IM536-D SP-125 PLUS March, 2001 For use with machine Code Numbers 10260, 10481,10685,10689,10690,10740 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thoughtful operation on your part. DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT. And, most importantly, think before you act and be careful.
i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. The Above For Diesel Engines The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS.
ii ii SAFETY ELECTRIC SHOCK can kill. 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 bare skin 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 full area of physical contact with work and ground.
iii iii SAFETY WELDING SPARKS can cause fire or explosion. 6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily available. 6.b.
iv iv SAFETY PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. Les circuits à l’électrode et à la piéce sont sous tension quand la machine à souder est en marche.
v v Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you! Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped, title passes to the purchaser upon receipt by the carrier.
vi TABLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications ........................................................................................A-1 Identify and Locate Components ...........................................................................A-2 Select Suitable Location ........................................................................................
vii SP-125 PLUS
A-1 INSTALLATION TECHNICAL SPECIFICATIONS – SP-125 Plus INPUT – SINGLE PHASE ONLY Standard Voltage/Frequency 115V/60Hz 115V/60Hz 115V/60Hz Input Current 20 Amps - Rated Output 25 Amps - Maximum Output 15 Amps - CSA Rated output RATED OUTPUT Duty Cycle 20% Duty Cycle – Rated DC Output 20% Duty Cycle - CSA Rated Output Amps 90 63 Volts at Rated Amperes 18 20 OUTPUT Welding Current Range (Continuous) Rated DC Output: 0 - 90 amps CSA Rated DC Output: 0 - 63 amps Maximum Open Circuit Voltage 28 Useable A
A-2 INSTALLATION FIGURE A.1 Read entire installation section before starting installation. SAFETY PRECAUTIONS WARNING 1 2 WELD ING 25-125AMP RA NGE ELECTRIC SHOCK can kill. • Only qualified personnel should perform this installation. • Only personnel that have read and understood the SP-125 Plus Operating Manual should install and operate this equipment. • Machine must be plugged into a receptacle which is grounded per any national, local or other applicable electrical codes.
A-3 INSTALLATION SELECT SUITABLE LOCATION Work Clamp Installation Locate the welder in a dry location where there is free circulation of clean air into the louvers in the back and out the front of the unit. A location that minimizes the amount of smoke and dirt drawn into the rear louvers reduces the chance of dirt accumulation that can block air passages and cause overheating. Attach the work clamp per the following: 1. Unplug the machine or turn the power switch to the “OFF” position. 2.
A-4 INSTALLATION 3. Route the cable under and around the back of the Wire Feed Gearbox (6). 4. For GMAW Only: Refer to Figure A.2. As delivered, the SP-125 Plus is wired for positive polarity. This is the appropriate configuration for the Gas Metal Arc Welding (GMAW) process. To complete installation, use the provided wing nut to connect the work cable’s terminal lug to the negative (–) output terminal (5) located above the Wire Feed Gearbox (6). Make sure that both wing nuts are tight. 5.
A-5 INSTALLATION WARNING BUILDUP OF SHIELDING GAS may harm health or kill. • Shut off shielding gas supply when not in use. • SEE AMERICAN NATIONAL STANDARD Z-49.1, “SAFETY IN WELDING AND CUTTING” PUBLISHED BY THE AMERICAN WELDING SOCIETY. 1. Chain the cylinder to a wall or other stationary support to prevent the cylinder from falling over. Insulate the cylinder from the work circuit and earth ground. 4. Refer to Figure A.6.
A-6 INSTALLATION CODE REQUIREMENTS FOR INPUT CONNECTIONS WARNING This welding machine must be connected to power source in accordance with applicable electrical codes. The United States National Electrical Code (Article 630-B, 1990 Edition) provides standards for amperage handling capability of supply conductors based on duty cycle of the welding source. If there is any question about the installation meeting applicable electrical code requirements, consult a qualified electrician.
OPERATION B-1 Read entire Operation section before operating the SP-125 Plus. WARNING ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrode with skin or wet clothing. Insulate yourself from work and ground. • Always wear dry insulating gloves. FUMES AND GASES can be dangerous. • Keep your head out of fumes. • Use ventilation or exhaust to remove fumes from breathing zone. WELDING SPARKS can cause fire or explosion. • Keep flammable material away.
B-2 OPERATION GENERAL DESCRIPTION ● Reversible, dual groove drive roll. Drive roll will The SP-125 Plus is a complete semiautomatic constant voltage DC arc welding machine. Included is a solid state controlled, single phase constant voltage transformer/ rectifier power source and a wire feeder for feeding solid steel electrode and cored electrode.
B-3 OPERATION WELDING OPERATIONS 2 1 SEQUENCE OF OPERATION WELDING AMP RANGE 25-125 3 SP-125 Plus FIGURE B.1a Refer to Figure B.1b 4. Circuit Breaker – Protects machine from damage if maximum output is exceeded. Button will extend out when tripped (Manual reset). 5. Optional K695-2 Spot/Stitch Controls (see ACCESSORIES section) - If present, replaces Blank Panel Assembly located on the center panel inside the case door: Mode Switch - Selects between Spot, Stitch, or Seam (normal welding) mode.
B-4 OPERATION FIGURE B.3 Wire Spindle Shaft FIGURE B.4 4" Wire Spool 2 1 To wire drive Wing Nut and Spacer 4 5 3 Note: The brake should be adjusted with a spool of wire installed. When properly adjusted it should move freely but not coast. Friction Brake Adjustments 1. With wire spool installed, check free movement and coast of the spool. 2. To tighten the brake turn the wing nut clockwise in 1/4 turn increments until coasting stops. 3.
B-5 OPERATION FIGURE B.5 FIGURE B.6 Gun Handle Contact Tip Gas Diffuser Contact Tip Wire Electrode Gas Nozzle Shielding Gas When using the GMAW process, a cylinder of shielding gas, must be obtained. Refer to the ACCESSORIES section for more information about selecting gas cylinders for use with the SP-125 Plus. 1. For CO2, open the cylinder very slowly. For argonmixed gas, open cylinder valve slowly a fraction of a turn. When the cylinder pressure gauge pointer stops moving, open the valve fully.
B-6 OPERATION 9. To stop welding, release the gun trigger and then pull the gun away from the work after the arc goes out. 10. When no more welding is to be done, close valve on gas cylinder (if used), momentarily operate gun trigger to release gas pressure, and turn off the SP-125 Plus. Cleaning Tip And Nozzle Clean the contact tip and nozzle to avoid arc bridging between the nozzle and contact tip which can result in a shorted nozzle, poor welds and an overheated gun.
OPERATION B-7 OVERLOAD PROTECTION Output Overload The SP-125 Plus is equipped with a circuit breaker which protects the machine from potential damage from excessive output current. The circuit breaker button will extend out when tripped. The circuit breaker must be manually reset. Thermal Protection The SP-125 Plus duty cycle is exceeded a thermostat will shut off the output until the machine cools to a normal operating temperature. This is an automatic function and is self resetting.
B-8 LEARNING TO WELD LEARNING TO WELD WARNING No one can learn to weld simply by reading about it. Skill comes only with practice. The following pages will help the inexperienced operator to understand welding and develop this skill. For more detailed information, order a copy of “New Lessons in Arc Welding” listed at the end of this manual. Fumes and slag generated from Innershield type electrodes recommended for use with this welding machine can be toxic. • Avoid contact with eyes and skin.
B-9 LEARNING TO WELD The “arc stream” is seen in the middle of the picture. This is the electric arc created by the electric current flowing through the space between the end of the wire electrode and the base metal. The temperature of this arc is about 6000°F, which is more than enough to melt metal. The arc is very bright, as well as hot, and cannot be looked at with the naked eye without risking painful injury.
B-10 LEARNING TO WELD 2. Can I afford the extra expense, space, and lack of portability required for gas cylinders and gas supply? 3. Do I require clean, finished-looking welds? If you have answered yes to all the above questions GMAW may be the process for you. If you have answered no to any of the above questions, then you should consider using the FCAW process. JOINT TYPES AND POSITIONS Five types of welding joints are: Butt Welds, Fillet Welds, Lap Welds, Edge Welds and Corner Welds. See Figure B.11.
B-11 LEARNING TO WELD 45° FIGURE B.12 Penetration Unless a weld penetrates close to 100% of the metal thickness, a butt weld will be weaker than the material welded together. In the example shown in Figure B.13, the total weld is only half the thickness of the material thus the weld is only approximately half as strong as the metal. FIGURE B.15 Welding In The Vertical Position Welding in the vertical position can be done either vertical-up or vertical-down.
B-12 LEARNING TO WELD MACHINE SET UP FOR THE SELF-SHIELDED FCAW PROCESS 1. See PROCESS GUIDELINES in the OPERATION section for selection of welding wire and shielding gas, and for range of metal thicknesses that can be welded. 2. See the Application Guide on the inside of wire feed section door for information on setting the controls. PROPER GUN ANGLE FOR GMAW PROCESS WELDING IN THE VERTICAL UP POSITION PROPER GUN ANGLE FOR FCAW PROCESS WELDING IN THE VERTICAL UP POSITION FIGURE B.
B-13 LEARNING TO WELD Contact Tip Wire Electrode FIGURE B.18 3/8 – 1/2” (10 – 12 mm) Electrical Stickout (ESO) WARNING FIGURE B.19 ARC RAYS can burn eyes and skin. When using an open arc process, it Is necessary to use correct eye, head and body protection. Protect yourself and others, read “ARC RAYS can burn” at the front of this manual. 2. The Correct Way To Strike An Arc 1. Be sure the work clamp makes good electrical contact to the work. 2. Position gun over joint.
B-14 LEARNING TO WELD Helpful Hints For the SP-125 Plus, use the following: 1. For general welding, it is not necessary to weave the 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 you will have to increase the welding speed, whereas when welding on heavy plate, it is necessary to go more slowly in order to get good penetration. 3. When welding sheet metal 16 gauge (1.
B-15 LEARNING TO WELD MACHINE SET UP FOR THE GMAW (MIG) PROCESS 1. See PROCESS GUIDELINES in the OPERATION section for selection of welding wire and shielding gas, and for range of metal thicknesses that can be welded. 2. See the Application Guide on the inside of wire feed section door for information on setting the controls. 3. Set the “Voltage” and “Wire Speed” controls to the settings suggested on the Application Guide for the welding wire and base metal thickness being used.
B-16 LEARNING TO WELD Helpful Hints 1. For general welding, it is not necessary to weave the arc, neither forward or backward nor sideways. Weld along at a steady pace. You will find it easier. Contact Tip Wire Electrode ESO FIGURE B.24 3. The Correct Electrical Stickout (ESO) The electrical stickout (ESO) is the distance from the end of the contact tip to the end of the wire. See Figure B.24. 2.
B-17 LEARNING TO WELD 4. After you strike the arc, practice the correct electrical stickout. Learn to distinguish it by its sound. 2. Decrease stickout. 5. When you are sure that you can hold the correct electrical stickout, with a smooth “crackling” arc, start moving. Look at the molten puddle constantly. 4. Decrease travel speed. 6. Run beads on a flat plate. Run them parallel to the top edge (the edge farthest away from you).
B-18 LEARNING TO WELD Proper Gun Handling Most feeding problems are caused by improper handling of the gun cable or electrodes. 1. Do not kink or pull the gun around sharp corners 2. 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 lubrication. Use only clean, rust-free electrode. 6. Replace contact tip when it becomes worn or the end is fused or deformed.
APPLICATION CHART B-19 SP-125 PLUS
C-1 ACCESSORIES OPTIONAL ACCESSORIES 1. K520 Utility Cart — Designed to transport the Lincoln family of small welders. Has provisions for mounting a single gas cylinder. Has front casters and large rear wheels. Handle height is easily adjustable. Bottom tray provided for tools and accessories. Easy assembly required; takes less than 15 minutes. 6. KP666-035C Knurled Drive Roll (optional) — Reversible Drive Roll with double knurled grooves for .035 (0.9 mm) cored electrode. 7.
C-2 ACCESSORIES INNERSHIELD (FCAW) CONVERSION Several changes are needed to convert the unit for operation with the Innershield (FCAW) process. The K549-1 Innershield Kit includes all the necessary accessories for this conversion and are provided for this purpose. The following conversions should be made using the contents of this kit: REPLACEMENT PARTS Complete Gun and Cable Assembly L8311-6 (K530-4) Contact Tip .025” (0.6 mm) S19726-1 Contact Tip .030” (0.8 mm) S19726-2 1.
D-1 MAINTENANCE MAINTENANCE AFTER FEEDING 50# OF FLUX CORED WIRE OR 300# OF SOLID WIRE SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill. • Disconnect input power by removing plug from receptacle before working inside SP-125 PLUS. Use only grounded receptacle. Do not touch electrically “hot” parts inside SP-125 PLUS. • Have qualified personnel do the maintenance and trouble shooting work. • Unplug machine or turn power switch to OFF – “O” position. Remove gun and cable from machine.
D-2 MAINTENANCE GUN AND CABLE MAINTENANCE FOR MAGNUM™ 100L GUN Gun Cable Cleaning Clean cable liner after using approximately 300 lbs (136 kg) of solid wire or 50 lbs (23 kg) of flux-cored wire. Remove the cable from the wire feeder and lay it out straight on the floor. Remove the contact tip from the gun. Using low pressure air, gently blow out the cable liner from the gas diffuser end. CAUTION Excessive pressure at the start may cause the dirt to form a plug.
D-3 MAINTENANCE COMPONENT REPLACEMENT PROCEDURES CHANGING THE CONTACT TIP 1. Unplug or turn power switch to Off “O” position. 2. Refer to Figure D.2. Remove the gas nozzle from the gun by unscrewing counter-clockwise. 3. Remove the existing contact tip from the gun by unscrewing counter-clockwise. 4. Insert and hand tighten desired contact tip. 5. Replace gas nozzle. CHANGING THE SP-125 Plus FOR USE WITH INNERSHIELD FLUX CORED WIRE • Change The Contact Tip 1. Refer to Figure D.2.
D-4 MAINTENANCE CHANGING LINER 1-1/4 (31.8 mm) Liner Trim Length Gas Diffuser Slotted Set Screw Brass Cable Connector Contact Tip (Threaded) Gas Nozzle or Gasless Nozzle (Threaded) Liner Assembly (Liner bushing to be seated tight against brass cable connector) FIGURE D.2 Liner trim length for gun with red trigger (Magnum™ 100L) NOTICE: The variation in cable lengths prevents the interchangeability of liners.
D-5 MAINTENANCE GUN HANDLE PARTS The gun handle consists of two halves that are held together with a collar on each end. To open up the handle, turn the collars approximately 60 degrees counter-clockwise until the collar reaches a stop. Then pull the collar off the gun handle. If the collars are difficult to turn, position the gun handle against a corner, place a screwdriver against the tab on the collar and give the screwdriver a sharp blow to turn the collar past an internal locking rib. See Figure D-3.
E-1 TROUBLESHOOTING HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
E-2 TROUBLESHOOTING TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION OUTPUT PROBLEMS Major physical or electrical damage is evident. Contact your LOCAL LINCOLN AUTHORIZED FIELD SERVICE FACILITY. No wire feed, weld output or gas flow when gun trigger is pulled. Fan does NOT operate. 1. Make sure correct voltage is applied to the machine (115 vac). 2.
E-3 TROUBLESHOOTING TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION FEEDING PROBLEMS No wire feed when gun trigger is pulled. Fan runs, gas flows and machine has correct open circuit voltage (28 vdc maximum) – weld output. 1. If the wire drive motor is running check to see if the correct wire is in the machine. 2.
E-4 TROUBLESHOOTING TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION WELDING PROBLEMS Arc is unstable – Poor starting 1. Check for correct input voltage to machine – 115 vac. 2. Check for proper electrode polarity for process. 3. Check gun tip for wear or damage – Replace. Contact your local Lincoln Authorized Field Service Facility. 4.
S1 31A 32 31 MOTOR FAN L1 531 BREAKER CIRCUIT AUX WDG. W-WHITE 32 3 5 6 531 206 31A 205 4 ( J1 ) * NOTES: N.A. DIODES D1 & D3 ARE MOUNTED ON THE OUTSIDE HEATSINK. N.B. DIODES D2 & D4 ARE MOUNTED ON THE INSIDE HEATSINK, WHICH IS CLOSEST TO THE CENTER PANEL. N.C. COMPONENT VIEWED FROM REAR. N.D. BOLTED ALUMINUM CONNECTIONS REQUIRE T12837 JOINT COMPOUND (DOW CORNING 340) WHEN REATTACHING. B-BLACK LEAD COLOR CODE: 2 24 VAC 207 1 ELECTRICAL SYMBOLS PER E1537 N.C.
F-2 SP-125 PLUS NOTES
NOTES SP-125 PLUS
Now Available...12th Edition The Procedure Handbook of Arc Welding New Lessons in Arc Welding This printing will go fast so don’t delay. Place your order now using the coupon below. Lessons, simply written, cover manipulatory techniques; machine and electrode characteristics; related subjects, such as distortion; and supplemental information on arc welding applications, speeds and costs. Practice materials, exercises, questions and answers are suggested for each lesson.
● Do not touch electrically live parts or WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENÇÃO ● Keep flammable materials away. ● Wear eye, ear and body protection. ● Mantenga el material combustible ● Protéjase los ojos, los oídos y el electrode with skin or wet clothing. ● Insulate yourself from work and ground. ● No toque las partes o los electrodos bajo carga con la piel o ropa mojada. ● Aislese del trabajo y de la tierra.
● Keep your head out of fumes. ● Use ventilation or exhaust to ● Turn power off before servicing. ● Do not operate with panel open or guards off. remove fumes from breathing zone. ● Los humos fuera de la zona de res- piración. ● Mantenga la cabeza fuera de los humos. Utilice ventilación o aspiración para gases. ● Gardez la tête à l’écart des fumées. ● Utilisez un ventilateur ou un aspira- ● Desconectar el cable de ali- mentación de poder de la máquina antes de iniciar cualquier servicio.
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