Lincoln Electric SP-100T Operator's Manual
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Lincoln Electric SP-100T Operator's Manual

Lincoln Electric SP-100T Operator's Manual

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For use with machine Code Number
This manual covers equipment which is no
longer in production by The Lincoln Electric Co.
Speci cations and availability of optional
features may have changed.
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
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and be careful.
Date of Purchase:
Serial Number:
Code Number:
Model:
Where Purchased:
• 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
SP- 100T
10262, 10271, 10480, 10484, 10739 & 10879
THIS
OPERATOR'S MANUAL
• World's Leader in Welding and Cutting Products •
Copyright © 2002 Lincoln Global Inc.
IM564-C
April, 2002

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Summary of Contents for Lincoln Electric SP-100T

  • Page 1 For use with machine Code Number 10262, 10271, 10480, 10484, 10739 & 10879 This manual covers equipment which is no longer in production by The Lincoln Electric Co. Speci cations and availability of optional features may have changed. Safety Depends on You...

  • 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 5. Toujours porter des lunettes de sécurité dans la zone de PRÉCAUTIONS DE SÛRETÉ soudage. Utiliser des lunettes avec écrans lateraux dans les zones où l’on pique le laitier. Pour votre propre protection lire et observer toutes les instruc- tions et les précautions de sûreté...
  • Page 6 QUALITY product by Lincoln Electric. We want you Thank You to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you! Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped, title passes to the purchaser upon receipt by the carrier.

  • 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 ..............P279 Series, P189-D & P202-E...

  • Page 8: Installation

    INSTALLATION TECHNICAL SPECIFICATIONS – SP-100T INPUT – SINGLE PHASE ONLY Standard Voltage/Frequency Input Current 115V/60Hz 20 Amps - Rated Output 115V/60Hz 15 Amps - CSA Rated output RATED OUTPUT Duty Cycle Amps Volts at Rated Amperes 20% Duty Cycle 20% Duty Cycle – CSA Rated Output...

  • 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-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.

  • 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 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

    FIGURE B.2 DO NOT SWITCH WHEN WELDING Wire Spool Spindle SP-100T 8” Wire Spool FIGURE B.1a Be sure that this stud engages the hole in the wire spool. To Wire Drive Wire Spool must be pushed all the way on the spindle so that the spindle’s tab will hold it in place.
  • Page 17 13. Refer to Figure B-6. Cut the wire off 1/4” – 3/8” (6 – 10 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.

  • Page 19: Overload Protection

    Thermal Protection 1. For CO 2 , open the cylinder very slowly. For argon- The SP-100T has a rated output duty cycle of 20%. If mixed gas, open cylinder valve slowly a fraction of the duty cycle is exceeded, a thermal protector will a turn.

  • Page 20: Learning To Weld

    FCAW (Innershield) welding arc. It closely them. resembles what is actually seen while welding. Electronic Components Burning of core materials Cored Wire inside wire electrode results in shield of gas. Protective Slag Arc Stream Weld Metal FIGURE B.9 Bearings Hinges FIGURE B.8 SP-100T...
  • Page 21 Arc Welding. process for the job you have at hand. In selecting a process, you should consider: For GMAW (MIG) Process 1. Is most of my welding performed on 16 gauge and lighter materials? SP-100T...
  • Page 22 “New Lessons in Arc for GMAW (MIG) Process”. Welding”. Regardless of the type of metal being welded, in order to get a quality weld, it is important that the metal is free of oil, paint, rust or other contaminants. SP-100T...
  • Page 23 When welding fillet welds, it is very important to hold problem. the wire electrode at a 45° angle between the two sides or the metal will not distribute itself evenly. The gun nozzle is generally formed at an angle to facilitate this. See Figure B.15. SP-100T...
  • Page 24 (if you are right handed). This enables you to clearly see what you are doing. (Left handers do the opposite.) Tilt the gun toward the direction of travel holding the electrode at an angle as shown in Figure B.18. SP-100T...
  • Page 25 FIGURE B.20 See Figure B.19. Once the arc has been established, maintaining the correct ESO becomes extremely important. The ESO should be approximately 3/8 to 1/2 inch (10 to 12 mm) long. SP-100T...
  • Page 26 B-13 B-13 LEARNING TO WELD Helpful Hints For the SP-100T, use the following: 12 gauge or 1/8 inch Mild Steel 1. For general welding, it is not necessary to weave (3.0 mm) the arc, neither forward or backward nor sideways.
  • Page 27 “forehand” push technique. gun trigger to release gas pressure, then turn off the machine. Hold the gun (of the gun and cable assembly) in your right hand and hold the shield with your left hand. (Left handers simply do the opposite.) SP-100T...
  • Page 28 4. The Correct Welding Speed For the SP-100T, use the following: The important thing to watch while welding is the puddle of molten metal right behind the arc. See...

  • Page 29: Troubleshooting Welds

    3. Decrease WFS (wire feed speed. * Stubbing occurs when the electrode drives through 4. Decrease travel speed. the molten puddle and hits the bottom plate tending 5. Decrease drag angle. to push the gun up. 6. Check for correct gas, if used. SP-100T...
  • Page 30 3. Do not allow dolly wheels or trucks to run over the cables. 4. Keep the cable clean. 5. Innershield electrode has proper surface lubrica- tion. Use only clean, rust-free electrode. 6. Replace contact tip when it becomes worn or the end is fused or deformed. SP-100T...

  • Page 31: Application Chart

    B-18 B-18 APPLICATION CHART SP-100T...

  • Page 32: Accessories

    10 lb. (4.5 kg.) spool of .035" (0.9 mm) Innershield This regulator comes standard with a 4.5 foot hose NR-211-MP. with the SP-100T. See “Innershield (FCAW) Conversion” in this sec- tion for installation instructions and MAINTE- NANCE section for proper feeding component con- figuration and installation.

  • Page 33: Replacement Parts

    Gas Nozzle M16294 Gas Nozzle-Tip Recessed 3/8” (9.5 mm) Opening I.D. M16684 Gas Nozzle-Tip Recessed 1/2” (12.7 mm) Opening I.D. M16684-1 Gas Nozzle-Tip Recessed 5/8” (15.9 mm) Opening I.D. M16684-2 Spot Welding Nozzle M17846 Gasless Nozzle (Innershield Only) M16418 SP-100T...

  • Page 34: 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 35: 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 S19726-1 M16291-6 KP665-035 SP-100T• .025” (0.6mm) .035” (0.9mm) 2 Smooth grooves Small .023-.025 (0.6mm) Large .030” (0.8mm) K549-1 .035” (0.9mm) S19726-3 M16291-6...

  • Page 36: 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 37 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 38 See Figure D-3. Counter-clockwise FIGURE D.3 SP-100T...

  • Page 39: 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 40: 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 41 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 42 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 43 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 44 NOTES SP-100T...
  • Page 45 Year AMERICAN EXPRESS USE THIS FORM TO ORDER: Order from: BOOK DIVISION, The Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199 for fastest service, FAX this completed form to: 216-361-5901 BOOKS OR FREE INFORMATIVE CATALOGS Telephone: 216-383-2211 or,...
  • Page 46 ● ● ● 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 47 ● ● ● 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 48 • 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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