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IM811
SP- 100T
September, 2004
For use with machine Code Number
11028
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.
OPERATOR'S MANUAL
Copyright © 2004 Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• 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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Table of Contents
Related Manuals for Lincoln SP-100T
Summary of Contents for Lincoln SP-100T
- Page 1 OPERATOR’S MANUAL Copyright © 2004 Lincoln Global Inc. • World's Leader in Welding and Cutting Products • • 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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Page 2: California Proposition 65 Warnings
351040, 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 PERFORMED ONLY BY QUALIFIED INDIVIDUALS. -
Page 3: Electric Shock Can Kill
SAFETY ARC RAYS can burn. ELECTRIC SHOCK can 4.a. Use a shield with the proper filter and cover kill. plates to protect your eyes from sparks and 3.a. The electrode and work (or ground) circuits the rays of the arc when welding or observing are electrically “hot”... - Page 4 SAFETY WELDING SPARKS can CYLINDER may explode cause fire or explosion. if damaged. 6.a. Remove fire hazards from the welding area. 7.a. Use only compressed gas cylinders If this is not possible, cover them to prevent containing the correct shielding gas for the the welding sparks from starting a fire.
- Page 5 SAFETY zones où l’on pique le laitier. PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de Pour votre propre protection lire et observer toutes les instructions prévenir tout risque d’incendie dû aux étincelles. et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté...
- Page 6 The code number is especially important when identifying the correct replacement parts. On-Line Product Registration - Register your machine with Lincoln Electric either via fax or over the Internet. • For faxing: Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it.
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Page 7: Table Of Contents
Items Requiring No Maintenance ................D-1 Routine Maintenance.....................D-1 Gun and Cable Maintenance.................D-2 Component Replacement Procedures ..............D-2 Troubleshooting ....................Section E Safety Precautions....................E-1 How to Use Troubleshooting Guide...............E-1 Troubleshooting Guide ..................E-2 Wiring Diagrams ....................Section F SP-100T Wiring Diagram ..................F-1 Parts Lists ..................P473 Series, P202-E... - Page 8 INSTALLATION TECHNICAL SPECIFICATIONS – SP-100T INPUT – SINGLE PHASE ONLY Standard Voltage/Frequency Input Current 115V/60Hz 20 Amps - Rated Output 15 Amps - CSA Rated output RATED OUTPUT Duty Cycle Current Voltage 20% Duty Cycle 88Amps 20% Duty Cycle – CSA Rated Output...
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Page 9: Installation
• Machine must be plugged into a receptacle which is grounded per any national, local or other applicable electrical codes. • The SP-100T 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
Figure A-3. STACKING 3. Fasten securely with the bolt and nut provided. SP-100T’s cannot be stacked. TILTING FIGURE A.3 Each machine must be placed on a secure, level sur- face, either directly or on either recommended cart. -
Page 11: Gas Connection
GUN INSTALLATION When using the GMAW process, a cylinder of shield- As shipped from the factory, the SP-100T is ready to ing gas, must be obtained. For more information about feed .023" – .025" (0.6 mm) solid wire. If .030" (0.8... - Page 12 STANDARD Z-49.1, “SAFETY IN tighten the union nut securely with a wrench. WELDING AND CUTTING” PUB- Connect the other end to the SP-100T Gas LISHED BY THE AMERICAN Solenoid Inlet Fitting (5/8-18 female threads — for WELDING SOCIETY.
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Page 13: Input Connections
(NEMA Type 5-15P) is factory installed on the SP-100T. Connect this plug to a mating grounded The SP-100T has a power input cable located on the receptacle which is connected to a 20 amp branch cir- rear of the machine. -
Page 14: Operation
• Use ventilation or exhaust to remove fumes from breathing RECOMMENDED PROCESSES zone. The SP-100T can be used for welding mild steel using the Gas Metal Arc Welding (GMAW or MIG, Metal WELDING SPARKS can Inert Gas) single pass process, which requires a sup- ply of shielding gas, or the flux-cored arc welding cause fire or explosion. -
Page 15: Welding Capability
(200 mm) diameter spools of wire. WELDING CAPABILITY FIGURE B.1a The SP-100T is rated at 88 amps, 18 volts, at 20% duty cycle on a ten minute basis. CSA rated output at 62 amps at 20 volts at 20% duty cycle. It is capable of higher output currents at lower duty cycles. -
Page 16: Welding Operations
Wire Spool must be pushed all the way on the spindle so that the spindle’s tab will hold it in place. The Wire Spool will rotate clock- wise when wire is dereeled. Load an 8” (200 mm) diameter spool on the wire spool spindle shown in Figure B.2. SP-100T... - Page 17 13. Refer to Figure B-6. Cut the wire off 3/8” – 1/2” (10 – 13 mm) from the end of the tip. The SP-100T is 6. The idle roll pressure adjustment wing nut is facto- now ready to weld.
- Page 18 PROCESS GUIDELINES required, is turned on. The SP-100T can be used for welding mild steel using 5. When using Innershield electrode, remove the gas the GMAW, single pass, process which requires a nozzle and install the gasless nozzle.
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Page 19: Overload Protection
1. For CO 2 , open the cylinder very slowly. For argon- Thermal Protection mixed gas, open cylinder valve slowly a fraction of The SP-100T has a rated output duty cycle of 20%. If a turn. When the cylinder pressure gauge pointer the duty cycle is exceeded, a thermal protector will stops moving, open the valve fully. -
Page 20: Application Chart
APPLICATION CHART SP-100T... -
Page 21: Accessories
.035 (0.9 mm) diameter flux-cored electrode. 4. K520 Utility Cart — Designed to transport the Lincoln family of small welders. Has provisions for mounting a single gas cylinder. Has front casters and large rear wheels. Handle height is easily adjustable. -
Page 22: Replacement Parts
Gas Nozzle KP1938-1 Gas Nozzle-Tip Recessed 3/8” (9.5 mm) Opening I.D. KP1942-1 Gas Nozzle-Tip Recessed 1/2” (12.7 mm) Opening I.D. KP1942-2 Gas Nozzle-Tip Recessed 5/8” (15.9 mm) Opening I.D. KP1942-3 Spot Welding Nozzle KP1956-1 Gasless Nozzle (Innershield Only) KP1939-1 SP-100T... -
Page 23: Maintenance
POWER SOURCE COMPARTMENT No user serviceable parts inside! Do not attempt to perform service in the power source (fixed) side of the SP-100T. Take the unit to an authorized Lincoln Service Center if you experi- ence problems. NO maintenance is required. -
Page 24: Gun And Cable Maintenance
Replace the gas nozzle or gasless nozzle. CONFIGURATION OF COMPONENTS IN WIRE FEEDING SYSTEM Contact Tip Cable Liner Drive Roll Components shipped with KP2039-1B1 KP1937-3 KP665-035 SP-100T• .025” (0.6mm) .030” (0.8mm) 2 Smooth grooves .035” (0.9mm) Small .023-.025 (0.6mm) Large .030” (0.8mm) K549-1 .035 (0.9mm) KP2039-3B1... -
Page 25: Component Replacement Procedures
6. Loosen the drive roll set screw with the 5/64" (2.0 mm) hex wrench supplied. 7. Remove the drive roll, flip over and reinstall with the .023 – .025" (0.6 mm) groove (the smaller groove) closest to the gearbox. SP-100T... - Page 26 Figure D.2. Remove any burrs from the end of the liner. 8. Screw the gas diffuser onto the end of the gun tube and securely tighten. 9. Replace the contact tip and nozzle. SP-100T...
- Page 27 See Figure D-3. Counter-clockwise FIGURE D.3 SP-100T...
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Page 28: Troubleshooting
HOW TO USE TROUBLESHOOTING GUIDE WARNING 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 29: Troubleshooting Guide
3. Gun trigger may be faulty. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. SP-100T... - Page 30 Authorized Field Service Facility. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. SP-100T...
- Page 31 8. Check liner for proper size. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. SP-100T...
- Page 32 DIAGRAMS NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. SP-100T...
- Page 33 ● ● ● Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection. WARNING electrode with skin or wet clothing. ● Insulate yourself from work and ground. Spanish ● ● ● No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el AVISO DE...
- Page 34 ● ● ● Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or ● Use ventilation or exhaust to guards off. WARNING remove fumes from breathing zone. ● Spanish Los humos fuera de la zona de res- ●...
- Page 35 • World's Leader in Welding and Cutting Products • • 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...