Lincoln Electric SP-100 Service Manual
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Lincoln Electric SP-100 Service Manual

Lincoln electric welder user manual
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See also: Operator's Manual
SVM102-A
RETURN TO MAIN INDEX
March, 1999
SP- 100
For use with machines
9284-10050
having Code Numbers
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 be careful.

SERVICE MANUAL

World's Leader in Welding and Cutting Products
Premier Manufacturer of Industrial Motors
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

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Summary of Contents for Lincoln Electric SP-100

  • Page 1: Service Manual

    SVM102-A RETURN TO MAIN INDEX March, 1999 SP- 100 For use with machines 9284-10050 having Code Numbers 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 ...

  • Page 2: Electric Shock Can Kill

    Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PER- FORMED ONLY BY QUALIFIED INDIVIDUALS.
  • Page 3 6.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations. 6.c. Ground the equipment in accordance with the U.S. National Electrical Code and the manufacturer’s recommendations. Mar. ‘93 SP-100...
  • Page 4 ___________________________________________________ 7.h. To avoid scalding, do not remove the radiator pressure cap when the engine is hot. SP-100 SAFETY ELECTRIC AND MAGNETIC FIELDS may be dangerous 8.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF).

  • Page 5: March

    électricien qualifié. 3. Avant de faires des travaux à l’interieur de poste, la debrancher à l’interrupteur à la boite de fusibles. 4. Garder tous les couvercles et dispositifs de sûreté à leur place. Mar. ‘93 SP-100...

  • Page 6: Table Of Contents

    Thermal Protection ...E-5 Troubleshooting and Repair...Section F How To Use Troubleshooting Guide...F-1 PC Board Troubleshooting Procedures ...F-2 Troubleshooting Guide...F-3 Oscilloscope Waveforms ...F-9 Replacement Procedures ...F-12 Retest After Repair ...F-14 Electrical Diagrams...Section G SP-100 Parts Manual ...P-180 SP-100 RETURN TO MAIN INDEX Page...
  • Page 7 Tilting...A-3 Output Connections ...A-3 Work Clamp Installation ...A-3 Work Cable Installation ...A-3 Gun Installation ...A-4 Connecting Gun Cable to the SP-100 ...A-4 Gas Connection ...A-4 Input Connections...A-5 Code Requirements For Input Connections...A-6 Requirements For Rated Output...A-6 Requirements For Maximum Output ...A-6 Requirements For CSA Rated Output ...A-6...

  • Page 8: Installation

    TECHNICAL SPECIFICATIONS – SP-100 Standard Voltage/Frequency 115V/60Hz 115V/60Hz 115V/60Hz Duty Cycle 20% Duty Cycle 30% Duty Cycle 20% Duty Cycle - CSA Rated Output Welding Current Range (Continuous) Maximum Open Circuit Voltage Rated DC Output: 0 - 90 amps Maximum DC Output: 0 - 100 amps...

  • Page 9: Identify And Locate Components

    • Machine must be plugged into a receptacle which is grounded per any national, local or other applicable electrical codes. • The SP-100 power switch is to be in the OFF (“O”) position when installing work cable and gun and when connecting power cord to input power.

  • Page 10: Select Suitable Location

    SELECT SUITABLE LOCATION Locate the welder in a dry location where there is free circulation of clean air into the louvers in the back and out the front of the unit. A location that minimizes the amount of smoke and dirt drawn into the rear louvers reduces the chance of dirt accumulation that can block air passages and cause overheating.

  • Page 11: Gun Installation

    (+) terminal (4). FIGURE A.4 GUN INSTALLATION As shipped from the factory, the SP-100 gun is ready to feed 0.023 - 0.025” (0,6 mm) wire. If 0.030” (0,8 mm) wire is to be used install the 0.030” (0.8 mm) contact tip.

  • Page 12: Input Connections

    Connect the other end to the SP-100 Gas Solenoid Inlet Fitting (5/8-18 female threads — for CGA — 032 fitting). Make certain the gas hose is not kinked or twisted.

  • Page 13: Code Requirements For Input Connections

    25 amp branch circuit with a nominal voltage rating of 115 to 125 volts, 60 Hertz, AC only. With this installa- tion the SP-100 can be used at an output of 100 amps, 17 volts, 30% duty cycle. Refer to the ACCESSORIES section for specific infor-...
  • Page 14 NOTES SP-100...

  • Page 15: General Description

    Shielding Gas ...B-5 Making a Weld ...B-5 Cleaning Tip and Nozzle...B-6 Changing Machine Over To Feed Other Wire Sizes ...B-6 Welding With Innershield ...B-6 Overload Protection ...B-6 Output Overload ...B-6 Thermal Protection ...B-6 Wire Feed Overload Protection ...B-6 Section B SP-100...

  • Page 16: Operation

    Read entire operation section before operating the SP-100. Observe all safety information throughout this manual. SP-100 OPERATION WARNING ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrode with skin or wet clothing. Insulate yourself from work and ground.

  • Page 17: General Description

    Lincoln Innershield .035” (0,9 mm) NR®-211- MP electrode. Easy to change polarity. WELDING CAPABILITY The SP-100 is rated at 90 amps, 18 volts, at 20% duty cycle on a ten minute basis. It is capable of higher duty cycles at lower output currents. LIMITATIONS Arc Gouging cannot be performed with the SP-100.

  • Page 18: Welding Operations

    FIGURE B.1b WELDING OPERATIONS PROCESS GUIDELINES The SP-100 can be used for welding mild steel using the GMAW, single pass, process which requires a supply of shielding gas or it can be used for the self shielded, Innershield electrode process.

  • Page 19: Friction Brake Adjustments

    FIGURE B.4 The Wire Drive Feed Roll can accommodate two wire sizes by flipping the wire drive feed roll over. The sizes are stenciled on the drive roll. SP-100...

  • Page 20: Shielding Gas

    11. Replace contact tip and gas nozzle. 12. Refer to Figure B-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. SHIELDING GAS When using the GMAW process, a cylinder of carbon...

  • Page 21: Overload Protection

    The circuit breaker must be manually reset. THERMAL PROTECTION The SP-100 has a rated output duty cycle of 20%. If the duty cycle is exceeded, a thermal protector will shut off the output until the machine cools to a normal operating temperature.
  • Page 22 NOTES SP-100...

  • Page 23: Replacement Parts

    TABLE OF CONTENTS Section C – ACCESSORIES SECTION – Accessories ...Section C Accessories ...C-1 Replacement Parts ...C-1 SP-100...

  • Page 24: Accessories

    INNERSHIELD WELDING KITS 0.035 (0.9 mm) Innershield Welding Kit – Includes a contact tip, a gasless nozzle and a cable liner to permit the SP-100 gun and cable to use a 0.035” (0,9 mm) dia- meter flux-cored electrode. Also included is a spool of 0.035 (0,9 mm) Innershield...

  • Page 25: Items Requiring No Maintenance

    After 5 Minutes of Welding...D-1 After Each Spool of Wire Feed ...D-1 Component Replacement Procedures ...D-2 Changing The Contact Tip ...D-2 Changing Drive Roll ...D-2 Replace Liner...D-3 Replace Internal Gun Handle Parts As Necessary ...D-3 Location of Components...D-4 Section D SP-100...

  • Page 26: Maintenance

    PERIODICALLY AS REQUIRED • Unplug machine or turn power switch to • Blow dirt out of the welder with low pres- • Blow dirt out of: Rectifier & Fan Motor • Vacuum accumulated dirt from gear- •...

  • Page 27: Component Replacement Procedures

    4. Replace gas nozzle. CHANGING DRIVE ROLL The SP-100 Wire Feed Drive Roll (1 ) has two grooves; one for 0.023” – 0.025” (0,6 mm) solid steel electrode and the other for 0.030” (0,8 mm) solid and 0.035” (O,9 mm) flux-cored steel electrode.
  • Page 28 9. Screw the gas diffuser onto the end of the gun tube and securely tighten. 10. Replace the contact tip and nozzle. SP-100 MAINTENANCE REPLACE INTERNAL GUN HANDLE PARTS AS NECESSARY The gun handle consists of two halves that are held together with a collar on each end.

  • Page 29: Location Of Components

    MAINTENANCE FIGURE D.4 – LOCATION OF COMPONENTS SP-100 SUB ASSEMBLIES Case Back and Bottom Assembly Center Panel Assembly Case Front Assembly Case Side Assembly Rectifier & Fan Motor Assembly Wire Drive Assembly SP-100...
  • Page 30 NOTES SP-100...

  • Page 31: Theory Of Operation ........................................................................................Section E Input Line Voltage, Fan Motor And Main Transformer

    Section E – THEORY OF OPERATION – Theory of Operation ...Section E Input Line Voltage, Fan Motor and Main Transformer ...E-1 Output Control, Rectification and Voltage Feedback...E-2 Trigger, Gas Solenoid and Wire Drive ...E-3 SCR Operation ...E-4 Thermal Protection ...E-5 SP-100...

  • Page 32: Theory Of Operation

    MOTOR AND MAIN TRANSFORMER The 115 vac input power is applied to the SP-100 through a receptacle located on the rear panel. The input power is connected to the fan motor, control board and main transformer through a line switch located on the front panel.

  • Page 33: Output Control, Rectification And Voltage Feedback

    NOTE: Unshaded areas of block logic diagram are the subject of discussion. reflected at the transformer secondary wind- ing and is applied to the rectifier diode bridge. This rectified DC voltage is filtered by the output capacitor and choke circuit and is applied to the machine’s output ter- minals. SP-100...

  • Page 34: Trigger, Gas Solenoid And Wire Drive

    The control board varies and controls power to the drive motor, which, in turn, controls the speed of the wire drive. The SP-100 also has an automatic protection circuit which protects the wire drive motor from excessive motor over-...

  • Page 35: Scr Operation

    If the SCR is turned on early in the positive half cycle, the conduction time is longer, resulting in greater SCR output. If the gate firing occurs later in the cycle, the conduction time is less, resulting in lower SCR output. SP-100...

  • Page 36: Thermal Protection

    15 minute period. If the fan is not turning or the air intake louvers are obstructed then the input power must be removed and the fan problem or air obstruction must be cor- rected. SP-100 operating temperatures.
  • Page 37 Oscilloscope Waveforms Normal Open Circuit Voltage Waveform ...F-9 Typical Output Voltage Waveform – Machine Loaded ...F-10 Abnormal Open Circuit Voltage Waveform ...F-11 Replacement Procedures Fan Blade and Motor Removal...F-12 Wire Drive Assembly Removal...F-13 Retest After Repair ...F-14 Section F SP-100...

  • Page 38: How To Use Troubleshooting Guide

    TROUBLESHOOTING & REPAIR HOW TO USE TROUBLESHOOTING GUIDE Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.

  • Page 39: Pc Board Troubleshooting Procedures

    6. Always indicate that this procedure was followed when warranty reports are to be submitted. NOTE: Following this procedure and writing on the warranty report, “INSTALLED AND Switched PC BOARDS TO VERIFY PROB- LEM,” will help avoid denial of legitimate PC board warranty claims. SP-100...

  • Page 40: Troubleshooting Guide

    Observe Safety Guidelines detailed in the beginning of this manual. RECOMMENDED COURSE OF ACTION Contact the Lincoln Electric Service Department. (216) 383-2531 or 800-833-9353 (WELD) 1. Check for 115 VAC at input to fan motor (leads #31 to #32). If...
  • Page 41 1. Remove main power supply to SP-100. With gun trigger pulled, check for continuity (zero ohms) from 8J2 (lead #213) to 9J2 (lead #211 ) at harness plug. If zero ohms is indicated, then trigger circuit is OK.
  • Page 42 If leads are OK, replace fan motor. See Figure F.1 2. Remove main power supply to SP-100. With gun trigger pulled check for continuity (zero ohms) from 8J2 (lead #213) to 9J2 (lead #211) at harness plug. If zero ohms is indicated then trig- ger circuit is OK.

  • Page 43: Feeding Problems

    If the resis- tance is below 500,000 ohms, replace the drive motor. 2. Check the wire speed control potentiometer and associated wires #208, #209 and #203 for loose or broken connections. 3. The control board may be faulty. Replace. SP-100...

  • Page 44: Gas Flow Problems

    If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed call 216-383-2531 or 1-800-833-9353. SP-100 TROUBLESHOOTING GUIDE POSSIBLE AREAS OF...

  • Page 45: Pc Board Connector Locations

    TROUBLESHOOTING & REPAIR PC BOARD CONNECTOR LOCATIONS FIGURE F.1 Codes 9794 and above 10J2 Codes below 9794 10J2 SP-100...

  • Page 46: Normal Open Circuit Voltage Waveform

    10 volts and that each hor- izontal division represents 20 milliseconds in time. Note: Scope probes connected at machine output ter- minals. Positive probe to (+) terminal, negative probe to (–) terminal. SP-100 20 ms/Div SCOPE SETTINGS Volts/Div ...10/Div Horizontal Sweep ...20 ms/Div Coupling ...DC...

  • Page 47: Typical Output Voltage Waveform - Machine Loaded

    The ammeter read 90 amps and the voltmeter read 19 vdc. Note: Scope probes connected at machine output ter- minals. Positive probe to (+) terminal, negative probe to (–) terminal. 20 ms SCOPE SETTINGS Volts/Div ...10/Div Horizontal Sweep ...20 ms/Div Coupling ...DC Trigger...Internal F-10 volts SP-100...

  • Page 48: Abnormal Open Circuit Voltage Waveform

    10 volts and that each hor- izontal division represents 20 milliseconds in time. Note: Scope probes connected at machine output ter- minals. Positive probe to (+) terminal, negative probe to (–) terminal. SP-100 20 ms SCOPE SETTINGS Volts/Div ...10/Div Horizontal Sweep ...20 ms/Div Coupling ...DC...
  • Page 49 13. Remove the two Phillips head screws holding the motor to the bracket. Remove the motor. 14. If the output diodes are to be removed, the leads must be removed from the diodes and the heat F-12 FIGURE F.2 FIGURE F.3 Gas Solenoid FIGURE F.4 Thermostat Diodes SP-100...

  • Page 50: Wire Drive Assembly Removal

    2. Using 1/4” nutdriver, remove two 8-32X1” thread forming screws connecting front to rear housing (2). Refer to Figure F-7 SP-100 FIGURE F.5 Two plastic fastener buttons attach the Connector Block to the Front Panel at these points. To remove the Connector Block, cut the heads off of the two fastener buttons.

  • Page 51: Retest After Repair

    2-20 vac Dependent on arc voltage control setting (min. to max.) @ OUTPUT (DC) 90 amps @ 18 vdc VOLTAGES 10 to 27 vdc Dependent on arc voltage control setting (min. to max.) Dependent on wire speed control setting 12/95 F-14 SP-100...
  • Page 52 F-15 NOTES: SP-100...
  • Page 53 TABLE OF CONTENTS Section G – ELECTRICAL DIAGRAMS SECTION – Electrical Diagrams ...Section G SP-100 Wiring Diagram (codes 9794 and above)...G-2 SP-100 Wiring Diagram (codes below 9794) ...G-3 Control PC Board (G1842) Components...G-4 Control PC Board (G2314) Components...G-6 Machine Schematic (codes 9794 and above) ...G-8 Machine Schematic (below code 9794) ...G-9...

  • Page 54: Wiring Diagrams

    WIRING DIAGRAMS SP-100 WIRING DIAGRAM: CODES 9794 and Above SP-100...
  • Page 55 WIRING DIAGRAMS SP-100 WIRING DIAGRAM: CODES Below 9794 SP-100...
  • Page 56 ELECTRICAL DIAGRAMS CONTROL P.C. BOARD G1842 NOTE: Lincoln Electric assumes no responsibility for liabilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. This Printed Circuit Board schematic is provided for reference only. It may not be totally applicable to your machine’s specific PC board version. This diagram is intended to provide general information regarding PC board function.
  • Page 57 R36, R63, R64, R67 RESISTOR-MF, 1/4W, 15.0K, 1% NOTE: Lincoln Electric assumes no responsibility for liabilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not avail- able from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician.
  • Page 58 ELECTRICAL DIAGRAMS CONTROL P.C. BOARD G2314 NOTE: Lincoln Electric assumes no responsibility for liabilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. This Printed Circuit Board schematic is provided for reference only. It may not be totally applicable to your machine’s specific PC board version. This diagram is intended to provide general information regarding PC board function.
  • Page 59 R36, R63, R64, R67 RESISTOR-MF, 1/4W, 15.0K, 1% NOTE: Lincoln Electric assumes no responsibility for liabilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not avail- able from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician.

  • Page 60: Electrical Diagrams

    5 3 9 3 5 V 3 . 3 2 K R 4 4 R 4 5 3 9 2 K 1 8 . 2 K D 2 0 D 2 1 R 7 5 2 6 7 2 0 3 SP-100...
  • Page 61 = C O M M O N C O N N E C T I O N = S O U R C E P O I N T C I R C U I T L O C A T I O N SP-100...
  • Page 62 Your Company__________________________ Your Name_____________________________ Please give detailed description below: ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ SD287 01/99 Thank You, Technical Services Group Lincoln Electric Co. 22801 ST. Clair Ave. Cleveland, Ohio 44117-1199 FAX 216-481-2309...

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