetal to the work cable and back to the weldingmachine. This circuit must be complete for the currentto flow.
The SP-100 welding circuit has a voltage output of 28volts DC maximum. This voltage is quite low and isonly present when the gun trigger is depressed.
To weld, the work clamp must be tightly connected toclean base metal. Remove paint, rust, dirt or oil asnecessary and connect the work clamp as close aspossible to the area you wish to weld. This helps pre-vent current from going through an unwanted path.Avoid allowing the welding circuit to pass throughhinges, bearings, electronic components, or similardevices that can be damaged. Always disconnectelectrical devices before welding upon them.
– 15 –
Fume and slag generated from Innershield typeelectrodes recommended for use with this weldingmachine can be toxic.
• Avoid contact with eyes and skin.• Do not take internally.• Keep out of reach of children.• Follow all safety precautions found in this oper-ating manual.
FIRST AID: If contact in eyes, flush immediatelywith clean water for at least 15 minutes. If swal-lowed, induce vomiting. Never give anything bymouth to an unconscious person. Call a physi-cian.----------------------------------------------------------------------The gun and cable assembly is held by the operatorwho guides the automatically fed wire along the joint,maintaining a contact tip to work distance of about 3/8to 1/2 inch (10 – 12 mm) (this is called electrical stick-out). This electrical stickout (ESO) must be properlymaintained by the operator. The electric arc is madein the gap between the work and the tip end of a smalldiameter wire. When the power source is properly set,the arc gap is maintained automatically.
Arc welding is a manual skill requiring a steady hand,good physical condition, and good eyesight. The oper-ator controls the welding arc, and, therefore, the quali-ty of the weld made.
THE SELF-SHIELDED FCAW WELDINGARCThe following drawing illustrates the action takingplace in the self-shielded FCAW (Innershield) weldingarc. It closely resembles what is actually seen whilewelding.
The “arc stream” is seen in the middle of the picture.This is the electric arc created by the electric currentflowing through the space between the end of the wireelectrode and the base metal. The temperature of thisarc is about 6000°F, which is more than enough tomelt metal. The arc is very bright, as well as hot, andcannot be looked at with the naked eye without riskingpainful injury. The very dark lens, specificallydesigned for arc welding, must be used with thehand or face shield whenever viewing the arc.
The arc melts the base metal and actually digs into it,much as water through a nozzle on a garden hosedigs into the earth. The molten metal forms a moltenpool or crater and tends to flow away from the arc. Asit moves away from the arc, it cools and solidifies.
The function of the Innershield cored wire electrode ismuch more than simply to carry current to the arc. Thewire core is composed of fluxes and/or alloying ingre-dients around which a steel sheath has been formed.It is simply a stick electrode turned inside out in a con-tinuous wire form.
LEARNING TO WELD
SP-100 Welderand controls
Gun cable
Base metal(work)Work clamp
Work cable
Arc
Electronic components
Hinges
WARNING
– 16 –
The cored wire melts in the arc and tiny droplets ofmolten metal shoot across the arc into the moltenpool. The wire sheath provides additional filler metalfor the joint to fill the groove or gap between the twopieces of the base metal.
The core materials also melt or burn in the arc andperform several functions. They make the arc stead-ier, provide a shield of smoke-like gas around the arcto keep oxygen and nitrogen in the air away from themolten metal, and provide a flux for the molten pool.The flux picks up impurities and forms the protectiveslag on top of the weld during cooling.
After running a weld bead, the slag may be removedwith a chipping hammer and wire brush. Thisimproves appearance and allows for inspection of thefinished weld.
Since machine size and output characteristics limit thesize and type of wire electrode which can be used,Lincoln .035" (0.9 mm) NR-211-MP Innershield elec-trode is recommended for Self-Shielded Flux CoredArc Welding with the SP-100.
MACHINE SET UP FOR THE SELF-SHIELDED FCAW PROCESS1. See page 6, “Recommended Processes and
Equipment” for selection of welding wire and shield-ing gas, and for range of metal thicknesses that canbe welded.
2. See the “Welding” chart on the inside of wire feedsection door for information on setting the controls.(Also on page 23 of this manual.)
3. Set the “Voltage” and “Wire Speed” controls to thesettings suggested on the chart for the welding wireand base metal thickness being used. The voltagecontrol is marked “V” and the wire feed speed ismarked “olo.”
4. Check that the polarity is correct for the weldingwire being used. Set the polarity for DC– whenwelding with NR-211-MP Innershield electrode.(See installation instructions on page 9 on how tomake output polarity connection.)
5. When using Innershield electrode, the gasless noz-zle may be used instead of a gas nozzle to giveimproved visibility.
6. Connect work clamp to metal to be welded. Workclamp must make good electrical contact to theworkpiece. The workpiece must also be groundedas stated in “Arc Welding Safety Precautions” sec-tion of this manual.
WELDING TECHNIQUES FOR THE SELF-SHIELDED FCAW PROCESSFour simple manipulations are of prime importance.With complete mastery of the four, welding will beeasy.
The Correct Welding Position.
Illustrated below is the correct welding position forright-handed people. (For left-handed, it is opposite.)
Hold the gun (of the gun and cable assembly) in yourright hand, and hold the hand shield with your lefthand. (Left handers simply do the opposite.)
When using the self-shielded FCAW process, weldfrom left to right (if you are right handed). This enablesyou to clearly see what you are doing. (Left handersdo the opposite.) Tilt the gun toward the direction oftravel holding the electrode at an angle as shownbelow.
The Correct Way to Strike an Arc.
1. Be sure the work clamp makes good electrical con-tact to the work.
2. Position gun over joint. End of wire may be lightlytouching the work.
3. Position faceshield to protect face and eyes, closegun trigger, and begin welding. Hold the gun so thatthe contact tip to work distance is about 3/8 to 1/2inch (10 to 12 mm).
4. To stop welding, release the gun trigger and thenpull the gun away from the work after the arc goesout.
5. A ball may form at the tip end of the wire after weld-ing. For easier restrikes (with Innershield wire), theball may be removed by feeding out a few inches ofwire and simply bending the wire back and forthuntil it breaks off.
6. When no more welding is to be done, turn off themachine.
Burning of core materialsinside wire electroderesults in shield of gas.
Arc stream
Base metalWeld metal
Protective slag
Cored wire
Molten pool
ARC RAYS can burn eyes and skin.• When using an open arc process, it is
necessary to use correct eye, headand body protection.
• Protect yourself and others; read thesection on Arc Burn at the front of this manual.
------------------------------------------------------------------------
WARNING
– 17 –
Practice.
The best way of getting practice in the four skills thatenable you to maintain:1. Correct welding position2. Correct way to strike an arc3. Correct electrical stickout4. Correct welding speed
is to spend a little more time on the following exercise.
Use the following:Mild Steel 16 gauge or 1/16 inch (1.6 mm)Electrode .035" (0.9 mm) NR-211-MP
Innershield wireVoltage setting “V” EWire feed speed olo 2
1. Learn to strike an arc by positioning the gun overthe joint and touching the wire to the work.
2. Position faceshield to protect face and eyes.3. Depress gun trigger, hold gun so contact tip to work
distance is about 3/8 to 1/2 inch (10 to 12 mm) andthe gun is at proper angle.
4. After you strike the arc, practice the correct electri-cal stickout. Learn to distinguish it by its sound.
5. When you are sure that you can hold the correctelectrical stickout, with a smooth “crackling” arc,start moving. Look at the molten puddle constantly,and look for the ridge where the metal solidifies.
6. Run beads on a flat plate. Run them parallel to thetop edge (the edge farthest away from you). Thisgives you practice in running straight welds, andalso gives you an easy way to check your progress.The 10th weld will look considerably better than thefirst weld. By constantly checking on your mistakesand your progress, welding will soon be a matter ofroutine.
COMMON METALSMost metals found around the farm, small shop orhome are low carbon steel, sometimes referred to asmild steel. Typical items made with this type of steelinclude most sheet metal, plate, pipe and rolledshapes such as channels and angle irons. This type of
The Correct Electrical Stickout
The electrical stickout (ESO) is the distance from theend of the contact tip to the end of the wire.
Once the arc has been established, maintaining thecorrect ESO becomes extremely important. The ESOshould be approximately 3/8 to 1/2 inch (10 to 12 mm)long.
The easiest way to tell whether the ESO is the correctlength is by listening to its sound. The correct ESOhas a distinctive “crackling” sound, very much likeeggs frying in a pan. A long ESO has a hollow, blow-ing or hissing sound. If the ESO is too short, you maystick the contact tip or nozzle to the weld puddleand/or fuse the wire to the contact tip.
The Correct Welding Speed
The important thing to watch while welding is the pud-dle of molten metal right behind the arc. Do not watchthe arc itself. It is the appearance of the puddle andthe ridge where the molten puddle solidifies that indi-cates correct welding speed. The ridge should beapproximately 3/8" (10 mm) behind the wire electrode.
Most beginners tend to weld too fast, resulting in athin, uneven, “wormy” looking bead. They are notwatching the molten metal.
Helpful Hints.
1. For general welding, it is not necessary to weavethe arc; neither forward or backward nor sideways.Weld along at a steady pace. You will find it easier.
2. When welding on thin plate, you will find that youwill have to increase the welding speed, whereaswhen welding on heavy plate, it is necessary to gomore slowly in order to get good penetration.
3. When welding sheet metal 16 gauge (1.5 mm) andlighter, heat buildup may cause part warpage andburnthrough. One way to eliminate these problemsis to use the backstepping method.
Contact tip
Wire electrode3/8 - 1/2” Electrical Stickout
Ridge where puddlesolidifies
Molten puddle
Contacttip 3/8-1/2”ESO
(10-12mm)
Gun angle
First weld from A to B; thenfrom C to A; then from D to C;then from E to D, and so on.
BACKSTEPPING
2-3”(50-75mm)
B A C D E
– 18 –
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 toweld. Basically, if a magnet sticks to the metal and ifyou can easily cut the metal with a file, chances aregood that you will be able to weld the materialwith the SP-100. For further information on identifying varioustypes of steels and other metals, and for proper proce-dures for welding them, we again suggest you pur-chase a copy of “New Lessons in Arc Welding” (seepage 29).
Regardless of the type of metal being welded, it isimportant in order to get a quality weld that it be freeof oil, paint, rust or other contaminant's.
TYPES OF WELDSFive types of welding joints are: Butt Welds, FilletWelds, Lap Welds, Edge Welds and Corner Welds.
Of these, the Butt Weld and Fillet Weld are the twomost common welds.
WELDING PROCEDURESButt Welds
Place two plates side by side, leaving a space approx-imately one half the thickness of the metal betweenthem in order to get deeper penetration.
Securely clamp or tack weld the plates at both ends,otherwise the heat will cause the plates to move apart(see drawing):
Now weld the two plates together. Weld from left toright (if right handed). Point the wire electrode down inthe crack between the two plates, keeping the gunslightly tilted in the direction of travel.
Watch the molten metal to be sure it distributes itselfevenly on both edges and in between the plates.
Penetration
Unless a weld penetrates close to 100% of the metalthickness, a butt weld will be weaker than the materialwelded together. In this example, the total weld is onlyhalf the thickness of the material; thus the weld is onlyapproximately half as strong as the metal.
In this example, the joint has been welded so that100% penetration could be achieved. The weld, ifproperly made, is as strong as or stronger than theoriginal metal.
Fillet Welds
When welding fillet welds, it is very important to holdthe wire electrode at a 45° angle between the twosides, or the metal will not distribute itself evenly. Thegun nozzle is generally formed at an angle to facilitatethis.
WELDING IN THE VERTICAL POSITIONWelding in the vertical position can be done either ver-tical-up or vertical-down. Vertical-up is used whenevera larger, stronger weld is desired. Vertical-down isused primarily on sheet metal 5/32" (3.9 mm) andunder for fast, low penetrating welds.
Use of the SP-100 on thicker materials than rec-ommended may result in poor welds. The weldsmay “look” good, but may just be “sitting” on topof the plate. This is called “Cold Casting” and willresult in weld failure. See Recommended Processesand Equipment.___________________________________________
Poor
Butt weld Lap weld
Edge weld Fillet weld Corner weld
Good
45˚
WARNING
– 19 –
Vertical-Up and Overhead Welding
The problem, when welding vertical-up, is to put themolten metal where it is wanted and make it staythere. If too much molten metal is deposited, gravitywill pull it downwards and make it “drip.” Therefore, acertain technique has to be followed.
When welding out-of-position, run stringer beads.Don’t whip, break the arc, move out of the puddle, ormove too fast in any direction. Use WFS in the lowportion of the range. General techniques are illustrat-ed below.
Generally, keep the electrode nearly perpendicular tothe joint as illustrated. The maximum angle above per-pendicular may be required if porosity becomes aproblem.
Vertical-Down Welding
Vertical-down welds are applied at a fast pace. Thesewelds are therefore shallow and narrow, and as suchare excellent for sheet metal. Vertical-down weldsmay be applied to 5/32" (3.9 mm) and lighter material.This material is within the range of the SP-100 whenused with .035" (0.9 mm) NR-211-MP Innershieldelectrode.
Use stringer beads and tip the gun in the direction oftravel so the arc force helps hold the molten metal inthe joint. Move as fast as possible consistent withdesired bead shape.
The important thing is to continue lowering the entirearm as the weld is made so the angle of the gun doesnot change. Move the electrode wire fast enough thatthe slag does not catch up with the arc. Vertical-downwelding gives thin, shallow welds. It should not beused on heavy material where large welds arerequired.
THE GMAW (MIG) WELDING ARCThe drawing below illustrates the GMAW (MIG) weld-ing arc. Solid wire does not contain fluxes or ingredi-ents to form its own shielding and no slag forms to
Maximum platethickness 5/16” (8.0mm)
protect the molten weld metal. For this reason, a con-tinuous even flow of shielding gas is needed to protectthe molten weld metal from atmospheric contaminan-t's such as oxygen and nitrogen. Shielding gas is sup-plied through the gun and cable assembly through thegas nozzle, and into the welding zone.
The shielding gas has several other functions besidesprotecting the molten weld metal. It helps shape thecross section of the weld deposit, may increase ordecrease arc temperature, stabilizes the arc, and reg-ulates penetration.
When comparing the GMAW and FCAW processes,you can see that the principal difference between thetwo lies in the type of shielding used. GMAW uses gasfor shielding, thus we have Gas Metal Arc Welding.FCAW uses the melting or burning of the core ingredi-ents for shielding, and is thus termed Self-ShieldedFlux Cored Arc Welding.
The recommended wire for Gas Metal Arc Welding(MIG) is Lincolnweld® .025" L-56 electrode.Lincolnweld® L-56 is capable of welding a wide rangeof mild steels in all positions, however, more skill isrequired for out-of-position welding with the GMAWprocess.
PROCESS SELECTIONBy gaining knowledge of the differences between thetwo processes, you will be able to select the bestprocess for the job you have at hand. In selecting aprocess, you should consider:
For GMAW (MIG) process
1. Is most of my welding performed on 16 gauge andlighter materials?
2. Can I afford the extra expense, space, and lack ofportability required for gas cylinders and gas supplylines?
3. Do I require clean, finished-looking welds?
If you have answered yes to all the above questions,GMAW may be the process for you. If you haveanswered no to any of the above questions then youshould consider using the FCAW process.
For FCAW (Innershield) process
1. Do I want simplicity and portability?2. Will welding be performed outdoors or under windy
conditions?3. Do I require good all position welding capability?4. Will most welding be performed on 16 gauge and
heavier, somewhat rusty or dirty materials?5. Weld must be cleaned prior to painting.
Gas nozzle
Shielding gas
Weld metal
Solid wireelectrode
Base metal
MACHINE SETUP FOR THE GMAW (MIG)PROCESS1. See “Recommended Processes and Equipment” for
selection of welding wire and shielding gas and forrange of metal thicknesses that can be welded.
2. See the “Welding ” chart on the inside of wire feedsection door or in this manual for information onsetting the controls.
3. Set the “Voltage” and “Wire Speed” controls to thesettings suggested for the welding wire and basemetal thickness being used. The voltage control ismarked “V” and the wire feed speed is marked olo.
4. Check that the polarity is correct for the weldingwire being used. Set the polarity for DC(+) whenwelding with the GMAW (MIG) process. (See page9 of the Installation Instructions on how to makeoutput polarity connections.)
5. Check that the gas nozzle and proper size liner andcontact tip are being used, and that the gas supplyis turned on. If adjustable, set for 15 to 20 cubicfeet per hour (7 to 10 liters/min) under normal con-ditions; increase as high as 35 CFH (17 liters/min)under drafty (slightly windy) conditions.NOTE: The gas regulators included in the optionalK463 and K499 kits are preset and nonadjustable.
6. Connect work clamp to metal to be welded. Workclamp must make good electrical contact to theworkpiece. The workpiece must also be groundedas stated in “Arc Welding Safety Precautions.”
WELDING TECHNIQUES FOR THE GMAW(MIG) PROCESSThe welding techniques for the GMAW (MIG) processon light gauge material are basically the same aswelding with .035" (0.9 mm) NR-211-MP Innershieldelectrode. (Review welding techniques in the self-shielded FCAW Innershield section on page 14.) Thefew exceptions are noted below.
The Correct Welding Position
When using the GMAW process on light gauge mater-ial, weld from right to left (if right handed) pushing theelectrode ahead of the arc (see figure following). Thistechnique results in a colder weld and has less ten-dency for burnthrough. You may weld in the oppositedirection as long as you are obtaining desirableresults.
The Correct Way to Strike an Arc
1. The arc is struck the same as for self-shieldedFCAW welding. However, for easier restrikes, theball at the tip end of the wire which forms after com-pleting a weld may be removed with wire cutters.
2. When no more welding is to be done, don’t forget tofirst close valve on gas cylinder (if used), momentarily
operate gun trigger to release gas pressure, then turn offthe machine.
The Correct Electrical Stickout
The electrical stickout (ESO) for GMAW (MIG) weld-ing is 3/8 to 1/2 inch (10 to 12 mm). The same rulesapply as when welding with .035" (0.9 mm) NR-211-MPInnershield wire.
The Correct Welding Speed
The same rules apply as those for self-shieldedFCAW welding. At first, it may be more difficult tojudge speed since no slag is forming behind themolten pool. Watch the ridge where the molten puddlesolidifies.
Practice
To practice your GMAW (MIG) welding skills, use thefollowing:Mild steel 16 gauge (about 1/16 inch)Electrode Lincolnweld® .025 L-56 electrodeShielding gas CO2Voltage setting “V” GWire feed speed olo 5
Then follow the instructions in the practice section onself-shielded FCAW welding.
WELDING PROCEDURESWhen GMAW (MIG) welding on sheet metal, remem-ber to use the “forehand” push technique, and reviewthe welding procedures section on self-shieldedFCAW Innershield welding.
Welding in the Vertical Position
One variation of welding procedure is welding in thevertical-up position. When welding in the vertical-upposition, use the proper gun angle shown below.
Gun angle for the GMAW process welding in the vertical-up position.
Push Technique
– 20 –
– 21 –
TROUBLESHOOTING WELDSGood welds have excellent appearance.
To Eliminate Porosity (in order of importance) —
Turn on gas supply, if used1. Decrease voltage2. Increase stickout3. Increase WFS (wire feed speed)4. Decrease drag angle5. Decrease travel speed.
NOTE: Always be sure the joint is free from mois-ture, oil, rust, paint or other contaminant's.
To Eliminate a Ropey Convex Bead (in order ofimportance)
1. Increase voltage2. Decrease stickout3. Decrease WFS (wire feed speed)4. Decrease travel speed5. Decrease drag angle6. Check for correct gas, if used
To Reduce Spatter (in order of importance)
1. Increase voltage2. Increase drag angle3. Decrease stickout4. Increase WFS (wire feed speed)5. Decrease travel speed6. Check for correct gas, if used
To Correct Poor Penetration (in order of importance)1. Decrease stickout2. Increase WFS (wire feed speed) (“oIo”)3. Decrease voltage (“V”)4. Increase speed5. Decrease drag angle6. Check for correct gas, if used
If Arc Blow Occurs (in order of importance)(NOTE: Try different ground connection locationsbefore adjusting procedures)
1. Decrease drag angle2. Increase stickout3. Decrease voltage (“V”)4. Decrease WFS (wire feed speed) (“oIo”) and
voltage (“V”)5. Decrease travel speed
To Eliminate Stubbing (in order of importance)1. Increase voltage (“V”)2. Decrease WFS (wire feed speed) (“oIo”)3. Decrease stickout4. Increase drag angle
Stubbing occurs when the electrode drives throughthe molten puddle and hits the bottom plate tending topush the gun up.
PROPER GUN HANDLINGMost feeding problems are caused by improper han-dling of the gun cable or electrodes.
1. Do not kink or pull the gun cable around sharp cor-ners.
2. Keep the gun cable straight as practical when weld-ing.
3. Do not allow dolly wheels or trucks to run over thecables.
4. Keep the cable clean per maintenance instructionsin this Operation Manual.
5. Innershield electrode has proper surface lubrica-tion. Use only clean, rust-free electrode.
6. Replace the contact tip when it becomes worn orthe end is fused or deformed.
ROUTINE MAINTENANCE
Requires NO Maintenance• Drive Motor and Gearbox - Lifetime lubrication• Fan Motor - Lifetime lubrication.• Wire Reel Spindle - Do NOT lubricate shaft.
Before Each Use• Check over machine and accessories for any obvious condition that may
prevent safe performance or operation, repair or replace items as necessaryto correct any abnormal condition.
After 5 minutes of welding or when spatter accumulates in nozzle• Clean nozzle to avoid bridging between nozzle and contact tip which results
in shorted nozzle, poor welds and overheated gun. Hint: Anti-stick spray or gel available from a welding supply distributor may reduce buildup and aid inspatter removal.
After each spool of wire feed• Remove contact tip and clean inside diameter with short piece of wire• Clean cable liner - when rough and erratic wirefeeding occur.
After feeding 50# of Flux Cored Wire or 300# of Solid WireUnplug machine or turn power switch to OFF - "O" position.Remove gun and cable from machine.Remove gas nozzle and contact tip from gunLay cable out straight - blow out gently with compressed air - Bend cableback and forth - blow out again - Repeat until clean. CAUTION Excessivepressure at start may cause the dirt to form a plug.
Perodically As Required• Blow dirt out of the welder with low pressure air to eliminate excessive dirt and
dust buildup that could cause welder to run hot.• Vacuum accumulated dirt from gearbox and wire feed section.• Inspect the incoming guide tube and clean inside diameter if necessary.
Replace when excessively worn.• Replace Contact Tip - when hole is enlarged or elongated
Unplug machine or turn power switch to OFF - "O" position.Unscrew nozzle by turning counterclockwise.Unscrew contact tip by turning counterclockwiseReplace contact tip - use correct size - see stencil on tip - tighten snugly.Replace gas nozzle.
– 22 –
ELECTRIC SHOCK can kill.• Disconnect input power by removing
plug from receptacle before workinginside SP-100.
• Use only grounded receptacle.• Do not touch electrically "hot" parts inside SP-100.• Have qualified personnel do the maintenance and
troubleshooting work.
WARNING
– 23 –
• Replace Liner - when wire feeding problems occur and other items have been checked.NOTICE: The variation in cable lengths prevents the interchangeability of liners.Once a liner has been cut for a particular gun, it should not be installed in another gun unless it can meet the liner cutoff length requirement.
Remove gun and cable assembly from machine.Remove the nozzle according to the instructions in contact tip replacement.Remove the gas diffuser from the gun tube by unscrewing counterclockwise.Lay the gun and cable out straight on a flat surface. Loosen the set screw located in the brass connector at the wire feeder end of the cable.Pull the liner out of the cable.Insert a new untrimmed liner into the connector end of the cable. Be sure the liner bushing is stencilled appropriately for the wire size beingused.Fully seat the liner bushing into the connector. Tighten the set screw onthe brass cable connector. At this time, the gas diffuser should not beinstalled onto the end of the gun tube.With the gas nozzle and diffuser removed from the gun tube, be sure the cable is straight, and then trim the liner to the length shown in the diagram below. Remove any burrs from the end of the liner.Screw the gas diffuser onto the end of the gun tube and securely tighten.Replace the contact tip and nozzle.
• Replace internal gun handle parts as necessary.The gun handle consists of two halves that are held together with a collaron each end. To open up the handle, turn the collars approximately 60 degrees counterclockwise (the same direction as removing a right handthread) until the collar reaches a stop. Then pull the collar off the gunhandle. If the collars are difficult to turn, position the gun handle againsta corner, place a screwdriver against the tab on the collar and give thescrewdriver a sharp blow to turn the collar past an internal locking rib.
Liner trim length for the Magnum 100L gun. (red trigger)
1-1/4"(1.25)(31.8 mm)Liner trimlength
Gas diffuser
Gas nozzleor gasless nozzle
Brass cableconnectorSet screw
Liner assembly(Liner bushing to be seated tightagainst brass cable connector)
COUNTERCLOCKWISE
– 24 –
GENERAL TROUBLESHOOTING GUIDE
ProblemsProblem Possible Cause What To Do
No Wire Feed, Weld Welder not ON (“I”) Turn welder power ON (“I”)Output or Gas Flow
Welder not plugged in Plug in - check both ends of input cable
Gun Cable Damaged Inspect or Replace
Trigger Switch Problem Repair or Replace
Circuit breaker or Thermostat Tripped See “Overload Protection Shutdown” Section
No Arc, Weak Arc Poor ground connection to work Check ground connection
Gun or Power cable connection loose Check - repair or replace cable or connectors
Voltage set too low Adjust Voltage
Tip too large for wire size Use correct tip
No Wire Feed Wire spool or reel empty Install new spool or reel
Drive Roll size incorrect Change Drive Roll - Refer to proper section
Drive Roll worn Replace
Wire Drive release open Close wire drive release
Wire welded to tip Peel wire off or use new tip
Kink or bend in Wire Remove wire, cut out kink, reload wire
Tip or cable liner to small for wire Insert correct tip or liner
Trigger circuit connections loose Check connections
Dirty or Worn cable liner Clean or Replace - Refer to proper section
Wire feed too fast or slow Wrong speed set for work Adjust wire feed speed at machine
ELECTRIC SHOCK can kill.• Disconnect input power by removing
plug from receptacle before workinginside SP-100.
• Use only grounded receptacle.• Do not touch electrically "hot" parts inside SP-100.• Have qualified personnel do the maintenance and
troubleshooting work.
WARNING
– 25 –
Low or no gas flow Cylinder valve closed Open cylinder valve
Gas flow not set correctly Set proper flow rate
Cylinder out of gas Get new cylinder of gas
Leak in gas line Inspect and replace
Clog or Leak in gun Check for obstruction or defective seals
Arc unstable Wrong welding polarity Check polarity - Refer to proper section
Erratic or Intermittent Wrong size, worn and/or Replace tip - remove any spatter on end of tipArc - Poor Starting melted contact tip"Hunting" Arc
Worn work cable or poor connections Inspect - repair or replace as necessary
Loose electrode connections Be sure electrode lead is tight, gun cable tight inwire feeder contact block, gun nozzle and guntip tight
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– 41 –
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– 42 –
WARNING
AVISO DEPRECAUCION
ATTENTION
WARNUNG
ATENÇÃO
Spanish
French
German
Portuguese
Japanese
Chinese
Korean
Arabic
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BEUSED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOSCONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS AETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
● Do not touch electrically live parts orelectrode with skin or wet clothing.
● Insulate yourself from work andground.
● No toque las partes o los electrodosbajo 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 contactavec des pièces sous tension.
● Isolez-vous du travail et de la terre.
● Berühren Sie keine stromführendenTeile oder Elektroden mit IhremKörper oder feuchter Kleidung!
● Isolieren Sie sich von denElektroden und dem Erdboden!
● Não toque partes elétricas e elec-trodos com a pele ou roupa molha-da.
● Isole-se da peça e terra.
● Keep flammable materials away.
● Mantenga el material combustiblefuera del área de trabajo.
● Gardez à l’écart de tout matérielinflammable.
● Entfernen Sie brennbarres Material!
● Mantenha inflamáveis bem guarda-dos.
● Wear eye, ear and body protection.
● Protéjase los ojos, los oídos y elcuerpo.
● Protégez vos yeux, vos oreilles etvotre corps.
● Tragen Sie Augen-, Ohren- und Kör-perschutz!
● Use proteção para a vista, ouvido ecorpo.
– 43 –
WARNING
AVISO DEPRECAUCION
ATTENTION
WARNUNG
ATENÇÃO
Spanish
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LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA ASPRÁTICAS DE SEGURANÇA DO EMPREGADOR.
● Keep your head out of fumes.● Use ventilation or exhaust to
remove fumes from breathing zone.
● Los humos fuera de la zona de res-piración.
● Mantenga la cabeza fuera de loshumos. Utilice ventilación oaspiración para gases.
● Gardez la tête à l’écart des fumées.● Utilisez un ventilateur ou un aspira-
teur pour ôter les fumées des zonesde travail.
● Vermeiden Sie das Einatmen vonSchweibrauch!
● Sorgen Sie für gute Be- undEntlüftung 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 máquinaantes de iniciar cualquier servicio.
● Débranchez le courant avant l’entre-tien.
● Strom vor Wartungsarbeitenabschalten! (Netzstrom völlig öff-nen; Maschine anhalten!)
● Não opere com as tampas removidas.● Desligue a corrente antes de fazer
serviço.● Não toque as partes elétricas nuas.
● Do not operate with panel open orguards off.
● No operar con panel abierto oguardas quitadas.
● N’opérez pas avec les panneauxouverts ou avec les dispositifs deprotection enlevés.
● Anlage nie ohne Schutzgehäuseoder Innenschutzverkleidung inBetrieb setzen!
● Mantenha-se afastado das partesmoventes.
● Não opere com os paineis abertosou guardas removidas.
STATEMENT OF WARRANTY:
The Lincoln Electric Company (Lincoln) warrants to theoriginal purchaser (end-user) of new equipment that it willbe free of defects in workmanship and material.
This warranty is void if Lincoln finds that the equipment hasbeen subjected to improper care or abnormal operation.
WARRANTY PERIOD:
All warranty periods date from the date of shipment to theoriginal purchaser and are as follows:
Three Years:Transformer WeldersMotor-generator WeldersSemiautomatic Wire FeedersPlasma-cutting Power SourceEngine Driven Welders (except engine and engine accessories) with operating speed under 2,000 RPM
Two Years:Engine Driven Welders (except engine and engineaccessories) with operating speed over 2,000 RPM
All engine and engine accessories are warranted by theengine or engine accessory manufacturer and are not cov-ered by this warranty.
Equipment not listed above such as guns and cableassemblies, automatic wire feeders and field-installedoptional equipment is warranted for one year.
TO OBTAIN WARRANTY COVERAGE:
You are required to notify Lincoln Electric, your LincolnDistributor, Lincoln Service Center or Field Service Shop ofany defect within the warranty period. Written notification isrecommended.
WARRANTY REPAIR:
If Lincoln's inspection of the equipment confirms the exis-tence of a defect covered by this warranty, the defect willbe corrected by repair or replacement at Lincoln's option.
WARRANTY COSTS:
You must bear the cost of shipping the equipment to aLincoln Service Center or Field Service Shop as well asreturn shipment to you from that location.
IMPORTANT WARRANTY LIMITATIONS:
• Lincoln will not accept responsibility for repairs madewithout its authorization.
• Lincoln shall not be liable for consequential damages(such as loss of business, etc.) caused by the defect or reasonable delay in correcting the defect.
• Lincoln's liability under this warranty shall not exceedthe cost of correcting the defect.
• This written warranty is the only express warranty provided by Lincoln with respect to its products. Warranties implied by law such as the Warranty ofMerchantability are limited to the duration of thislimited warranty for the equipment involved.
LIMITED WARRANTY
PP
ERFORMANCELUSPROTECTION
3YEARWARRANTY
PARTS &LABOR
R
Sales and Service through Subsidiaries and Distributors Worldwide22801 St. Clair Ave. Cleveland, Ohio 44117-1199 U.S.A. Tel. (216) 481-8100
World's Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors
warranty superseded
see imws 1
