IM564-C SP-100T - Welders, Welding Wire, Welding …

SP-100T

OPERATOR’S MANUAL

IM564-CApril, 2002

Safety Depends on YouLincoln arc welding and cuttingequipment is designed and builtwith safety in mind. However, youroverall safety can be increased byproper installation ... and thought-ful operation on your part. DONOT INSTALL, OPERATE ORREPAIR THIS EQUIPMENTWITHOUT READING THISMANUAL AND THE SAFETYPRECAUTIONS CONTAINEDTHROUGHOUT. And, mostimportantly, think before you actand be careful.

For use with machine Code Number 10262, 10271, 10480, 10484, 10739 & 10879

SP-100T

• 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

• World's Leader in Welding and Cutting Products •

Date of Purchase:Serial Number:Code Number:Model:Where Purchased:

Copyright © 2002 Lincoln Global Inc.

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.

FOR ENGINEpowered equipment.

1.a. Turn the engine off before troubleshooting and maintenancework unless the maintenance work requires it to be running.

____________________________________________________1.b.Operate engines in open, well-ventilated

areas or vent the engine exhaust fumes outdoors.

____________________________________________________1.c. Do not add the fuel near an open flame

welding arc or when the engine is running.Stop the engine and allow it to cool beforerefueling to prevent spilled fuel from vaporiz-ing on contact with hot engine parts andigniting. Do not spill fuel when filling tank. Iffuel is spilled, wipe it up and do not startengine until fumes have been eliminated.

____________________________________________________1.d. Keep all equipment safety guards, coversand devices in posi-

tion and in good repair.Keep hands, hair, clothing and toolsaway from V-belts, gears, fans and all other moving partswhen starting, operating or repairing equipment.

____________________________________________________

1.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.

___________________________________________________1.f. Do not put your hands near the engine fan.

Do not attempt to override the governor oridler by pushing on the throttle control rodswhile the engine is running.

___________________________________________________1.g. To prevent accidentally starting gasoline engines while

turning the engine or welding generator during maintenancework, disconnect the spark plug wires, distributor cap ormagneto wire as appropriate.

iSAFETYi

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.KEEP CHILDREN AWAY. 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 youpurchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is availablefrom the Lincoln 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.

WARNING

Mar ‘95

ELECTRIC AND MAGNETIC FIELDSmay be dangerous

2.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines

2.b. EMF fields may interfere with some pacemakers, andwelders having a pacemaker should consult their physicianbefore welding.

2.c. Exposure to EMF fields in welding may have other healtheffects which are now not known.

2.d. All welders should use the following procedures in order tominimize exposure to EMF fields from the welding circuit:

2.d.1. Route the electrode and work cables together - Securethem with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.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.

2.d.4. Connect the work cable to the workpiece as close aspossible to the area being welded.

2.d.5. Do not work next to welding power source.

1.h. To avoid scalding, do not remove theradiator pressure cap when the engine ishot.

Diesel engine exhaust and some of its constituentsare known to the State of California to cause can-cer, birth defects, and other reproductive harm.

The engine exhaust from this product containschemicals known to the State of California to causecancer, birth defects, or other reproductive harm.

CALIFORNIA PROPOSITION 65 WARNINGS

The Above For Diesel Engines The Above For Gasoline Engines

iiSAFETYii

ARC RAYS can burn.4.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.

4.b. Use suitable clothing made from durable flame-resistantmaterial to protect your skin and that of your helpers fromthe arc rays.

4.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.3.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-free

gloves to insulate hands.

3.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 hazardousconditions (in damp locations or while wearing wetclothing; on metal structures such as floors, gratings orscaffolds; when in cramped positions such as sitting,kneeling or lying, if there is a high risk of unavoidable oraccidental contact with the workpiece or ground) usethe following equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.• DC Manual (Stick) Welder.• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode,electrode reel, welding head, nozzle or semiautomaticwelding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electricalconnection with the metal being welded. The connectionshould be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical(earth) ground.

3.f. Maintain the electrode holder, work clamp, welding cable andwelding machine in good, safe operating condition. Replacedamaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically “hot” parts ofelectrode holders connected to two welders because voltagebetween the two can be the total of the open circuit voltageof both welders.

3.i. When working above floor level, use a safety belt to protectyourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

FUMES AND GASEScan be dangerous.5.a. Welding may produce fumes and gases

hazardous to health. Avoid breathing thesefumes and gases.When welding, keepyour head out of the fume. Use enoughventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. Whenwelding with electrodes which require specialventilation such as stainless or hard facing (seeinstructions on container or MSDS) or on lead orcadmium plated steel and other metals or coatingswhich produce highly toxic fumes, keep exposure aslow as possible and below Threshold Limit Values (TLV)using local exhaust or mechanical ventilation. Inconfined spaces or in some circumstances, outdoors, arespirator may be required. Additional precautions arealso required when welding on galvanized steel.

5.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 products.

5.c. Shielding gases used for arc welding can displace air andcause injury or death. Always use enough ventilation,especially in confined areas, to insure breathing air is safe.

5.d. Read and understand the manufacturer’s instructions for thisequipment and the consumables to be used, including thematerial safety data sheet (MSDS) and follow youremployer’s safety practices. MSDS forms are available fromyour welding distributor or from the manufacturer.

5.e. Also see item 1.b. Mar ‘95

FOR ELECTRICALLYpowered equipment.

8.a. Turn off input power using the disconnectswitch at the fuse box before working onthe equipment.

8.b. Install equipment in accordance with the U.S. NationalElectrical Code, all local codes and the manufacturer’srecommendations.

8.c. Ground the equipment in accordance with the U.S. NationalElectrical Code and the manufacturer’s recommendations.

CYLINDER may explodeif damaged.7.a. Use only compressed gas cylinders

containing the correct shielding gas for theprocess used and properly operatingregulators designed for the gas and

pressure used. All hoses, fittings, etc. should be suitable forthe application and maintained in good condition.

7.b. Always keep cylinders in an upright position securelychained to an undercarriage or fixed support.

7.c. Cylinders should be located:• Away from areas where they may be struck or subjected tophysical damage.

• A safe distance from arc welding or cutting operations andany other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any otherelectrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outletwhen opening the cylinder valve.

7.f. Valve protection caps should always be in place and handtight except when the cylinder is in use or connected foruse.

7.g. Read and follow the instructions on compressed gascylinders, 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.

iiiSAFETYiii

Mar ‘95

WELDING SPARKS cancause fire or explosion.6.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.

6.b. Where compressed gases are to be used at the job site,special precautions should be used to prevent hazardoussituations. Refer to “Safety in Welding and Cutting” (ANSIStandard Z49.1) and the operating information for theequipment being used.

6.c. When not welding, make certain no part of the electrodecircuit is touching the work or ground. Accidental contactcan cause overheating and create a fire hazard.

6.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).

6.e. Vent hollow castings or containers before heating, cutting orwelding. They may explode.

6.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 awelding area.

6.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 passingthrough lifting chains, crane cables or other alternate cir-cuits. This can create fire hazards or overheat lifting chainsor cables until they fail.

6.h. Also see item 1.c.

ivSAFETYiv

PRÉCAUTIONS DE SÛRETÉPour votre propre protection lire et observer toutes les instruc-tions et les précautions de sûreté specifiques qui parraissentdans ce manuel aussi bien que les précautions de sûretégénérales suivantes:

Sûreté Pour Soudage A L’Arc1. 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 nueou les vétements mouillés. Porter des gants secs et sanstrous pour isoler les mains.

b. Faire trés attention de bien s’isoler de la masse quand onsoude dans des endroits humides, ou sur un planchermetallique ou des grilles metalliques, principalement dans

les positions assis ou couché pour lesquelles unegrande partie du corps peut être en contact avec lamasse.

c. Maintenir le porte-électrode, la pince de masse, le câblede soudage et la machine à souder en bon et sûr étatdefonctionnement.

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 soud-er parce que la tension entre les deux pinces peut être letotal 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 pro-téger contre les chutes dans le cas ou on recoit un choc. Nejamais enrouler le câble-électrode autour de n’importe quellepartie du corps.

3. Un coup d’arc peut être plus sévère qu’un coup de soliel,donc:

a. Utiliser un bon masque avec un verre filtrant appropriéainsi qu’un verre blanc afin de se protéger les yeux durayonnement de l’arc et des projections quand on soudeou quand on regarde l’arc.

b. Porter des vêtements convenables afin de protéger lapeau de soudeur et des aides contre le rayonnement del‘arc.

c. Protéger l’autre personnel travaillant à proximité ausoudage à l’aide d’écrans appropriés et non-inflamma-bles.

4. Des gouttes de laitier en fusion sont émises de l’arc desoudage. Se protéger avec des vêtements de protectionlibres de l’huile, tels que les gants en cuir, chemise épaisse,pantalons sans revers, et chaussures montantes.

5. Toujours porter des lunettes de sécurité dans la zone desoudage. Utiliser des lunettes avec écrans lateraux dans leszones 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 unéchauffement et un risque d’incendie.

8. S’assurer que la masse est connectée le plus prés possiblede la zone de travail qu’il est pratique de le faire. Si on placela masse sur la charpente de la construction ou d’autresendroits éloignés de la zone de travail, on augmente le risquede voir passer le courant de soudage par les chaines de lev-age, câbles de grue, ou autres circuits. Cela peut provoquerdes risques 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 lesvapeurs du solvant pour produire du phosgéne (gas forte-ment toxique) ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté,voir le code “Code for safety in welding and cutting” CSAStandard W 117.2-1974.

PRÉCAUTIONS DE SÛRETÉ POURLES MACHINES À SOUDER ÀTRANSFORMATEUR ET ÀREDRESSEUR

1. Relier à la terre le chassis du poste conformement au codede l’électricité et aux recommendations du fabricant. Le dis-positif de montage ou la piece à souder doit être branché àune bonne mise à la terre.

2. Autant que possible, I’installation et l’entretien du posteseront effectués par un électricien qualifié.

3. Avant de faires des travaux à l’ interieur de poste, ladebrancher à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leurplace.

Mar. ‘93

Thank You for selecting a QUALITY product by Lincoln Electric. We want youto take pride in operating this Lincoln Electric Company product••• as much pride as we have in bringing this product to you!

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep ithandy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.The level of seriousness to be applied to each is explained below:

WARNINGThis statement appears where the information must be followed exactly to avoid serious personal injury orloss of life.

This statement appears where the information must be followed to avoid minor personal injury or damage tothis equipment.

CAUTION

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 thetime the shipment is received.

Please record your equipment identification information below for future reference. This information can befound on your machine nameplate.

Model Name & Number _____________________________________

Code & Serial Number _____________________________________

Date of Purchase _____________________________________

Whenever you request replacement parts for or information on this equipment always supply the informationyou have recorded above.

vv

vi

MASTER TABLE OF CONTENTS FOR ALL SECTIONS

Page

Installation .......................................................................................................Section ATechnical Specifications ........................................................................................A-1Identify and Locate Components ...........................................................................A-2Select Suitable Location ........................................................................................A-3Output Connections...............................................................................................A-3Input Connections..................................................................................................A-6Code Requirements ..............................................................................................A-6

Operation .........................................................................................................Section BSafety Precautions ................................................................................................B-1General Description ...............................................................................................B-1Design Features ....................................................................................................B-1Welding Capability .................................................................................................B-2Limitations..............................................................................................................B-2Controls and Settings ............................................................................................B-2Welding Operations ...............................................................................................B-3Overload Protection...............................................................................................B-6Learning to Weld....................................................................................................B-7Application Chart .................................................................................................B-18

Accessories .....................................................................................................Section CAccessories ...........................................................................................................C-1Replacement Parts ................................................................................................C-2

Maintenance ....................................................................................................Section DSafety Precautions ................................................................................................D-1Items Requiring No Maintenance ..........................................................................D-1Routine Maintenance.............................................................................................D-1Gun and Cable Maintenance.................................................................................D-2Component Replacement Procedures ..................................................................D-2

Troubleshooting ..............................................................................................Section ESafety Precautions.................................................................................................E-1How to Use Troubleshooting Guide.......................................................................E-1Troubleshooting Guide ..........................................................................................E-2

Wiring Diagrams ..............................................................................................Section FSP-100T Wiring Diagram.......................................................................................F-1

Parts Lists .....................................................................P279 Series, P189-D & P202-E

A-1

SP-100T

A-1

Fuse orOutput Mode Input Voltage Breaker Size Input Amps Power Cord Extension Cord

RATED 115V/60Hz 20 Amp 20 15 Amp, 125V, Three Conductor

Three Prong Plug #14 AWG

(NEMA Type 5-15P) (2.1 mm2) or LargerUp to 25 Ft. (7.6 mm)

CSA 115V/60Hz 15 Amp 15 15 Amp, 125V, Three ConductorThree Prong Plug #12 AWG

(NEMA Type 5-15P) (3.3 mm2) or LargerUp to 50 Ft. (15.2 mm)

INSTALLATION

TECHNICAL SPECIFICATIONS – SP-100TINPUT – SINGLE PHASE ONLY

RATED OUTPUT

OUTPUT

RECOMMENDED INPUT CABLE AND FUSE SIZES

Height Width Depth Weight12.0 in 9.75 in 16.5 in 48 Ibs305 mm 248 mm 419 mm 21.8 kg

PHYSICAL DIMENSIONS

Standard Voltage/Frequency Input Current115V/60Hz 20 Amps - Rated Output115V/60Hz 15 Amps - CSA Rated output

Duty Cycle Amps Volts at Rated Amperes20% Duty Cycle 88 18

20% Duty Cycle – CSA Rated Output 62 20

Welding Current Range Maximum Open Circuit Voltage Wire Speed RangeRated DC Output: 30 - 88 amps 32 50 - 300 in/min

CSA Rated DC Output: 30 - 62 amps (1.3 - 7.6 m/min)

A-2INSTALLATION

SP-100T

A-2

Read entire installation section before startinginstallation.

SAFETY PRECAUTIONS

IDENTIFY AND LOCATE COMPONENTSIf you have not already done so, unpack the SP-100Tfrom its carton and remove all packing materialaround the SP-100T. Remove the following looseitems from the carton (see Figure A.1):

1. SP-100T

2. Gun and cable assembly(1)

3. Literature and miscellaneous including:

a) This operating manual

b) 6 extra .023"-.025” (0.6 mm) contact tips

c) Hex key wrench for removal of drive roll.

4. 10 ft (3.0 m) work cable.

5. Work clamp.

6. Sample spool of .025” (0.6 mm) L-56 MIG wire.

7. Handshield with filter plate and lens.

8. Instructional video.

9. Adjustable mixed-Gas Regulator & Hose.

For available options and accessories refer to theAccessories Section of this manual.

1) As shipped from the factory, the SP-100T gun lineris ready to feed .023” (0.6 mm) -.035 (0.9 mm) wire.The contact tip is sized for .023”-.025” (0.6 mm) wirefeeding.

ELECTRIC SHOCK can kill.

• Only qualified personnel should performthis installation.

• Only personnel that have read and under-stood the SP-100T Operating Manualshould install and operate this equipment.

• Machine must be plugged into a receptaclewhich is grounded per any national, localor other applicable electrical codes.

• The SP-100T power switch is to be in theOFF (“O”) position when installing workcable and gun and when connecting powercord to input power.

WARNING

FIGURE A.1

SP-100TSP-100T

12

3

4

6

7

8

9

5

A-3INSTALLATION

SP-100T

A-3

SP-100T

45

8

3 6 71 2

DO NOT SWITCHDO NOT SWITCHWHEN WELDINGWHEN WELDING

+

-

FIGURE A.2

Work Clamp Installation

Attach the work clamp per the following:

1. Unplug the machine or turn the power switch to the“OFF” position.

2. Insert the work cable terminal lug with the largerhole through the strain relief hole in the work clampas shown in Figure A-3.

3. Fasten securely with the bolt and nut provided.

FIGURE A.3

SELECT SUITABLE LOCATION

Locate the welder in a dry location where there is freecirculation of clean air into the louvers in the back andout the front of the unit. A location that minimizes theamount of smoke and dirt drawn into the rear louversreduces the chance of dirt accumulation that can blockair passages and cause overheating.

STACKING

SP-100T’s cannot be stacked.

TILTING

Each machine must be placed on a secure, level sur-face, either directly or on either recommended cart.The machine may topple over if this procedure is notfollowed.

OUTPUT CONNECTIONS

Refer to Figure A.2.

1. Work Cable Access Hole. 2. Gun Cable and Control Lead Access Hole. 3. Connector Block. 4. Gun Trigger Lead Connectors. 5. Positive (+) and negative (–) output terminals.6. Wire Feed Gearbox.7. Cable Hanger.8. Thumbscrew.

Strain Relief Hole

Nut & Bolt

Work Clamp

Work Cable

Work Cable Installation


1. Open the wire feed section door on the right side ofthe SP-100T.

2. Pass the end of the work cable that has the termi-nal lug with the smaller hole through the WorkCable Access Hole (1) in the case front.

3. Route the cable under and around the back of theWire Feed Gearbox (6).

4. For GMAW Only: Refer to Figure A.2. As deliv-ered, the machine is connected for positive elec-trode polarity. This is the appropriate configurationfor the GMAW (MIG) process. To complete installa-tion, use the provided wing nut to connect the workcable’s terminal lug to the negative (–) output ter-minal (5) located above the Wire Feed Gearbox(6). Make sure that both wing nuts are tight.

5. For Innershield Only: Refer to Figure A.4. To wirefor negative polarity (required for the Innershieldprocess), connect the short cable attached to theconnector block (1) to the negative (–) output termi-nal (2) and the work cable (3) to the positive (+)terminal (4).

A-4INSTALLATION

SP-100T

A-4

Connecting Gun Cable to the SP-100T

1. Refer to Figure A.2. Unplug the machine or turnpower switch to the OFF “O” position.

2. Pass the insulated terminals of the gun trigger con-trol leads, one at a time, through the Gun Cableand Control Lead Access Slot (2) in the case front.The leads are to be routed under the Wire FeedGearbox (6) and through the Cable Hanger (7) onthe inner panel.

3. Insert the connector on the gun conductor cablethrough the Gun Cable Access Hole (2) in the SP-100T case front. Make sure the connector is all theway in the brass connector block. Unscrew thumb-screw on the connector block a few turns if gunconnector will not insert fully. Rotate the connectorso control leads are on the underside and tightenthe Thumbscrew (8) in the connector block.

4. Connect the gun trigger control lead terminals tothe two insulated 1/4" (6.4 mm) tab terminal con-nector bushings located below the “Gun TriggerConnection” decal in the wire feed section (4).Either lead can go to either connector. Form theleads so that they are as close as possible to theinside panel.

If the gun trigger switch being used is other thanthat supplied with the SP-100T, the switch must bea normally open, momentary switch. The terminalsof the switch must be insulated from the weldingcircuit. Malfunction of the SP-100T may result ifthis switch shorts to the SP-100T welding outputcircuit or is common to any electrical circuit otherthan the SP-100T trigger circuit.

GAS CONNECTION

When using the GMAW process, a cylinder of shield-ing gas, must be obtained. For more information aboutselecting gas cylinders for use with the SP-100T referto the ACCESSORIES section.

2

43

1

FIGURE A.4

GUN INSTALLATION

As shipped from the factory, the SP-100T is ready tofeed .023" – .025" (0.6 mm) solid wire. If .030" (0.8mm) solid wire is to be used, change the contact tip tothe appropriate size.

NOTE: If .035" (0.9 mm) Innershield flux-cored wire isto be used, the .035” Innershield Welding kit isrequired (see ACCESSORIES section).

CAUTION

CYLINDER may explode if dam-aged. Keep cylinder upright andchained to support

• Keep cylinder away from areaswhere it may be damaged.

• Never lift welder with cylinderattached.

• Never allow welding electrode totouch cylinder.

• Keep cylinder away from weldingor other live electrical circuits.

BUILDUP OF SHIELDING GAS mayharm health or kill.

• Shut off shielding gas supplywhen not in use.

• SEE AMERICAN NATIONALSTANDARD Z-49.1, “SAFETY INWELDING AND CUTTING” PUB-LISHED BY THE AMERICANWELDING SOCIETY.

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. Refer to Figure A.5.

FIGURE A.5

A-5INSTALLATION

SP-100T

A-5

WARNING

Cylinder Valve

Gas Hose

Flow Regulator

WARNING

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 which mayhave accumulated in the valve outlet.

BE SURE TO KEEP YOUR FACE AWAY FROMTHE VALVE OUTLET WHEN “CRACKING” THEVALVE. Never stand directly in front of or behindthe flow regulator when opening the cylindervalve. Always stand to one side.

3. Attach the flow regulator to the cylinder valve andtighten the union nut securely with a wrench.

NOTE: If connecting to 100% CO2 cylinder, makecertain the plastic washer is seated in the fittingthat attaches to the CO2 cylinder.

4. Refer to Figure A.6. Attach one end of inlet gashose to the outlet fitting of the flow regulator andtighten the union nut securely with a wrench.Connect the other end to the SP-100T GasSolenoid Inlet Fitting (5/8-18 female threads — forCGA — 032 fitting). Make certain the gas hose isnot kinked or twisted.

WARNING

A-6INSTALLATION

SP-100T

A-6

INPUT CONNECTIONS


The SP-100T has a power input cable located on therear of the machine.

FIGURE A.6

CODE REQUIREMENTS FOR INPUT CONNECTIONS

This welding machine must be connected to apower source in accordance with applicable elec-trical codes.

The United States National Electrical Code (Article630-B, 1990 Edition) provides standards foramperage handling capability of supply conduc-tors based on duty cycle of the welding source.

If there is any question about the installationmeeting applicable electrical code requirements,consult a qualified electrician.

Requirements For Rated Output

A power cord with a 15 amp, 125 volt, three prongplug (NEMA Type 5-15P) is factory installed on theSP-100T. 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 88 amps, 18Volts, 20% duty cycle (2 minutes of every 10 minutesused for welding).

Do not connect the SP-100T to an input powersupply with a rated voltage that is greater than 125volts.

Do not remove the power cord ground prong.

Requirements For CSA Rated Output

A 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-100T can be used at anoutput of 62 amps, 20 volts, 20% duty cycle.

POWER INPUTCABLE

GAS SOLENOIDINLET FITTING

WARNING

CAUTION

B-1OPERATIONB-1

SP-100T

Read entire operation section beforeoperating the SP-100T.

ELECTRIC SHOCK can kill.• Do not touch electrically live

parts or electrode with skin orwet clothing. Insulate yourselffrom work and ground.

• Always wear dry insulatinggloves.

FUMES AND GASES can bedangerous.• Keep your head out of fumes.

• Use ventilation or exhaust toremove fumes from breathingzone.

WELDING SPARKS cancause fire or explosion.• Keep flammable material away.

• Do not weld on closed contain-ers.

ARC RAYS can burn eyesand skin.• Wear eye, ear and body protec-

tion.

Observe all safety information throughoutthis manual.

WARNING

GENERAL DESCRIPTIONThe SP-100T is a complete semiautomatic constant-voltage DC wire feeder / power source arc welder. Ithas been designed for workshop, hobby, automotiveand light maintenance. Included is a tap-switch con-trolled, single phase constant voltage transformer /rectifier power source and a wire feeder welding gunfor feeding .023 - .025” (0.6 mm) through .030” (0.8mm) solid steel electrode. An optional kit is availablefor feeding .035” (0.9 mm) Innershield® NR-211-MPflux-cored wire.

The SP-100T 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 (selfshielded flux cored or FCAW). The SP-100T is arugged and reliable machine that has been designedfor dependable service and long life.

RECOMMENDED PROCESSES

The SP-100T can be used for welding mild steel usingthe Gas Metal Arc Welding (GMAW or MIG, MetalInert Gas) single pass process, which requires a sup-ply of shielding gas, or the flux-cored arc welding(FCAW) process using Innershield® electrode wire.The SP-100T is configured for use with the GMAWprocess as delivered from the factory.

OPERATIONAL CONTROLS

The SP-100T has the following controls as standard:Control Power ON/OFF Switch, Voltage Control, WireSpeed Control, Trigger Switch, and a Circuit Breaker.

DESIGN FEATURES ● Operates on 115 volt input — no special wiring

required.

● “Cold electrode” until gun trigger is pressed for anadded measure of safety.

● Overload protection — incorporates both a thermo-stat and a circuit breaker.

● Quality wire drive with electronic overload protec-tion.

● “Quick Release” idle roll pressure arm is easilyadjusted.

● Reversible, dual groove drive roll. Drive roll willfeed .023 – .025” (0.6 mm) and .030" - .035" (0.8 -0.9 mm) diameter wire.

B-2OPERATIONB-2

5. Gun Trigger - Activates welding output, wire feed,and gas solenoid operation. Releasing the triggerdeactivates welding and simultaneously activatesthe “burnback” function so that the welding wiredoes not stick in the weld puddle.

● No external shielding gas is required when usedwith Lincoln Innershield .035” (0.9 mm) NR®-211-MP electrode.

● Accommodates both 4” (100 mm) diameter and 8”(200 mm) diameter spools of wire.

WELDING CAPABILITYThe SP-100T is rated at 88 amps, 18 volts, at 20%duty cycle on a ten minute basis. CSA rated output at62 amps at 20 volts at 20% duty cycle. It is capable ofhigher output currents at lower duty cycles.

LIMITATIONSArc Gouging cannot be performed with the SP-100T.The SP-100T is not recommended for pipe thawing orTIG welding.

CONTROLS AND SETTINGSRefer to Figure B.1a.

1. Control Power ON/OFF Switch— When the power is on thefan motor will run and air will beexhausted out the louvers in thefront of the machine. The weld-ing output and wire feederremain off until the gun triggeris pressed.

2. Wire Speed Control —Controls the wire feed speedfrom 50 – 300 in /min (1.3 –7.6 m/min). The control canbe preset on the dial to thesetting specified on the SP-100T Application Chartlocated on the inside of thewire feed section door.

3. Voltage Control — A 4-posi-tion tap selector switch givesfull range adjustment ofpower source output voltage.Do not switch while welding.

Refer to Figure B-1b.

4. Circuit Breaker – Protects machine from damage ifmaximum output is exceeded. Button will extendout when tripped (Manual reset).

SP-100T

OFF

ON

ARC VOLTS

WIRE SPEED

B-3OPERATIONB-3

FIGURE B.1a

FIGURE B.1b

WELDING OPERATIONS

SEQUENCE OF OPERATION

Wire LoadingRefer to Figures B.2 and B.3.

The machine power switch should be turned to theOFF (“O”) position before working inside the wire feedenclosure.

The welder is shipped from the factory ready to feed8" (200 mm) diameter spools with 2.2" (56 mm) maxi-mum width. These spools fit on a 2" (51 mm) diameterspindle that has a built in, adjustable friction brake toprevent overrun of the spool and excess slack in the wire.

Note:When loading and removing the 8” Spools makesure that the wing nut (inside the wire spool spindlehub) is turned 90° from the wire spool spindle lockingtab. If the wing nut is positioned in line with the lockingtab, the tab cannot be depressed to load or unload thewire spool.

FIGURE B.2

Load an 8” (200 mm) diameter spool on the wire spoolspindle shown in Figure B.2.

To use 4” (100 mm) diameter spools, the 2” (50 mm)diameter spindle must be removed (See Figure B.3).Remove the wing nut and spacer at the end of theshaft and remove the outside plastic wire spool spin-dle. The spindle can be stored in the wire feed com-partment. A 4” (100 mm) diameter spool is mounteddirectly on the 5/8” (16 mm) diameter shaft and held inplace with the previously removed hardware. Alsomake certain the start end of the wire, which may pro-trude through the side of the spool does not contactany metallic case parts.

FIGURE B.3

SP-100T

SP-100T

DO NOT SWITCHWHEN WELDING

3

21

4

5

+

-

Wire Spindle Shaft

To Wire Drive

4" Wire Spool

Wing Nut and Spacer

Wire Spool must be pushed all the way on the spindle so that thespindle’s tab will hold it in place. The Wire Spool will rotate clock-wise when wire is dereeled.

Be sure that this stud engagesthe hole in the wire spool.

To Wire Drive

Wire Spool Spindle

8” Wire Spool

B-4OPERATIONB-4

Friction Brake Adjustment

With wire spool installed on the spindle shaft and thewing nut loose, turn the spool by hand while slowlytightening the wing nut until a light drag is felt. Tightenthe wing nut an additional 1/4 turn.

Note: When properly adjusted, the brake should pro-vide only enough drag to prevent overrun of the spooland excess slack in the wire. Too much drag mayresult in wire feeding problems, and may cause pre-mature wear of wire drive system components.

Wire Threading Refer to Figure B.4

1. Release the Spring Loaded Pressure Arm (1)rotate the Idle Roll Arm (2) away from. the WireFeed Drive Roll (3). Ensure that the groove size inthe feeding position on the drive roll matches thewire size being used.

2. Carefully detach the end of the wire from thespool. To prevent the spool from unwinding, maintain tension on 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 In-going guide tube(4), over the drive roll (3), and into the out-goingguide tube (5).

5. Close the idle roll arm (2) and latch the springloaded pressure arm (1) in place. Rotate the spoolcounterclockwise if required in order to take upextra slack in the wire.

6. The idle roll pressure adjustment wing nut is facto-ry set to approximately five full turns from wherethe wing nut first engages the threads of the pres-sure arm (1). If feeding problems occur becausethe wire is flattened excessively, turn the pressureadjustment counter-clockwise to reduce distortionof the wire. Slightly less pressure may be requiredwhen using 0.023 – 0.025" (0,6 mm) wire. If thedrive roll slips while feeding wire, the pressureshould be increased until the wire feeds properly.

When inching the welding wire, the drive rolls, thegun connector block and the gun contact tip areelectrically energized relative to work and groundand remain energized for several seconds afterthe gun trigger is released.

FIGURE B.4

7. Refer to Figure B.5. Remove gas nozzle and con-tact tip from end of gun.

8. Turn the SP-100T ON (“I”).

9. Straighten the gun cable assembly.

10. 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.

11. Turn the SP-100T OFF (“O”).

12. Replace contact tip and gas nozzle.

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 isnow ready to weld.

FIGURE B.5

SP-100T

WARNING

The Wire Drive Feed Roll canaccommodate two wire sizesby flipping the wire drive feedroll over.

1

2

345

Gun Handle

Gas Diffuser/Contact Tip

Gas Nozzle

B-5OPERATIONB-5

FIGURE B.6

Making A Weld1. See “Process Guidelines” in this section for selec-

tion of welding wire and shielding gas and forrange of metal thicknesses that can be welded.

2. See the Application chart on the inside of the wirefeed compartment door for information on settingthe SP-100T controls. Refer to Table B.1 for alu-minum and stainless wire.

3. Set the Voltage (“V”) and Wire Speed (“olo’”) con-trols to the settings suggested for the welding wireand base metal thickness being used, refer toApplications chart on the inside of the wire drivecompartment door.

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 the gasnozzle and install the gasless nozzle. This willimprove visibility of the arc and protect the gas dif-fuser from weld spatter. Refer to the MAINTE-NANCE section for details on nozzle replacement.

FIGURE B.7

6. Refer to Figure B.7. Connect work clamp to metalto be welded. Work clamp must make good elec-trical contact to the workpiece. The workpiecemust also be grounded as stated in “Arc WeldingSafety Precautions” in the beginning of this manu-al.

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 theSP-100T.

Cleaning Tip And NozzleClean the contact tip and nozzle to avoid arc bridgingbetween the nozzle and contact tip which can result ina shorted nozzle, poor welds and an overheated gun.Hint: Anti-stick spray or gel, available from a weldingsupply distributor, may reduce buildup and aid in spat-ter removal.

PROCESS GUIDELINES

The SP-100T 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® process (FCAW).

The recommended gases and electrodes for GMAWare welding grade CO2 gas or an argon-CO2 blendedgas (75 to 80% argon and 25 to 20% CO2) and .025"(0.6 mm) diameter Lincoln L-56 mild-steel weldingwire, supplied on 12-1/2 lb (5.7 kg) spools. The blend-ed gas is recommended for welding on heavier steel,14 gauge (2.0 mm), for example.

The recommended electrode for the self-shieldedprocess is .035” (0.9 mm) diameter LincolnInnershield® NR-211-MP on 10 lb (4.5 kg) spools.This electrode can be used for all position welding of20 gauge (1.0 mm) through 5/16" (8 mm) steel.Thickness of 1/4" (6 mm) and 5/16" (8 mm) requiremultiple passes. This wire can also be used for thewelding of galvanized coated sheet metal.

SP-100T

3/8" – 1/2" Electrical Stickout

Contact Tip

Wire Electrode

SP-100T

WORKPIECE

GUN CABLE

ARC

WORK CLAMP

B-6OPERATIONB-6

The SP-100T is suitable for .035" aluminum wire and.030" stainless wire. Refer to Table B.1 for recom-mended procedure settings (requires K499 ArgonRegulator Kit).

TABLE B.1

CHANGING MACHINE OVER TOFEED OTHER WIRE SIZES

The SP-100T is shipped from the factory ready to feed.023”-.025” (0.6 mm) diameter wire. To operate theSP-100T with other sizes of wire, it is necessary tochange the contact tip and change the drive roll overto other sizes. Refer to Changing the Contact Tip andChanging the Drive Roll, in the MAINTENANCE sec-tion, for specific information on these procedures.

WELDING WITH GMAW (MIG)

Shielding Gas

When using the GMAW process, obtain and install agas regulator and hose kit; K463 (for CO2) or K499(Argon mixed) gas regulator and hose kit.

1. For CO2, open the cylinder very slowly. For argon-mixed gas, open cylinder valve slowly a fraction ofa turn. When the cylinder pressure gauge pointerstops moving, open the valve fully.

2. If using a regulator with an adjustable flow meter,close the gun trigger and adjust the flow to give 15– 20 cubic ft per hour (CFH) (7 – 10 I/min) [use 20– 25 CFH (10 – 12 I/min) when welding out ofposition or in a drafty location for CO2]. For argonmixed gas, trigger to release gas pressure, andadjust the flow to give 25 – 30 CFH (12 – 14I/min).

3. Keep the cylinder valve closed, except when usingthe SP-100T. When finished welding:

a) Close the cylinder valve to stop gas flow.

b) Depress the gun trigger briefly to release thepressure in the gas hose.

c) Turn off the SP-100T.

WELDING WITH FCAW (Innershield)

When using the FCAW process, the correct drive rolland electrode polarity must be used. See Work CableInstallation in INSTALLATION section for changingthe polarity.

Innershield welding kit K549-1 (for .035" / 0.9mm) isalso available.

OVERLOAD PROTECTION

Output OverloadThe SP-100T is equipped with a circuit breaker and athermostat which protects the machine from damage ifmaximum output is exceeded. The circuit breaker but-ton will extend out when tripped. The circuit breakermust be manually reset.

Thermal ProtectionThe SP-100T has a rated output duty cycle of 20%. Ifthe duty cycle is exceeded, a thermal protector willshut off the output until the machine cools to a reason-able operating temperature. This is an automatic func-tion of the SP-100T and does not require user inter-vention. The fan continues to run during cooling.

Electronic Wire Drive Motor ProtectionThe SP-100T has built-in protection for wire drivemotor overload.

SP-100T

Shielding Voltage/Wire SpeedProcess Welding Wire Gas 16 ga 14 ga 12 ga 10 ga

MIG DC+ .035 Dia 100% Argon B-5 D-7 D-9 D-94043 AluminumWire

MIG DC+ .035 Dia 100% Argon B-5 C-7 D-9 D-105356 AluminumWire

MIG DC+ .030 Dia 98% Argon/ A-3 C-6 D-7.5 D-7.5308L Stainless 2% OxygenSteel Wire

B-7LEARNING TO WELDB-7

LEARNING TO WELD

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 at the end of this manual.

THE ARC-WELDING CIRCUIT

The 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. Figure B.7 illustratesthe welding circuit for a typical welding machine. Thecircuit begins where the gun cable is attached to thewelding machine. Current flows through the guncable, gun, and contact tip, to the wire and across thearc. On the work side of the arc, current flows throughthe base metal to the work cable and back to thewelding machine. This circuit must be complete for thecurrent to flow.

This machine’s welding circuit has a voltage output of32 volts DC maximum. This voltage is quite low and isonly present when the gun triggers 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. See Figure B.8. Alwaysdisconnect electrical devices before welding uponthem.

FIGURE B.8

Fumes and slag generated fromInnershield type electrodes recom-mended 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 precautionsfound in this operating manual.

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 WELDINGARC

Figure B.9 illustrates the action taking place in the selfshielded FCAW (Innershield) welding arc. It closelyresembles what is actually seen while welding.

FIGURE B.9

SP-100T

Electronic Components

Hinges Bearings

WARNING

Burning of core materialsinside wire electroderesults in shield of gas.

Arc Stream

Cored Wire

Protective Slag

Weld Metal


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, specif icallydesigned for arc welding must be used with the handor face shield whenever viewing the arc.

The arc melts the base metal and actually digs into itmuch 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.

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 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 0.035’ (0.9 mm) NR-211-MP Innershield elec-trode is recommended for Self-Shielded Flux CoredArc Welding.

THE GMAW (MIG) WELDING ARC

Figure B.10 illustrates the GMAW (MIG) welding arc.Solid wire does not contain fluxes or ingredients toform its own shielding and no slag forms to protect themolten weld metal. For this reason, a continuous evenflow of shielding gas is needed to protect the moltenweld metal from atmospheric contaminants such asoxygen and nitrogen. Shielding gas is suppliedthrough the gun and cable assembly, through the gasnozzle and into the welding zone.

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 0.025” (0.6 mm) 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 SELECTION

By 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) Process1. Is most of my welding performed on 16 gauge and

lighter materials?

SP-100T

FIGURE B.10

Gas nozzle

Shielding gasSolid wireelectrode

Base metalWeld metal


SP-100T

2. Can I afford the extra expense, space, and lack ofportability required for gas cylinders and gas sup-ply?

3. Do I require clean, finished-looking welds?

If you have answered yes to all the above questionsGMAW 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) Process1. Do I want simplicity and portability?

2. Will welding be performed outdoors or under windyconditions?

3. Do I require good all position welding capability?

4. Will most welding be performed on 16 gauge andheavier, somewhat rusty or dirty materials?

5. Weld must be cleaned prior to painting.

COMMON METALS

Most 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 ofsteel 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 andyou can easily cut the metal with a file, chances aregood that the metal is mild steel and that you will beable to weld the material. In addition, aluminum andstainless steel can be welded using the K664-1Aluminum Welding Kit. For further information onidentifying various types of steels and other metals,and for proper procedures for welding them, we againsuggest you purchase a copy of “New Lessons in ArcWelding”.

Regardless of the type of metal being welded, in orderto get a quality weld, it is important that the metal isfree of oil, paint, rust or other contaminants.

JOINT TYPES AND POSITIONS

Five types of welding joints are: Butt Welds, FilletWelds, Lap Welds, Edge Welds and Corner Welds.See Figure B.11.

Of these, the Butt Weld and Fillet Weld are the twomost common welds.

FIGURE B.11

Butt WeldsPlace 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 Figure B.12.

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 themolten metal to be sure it distributes itself evenly onboth edges and in between the plates. This is referredto as the “pull technique”. On thin gauge sheet metal,use the “push technique”. See “Welding Techniquesfor GMAW (MIG) Process”.

Butt weld Lap weld

Edge weld Fillet weld Corner weld


SP-100T

FIGURE B.12PenetrationUnless a weld penetrates close to 100% of the metalthickness, a butt weld will be weaker than the materialwelded together. In the example shown in FigureB.13, the total weld is only half the thickness of thematerial thus the weld is only approximately half asstrong as the metal.

FIGURE B.13

FIGURE B.14

In the example shown in Figure B.14, the joint hasbeen welded so that 100% penetration could beachieved. The weld, if properly made, is as strong asor stronger than the original metal.

Fillet WeldsWhen 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. See Figure B.15.

FIGURE B.15

Welding In The Vertical Position

Welding 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 this unit on thicker materials than recom-mended may result in poor welds. The welds may“look” good, but may just be “sitting” on top, ofthe plate. This is called “Cold Casting” and willresult in weld failure.

Vertical-up And Overhead WeldingThe 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 Wire Feed Speed(WFS) in the low portion of the range. The generaltechnique and proper gun angle is illustrated in FigureB.16.

Generally, keep the electrode nearly perpendicular tothe joint as illustrated. The maximum angle above per-pendicular may be required if porosity becomes aproblem.

45°

WARNING


SP-100T

FIGURE B.16

Vertical-down WeldingRefer to Figure B.17 Vertical-down welds are appliedat a fast pace. These welds are therefore shallow andnarrow and, as such, are excellent for sheet metal.Vertical-down welds may be applied to 5/32” (3.9 mm)and lighter material.

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.

FIGURE B.17

PROPER GUN ANGLEFOR GMAW PROCESSWELDING IN THE VERTICAL UP POSITION

PROPER GUN ANGLEFOR FCAW PROCESSWELDING IN THE VERTICAL UP POSITION

MACHINE SET UP FOR THE SELF-SHIELDED FCAW PROCESS

1. See PROCESS GUIDELINES in the OPERATIONsection for selection of welding wire and shieldinggas, and for range of metal thicknesses that can bewelded.

2. See the Application Guide on the inside of wirefeed section door for information on setting thecontrols.

3. Set the “Voltage” and “Wire Speed” controls to thesettings suggested on the Application Guide for thewelding wire and base metal thickness being used.The voltage control is marked “V” and the wire feedspeed is marked ‘’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 Work Cable Installation in the INSTALLATIONsection for instructions on changing polarity.

5. When using Innershield electrode, the gasless noz-zle may be used instead of a gas nozzle to improvevisibility of the arc.

6. Connect work clamp to metal to be welded. Workclamp must make good electrical contact to thework piece. The work piece must also be groundedas stated in the “Arc Welding Safety Precautions”at the beginning of this manual.

WELDING TECHNIQUES FOR THE SELF-SHIELDED FCAW PROCESS

Four simple manipulations are of prime importancewhen welding. With complete mastery of the four,welding will be easy. They are as follows:

1. The Correct Welding PositionFigure B.18 illustrates the correct welding positionfor right handed people. (For left handed people, itis the opposite.)

Hold the gun (of the gun and cable assembly) inyour right hand and hold the shield with your lefthand. (Left handers simply do the opposite.)

When using the FCAW Process, weld from left toright (if you are right handed). This enables you toclearly see what you are doing. (Left handers dothe opposite.) Tilt the gun toward the direction oftravel holding the electrode at an angle as shownin Figure B.18.


SP-100T

ARC RAYS can burn eyes and skin.

When using an open arc process, itIs necessary to use correct eye,head and body protection.

Protect yourself and others, read“ARC RAYS can burn” at the frontof this manual.

2. The Correct Way To Strike An Arc1. Be sure the work clamp makes good electrical

contact to the work.

2. Position gun over joint. End of wire may belightly touching the work.

3. Position face shield to protect face and eyes,close gun trigger, and begin welding. Hold thegun so that the contact tip to work distance isabout 3/8 to 1/2 inch (10 – 12 mm).

4. To stop welding, release the gun trigger andthe pull the gun away from the work after thearc goes out.

5. A ball may form at the tip end of the wire afterwelding. For easier restrikes (with Innershieldwire) the ball may be removed by feeding out afew inches of wire and simply bending the wireback and forth until it breaks off.

6. When no more welding is to be done, turn offthe machine.

3. The Correct Electrical Stickout (ESO)The electrical stickout (ESO) is the distance fromthe end of the contact tip to the end of the wire.

See Figure B.19.

Once the arc has been established, maintainingthe correct ESO becomes extremely important.The ESO should be approximately 3/8 to 1/2 inch(10 to 12 mm) long.

The easiest way to tell whether the ESO is the cor-rect length is by listening to its sound. The correctESO has a distinctive “crackling” sound, very muchlike eggs frying in a pan. A long ESO has a hollow,blowing or hissing sound. If the ESO is too short,you may stick the contact tip or nozzle to the weldpuddle and/or fuse the wire to the contact tip.

4. The Correct Welding SpeedThe important thing to watch while welding is thepuddle of molten metal right behind the arc. SeeFigure B.20. Do not watch the arc itself. It is theappearance of the puddle and the ridge where themolten puddle solidifies that indicates correct weld-ing speed. The ridge should be approximately 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.

FIGURE B.20

FIGURE B.18

WARNINGFIGURE B.19

3/8 – 1/2” (10 – 12 mm)Electrical Stickout (ESO)

Contact Tip

Wire Electrode

Solidifying ridgeMolten puddle


SP-100T

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 andburn through. One way to eliminate these problemsis to use the back-stepping method illustrated inFigure B.21.

FIGURE B.21

Practice

The best way of getting practice in the four skills thatenable you to maintain:

1. Correct welding position

2. Correct way to strike an arc

3. Correct electrical stickout

4. Correct welding speed

is to perform the following exercise.

Refer to Figure B.22.

1. Learn to strike an arc by positioning the gun overthe joint and touching the wire to the work.

2. Position face shield to protect face and eyes.

3. Depress gun trigger, hold gun so contact tip towork distance is about 3/8 to 1/2 inch (10 to 12mm) and the 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” arcstart moving. Look at the molten puddle constantly,and look at 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 yourprogress. The 10th weld will look considerably bet-ter than the first weld. By constantly checking onyour mistakes and your progress, welding will soonbe a matter of routine.

First weld from A to B; then from C to A; thenfrom D to C; then from E to D, and so on.

B A C D E

Back-Stepping

FIGURE B.22

ContactTip

Gun Angle

ESO

Mild Steel 12 gauge or 1/8 inch(3.0 mm)

Electrode 0.035" (0.9 mm)NR-211-MP

Innershield Wire

Voltage Setting “V” D

Wire Feed Speed “o|o” 3

For the SP-100T, use the following:


SP-100T

MACHINE SET UP FOR THE GMAW (MIG)PROCESS

1. See PROCESS GUIDELINES in the OPERATIONsection for selection of welding wire and shieldinggas, and for range of metal thicknesses that can bewelded.

2. See the Application Guide on the inside of wirefeed section door for information on setting thecontrols.

3. Set the “Voltage” and “Wire Speed” controls to thesettings suggested on the Application Guide for thewelding wire and base metal thickness being used.The voltage control is marked “V” and the wire feedspeed 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 WorkCable Installation in the INSTALLATION section forinstructions for changing polarity.

5. Check that the gas nozzle and proper size linerand contact tip are being used and that the gassupply is turned on. If adjustable, set for 15 to 20cubic feet per hour (7 to 10 l/min.) under normalconditions, increase to as high as 35 CFH (17I/min.) under drafty (slightly windy) conditions.

6. Connect work clamp to metal to be welded. Workclamp must make good electrical contact to thework piece. The work piece must also be groundedas stated in the “Arc Welding Safety Precautions”at the beginning of this manual.

WELDING TECHNIQUES FOR THE GMAW(MIG) PROCESS

Four simple manipulations are of prime importancewhen welding. With complete mastery of the four,welding will be easy. They are as follows:

1. The Correct Welding PositionFigure B.23 illustrates the correct welding positionfor right handed people. (For left handed people, itis the opposite.)

When GMAW (MIG) welding on sheet metal, it isimportant to use the “forehand” push technique.

Hold the gun (of the gun and cable assembly) inyour right hand and hold the shield with your lefthand. (Left handers simply do the opposite.)

FIGURE B.23

When using the GMAW process on light gauge mater-ial, weld from right to left (if you are right handed).This results in a colder weld and has less tendency forburn through.

2. The Correct Way To Strike An Arc

ARC RAYS can burn eyes and skin.

When using an open arc process, itIs necessary to use correct eye,head and body protection.

Protect yourself and others, read“ARC RAYS can burn” at the frontof this manual.

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 face shield to protect face and eyes, closegun trigger, and begin welding. Hold the gun sothat the contact tip to work distance is about 3/8 to1/2 inch (10 – 12 mm).

4. To stop welding, release the gun trigger and pullthe gun away from the work after the arc goes out.

5. A ball may form at the tip end of the wire afterwelding. For easier restrikes, the ball may beremoved by feeding out a few inches of wire andcutting off the end of the wire with wire cutters.

6. When no more welding is to be done, close thevalve on the gas cylinder, momentarily operate thegun trigger to release gas pressure, then turn offthe machine.

WARNING


SP-100T

FIGURE B.24

3. The Correct Electrical Stickout (ESO)The electrical stickout (ESO) is the distance fromthe end of the contact tip to the end of the wire.See Figure B.24.

Once the arc has been established, maintainingthe correct ESO becomes extremely important.The ESO should be approximately 3/8 to 1/2 inch(10 to 12 mm) long.

The easiest way to tell whether the ESO is the cor-rect length is by listening to its sound. The correctESO has a distinctive “crackling” sound, very muchlike eggs frying in a pan. A long ESO has a hollow,blowing or hissing sound. If the ESO is too short,you may stick the contact tip or nozzle to the weldpuddle and/or fuse the wire to the contact tip.

4. The Correct Welding SpeedThe important thing to watch while welding is thepuddle of molten metal right behind the arc. SeeFigure B.25. Do not watch the arc itself. It is theappearance of the puddle and the ridge where themolten Puddle solidifies that indicates correct weld-ing speed. The ridge should be approximately 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.

FIGURE B.25

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 andburn through. One way to eliminate these problemsis to use the back-stepping method illustrated inFigure B.21.

Practice

The best way of getting practice in the four skills thatenable you to maintain:

1. Correct welding position

2. Correct way to strike an arc

3. Correct electrical stickout

4. Correct welding speed

is to perform the following exercise.

Refer to Figure B.22.

1. Learn to strike an arc by positioning the gun overthe joint and touching the wire to the work.

2. Position face shield to protect face and eyes.

3. Depress gun trigger, hold gun so contact tip towork distance Is about 3/8 to 1/2 inch (10 to 12mm) and the gun is at proper angle.

Contact Tip

Wire Electrode

ESO

Molten puddle

Base metalWeld metal ridge

Mild Steel 16 gauge or 1/16 inch(1.6 mm)

Electrode Lincolnweld 0.025 L-56electrode

CO2Voltage Setting “V” C

Wire Feed Speed “o|o” 4

For the SP-100T, use the following:


TROUBLESHOOTING WELDS

Good welds have excellent appearance.

To Eliminate Porosity (in order of importance):

1. Turn on gas supply, if used2. Decrease voltage.3. Increase stickout.4. Increase WFS (wire feed speed).5. Decrease drag angle.6. Decrease travel speed.NOTE: Always be sure the joint is free from moisture,oil, rust, paint or other contaminants.

To Eliminate a Ropy Convex Bead(in order of importance):

1. Increase voltage.2. Decrease stickout.3. Decrease WFS (wire feed speed.4. Decrease travel speed.5. Decrease drag angle.6. Check for correct gas, if used.

To Reduce Spatter (in order of importance):

1. Increase voltage.2. Increase drag angle.3. Decrease stickout.4. Increase WFS (wire feed speed).5. Decrease travel speed.6. Check for correct gas, if used.

To Correct Poor Penetration (in order of impor-tance):1. Decrease stickout.2. Increase WFS (wire feed speed).3. Increase voltage.4. Decrease speed.5. Decrease drag angle.6. 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 angle.2. Increase stickout.3. Decrease voltage.4. Decrease WFS (wire feed speed.5. Decrease travel speed.

To Eliminate Stubbing* (in order of importance):

1. Increase voltage2. Decrease WFS (wire feed speed)3. Decrease stickout4. Increase drag angle * Stubbing occurs when the electrode drives through

the molten puddle and hits the bottom plate tendingto push the gun up.

SP-100T


Proper Gun Handling

Most feeding problems are caused by improper han-dling of the gun cable or electrodes.1. Do not kink or pull the gun around sharp corners2. Keep the gun cable as straight as practical when

welding.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

B-18APPLICATION CHARTB-18

SP-100T

C-1ACCESSORIESC-1

OPTIONAL ACCESSORIES1. K549-1 .035" (0.9 mm) Innershield® Welding Kit

— Includes a contact tip, a gasless nozzle and a.035/.045" (.9/1.2 mm) cable liner to permit theMagnum™ 100L gun and cable to use .035" (0.9mm) diameter flux-cored electrode. The fitting onthe end of the liner is stenciled with the maximumrated wire size (.045"/1.2 mm). Also included is a10 lb. (4.5 kg.) spool of .035" (0.9 mm) InnershieldNR-211-MP.

See “Innershield (FCAW) Conversion” in this sec-tion for installation instructions and MAINTE-NANCE section for proper feeding component con-figuration and installation.

2. K664-2 Aluminum Feeding Kit — This kitrequired for welding with .035 Aluminum wire. Thiskit may also be used for feeding .035 stainlesswire. Included with this kit are a drive roll, liner andcontact tip. It is important when changingbetween welding with steel wire and aluminumto exchange these components due to thelubricant applied to steel wire. Failure to do somay result in contaminated welds when weld-ing aluminum.

3. KP665-045C Drive Roll – Optional — Knurleddrive roll for feeding .035 (0.9 mm) diameter flux-cored electrode.

4. K520 Utility Cart — Designed to transport theLincoln family of small welders. Has provisions formounting a single gas cylinder. Has front castersand large rear wheels. Handle height is easilyadjustable. Bottom tray provided for tools andaccessories. Easy assembly required; takes lessthan 15 minutes.

5. K1800-1 CO2 Adjustable Regulator and Hose Kit —Includes an adjustable pressure flow regulator foruse on CO2 cylinders.Weld shielding gas may be obtained from a weld-ing supply distributor.

Also included is a gas hose which connects to therear of the welder.

See “Gas Connection” in Installation section forinstallation instructions.

6. K1799-1 Argon-Mixed Gas Adjustable Regulatorand Hose Kit (1)

Includes an adjustable pressure and flow regulatorfor use on argon-mixed gas cylinders. Also includ-ed is a gas hose which connects to the rear of thewelder.

7. K586-1 Deluxe Adjustable Gas Regulator &Hose KitAccommodates CO2 or mixed Gas Cylinders.

8. K697-1 Power Cord Extension — Extension 115Vpower cord (20’/6.1m) allows extra conveniencewhen work is located some distance away frompower receptacle.

(1) This regulator comes standard with a 4.5 foot hosewith the SP-100T.

SP-100T

C-2ACCESSORIESC-2

INNERSHIELD (FCAW) CONVERSION

Several changes are needed to convert the unit foroperation with the Innershield (FCAW) process. TheK549-1 or K549-2 Innershield Kits include all the nec-essary accessories for this conversion and are provid-ed for this purpose. The following conversions shouldbe made using the contents of this kit:

1. Change the output polarity to DC(–). See “WorkCable Installation” in Installation section for details.

2. Install proper drive roll for the wire size selected.See “Changing Drive Roll” in Maintenance sectionfor details.

3. Install the proper gun liner and tip for the wire sizeselected. See “Component Replacement” inMaintenance section for details.

4. Remove gas nozzle (if installed) and install gaslessnozzle. To remove, simply unscrew.

5. Load wire into machine and thread into gun andcable per “Welding Wire Loading” section.

REPLACEMENT PARTS

Complete Gun and Cable AssemblyL8311-6 (K530-4)

Contact Tip .025” (0.6 mm)S19726-1

Contact Tip .030” (0.8 mm)S19726-2

Contact Tip .035” (0.9 mm)S19726-3

Contact Tip-Tapered .025” (0.6 mm)S20278-1



Liner .023 - .030” (0.6 - 0.8 mm)M16291-2

Liner .030 - .035” (0.8 - 0.9 mm)M16291-6

Liner .035/.045” (0.9/1.2 mm)M16291-1

Gas DiffuserS19728

Gas NozzleM16294

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 NozzleM17846

Gasless Nozzle (Innershield Only)M16418

SP-100T

MAINTENANCE

SAFETY PRECAUTIONS

ELECTRIC SHOCK can kill.

• Disconnect input power by removingplug from receptacle before workinginside SP-100T. Use only groundedreceptacle. Do not touch electrically“hot” parts inside SP-100T.

• Have qualified personnel do the mainte-nance and trouble shooting work.

ROUTINE MAINTENANCE

POWER SOURCE COMPARTMENTNo user serviceable parts inside! Do not attempt to performservice in the power source (fixed) side of the SP-100T. Takethe unit to an authorized Lincoln Service Center if you experi-ence problems. NO maintenance is required.

In extremely dusty locations, dirt may clog the air passagescausing the welder to run hot with premature tripping of ther-mal protection. If so, blow dirt out of the welder with low pres-sure air at regular intervals to eliminate excessive dirt and dustbuild-up on internal parts.

WIRE FEED COMPARTMENT

1. When necessary, vacuum accumulated dirt from gearboxand wire feed section.

2. Occasionally inspect the incoming guide tube and cleaninside diameter if necessary.

3. Motor and gearbox have lifetime lubrication and require nomaintenance.

FAN MOTOR

Has lifetime lubrication — requires no maintenance.

WIRE REEL SPINDLE

Requires no maintenance. Do not lubricate shaft.

D-1MAINTENANCED-1

SP-100T

WARNING

D-2MAINTENANCED-2

SP-100T

GUN AND CABLE MAINTENANCE

FOR MAGNUM™ 100L GUN

Gun Cable CleaningClean cable liner after using approximately 300 lbs(136 kg) of solid wire or 50 lbs (23 kg) of flux-coredwire. Remove the cable from the wire feeder and lay itout straight on the floor. Remove the contact tip fromthe gun. Using low pressure air, gently blow out thecable liner from the gas diffuser end.

Excessive pressure at the start may cause the dirtto form a plug.

Flex the cable over its entire length and again blowout the cable. Repeat this procedure until no furtherdirt comes out.

Contact Tips, Nozzles, and Gun Tubes1. Dirt can accumulate in the contact tip hole and

restrict wire feeding. After each spool of wire isused, remove the contact tip and clean it by push-ing a short piece of wire through the tip repeatedly.Use the wire as a reamer to remove dirt that maybe adhering to the wall of the hole through the tip.

2. Replace worn contact tips as required. A variableor “hunting” arc is a typical symptom of a worn con-tact tip. To install a new tip, choose the correct sizecontact tip for the electrode being used (wire size isstenciled on the side of the contact tip) and screw itsnugly into the gas diffuser.

3. Remove spatter from inside of gas nozzle and fromtip after each 10 minutes of arc time or as required.

4. Be sure the gas nozzle is fully screwed onto thediffuser for gas shielded processes. For theInnershield® process, the gasless nozzle shouldbe screws onto the diffuser.

5. To remove gun tube from gun, remove gas nozzleor gasless nozzle and remove diffuser from guntube. Remove both collars from each end of thegun handle and separate the handle halves.Loosen the locking nut holding the gun tube inplace against the gun end cable connector.Unscrew gun tube from cable connector. To installgun tube, screw the locking nut on the gun tube asfar as possible. Then screw the gun tube into thecable connector until it bottoms. Then unscrew (nomore than one turn) the gun tube until its axis isperpendicular to the flat sides of the cable connec-tor and pointed in the direction of the trigger.Tighten the locking nut so as to maintain the properrelationship between the gun tube and the cableconnector. Replace the gun handle, trigger and dif-fuser. Replace the gas nozzle or gasless nozzle.

CONFIGURATION OF COMPONENTS IN WIRE FEEDING SYSTEMContact Tip Cable Liner Drive Roll

Components shipped with S19726-1 M16291-6 KP665-035SP-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 KP665-035 - Use Large grooveInnershield Welding Kit .035” (0.9mm) .035 (0.9mm)

K664-2 .035 (0.9mm) S24221-1 M18971-1 M19631Aluminum or Stainless Kit* .035A (0.9mm) .035” (0.9mm)

• If .030 Solid wire feeding is desired obtain an S19726-2 Contact Tip.

* It is important when changing between welding with steel wire and aluminum to exchange feeding components due to the lubricant applied to steel wire. Failureto do so may result in contaminated welds when welding aluminum.

CAUTION

D-3MAINTENANCED-3

SP-100T

COMPONENTREPLACEMENTPROCEDURES

CHANGING THE CONTACT TIP

1. Refer to Figure D.2. Remove the gas nozzle fromthe gun by unscrewing counter-clockwise.

2. Remove the existing contact tip from the gun byunscrewing counter-clockwise.

3. Insert and hand tighten desired contact tip.

4. Replace gas nozzle.

CHANGING DRIVE ROLL

The drive roll has two grooves; one for .023" – .025"(0.6 mm) solid steel electrode and a larger knurledgroove for .030" (0.8 mm) solid and .035" (0.9 mm)flux-cored steel electrode. As shipped, the drive roll isinstalled in the .030"/.035" (0.8/0.9 mm) position.

If .023" – .025" (0.6 mm) wire is to be used, the driveroll must be reversed as follows:

1. Connect the machine to its rated input power perinstructions in Installation section.

2. Release the spring-loaded pressure arm and lift theidle roll arm away from the drive roll.

3. Turn the power switch to ON (marked “I”).

4. Set the wire speed to minimum and jog the driveunit with the trigger switch until the drive roll setscrew is facing up.

When inching the welding wire, the drive rolls,gun connector block, and gun contact tip areenergized relative to work and ground and remainenergized for several seconds after the gun trig-ger is released.

5. Turn the power switch to OFF (marked “O”).

6. Loosen the drive roll set screw with the 5/64" (2.0mm) 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.

8. Push a length of straightened welding wire throughthe wire feeder guide tubes and adjust the positionof the drive roll so that the groove is centered onthe wire. Make certain the set screw is located onthe flat portion of the shaft and tighten.

3

2

1

FIGURE D.1

CAUTION

D-4MAINTENANCED-4

CHANGING LINER

NOTICE: The variation in cable lengths pre-vents the interchangeability of liners. Oncea liner has been cut for a particular gun, itshould not be installed in another gununless it can meet the liner cutoff lengthrequirement. Refer to Figure D.2.

1. Remove the gas nozzle from the gun byunscrewing counter-clockwise.

2. Remove the existing contact tip from thegun by unscrewing counter-clockwise.

3. Remove the gas diffuser from the guntube by unscrewing counter-clockwise.

4. Lay the gun and cable out straight on aflat surface. Loosen the set screw locat-ed in the brass connector at the wirefeeder end of the cable. Pull the liner outof the cable.

5. Insert a new untrimmed liner into theconnector end of the cable. Be sure theliner bushing is stenciled appropriatelyfor the wire size being used.

6. Fully seat the liner bushing into the con-nector. Tighten the set screw on thebrass cable connector. At this time, thegas diffuser should not be installed ontothe end of the gun tube.

7. With the gas nozzle and diffuserremoved from the gun tube, be sure thecable is straight, and then trim the linerto the length shown in the Figure D.2.Remove any burrs from the end of theliner.

8. Screw the gas diffuser onto the end ofthe gun tube and securely tighten.

9. Replace the contact tip and nozzle.

SP-100T

1-1/4 (31.8 mm)Liner Trim Length

Gas Diffuser

Gas Nozzle orGasless NozzleSet Screw Brass Cable

Connector

Liner Assembly (Liner bushing to be sealed tightagainst brass cable connector)

FIGURE D.2Liner trim length

D-5MAINTENANCED-5

GUN HANDLE PARTS

The gun handle consists of two halves that are heldtogether with a collar on each end. To open up thehandle, turn the collars approximately 60 degreescounter-clockwise until the collar reaches a stop. Thenpull the collar off the gun handle. If the collars are diffi-cult to turn, position the gun handle against a corner,place a screwdriver against the tab on the collar andgive the screwdriver a sharp blow to turn the collarpast an internal locking rib. See Figure D-3.

FIGURE D.3

SP-100T

➣

Counter-clockwise

E-1TROUBLESHOOTINGE-1

SP-100T

This Troubleshooting Guide is provided tohelp you locate and remedy possible prob-lems with machine setup or operation.Simply follow the three-step procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).Look under the column labeled “PROBLEM(SYMPTOMS)”. This column describes pos-sible symptoms that the machine mayexhibit. Find the listing that best describesthe symptom that the machine is exhibiting.

Symptoms are grouped into three main cat-egories: output problems, function prob-lems, welding problems.

Step 2. PERFORM EXTERNAL TESTS.The second column labeled “POSSIBLEAREAS OF MISADJUSTMENT(S)” lists theobvious external possibilities that may con-tribute to the machine symptom. Performthese tests/checks in the order listed. Ingeneral, these tests can be conducted with-out removing the case wrap-around cover.

Step 3. PERFORM COMPONENT TESTS.If you have exhausted all of the recom-mended tests in Step 2, Consult your LocalAuthorized Field Service Facility.

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 andmachine operator and will invalidate your factory warranty. For your safety and to avoidElectrical Shock, please observe all safety notes and precautions detailed throughout this manual.__________________________________________________________________________

WARNING

If for any reason you do not understand the test procedures or are unable to performthe tests/repairs safely, contact your LOCAL AUTHORIZED LINCOLN ELECTRICFIELD SERVICE FACILITY for assistance before you proceed._____________________________________________________________________

CAUTION


SP-100T

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

CAUTION

Observe Safety Guidelinesdetailed in the beginning of this manual.

TROUBLESHOOTING GUIDE

PROBLEMS(SYMPTOMS)

Major physical or electrical damageis evident.

No wire feed, weld output or gasflow when gun trigger is pulled. Fandoes NOT operate.

No wire feed, weld output or gasflow when gun trigger is pulled Fanoperates normally.

POSSIBLE AREAS OFMISADJUSTMENT(S)

NoneContact your local Authorized FieldService Facility.

1. Make sure correct voltage isapplied to the machine (115vac).

2. Make certain that power switchis in the ON position.

3. Make sure circuit breaker insidewire drive compartment is reset.

1. The thermostat may be trippeddue to overheating. Let machinecool. Weld at lower duty cycle.

2. Check for obstructions in airflow. Check Gun Trigger connec-tions. See Installation section.

3. Gun trigger may be faulty.

RECOMMENDEDCOURSE OF ACTION

Contact your local LincolnAuthorized Field Service Facility.

OUTPUT PROBLEMS


SP-100T


CAUTION

TROUBLESHOOTING GUIDEObserve Safety Guidelinesdetailed in the beginning of this manual.

PROBLEMS(SYMPTOMS)

No wire feed when gun trigger ispulled. Fan runs, gas flows andmachine has correct open circuitvoltage (32VDC maximum) – weldoutput.


1. If the wire drive motor is runningmake sure that the correct driverolls are installed in the machine.

2. Check for clogged cable liner orcontact tip.

3. Check for proper size cable linerand contact tip.



FEEDING PROBLEMS

PROBLEMS(SYMPTOMS)

Low or no gas flow when guntrigger is pulled. Wire feed, weldoutput and fan operate normally.


1. Check gas supply, flow regulatorand gas hoses.

2. Check gun connection tomachine for obstruction or leakyseals.



GAS FLOW PROBLEMS


SP-100T


CAUTION

Observe Safety Guidelinesdetailed in the beginning of this manual.

TROUBLESHOOTING GUIDE

PROBLEMS(SYMPTOMS)

Arc is unstable – Poor starting


1. Check for correct input voltageto machine – 115vac.

2. Check for proper electrodepolarity for process.

3. Check gun tip for wear or dam-age and proper size – Replace.

4. Check for proper gas and flowrate for process. (For MIG only.)

5. Check work cable for loose orfaulty connections.

6. Check gun for damage orbreaks.

7. Check for proper drive roll orien-tation and alignment.

8. Check liner for proper size.



WELDING PROBLEMS

F-1DIAGRAMSF-1

SP-100T

S1

SWIT

CH

D1

D3

D2

D4

204

204

204

203

203

203

C1

59,0

00 f

40V

203

204

-

+G

UN

CAB

LEC

ON

DU

CTO

RB

LOC

K TO WO

RK

ELEC

TRIC

AL S

YMB

OLS

PER

E15

37

CAV

ITY

NU

MB

ERIN

G S

EQU

ENC

E( C

OM

PON

ENT

SID

E O

F B

OAR

D )

539

541

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NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. Thespecific diagram for a particular code is pasted inside the machine on one of the enclosure panels.

NOTES

SP-100T

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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.

WARNING

AVISO DEPRECAUCION

ATTENTION

WARNUNG

ATENÇÃO

Spanish

French

German

Portuguese

Japanese

Chinese

Korean

Arabic

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.

• 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

• World's Leader in Welding and Cutting Products •

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