SP100

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SVM102-A
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December, 1995
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SP-100
For use with machines
having Code Numbers 9284-10050
Safety Depends on You

Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However, your
overall safety can be increased by
proper installation ... and thought-

ful operation on your part. DO
View Safety Info
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.
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SERVICE MANUAL
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World's Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors
Sales and Service through Subsidiaries and Distributors Worldwide
22801 St. Clair Ave. Cleveland, Ohio 44117-1199 U.S.A. Tel. (216) 481-8100
i SAFETY
WARNING
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 you pur-
chase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040,
Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the
Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PER-
FORMED ONLY BY QUALIFIED INDIVIDUALS.
ELECTRIC SHOCK can ARC RAYS can burn.

2.a. Use a shield with the proper filter and cover
kill. plates to protect your eyes from sparks and
1.a. The electrode and work (or ground) circuits
the rays of the arc when welding or observing
are electrically “hot” when the welder is on.
open arc welding. Headshield and filter lens

Do not touch these “hot” parts with your bare should conform to ANSI Z87. I standards.
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands. 2.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
1.b. Insulate yourself from work and ground using dry insulation. the arc rays.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground. 2.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
In addition to the normal safety precautions, if welding themselves to the arc rays or to hot spatter or metal.
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or FUMES AND GASES
scaffolds; when in cramped positions such as sitting,
kneeling or Iying, if there is a high risk of unavoidable or can be dangerous.
accidental contact with the workpiece or ground) use 3.a. Welding may produce fumes and gases
the following equipment: hazardous to health. Avoid breathing these
• Semiautomatic DC Constant Voltage (Wire) Welder. fumes and gases.When welding, keep
• DC Manual (Stick) Welder. your head out of the fume. Use enough
• AC Welder with Reduced Voltage Control. ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When

1.c. In semiautomatic or automatic wire welding, the electrode, welding with electrodes which require special
electrode reel, welding head, nozzle or semiautomatic ventilation such as stainless or hard facing (see
welding gun are also electrically “hot”. instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
1.d. Always be sure the work cable makes a good electrical which produce highly toxic fumes, keep exposure as
connection with the metal being welded. The connection low as possible and below Threshold Limit Values (TLV)
should be as close as possible to the area being welded. using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
1.e. Ground the work or metal to be welded to a good electrical respirator may be required. Additional precautions are
(earth) ground. also required when welding on galvanized steel.
1.f. Maintain the electrode holder, work clamp, welding cable and 3.b. Do not weld in locations near chlorinated hydrocarbon vapors
welding machine in good, safe operating condition. Replace coming from degreasing, cleaning or spraying operations.
damaged insulation. The heat and rays of the arc can react with solvent vapors to
form phosgene, a highly toxic gas, and other irritating
1.g. Never dip the electrode in water for cooling. products.
1.h. Never simultaneously touch electrically “hot” parts of 3.c. Shielding gases used for arc welding can displace air and
electrode holders connected to two welders because voltage cause injury or death. Always use enough ventilation,
between the two can be the total of the open circuit voltage especially in confined areas, to insure breathing air is safe.
of both welders.
3.d. Read and understand the manufacturer’s instructions for this
1.i. When working above floor level, use a safety belt to protect equipment and the consumables to be used, including the
yourself from a fall should you get a shock. material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
1.j. Also see Items 4.c. and 6. your welding distributor or from the manufacturer.
3.e. Also see item 7b.
Apr. ‘93
SP-100
Return to Master TOC SAFETY ii
WELDING SPARKS can CYLINDER may explode

cause fire or explosion. if damaged.
4.a. Remove fire hazards from the welding area.
If this is not possible, cover them to prevent 5.a. Use only compressed gas cylinders
the welding sparks from starting a fire. containing the correct shielding gas for the
Remember that welding sparks and hot process used and properly operating
materials from welding can easily go through small cracks regulators designed for the gas and
and openings to adjacent areas. Avoid welding near pressure used. All hoses, fittings, etc. should be suitable for
hydraulic lines. Have a fire extinguisher readily available. the application and maintained in good condition.
4.b. Where compressed gases are to be used at the job site, 5.b. Always keep cylinders in an upright position securely
special precautions should be used to prevent hazardous chained to an undercarriage or fixed support.
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the 5.c. Cylinders should be located:
equipment being used. • Away from areas where they may be struck or subjected to
physical damage.
4.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact • A safe distance from arc welding or cutting operations and
can cause overheating and create a fire hazard. any other source of heat, sparks, or flame.
4.d. Do not heat, cut or weld tanks, drums or containers until the 5.d. Never allow the electrode, electrode holder or any other
proper steps have been taken to insure that such procedures electrically “hot” parts to touch a cylinder.
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even though they have 5.e. Keep your head and face away from the cylinder valve outlet
been “cleaned”. For information, purchase “Recommended when opening the cylinder valve.
Safe Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous 5.f. Valve protection caps should always be in place and hand
Substances”, AWS F4.1 from the American Welding Society tight except when the cylinder is in use or connected for
(see address above). use.
4.e. Vent hollow castings or containers before heating, cutting or 5.g. Read and follow the instructions on compressed gas
welding. They may explode. cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
4.f. Sparks and spatter are thrown from the welding arc. Wear oil Cylinders,” available from the Compressed Gas Association
free protective garments such as leather gloves, heavy shirt, 1235 Jefferson Davis Highway, Arlington, VA 22202.
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a FOR ELECTRICALLY
welding area.
powered equipment.
4.g. Connect the work cable to the work as close to the welding 6.a. Turn off input power using the disconnect
area as practical. Work cables connected to the building switch at the fuse box before working on
framework or other locations away from the welding area the equipment.
increase the possibility of the welding current passing
6.b. Install equipment in accordance with the U.S. National
through lifting chains, crane cables or other alternate cir-
Electrical Code, all local codes and the manufacturer’s
cuits. This can create fire hazards or overheat lifting chains
recommendations.
or cables until they fail.
6.c. Ground the equipment in accordance with the U.S. National
4.h. Also see item 7c.
Electrical Code and the manufacturer’s recommendations.
Mar. ‘93
SP-100
Return to Master TOC iii SAFETY
FOR ENGINE ELECTRIC AND MAGNETIC
powered equipment. FIELDS
7.a. Turn the engine off before troubleshooting and maintenance may be dangerous
work unless the maintenance work requires it to be running.
____________________________________________________
8.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
7.b. Operate engines in open, well-ventilated current creates EMF fields around welding cables and
areas or vent the engine exhaust fumes welding machines
outdoors.
8.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
____________________________________________________ before welding.
8.c. Exposure to EMF fields in welding may have other health

7.c. Do not add the fuel near an open flame effects which are now not known.
welding arc or when the engine is running.
Stop the engine and allow it to cool before 8d. All welders should use the following procedures in order to
refueling to prevent spilled fuel from minimize exposure to EMF fields from the welding circuit:
vaporizing on contact with hot engine parts

and igniting. Do not spill fuel when filling 8.d.1. Route the electrode and work cables together - Secure
tank. If fuel is spilled, wipe it up and do not them with tape when possible.
start engine until fumes have been
eliminated. 8.d.2. Never coil the electrode lead around your body.
____________________________________________________ 8.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.
7.d. Keep all equipment safety guards, covers
and devices in position and in good repair. 8.d.4. Connect the work cable to the workpiece as close as
Keep hands, hair, clothing and tools away possible to the area being welded.
from V-belts, gears, fans and all other
moving parts when starting, operating or 8.d.5. Do not work next to welding power source.
repairing equipment.
____________________________________________________ Mar. ‘93
7.e. In some cases it may be necessary to remove safety

guards to perform required maintenance. Remove

guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.
7.f. Do not put your hands near the engine fan. Do not
attempt to override the governor or idler by pushing on
the throttle control rods while the engine is running.
7.g. To prevent accidentally starting gasoline engines while

turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
___________________________________________________
7.h. To avoid scalding, do not remove the

radiator pressure cap when the engine is
hot.
SP-100
Return to Master TOC SAFETY iv
5. Toujours porter des lunettes de sécurité dans la zone de

PRÉCAUTIONS DE SÛRETÉ soudage. Utiliser des lunettes avec écrans lateraux dans les
Pour votre propre protection lire et observer toutes les instruc- zones où l’on pique le laitier.
tions et les précautions de sûreté specifiques qui parraissent
dans ce manuel aussi bien que les précautions de sûreté 6. Eloigner les matériaux inflammables ou les recouvrir afin de
générales suivantes: prévenir tout risque d’incendie dû aux étincelles.
Sûreté Pour Soudage A L’Arc 7. Quand on ne soude pas, poser la pince à une endroit isolé de
1. Protegez-vous contre la secousse électrique: la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours 8. S’assurer que la masse est connectée le plus prés possible
tout contact entre les parties sous tension et la peau nue de la zone de travail qu’il est pratique de le faire. Si on place
ou les vétements mouillés. Porter des gants secs et sans la masse sur la charpente de la construction ou d’autres
trous pour isoler les mains. endroits éloignés de la zone de travail, on augmente le risque
b. Faire trés attention de bien s’isoler de la masse quand on de voir passer le courant de soudage par les chaines de lev-
soude dans des endroits humides, ou sur un plancher age, câbles de grue, ou autres circuits. Cela peut provoquer
metallique ou des grilles metalliques, principalement dans des risques d’incendie ou d’echauffement des chaines et des
les positions assis ou couché pour lesquelles une câbles jusqu’à ce qu’ils se rompent.
grande partie du corps peut être en contact avec la
masse. 9. Assurer une ventilation suffisante dans la zone de soudage.
c. Maintenir le porte-électrode, la pince de masse, le câble Ceci est particuliérement important pour le soudage de tôles
de soudage et la machine à souder en bon et sûr état galvanisées plombées, ou cadmiées ou tout autre métal qui
defonctionnement. produit des fumeés toxiques.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir. 10. Ne pas souder en présence de vapeurs de chlore provenant
e. Ne jamais toucher simultanément les parties sous tension d’opérations de dégraissage, nettoyage ou pistolage. La
des porte-électrodes connectés à deux machines à soud- chaleur ou les rayons de l’arc peuvent réagir avec les
er parce que la tension entre les deux pinces peut être le vapeurs du solvant pour produire du phosgéne (gas forte-
total de la tension à vide des deux machines. ment toxique) ou autres produits irritants.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions 11. Pour obtenir de plus amples renseignements sur la sûreté,
pour le porte-électrode s’applicuent aussi au pistolet de voir le code “Code for safety in welding and cutting” CSA
soudage. Standard W 117.2-1974.
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. Ne
jamais enrouler le câble-électrode autour de n’importe quelle
partie du corps.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:
TRANSFORMATEUR ET À
REDRESSEUR
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du
rayonnement de l’arc et des projections quand on soude 1. Relier à la terre le chassis du poste conformement au code
ou quand on regarde l’arc. de l’électricité et aux recommendations du fabricant. Le dis-
b. Porter des vêtements convenables afin de protéger la positif de montage ou la piece à souder doit être branché à
peau de soudeur et des aides contre le rayonnement de une bonne mise à la terre.
l‘arc.
c. Protéger l’autre personnel travaillant à proximité au 2. Autant que possible, I’installation et l’entretien du poste
soudage à l’aide d’écrans appropriés et non-inflamma- seront effectués par un électricien qualifié.
bles.
3. Avant de faires des travaux à l’interieur de poste, la
4. Des gouttes de laitier en fusion sont émises de l’arc de debrancher à l’interrupteur à la boite de fusibles.
soudage. Se protéger avec des vêtements de protection
libres de l’huile, tels que les gants en cuir, chemise épaisse, 4. Garder tous les couvercles et dispositifs de sûreté à leur
pantalons sans revers, et chaussures montantes. place.
Mar. ‘93
SP-100
v RETURN TO MAIN INDEX
MASTER TABLE OF CONTENTS FOR ALL SECTIONS
Page
Installation .......................................................................................................Section A
Technical Specifications ........................................................................................A-1
Identify and Locate Components ...........................................................................A-2
Select Suitable Location ........................................................................................A-3
Output Connections ...............................................................................................A-3
Input Connections..................................................................................................A-5
Code Requirements ..............................................................................................A-6
Operation .........................................................................................................Section B
Safety Precautions ................................................................................................B-1
General Description ...............................................................................................B-2
Design Features and Advantages...................................................................B-2
Welding Capability ..........................................................................................B-2
Limitations .......................................................................................................B-2
Controls and Settings......................................................................................B-2
Welding Operations ...............................................................................................B-3
Overload Protection ...............................................................................................B-6
Accessories .....................................................................................................Section C
Accessories ...........................................................................................................C-1
Replacement Parts ................................................................................................C-1
Maintenance ....................................................................................................Section D
Safety Precautions ................................................................................................D-1
Items Requiring No Maintenance ..........................................................................D-1
Routine and Periodic Maintenance........................................................................D-1
Component Replacement Procedures ..................................................................D-2
Location of Components........................................................................................D-4
Theory of Operation ........................................................................................Section E

Input Line Voltage, Fan Motor and Main Transformer ...........................................E-1
Output Control, Rectification and Voltage Feedback.............................................E-2
Trigger, Gas Solenoid and Wire Drive ...................................................................E-3
SCR Operation ......................................................................................................E-4
Thermal Protection ................................................................................................E-5
Troubleshooting and Repair...........................................................................Section F

How To Use Troubleshooting Guide......................................................................F-1
PC Board Troubleshooting Procedures .................................................................F-2
Troubleshooting Guide...........................................................................................F-3
Oscilloscope Waveforms .......................................................................................F-9
Replacement Procedures ....................................................................................F-12
Retest After Repair ..............................................................................................F-14
Electrical Diagrams.........................................................................................Section G
SP-100 Parts Manual ........................................................................................Appendix
SP-100
TABLE OF CONTENTS Section A
– INSTALLATION SECTION –
Installation ......................................................................................................Section A
Technical Specifications ........................................................................................A-1
Input and Output Specifications ......................................................................A-1
Cable and Fuse Sizes .....................................................................................A-1
Physical Dimensions .......................................................................................A-1
Identify and Locate Components ...........................................................................A-2
Select Suitable Location ........................................................................................A-3
Stacking ..........................................................................................................A-3
Tilting...............................................................................................................A-3
Output Connections ..............................................................................................A-3
Work Clamp Installation .................................................................................A-3
Work Cable Installation ..................................................................................A-3
Gun Installation ...............................................................................................A-4

Connecting Gun Cable to the SP-100 ............................................................A-4
Gas Connection ..............................................................................................A-4
Input Connections..................................................................................................A-5
Code Requirements For Input Connections....................................................A-6
Requirements For Rated Output...............................................................A-6
Requirements For Maximum Output ........................................................A-6
Requirements For CSA Rated Output .....................................................A-6
Extension Cord Usage ...................................................................................A-6
SP-100
A-1 INSTALLATION
Return to Section TOC
TECHNICAL SPECIFICATIONS – SP-100

INPUT – SINGLE PHASE ONLY
Standard Voltage/Frequency Input Current
115V/60Hz 20 Amps - Rated Output
115V/60Hz 25 Amps - Maximum Output
115V/60Hz 12 Amps - CSA Rated output
RATED OUTPUT
Duty Cycle Amps Volts at Rated Amperes
20% Duty Cycle 90 18
30% Duty Cycle 100 17
20% Duty Cycle - CSA Rated Output 63 20
OUTPUT
Welding Current Range (Continuous) Maximum Open Circuit Voltage Auxiliary Power
Rated DC Output: 0 - 90 amps 28 N/A

Maximum DC Output: 0 - 100 amps
CSA Rated DC Output: 0 - 63 amps
RECOMMENDED INPUT CABLE AND FUSE SIZES

Fuse or
Output 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 Larger
For lengths up to
MAXIMUM 115V/60Hz 25 Amp 25 25 Amp, 125V, 25 Ft. (7.5 m)
Three Prong Plug
(NEMA Type 5-20P) Three Conductor
#12 AWG
CSA 115V/60Hz 15 Amp 12 15 Amp, 125V, (3.3 mm2)

Three Prong Plug For lengths up to
(NEMA Type 5-15P) 50 Ft. (15 m)
PHYSICAL DIMENSIONS
Height Width Depth Weight
12.0 in 9.75 in 16.5 in 54 Ibs
305 mm 248 mm 419 mm 24.3 kg
SP-100
INSTALLATION A-2
Read entire installation section before starting FIGURE A.1

installation.
SAFETY PRECAUTIONS 1
WARNING
ELECTRIC SHOCK can kill.
• Only qualified personnel should perform
this installation.
• Only personnel that have read and under-
stood the SP-100 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.
• The SP-100 power switch is to be in the

OFF (“O”) position when installing work
cable and gun and when connecting power
2
cord to input power.
IDENTIFY AND LOCATE 3a

COMPONENTS
If you have not already done so, unpack the SP-100
from its carton and remove all packing material
around the SP-100. Remove the following loose items
from the carton (see Figure A.1): 3b
1. SP-100
2. Gun and cable assembly(1)
3. Literature envelope which contains:

a) This operating manual 4
b) A contact tip for .030” (0,8 mm) diameter wire.
4. 10 ft (3,0 m) work cable.
5. Work clamp.
5
(1) Gun is ready to feed .025" (0.6 mm) diameter wire

(also .023 and .024 diameter wire).
SP-100
A-3 INSTALLATION
SELECT SUITABLE LOCATION WORK CLAMP INSTALLATION
Locate the welder in a dry location where there is free Attach the work clamp per the following:
circulation of clean air into the louvers in the back and
out the front of the unit. A location that minimizes the 1. Unplug the machine or turn the power switch to the
amount of smoke and dirt drawn into the rear louvers “OFF” position.
reduces the chance of dirt accumulation that can block
air passages and cause overheating. 2. Insert the work cable terminal lug with the larger
hole through the strain relief hole in the work clamp
as shown in Figure A-3.
STACKING
3. Fasten securely with the bolt and nut provided.
SP-100’s cannot be stacked.
FIGURE A.3
TILTING
Strain Relief Hole
Each machine must be placed on a secure, level sur- Work Cable

Nut & Bolt
face, either directly or on a recommended undercar-
riage. The machine may topple over if this procedure
is not followed.
Work Clamp
OUTPUT CONNECTIONS
Refer to Figure A.2. WORK CABLE INSTALLATION
1. Work Cable Access Hole. Refer to Figure A.2.
2. Gun Cable and Control Lead Access Hole. 1. Open the wire feed section door on the right side of
the SP-100.
3. Connector Block.
2. Pass the end of the work cable that has the termi-
4. Gun Trigger Lead Connectors. nal lug with the smaller hole through the Work
Cable Access Hole (1) in the case front.
5. Positive (+) and negative (–) output terminals.
FIGURE A.2
5
8
2
1
3 7
6
SP-100
INSTALLATION A-4
3. Route the cable under and around the back of the 3. Insert the connector on the gun conductor cable
Wire Feed Gearbox (6). into the Gun Cable Access Hole (2) in the SP-100
case front. Make sure the connector is all the way
4. For GMAW Only: Refer to Figure A.2. As deliv- in the metal connector block to obtain proper gas
ered, the SP-100 is wired for positive polarity. This flow. Rotate the connector so control leads are on
is the appropriate configuration for the Gas Metal the underside and tighten the Thumbscrew (8) in
Arc Welding (GMAW) process. To complete instal- the connector block.
lation, use the provided wing nut to connect the
work cable’s terminal lug to the negative (–) output 4. Connect the gun trigger control lead terminals to
terminal (5) located above the Wire Feed Gearbox the two insulated 1/4" (6,4 mm) tab connector
(6). Make sure that both wing nuts are tight. bushings located above the “Gun Trigger
Connection” decal in the wire feed section (4).
5. For Innershield Only: Refer to Figure A.4. To wire Either lead can go to either connector. Form the
for negative polarity, connect the short cable leads so that they are as close as possible to the
attached to the connector block (1) to the negative inside panel.
(–) output terminal (2) and the work cable (3) to the
positive (+) terminal (4).
FIGURE A.4 CAUTION

4 3 If the gun trigger switch being used is other than
that supplied with the SP-100, the switch must be
a normally open, momentary switch. The terminals
of the switch must be insulated from the welding
2 circuit. Malfunction of the SP-100 may result if this
switch shorts to the SP-100 welding output circuit
or is common to any electrical circuit other than
1 the SP-100 trigger circuit.
GAS CONNECTION
Refer to Figure A.5

When using the GMAW process, a cylinder of carbon

dioxide (CO2) or argon-carbon dioxide mixed shielding
gas, flow regulator, and an inlet gas hose must be
obtained. For more information about selecting gas
GUN INSTALLATION cylinders for use with the SP-100, refer to the ACCES-
SORIES section.
As shipped from the factory, the SP-100 gun is ready
to feed 0.023 - 0.025” (0,6 mm) wire. If 0.030” (0,8
mm) wire is to be used install the 0.030” (0.8 mm)
contact tip. Refer to the MAINTENANCE section for WARNING
contact tip installation details.
CYLINDER may explode if dam-
CONNECTING GUN CABLE TO THE SP-100 aged. Keep cylinder upright and
chained to support
1. Refer to Figure A.2. Unplug the machine or turn
power switch to the off “O” position. • Keep cylinder away from areas
where it may be damaged.
2. Pass the insulated terminals of the gun trigger con- • Never lift welder with cylinder
trol leads, one at a time, through the Gun Cable attached.
and Control Lead Access Slot (2) in the case front. • Never allow welding electrode to
The leads are to be routed under the Wire Feed touch cylinder.
Gearbox (6) and through the Cable Hanger (7) on
the inner panel. • Keep cylinder away from welding
or other live electrical circuits.
SP-100
A-5 INSTALLATION
3. Attach the flow regulator to the cylinder valve and
WARNING tighten the union nut securely with a wrench. The

flow regulator for carbon dioxide must have a plas-
BUILDUP OF SHIELDING GAS may
tic washer seated in the fitting that attaches to the
harm health or kill.
cylinder to prevent leakage.
• Shut off shielding gas supply
when not in use. 4. Refer to Figure A.6. Attach one end of inlet gas
• SEE AMERICAN NATIONAL hose to the outlet fitting of the flow regulator and
STANDARD Z-49.1, “SAFETY IN tighten the union nut securely with a wrench.
WELDING AND CUTTING” PUB- Connect the other end to the SP-100 Gas Solenoid
LISHED BY THE AMERICAN Inlet Fitting (5/8-18 female threads — for CGA —
WELDING SOCIETY. 032 fitting). Make certain the gas hose is not
kinked or twisted.
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 earth
INPUT CONNECTIONS
ground.
Refer to Figure A.6.
FIGURE A.5
The SP-100 has two input connections, the power
input cable, and the Gas Solenoid Inlet Fitting. Both
Flow Regulator Cylinder Valve connections are located on the rear of the machine.
FIGURE A.6
Gas Hose
Gas Solenoid
Inlet Fitting
2. With the cylinder securely installed, remove the Power

cylinder cap. Stand to one side away from the out- Input
let and open the cylinder valve very slightly for an Cable
instant. This blows away any dust or dirt which may
have accumulated in the valve outlet.
WARNING
BE SURE TO KEEP YOUR FACE AWAY FROM THE

VALVE OUTLET WHEN “CRACKING” THE VALVE.
Never stand directly in front of or behind the flow

regulator when opening the cylinder valve. Always
stand to one side.
SP-100
INSTALLATION A-6
CODE REQUIREMENTS FOR INPUT REQUIREMENTS FOR MAXIMUM OUTPUT

CONNECTIONS
An optional power cord (K467 Input Line Cord) is
available to permit the SP-100 to be connected to a
25 amp branch circuit with a nominal voltage rating of
WARNING 115 to 125 volts, 60 Hertz, AC only. With this installa-
This welding machine must be connected to tion the SP-100 can be used at an output of 100
power source in accordance with applicable elec- amps, 17 volts, 30% duty cycle.
trical codes.
Refer to the ACCESSORIES section for specific infor-
mation about the K467 Input Line Cord
The United States National Electrical Code (Article
630-B, 1990 Edition) provides standards for amperage
handling capability of supply conductors based on REQUIREMENTS FOR CSA RATED OUTPUT
duty cycle of the welding source.
A line cord with a 15 amp, 125 volt, three-prong plug
If there is any question about the installation meeting (NEMA Type 5-15P) is factory installed. Connect this
applicable electrical code requirements, consult a plug to a mating grounded receptacle which is con-
qualified electrician. 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-100 can be used at an
output of 63 amps, 20 volts, 20% duty cycle.
CAUTION EXTENTION CORD USAGE
Do not connect the SP-100 to an input power sup-
ply with a rated voltage that is greater than 125 If an extension cord is required, use one that is rated
volts. for the application and is 3 conductor #14 AWG (2.1
mm2) or larger. The recommended maximum lengths
Do not remove the power cord ground prong. are 25 ft (7.5 m) if #14 AWG (2.1 mm2) is used and
50 ft (15 m) if #12 AWG* (3.3 mm2) is used.
REQUIREMENTS FOR RATED OUTPUT

A power cord with a 15 amp, 125 volt, three prong

plug (NEMA Type 5-15P) is factory installed on the
SP-100. Connect this plug to a mating grounded
receptacle 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 90 amps, 18

Volts, 20% duty cycle (2 minutes of every 10 minutes
used for welding).
SP-100
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC A7
SP-100
NOTES
TABLE OF CONTENTS Section B
– OPERATION SECTION –
Operation ...........................................................................................................Section B
Safety Precautions ......................................................................................................B-1
General Description ....................................................................................................B-2
Recommended Processes.....................................................................................B-2
Operational Features and Controls........................................................................B-2
Design Features and Advantages .........................................................................B-2
Welding Capability ................................................................................................B-2
Limitations .............................................................................................................B-2
Controls and Settings...................................................................................................B-2
Welding Operations......................................................................................................B-3
Process Guidelines................................................................................................B-3
Sequence of Operations ........................................................................................B-3
Wire Loading..........................................................................................................B-3
Friction Brake Adjustments....................................................................................B-4
Wire Threading ......................................................................................................B-4
Shielding Gas .......................................................................................................B-5

Making a Weld ......................................................................................................B-5
Cleaning Tip and Nozzle........................................................................................B-6
Changing Machine Over To Feed Other Wire Sizes .............................................B-6
Welding With Innershield .......................................................................................B-6
Overload Protection .....................................................................................................B-6
Output Overload ....................................................................................................B-6
Thermal Protection ................................................................................................B-6
Wire Feed Overload Protection ............................................................................B-6
SP-100
B-1 OPERATION
Read entire operation section before

operating the SP-100.
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.
• Do not weld on closed contain-
ers.
ARC RAYS can burn eyes

and skin.
• Wear eye, ear and body protec-
tion.
Observe all safety information throughout

this manual.
SP-100
OPERATION B-2
GENERAL DESCRIPTION ● Reversible, dual groove drive roll. Drive roll will
feed .023-.025” (0,6- 0,9 mm) diameter wire.

The SP-100, Type K462, is a complete semiautomatic ● Accommodates both 8” (200 mm) diameter and 4”
constant voltage DC arc welding machine. Included is (100 mm) diameter spools of wire.
a solid state controlled, single phase constant voltage
transformer/ rectifier power source and a wire feeder ● No external shielding gas is required when used
for feeding solid steel electrode and cored electrode. with Lincoln Innershield .035” (0,9 mm) NR®-211-
MP electrode.
The SP-100 is ideally suited for individuals having ● Easy to change polarity.
access to 115 volt AC input power, and wanting the
ease of use, quality and dependability of both gas
metal arc welding or GMAW (also known as MIG WELDING CAPABILITY
welding) and the Innershield electrode process (self
shielded flux cored or FCAW). The SP-100 is a The SP-100 is rated at 90 amps, 18 volts, at 20% duty
rugged and reliable machine that has been designed cycle on a ten minute basis. It is capable of higher
for dependable service and long life. duty cycles at lower output currents.
RECOMMENDED PROCESSES LIMITATIONS

The SP-100 can be used for welding mild steel using Arc Gouging cannot be performed with the SP-100.
the GMAW, single pass, process which requires a The SP-100 is not recommended for pipe thawing.
supply of shielding gas or it can be used for the self
shielded, Innershield electrode process (FCAW). The
SP-100 is configured for use with the GMAW (MIG) CONTROLS AND SETTINGS
process as delivered from the factory.
Refer to Figure B.1a.
OPERATIONAL FEATURES AND 1. Power ON/OFF Switch —

CONTROLS
The SP-100 has the following controls as standard:

When the power is on the
fan motor will run and air will
be exhausted out the louvers
I On
Power ON/OFF Switch, Voltage Control, Wire Speed in the front of the machine.
O Off
Control, and a Circuit Breaker. The welding output and wire

feeder remain off until the
gun trigger is pressed.
DESIGN FEATURES AND
ADVANTAGES 2. Voltage Control — A contin-
● Operates on 115 volt input — no special wiring

required.
uous control that gives full
range adjustment of power
source output voltage.
V
Voltage can be adjusted Arc Volts
● Solid state output control.
while welding.
● “Cold electrode” until gun trigger is pressed for an
added measure of safety. 3. Wire Speed Control —
Controls the wire feed speed
● Overload protection — incorporates both a thermo-
from 50 – 400 in /min (1.3 –
stat and a circuit breaker.
● Quality wire drive with electronic overload protec-
tion.
10 m/min). The control can
be preset on the dial to the
setting specified on the SP-
o|o
Wire Speed
100 Application Guide locat-

● Easy-to-set continuous range controls for precise
ed on the inside of the wire
setting of arc voltage and wire speed.
feed section door. Wire
● Continuous voltage control. speed is not affected when
changes are made in the
● “Quick Release” idle roll pressure arm is easily
voltage control.
adjusted.
SP-100
B-3 OPERATION
FIGURE B.1a The recommended gas and electrode for GMAW is
welding grade CO2 gas and 0.025” (0 6 mm) diameter

Lincoln L-56 mild-steel welding wire [supplied on
121/2 Ib (6 kg) spools]. For 14 gauge (2,0 mm) and
thinner, CO2 gas is recommended because it gives
equal or better performance than a blended gas at a
1 2 lower cost. A mixed gas consisting of 75 to 80% Argon
and 20 to 25% CO2 is recommended for welding on
heavier gauge [12 gauge (2,5 mm) for example] steel.
The recommended electrode for the self-shielded

3 process is 0.035” (0,9 mm) diameter Lincoln
Innershield NR-211-MP on 10 Ib (4,5 kg) spools. This
electrode can be used for all position welding of 20
gauge through 5/16” (1 0 – 8,0 mm) thick steel [multi-
ple passes are required for 1/4” and 5/16” (6,0 and 8,0
mm)].
SEQUENCE OF OPERATION
WIRE LOADING
Refer to Figure B.2. and B.3.
Refer to Figure B-1b.
The machine power switch should be turned to the
4. Circuit Breaker - Protects machine from damage if OFF (“O”) position before working inside the wire feed
maximum output is exceeded. Button will extend enclosure.
out when tripped (Manual reset).
The machine is shipped from the factory ready to
feed 8” (200 mm) diameter spools [2.2” (56 mm)
FIGURE B.1b max. width]. These spools fit on a 2” (50 mm) diame-
ter spindle that has a built-in adjustable* friction brake
to prevent overrun of the spool and excess slack in
the wire. The thumb screw at the end of the shaft is
4 not intended to be loosened. It should be tightened full

clockwise. NOTE: If full tightening of the spindle
thumbscrew causes too much tension in the wire
spool, the thumb screw stop point should be
adjusted.
*Earlier spindle shafts did not include a set screw to

adjust brake friction. If a set screw is desired, order
Lincoln part number T12932-2.
Load an 8” (200 mm) diameter spool on the wire spool

spindle 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 thumb screw at the end of the shaft
WELDING OPERATIONS and remove the spindle. The spindle can be stored in
the wire feed compartment. A 4’ (100 mm) diameter
PROCESS GUIDELINES spool is mounted directly on the 5/8” (16 mm) diame-
ter shaft and held in place with the previously removed
The SP-100 can be used for welding mild steel using thumb screw. Make certain that the thumbscrew is
the GMAW, single pass, process which requires a
supply of shielding gas or it can be used for the self
shielded, Innershield electrode process.
SP-100
OPERATION B-4
FIGURE B.2 WIRE THREADING

Refer to Figure B-4
Wire Spool Spindle 8” Wire Spool

FIGURE B.4
2
Be sure that this stud engages
the hole in the wire spool.
1
To Wire Drive
5 4
Wire Spool must be pushed all the way on the spindle so that the
spindle’s tab will hold it in place. The Wire Spool will rotate clock- 3 The Wire Drive Feed Roll can
accommodate two wire sizes by
wise when wire is dereeled.
flipping the wire drive feed roll
over. The sizes are stenciled on
the drive roll.
tightened fully clockwise. Also make certain the start

end of the wire, which may protrude through the side
of the spool does not contact any metallic case parts. 1. Release the Spring Loaded Pressure Arm (1)
rotate the Idle Roll Arm (2) away from. the Wire
Feed Drive Roll (3). Ensure that the visible, .sten-
FIGURE B.3 ciled size on the drive roll matches the wire size
being used.
2. Carefully detach the end of the wire from the

Wire Spindle Shaft
spool. To prevent the spool from unwinding, do
4" Wire Spool not release the wire until after step 5.
3. Cut the bent portion of wire off and straighten the

first 4” (100 mm).
4. Thread the wire through the In-going guide tube

Thumb Screw (4), over the drive roll (3), and into the out-going
guide tube (5).
To Wire Drive
5. Close the idle roll arm and latch the spring loaded
pressure arm (2) in place (now you may release
the welding wire).
FRICTION BRAKE ADJUSTMENTS
1. Remove the Wire Spool thumbscrew. 6. The idle roll pressure adjustment wing nut is nor-
mally set for mid-position on the pressure arm
2. Using a 3/16” (4,8 mm) hex wrench, turn the set threads. If feeding problems occur because the
screw, located inside the tapped hole in the spindle wire is flattened excessively, turn the pressure
shaft, one or two turns counter-clockwise. adjustment counter-clockwise to reduce distortion
of the wire. Slightly less pressure may be required

3. Fully reinstall the thumbscrew and check for proper when using 0.023 – 0.025” (0,6 mm) wire. If the
brake force to prevent spool overrun, but still allow drive roll slips while feeding wire, the pressure
smooth and easy wire feeding. Readjust, if neces- should be increased until the wire feeds properly.
sary.
SP-100
B-5 OPERATION
FIGURE B.5 FIGURE B.6
Gun Handle
Contact Tip
Gas Diffuser/
Contact Tip Wire Electrode
Gas Nozzle 3/8" – 1/2" Electrical Stickout
WARNING
2. If using a regulator with an adjustable flow meter,

When inching the welding wire, the drive rolls, the close the gun trigger and adjust the flow to give 15
gun connector block and the gun contact tip are – 20 cubic ft per hour (CFH) (7 – 10 I/min) [use 20
always energized relative to work and ground and -– 25 CFH (10 – 12 I/min) when welding out of
remain energized several seconds after the gun position or in a drafty location for CO2]. For argon
trigger is released. mixed gas, trigger to release gas pressure, and
turn off the adjust the flow to give 25 – 30 CFH
(12 – 14 I/min).
7. Refer to Figure B.5. Remove gas nozzle and con- 3. Keep the cylinder valve closed, except when using
tact tip from end of gun. the SP-100. When finished welding:
a) Close the cylinder valve to stop gas flow.
8. Turn the SP-100 ON (“I”).
b) Depress the gun trigger briefly to release the
9. Straighten the gun cable assembly. pressure in the gas hose.
c) Turn off the SP-100.
10. Depress the gun trigger switch and feed welding
wire through the gun and cable. (Point gun away

from yourself and others while feeding wire.) MAKING A WELD
Release gun trigger after wire appears at end of 1. See Recommended Processes And Equipment
gun. section for selection of welding wire and shielding
gas and for range of metal thicknesses that can be
11. Replace contact tip and gas nozzle. welded.
12. Refer to Figure B-6. Cut the wire off 1/4” – 3/8” (6 2. See the Application Guide on the inside of wire
– 10 mm) from the end of the tip. The SP-100 is feed section door for information on setting the
now ready to weld. SP-100 controls.
SHIELDING GAS 3. Set the Voltage (“V”) and Wire Speed (“olo’”) con-
When using the GMAW process, a cylinder of carbon trols to the settings suggested for the welding wire
dioxide (CO2) or argon-carbon dioxide mixed shielding and base metal thickness being used.
gas, flow regulator, and an inlet gas hose must be
obtained. Refer to the ACCESSORIES section for 4. Check that the polarity is correct for the welding
more information about selecting gas cylinders for use wire being used and that the gas supply, if
with the SP-100. required, is turned on.
1. For CO2, open the cylinder very slowly. For argon- 5. When using Innershield electrode, remove the gas
mixed gas, open cylinder valve slowly a fraction of nozzle and install the gasless nozzle. This will
a turn. When the cylinder pressure gauge pointer improve visibility of the arc and protect the gas dif-
stops moving, open the valve fully. fuser from weld spatter. Refer to the MAINTE-
NANCE section for details on nozzle replacement.
SP-100
OPERATION B-6
FIGURE B.7 CHANGING MACHINE OVER TO FEED

OTHER WIRE SIZES

The SP-100 is shipped from the factory ready to feed
0.023-0.025” (0,6 mm) diameter wire. To operate the
SP-100 with other sizes of wire, it is necessary to
Gun Cable change the contact tip and change the drive roll over
to other sizes. Refer to Changing the Contact Tip and
Changing the Drive Roll, in the MAINTENANCE sec-
tion, for specific information on these procedures.
Arc WELDING WITH INNERSHIELD

Work Piece
Welding with Innershield requires an Innershield
Welding Kit. A gasless nozzle is provided in the
Innershield Welding Kit. When using Innershield elec-

trode, installing the gasless nozzle will improve visibili-
6. Refer to Figure B.7. Connect work clamp to metal ty of the arc and protect the gas diffuser from weld
to be welded. Work clamp must make good elec- spatter. Additionally included is a gun cable liner to
trical contact to the workpiece. The workpiece permit proper feeding of .035” (0,9 mm) Innershield
must also be grounded as stated in “Arc Welding wire. Refer to the ACCESSORIES section for details
Safety Precautions” in the beginning of this manu- on obtaining this kit.
al.
7. Position gun over joint. End of wire may be lightly OVERLOAD PROTECTION
touching the work.
OUTPUT OVERLOAD
8. Lower welding helmet, close gun trigger, and The SP-100 is equipped with a circuit breaker which
begin welding Hold the gun so the contact tip to protects the machine from damage if maximum output
work distance is about 3/8 inch (10 mm). is exceeded. The circuit breaker button will extend out
when tripped. The circuit breaker must be manually
9. To stop welding, release the gun trigger and then
reset.
pull the gun away from the work after the arc goes
out
THERMAL PROTECTION
10. When no more welding is to be done, close valve The SP-100 has a rated output duty cycle of 20%. If
on gas cylinder (if used), momentarily operate gun the duty cycle is exceeded, a thermal protector will
trigger to release gas pressure, and turn off the shut off the output until the machine cools to a normal
SP-100. operating temperature. This is an automatic function
of the SP-100 and does not require user intervention.
CLEANING TIP AND NOZZLE

Clean the contact tip and nozzle to avoid arc bridging WIRE FEED OVERLOAD PROTECTION
between the nozzle and contact tip which can result in The SP-100 has an automatic electronic protection cir-
a shorted nozzle, poor welds and an overheated gun. cuit to protect the wire feed motor. If excessive motor
Hint: Anti-stick spray or gel, available from a welding overload occurs (due to excessive feeding force
supply distributor, may reduce buildup and aid in spat- jammed drive rolls, or shorted motor leads) the circuit
ter removal. will shut down the wire feed motor and the welding
power output.
The wire feed shut-down circuit will reset automatically

when the gun trigger is released. However shut-down
will reoccur if the overload situation is not corrected.
SP-100
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC B-7
SP-100
NOTES
TABLE OF CONTENTS Section C
– ACCESSORIES SECTION –
Accessories .....................................................................................................Section C
Accessories ...........................................................................................................C-1
Replacement Parts ................................................................................................C-1
SP-100
C-1 ACCESSORIES
LINCOLN GAS REGULATOR KITS K467 INPUT LINE CORD
The Lincoln K463 CO2 or K499 Ar-mixed The K467 Input Line Cord is the same as
Gas Regulator and Hose Kit is recommend- the line cord supplied with the SP-100, but
ed for use with the SP100. has a NEMA type 5-20P plug for use on 25
amp branch circuits.
K463 CO2 Regulator
The K463 kit includes a preset, non- To install optional features, refer to in-
adjustable pressure flow regulator for use structions included with the kit.
on CO2 cylinders. The K463 CO2 pressure-
flow regulator is preset at the factory to pro-
vide a flow rate of 20 cubic feet per hour (10
l/min). This setting cannot be changed. Also
included is a 10 foot (3,0 m) gas hose which REPLACEMENT PARTS
connects to the rear of the SP-100.
Complete Gun and Cable Assembly
The K463 CO2 pressure-flow regulator can L7538 – Black Trigger; L8311-2 (K530-2) –
be used with a cylinder of argon mixed gas Red Trigger

if a CGA-580-320 (Western Enterprises No.
810) adapter is used between the cylinder Contact Tip 0.025” (0,6 mm)
and the regulator. S18704-1 – Black Trigger; S19726-1 – Red
Trigger
Weld shielding gas may be obtained from a
welding supply distributor. Contact Tip 0.030” (0,8 mm)
S18704-2 – Black Trigger; S19726-2 – Red
K499 Ar-Mixed Gas Regulator Trigger
K499 Ar-Mixed Gas Regulator and Hose Kit
– Includes a preset, non-adjustable pres- Contact Tip 0.035” (0,9 mm)
sure and flow regulator for use on argon- S18704-3 – Black Trigger; S19726-3 – Red
mixed gas cylinders. Also included is a 10 Trigger
foot (3 0 m) gas hose which connects to the
rear of the SP-100. Liner 0.023 - 0.030” (0,6 - 0,8 mm)
S18704-4 – Black Trigger; M16291-2 – Red
Trigger
INNERSHIELD WELDING KITS

Liner 0.035” (0,9 mm)
0.035 (0.9 mm) Innershield Welding Kit S18704-5 – Black Trigger; M16291-1 – Red
– Includes a contact tip, a gasless nozzle Trigger
and a cable liner to permit the SP-100 gun
and cable to use a 0.035” (0,9 mm) dia- Gas Diffuser
meter flux-cored electrode. Also included S18704-6 – Black Trigger; S19728 – Red
is a spool of 0.035 (0,9 mm) Innershield Trigger
NR-211-MP.
Gas Nozzle
Two kits are available: S18704-7 – Black Trigger; M16294 – Red
Trigger
K549-1 kit is for use with Magnum 100L
gun (with red trigger).
Gasless Nozzle (Innershield Only)
K464 kit is for use with the original S18704-14 – Black Trigger; M16418 – Red
Lincoln Electric gun (with black trigger). Trigger
DRIVE ROLL
M15448-1 Reversible Drive Roll with double

knurled grooves for 0.035 (0,9 mm) cored
electrode.
SP-100
TABLE OF CONTENTS Section D
– MAINTENANCE SECTION –
Maintenance ...................................................................................................Section D
Safety Precautions ...............................................................................................D-1
Items Requiring No Maintenance .........................................................................D-1
Routine and Periodic Maintenance........................................................................D-1
Before Each Use.............................................................................................D-1
After 5 Minutes of Welding..............................................................................D-1
After Each Spool of Wire Feed .......................................................................D-1
Component Replacement Procedures ..................................................................D-2
Changing The Contact Tip ..............................................................................D-2
Changing Drive Roll .......................................................................................D-2
Replace Liner..................................................................................................D-3
Replace Internal Gun Handle Parts As Necessary .........................................D-3

Location of Components........................................................................................D-4
SP-100
D-1 MAINTENANCE
SAFETY PRECAUTIONS AFTER EACH SPOOL OF WIRE
FEED
WARNING
• Remove contact tip and clean inside diam-
ELECTRIC SHOCK can eter with short piece of wire
kill. • Clean cable liner – when rough and erratic
wire feeding occur.
• Disconnect input power
by removing plug from
receptacle before work- AFTER FEEDING 50# OF FLUX
ing inside SP-100.Use CORED WIRE OR 300# OF SOLID
only grounded recepta- WIRE
cle. Do not touch electri-
cally “hot” parts inside • Unplug machine or turn power switch to
SP-1 00. OFF – “O” position. Remove gun and
cable from machine.
• Have qualified person- • Remove gas nozzle and contact tip from
nel do the maintenance gun

and trouble shooting
work. • Lay cable out straight - blow out gently
with compressed air. Bend cable back and
forth – blow out again – Repeat until clean.
ITEMS REQUIRING NO
MAINTENANCE CAUTION
• Drive Motor and Gearbox – Lifetime Excessive pressure at start may cause
lubrication the dirt to form a plug.
• Fan Motor- Lifetime lubrication.
• Wire Reel Spindle – Do NOT lubricate
shaft. PERIODICALLY AS REQUIRED
• Unplug machine or turn power switch to

ROUTINE AND PERIODIC OFF – “O” position.
MAINTENANCE
• Blow dirt out of the welder with low pres-

BEFORE EACH USE sure air to eliminate excessive dirt and
• Check over machine and accessories for dust buildup that could cause welder to
any obvious condition that may prevent run hot.
safe performance or operation, repair or
replace items as necessary to correct any • Blow dirt out of: Rectifier & Fan Motor
abnormal condition. Assembly; PC Board located on Case
Side Assembly; and Center Assembly
AFTER 5 MINUTES OF WELDING components. Refer to Figure D.4.
or when spatter accumulates in
nozzle • Vacuum accumulated dirt from gear-
box and wire feed section. Refer to
• Clean nozzle to avoid bridging between Figure D.4
nozzle and contact tip which results in
shorted nozzle, poor welds and overheat- • Inspect the incoming guide tube and
ed gun. Hint: Anti-stick spray or gel avail- clean inside diameter if necessary.
able from a welding supply distributor may Replace when excessively worn.
reduce buildup and aid in spatter removal.
• Replace Contact Tip – when hole is
enlarged or elongated (refer to Changing
Contact Tip, below).
SP-100
MAINTENANCE D-2
• Replace Liner – when wire feeding prob- FIGURE D.1

lems occur and other items have been

checked (refer to Changing Liner, in this
section).
COMPONENT REPLACE-
MENT PROCEDURES 3
CHANGING THE CONTACT TIP
1. Refer to Figure D.2. Remove the gas 2

nozzle from the gun by unscrewing
counter-clockwise.
Wire size is stenciled
2. Remove the existing contact tip from the

1 on the ends of the
drive roll.
gun by unscrewing counter-clockwise.
3. Insert and hand tighten desired contact

tip. 1. Make certain the SP-100 power switch is
off “O”.
4. Replace gas nozzle.
2. Open the Spring Loaded Pressure Arm
(2); Lift up the Idle Roll Arm (3).
CHANGING DRIVE ROLL 3. Remove the drive roll retaining screw and
washer.
The SP-100 Wire Feed Drive Roll (1 ) has
two grooves; one for 0.023” – 0.025” (0,6 4. Remove the drive roll, flip over and install
mm) solid steel electrode and the other for with the 0.030/0.035” (0.8/0.9 mm) stencil
0.030” (0,8 mm) solid and 0.035” (O,9 mm) visible (away from gearbox). Make cer-
flux-cored steel electrode. See Figure D.1. tain the small key is in place in the key-
As shipped, the drive roll is installed in the way.
0.023” – 0.025” (0,6 mm) position (as indi-

cated by the stenciling on the exposed side 5. Replace the washer and retaining screw.
of the drive roll). If 0.030” (0,8 mm) or
0.035” (0,9 mm) wire is to be used, the drive
roll must be reversed as follows:
FIGURE D.2
Liner trim length for the Magnum 100L gun (red trigger)
1-1/4 (31.8 mm)
Liner Trim Length
Gas Diffuser
Set Screw Brass Cable

Gas Nozzle or
Connector Gasless Nozzle
Liner Assembly
(Liner bushing to be sealed tight
against brass cable connector)
SP-100
D-3 MAINTENANCE
CHANGING LINER REPLACE INTERNAL GUN
HANDLE PARTS AS NECESSARY

NOTICE: The variation in cable lengths pre-
vents the interchangeability of liners. Once The gun handle consists of two halves that
a liner has been cut for a particular gun, it are held together with a collar on each end.
should not be installed in another gun To open up the handle, turn the collars
unless it can meet the liner cutoff length approximately 60 degrees counter-clock-
requirement. Refer to Figure D.2. wise (the same direction as removing a right
hand thread) until the collar reaches a stop.
1. Remove gun and cable assembly from Then pull the collar off the gun handle. If the
machine. collars are difficult to turn, position the gun
handle against a corner, place a screwdriv-
2. Remove the gas nozzle from the gun by er against the tab on the collar and give the
unscrewing counter-clockwise. screwdriver a sharp blow to turn the collar
past an internal locking rib. See Figure D-3.
3. Remove the existing contact tip from the
gun by unscrewing counter-clockwise. FIGURE D.3
4. Remove the gas diffuser from the gun

tube by unscrewing counter-clockwise.
5. Lay the gun and cable out straight on a

flat surface. Loosen the set screw locat-
ed in the brass connector at the wire
feeder end of the cable. Pull the liner out
of the cable.
➣
Counter-clockwise
6. Insert a new untrimmed liner into the
connector end of the cable. Be sure the
liner bushing is stenciled appropriately
for the wire size being used.
7. Fully seat the liner bushing into the con-

nector. Tighten the set screw on the

brass cable connector. At this time, the

gas diffuser should not be installed onto
the end of the gun tube.
8. With the gas nozzle and diffuser

removed from the gun tube, be sure
the cable is straight, and then trim the
liner to the length shown in the Figure
D.2. Remove any burrs from the end of
the liner.
9. Screw the gas diffuser onto the end of

the gun tube and securely tighten.
10. Replace the contact tip and nozzle.

SP-100
MAINTENANCE D-4
FIGURE D.4 – LOCATION OF COMPONENTS
4 2
6
5
SP-100 SUB ASSEMBLIES

1 Case Back and Bottom Assembly
2 Center Panel Assembly
3 Case Front Assembly

4 Case Side Assembly
5 Rectifier & Fan Motor Assembly
6 Wire Drive Assembly
SP-100
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC D-5
SP-100
NOTES
TABLE OF CONTENTS Section E
– THEORY OF OPERATION –
Theory of Operation ........................................................................................Section E

Input Line Voltage, Fan Motor and Main Transformer ...........................................E-1
Output Control, Rectification and Voltage Feedback.............................................E-2
Trigger, Gas Solenoid and Wire Drive ..................................................................E-3
SCR Operation ......................................................................................................E-4
Thermal Protection ................................................................................................E-5
SP-100
E-1 THEORY OF OPERATION
FIGURE E.1 – Input Power Circuits
INPUT LINE VOLTAGE, FAN

MOTOR AND MAIN
TRANSFORMER
The 115 vac input power is applied to the

SP-100 through a receptacle located on the
rear panel. The input power is connected to
the fan motor, control board and main
transformer through a line switch located on
the front panel. A circuit breaker is incorpo-
rated in the 115 vac circuit to protect the
unit from current overloads. The fan motor
employs a 24 vac auxiliary winding which
powers the control board. The main trans-
former changes the high voltage, low cur-
rent input power to a low voltage, high cur-

rent output for welding.
NOTE: Unshaded areas of block logic diagram are the subject of discussion.
SP-100
THEORY OF OPERATION E-2
FIGURE E.2 – Output Circuits

OUTPUT CONTROL, RECTIFICA- reflected at the transformer secondary wind-

TION AND VOLTAGE FEEDBACK ing and is applied to the rectifier diode
bridge. This rectified DC voltage is filtered
The AC voltage that is applied to the main by the output capacitor and choke circuit
transformer primary is controlled at the con- and is applied to the machine’s output ter-
trol board by two SCR’s (Silicon Controlled minals.
Rectifiers). The SCR’s are controlled by a
pulse signal developed on the control board.
The control board compares the commands
of the arc voltage control with the voltage
feedback signal. The board circuitry then
sends a pulse to turn on the SCR’s. In this
manner, the voltage applied to the primary
of the transformer is varied and controlled.
This variable and controlled voltage is

SP-100
FIGURE E.3 – Trigger, Gas Solenoid and Wire Drive
TRIGGER, GAS SOLENOID AND The welding output voltage that powers the
WIRE DRIVE wire drive motor is varied and controlled on
the control board. The control board moni-
Closure of the trigger circuit (pulling the gun tors the drive motor armature current and
trigger) signals the control board to start voltage and compares the feedback infor-
several functions. 115 vac is applied to the mation with the commands sent from the
gas solenoid to allow shielding gas to flow. wire speed control. The control board varies
The SCRs are activated and voltage is and controls power to the drive motor,
applied to the main transformer. Output volt- which, in turn, controls the speed of the wire
age is developed at the output terminals and drive. The SP-100 also has an automatic
fed back to the control board. This welding protection circuit which protects the wire
output voltage is also used to power the wire drive motor from excessive motor over-
drive motor. loads.
SP-100
THEORY OF OPERATION E-4
SCR OPERATION An SCR is fired by a short burst of current

into the gate. This gate pules must be more

A silicon controlled rectifier (SCR) is a three positive than the cathode voltage. Since
terminal device used to control large cur- there is a standard PN junction between
rents to a load. An SCR acts very much like gate and cathode, the voltage between
a switch. When it is turned on there is cur- these terminals must be slightly greater
rent flow from anode to cathode. In the ON than 0.6V. Once the SCR has fired, it is not
state, the SCR acts like a closed switch. necessary to continue the flow of gate cur-
When the SCR is turned OFF, there is no rent. As long as current continues to flow
current flow from anode to cathode, thus the from anode to cathode, the SCR will remain
device acts like an open switch. As the on. When the anode to cathode current
name suggests, the SCR is a rectifier, so it drops below a minimum value, called hold-
passes current only during positive half ing current, the SCR will shut off. This nor-
cycles of the AC supply. The positive half mally occurs as the AC voltage passes
cycle is the portion of the sine wave in through zero into the negative portion of the
which the anode of the SCR is more posi- sine wave. If the SCR is turned on early in
tive than the cathode. the positive half cycle, the conduction time
is longer, resulting in greater SCR output. If

When an AC supply voltage is applied to the gate firing occurs later in the cycle, the
the SCR, the device spends a certain por- conduction time is less, resulting in lower
tion of the AC cycle time in the ON state SCR output.
and the remainder of the time in the OFF
state. The amount of time spent in each
state is controlled by the Gate.
Note: As the gate pulse is applied later in the cycle, the SCR output is decreased.
FIGURE E.4 SCR OPERATION

SP-100
THERMAL PROTECTION
A thermostat protects the machine from

excessive operating temperatures.
Excessive operating temperatures may be
caused by lack of cooling or operating the
machine beyond the duty cycle and output
rating. If excessive operating temperature
should occur, the thermostat will prevent
voltage and wire drive. The fan will remain
on during this period. The thermostat is self-
resetting once the machine cools sufficient-
ly. If the thermostat shutdown is caused by
excessive output or duty cycle and the fan
is running normally, the power switch may
be left on and the reset should occur within
a 15 minute period. If the fan is not turning
or the air intake louvers are obstructed then

the input power must be removed and the
fan problem or air obstruction must be cor-
rected.
SP-100
TABLE OF CONTENTS Section F
– TROUBLESHOOTING SECTION –
Troubleshooting .............................................................................................Section F
Safety Precautions ................................................................................................F-1
How To Use Troubleshooting Guide .....................................................................F-1
PC Board Troubleshooting Procedures .................................................................F-2
Troubleshooting Guide...........................................................................................F-3
Output Problems .............................................................................................F-3
Feeding Problems ...........................................................................................F-6
Gas Flow Problems .........................................................................................F-7
Welding Problems ..........................................................................................F-7
PC Board Connector Locations .............................................................................F-8
Oscilloscope Waveforms
Normal Open Circuit Voltage Waveform .........................................................F-9
Typical Output Voltage Waveform – Machine Loaded .................................F-10
Abnormal Open Circuit Voltage Waveform ..................................................F-11

Replacement Procedures
Fan Blade and Motor Removal......................................................................F-12
Wire Drive Assembly Removal......................................................................F-13
Retest After Repair .............................................................................................F-14
SP-100
F-1 TROUBLESHOOTING & REPAIR
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.
__________________________________________________________________________
This Troubleshooting Guide is provided to help you locate and correct possible machine
malfunctions or misadjustments. Simply follow the three-step procedure listed below.
Step 1. LOCATE PROBLEM (SYMPTOM). Step 3. PERFORM COMPONENT TESTS.

Look under the column labeled “PROBLEM The last column labeled “Recommended
(SYMPTOMS)”. This column describes pos- Course of Action” lists the most likely com-
sible symptoms that the machine may ponents that may have failed in your
exhibit. Find the listing that best describes machine. It also specifies the appropriate
the symptom that the machine is exhibiting. test procedure to verify that the subject
component is either good or bad. If there
Symptoms are grouped into the following are a number of possible components
categories: Output Problems; Feeding check the components in the order listed to
Problems; Gas Flow Problems; and eliminate one possibility at a time until you
Welding Problems. locate the cause of you problem.
Step 2. PERFORM EXTERNAL TESTS. All the needed test specifications and repair
The second column labeled “POSSIBLE procedures are described in detail on the
AREAS OF MISADJUSTMENT(S)” lists the referenced pages. All the needed electrical
obvious external possibilities that may con- test points, terminal strips, junctions, etc.,
tribute to the machine symptom. Perform can be found on the referenced electrical
these tests/checks in the order listed. In wiring diagrams and schematics. See
general, these tests can be conducted with- Electrical Diagram Section.

out removing the case wrap-around cover.
CAUTION
If for any reason you do not understand the test procedures or are unable to Perform
the tests/repairs safely, contact your LOCAL AUTHORIZED LINCOLN ELECTRIC
FIELD SERVICE FACILITY for assistance before you proceed. Call 216-383-3531
or 1-800-833-9353
_______________________________________________________
SP-100
TROUBLESHOOTING & REPAIR F-2
PC BOARD TROUBLESHOOTING PROCEDURES

4. Test the machine to determine if the fail-

WARNING ure symptom has been corrected by the
ELECTRIC SHOCK can replacement PC board.
kill.
NOTE: Allow the machine to heat up so that
Have an electrician install all electrical components can reach their
and service this equip- operating temperature.
ment. Turn the input
power OFF and unplug 5. Remove the replacement PC board and
the machine before work- substitute it with the original PC board to
ing on equipment. Do not recreate the original problem.
touch electrically hot
parts. a. If the original problem does not reap-
pear by substituting the original
board, then the PC board was not
CAUTION: Sometimes machine failures the problem. Continue to look for bad
appear to be due to PC board failures. connections in the control wiring har-

These problems can sometimes be traced ness, junction blocks, and the termi-
to poor electrical connections. To avoid nal strips.
problems when troubleshooting and replac-
ing PC boards, please use the following b. If the original problem is recreated by
procedure: the substitution of the original board,
then the PC board was the problem.
1. Determine to the best of your technical Reinstall the replacement PC board
ability that the PC board is the most like- and test the machine.
ly component causing the failure symp-
tom. 6. Always indicate that this procedure was
followed when warranty reports are to be
2. Check for loose connections at the PC submitted.
board to assure that the PC board is
properly connected. NOTE: Following this procedure and writing
on the warranty report, “INSTALLED AND
3. If the problem persists, replace the sus- Switched PC BOARDS TO VERIFY PROB-
pect PC board using standard practices LEM,” will help avoid denial of legitimate PC
to avoid static electrical damage and board warranty claims.
electrical shock. (Read the warning
inside the static resistant bag.)
NOTE: It is desirable to have a spare

(known good) PC board available for PC
board troubleshooting.
SP-100
TROUBLESHOOTING GUIDE Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS POSSIBLE AREAS OF RECOMMENDED

(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
OUTPUT PROBLEMS
Major physical or electrical damage Contact your LOCAL LINCOLN Contact the Lincoln Electric Service
is evident. AUTHORIZED FIELD SERVICE Department. (216) 383-2531 or 1-
FACILITY. 800-833-9353 (WELD)
No wire feed, weld output or gas 1. Make sure correct voltage is 1. Check for 115 VAC at input to
flow when gun trigger is pulled. Fan applied to the machine (115 fan motor (leads #31 to #32). If
does NOT operate. vac). correct voltage is present and fan
motor does not function, replace
the fan motor. See wiring dia-
2. Make certain that power switch
gram.
is in the ON position.
2. If 115 vac is not present at leads

#31 to #32, then check the power
switch and input line cord. (SI)
No weld output or wire feed when Contact your LOCAL LINCOLN 1. Check voltage from leads #202
gun trigger is pulled. Fan runs and AUTHORIZED FIELD SERVICE to #201 at the output diode heat
gas flows normally. FACILITY. sinks. Normal voltage is from 2
vac to 20 VAC, depending on arc
voltage control setting. If the cor-
rect AC voltage is present, check
the output diodes and connec-
tions. Also check the output ca-
pacitor, C1. See wiring diagram.
2. If the correct AC voltage is not

present at the diode heat sink
leads #202 to #201, then check

the AC voltage on the trans-

former (TI) primary leads #531 to
#32 (normal is 115 vac with arc
voltage control at maximum). If
the correct voltage is present at
the transformer primaries (#531
to #32), the transformer may be
faulty. See wiring diagram.
3. If the correct voltage is not pre-

sent at leads #531 to #32, then
check the arc voltage control
potentiometer (RI)and associated
wires #205, #206 and #207 for
loose or broken connections.
See wiring diagram.
4. The control board may be faulty

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


OUTPUT PROBLEMS
No weld output when gun trigger is 1. Arc voltage may be set too low. 1. Check for open circuit voltage
pulled. Fan runs, gas flows and (OCV) at the machine’s output
wire feeds normally. 2. Gun tip may be worn – Replace. terminals, located in wire drive
compartment. Normal OCV is
3. Check for correct input voltage from 10 vdc to 28 vdc depending
to machine. on arc voltage control setting. If
correct OCV is present, check
4. Gun or work cable may be gun and work cable.
faulty.
2. If correct OCV is not present at
the output terminals, then check

for broken leads at the output
choke or at the positive output
terminal.
BELOW CODE 9794 ONLY 1. Check the circuit breaker locat- 1. Remove main power supply to
ed in the machine’s wire drive SP-100. With gun trigger pulled,
No wire feed, weld output or gas compartment. Reset if tripped. check for continuity (zero ohms)
flow when gun trigger is pulled Fan from 8J2 (lead #213) to 9J2 (lead
operates normally. 2. The thermostat may be tripped #211 ) at harness plug. If zero
due to overheating. Let machine ohms is indicated, then trigger
cool. Weld within the duty cycle circuit is OK. See wiring diagram
or remove any air obstruction to and Figure F.1.
machine.
2. If an open circuit or high resis-
3. Wire feed motor may be over- tance is indicated in Step 1, then
loaded. Correct feeding prob- check leads #211,#212 and #213

lem. for loose or broken connections.
Also check the normally closed
4. Gun trigger may be faulty. thermostat mounted on the diode
heat sink assembly. See wiring
diagram.
3. Check for 115 vac at lead #31A

to plug 3J1 on control board. If
115 vac is NOT present, remove
main supply power to machine.
Test continuity (zero ohms) of
leads #32 and #31A. See Figure
F.1.
4. If 115 vac is present at lead

#31A to plug 3J1 (lead #32), then
control board may be faulty –

Replace. See Figure F.1.
CAUTION
SP-100
TROUBLESHOOTING GUIDE Observe Safety Guidelines

OUTPUT PROBLEMS
CODE 9794 and ABOVE 1. Check the circuit breaker in the 1. Check for 24 vac at plug 2J1 to
machine – Located in the wire 6J1 on the control board. If volt-
No Wire feed, weld output or gas drive compartment. Reset if age is not present, check conti-
flow when the gun trigger is pulled - tripped. nuity of leads to fan motor. If
Fan operates normally. leads are OK, replace fan motor.
2. The thermostat may be tripped See Figure F.1
due to overheating. Let machine
cool. Weld within the duty cycle 2. Remove main power supply to
or remove any air obstruction to SP-100. With gun trigger pulled
machine. check for continuity (zero ohms)
from 8J2 (lead #213) to 9J2

3. Wire feed motor may be over- (lead #211) at harness plug. If
loaded – correct feeding prob- zero ohms is indicated then trig-
lem. ger circuit is OK. See Figure
F.1.
4. Gun trigger may be faulty.
3. If an open circuit or high resis-
tance is indicated in Step 2, then
check leads #211, #212 and
#213 for loose or broken con-
nections. Also check the normal-
ly closed thermostat mounted on
the diode heat sink assembly.
4. The control board may be faulty

– Replace.
CAUTION
SP-100


FEEDING PROBLEMS
No wire feed when gun trigger is 1. If the wire drive motor is running 1. Check for a DC voltage at wire
pulled. Fan runs, gas flows and check to see if the correct wire drive motor armature (leads
machine has correct open circuit is in the machine. #539 to #541). The voltage
voltage (28 vdc maximum) – weld should be between 2 vdc and 10
output. 2. If the wire drive motor is running vdc. This voltage will vary with
make sure that the correct drive the wire speed control setting. If
rolls are installed in the the correct voltage is present,
machine. the drive motor may be faulty.
Replace. See wiring diagram.
3. Check for clogged cable liner or
feeding problems. 2. If the motor armature voltage is

not present, then check for OCV
at leads #203 (3J2) and #204
(4J2) on the control board. If
correct voltage is present, go to
Step 3. If OCV is not present at
leads #203 and #204, check
continuity (zero ohms) of leads.
3. If the motor armature voltage is

not present, then check the wire
speed control potentiometer and
associated wires #208, #209
and #203 for faulty connections.
4. The control board may be faulty.

Replace.
Wire feed speed motor runs very 1. Make sure that the wire speed 1. Remove main supply power to
fast. Weld output, gas flow and fan control is not set at maximum. machine. Disconnect plug J2
operate normally. from the control board. Test the
resistance from lead #539 (2J2)
in the harness plug to the wire
feed motor case. If the resis-
tance is below 500,000 ohms,
replace the drive motor.
2. Check the wire speed control

potentiometer and associated
wires #208, #209 and #203 for
loose or broken connections.
3. The control board may be faulty.

Replace.
CAUTION
SP-100

GAS FLOW PROBLEMS
Low or no gas flow when gun 1. Check gas supply, flow regulator 1. Check for 115 vac at the gas
trigger is pulled. Wire feed, weld and gas hoses. solenoid leads #7 to #32A. If the
output and fan operate normally. correct voltage is present but
2. Check gun connection to the solenoid does not activate,
machine for obstruction or leaky replace solenoid. See wiring dia-
seals. gram .
2. If voltage is not present at leads

#7 to #32A, remove main supply
power to machine. Test leads #7
and #32A for continuity (zero

ohms) to the control board.
3. Control board may be faulty.

Replace.

WELDING PROBLEMS
Arc is unstable – Poor starting 1. Check for correct input voltage 1. Check for correct open circuit
to machine – 115 vac. voltage (OCV) at machine’s out-
put terminals, 10 vdc to 28 vdc,
2. Check for proper electrode depending on arc voltage con-
polarity for process. trol setting. If correct OCV is

present check gun and work
3. Check gun tip for wear or dam- cable.
age – Replace.
2. If OCV is low, check output
4. Check for proper gas and flow capacitor and output diodes.
rate for process.
3. Check arc voltage control poten-
5. Check work cable for loose or tiometer and associated wires
faulty connections. #205, #206 and #207 for loose
or broken connections. See
6. Check gun for damage or wiring diagram.
breaks.
4. Control board may be faulty.
Replace.
CAUTION
SP-100
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
Codes below 9794

Codes 9794 and above
6J1
1J1
6J1
1J1
FIGURE F.1
10J2
PC BOARD CONNECTOR LOCATIONS
10J2
TROUBLESHOOTING & REPAIR
1J2
1J2
SP-100
F-8
NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM
C1
0
volts
10 volts/Div 20 ms/Div
This is the typical output voltage waveform generated SCOPE SETTINGS

from a properly operating machine. Note that each
vertical division represents 10 volts and that each hor- Volts/Div ........................................................10/Div
izontal division represents 20 milliseconds in time. Horizontal Sweep .....................................20 ms/Div
Note: Scope probes connected at machine output ter- Coupling .............................................................DC

minals. Positive probe to (+) terminal, negative probe Trigger..........................................................Internal
to (–) terminal.
SP-100
TYPICAL OUTPUT VOLTAGE WAVEFORM – MACHINE LOADED

C1
0
volts
10 volts 20 ms
This is the typical output voltage waveform generated SCOPE SETTINGS

from a properly operating machine. Note that each
vertical division represents 10 volts and that each hor- Volts/Div ........................................................10/Div
izontal division represents 20 milliseconds in time. Horizontal Sweep .....................................20 ms/Div
The machine was loaded with a resistance grid bank.
The ammeter read 90 amps and the voltmeter read Coupling .............................................................DC
19 vdc. Trigger..........................................................Internal
Note: Scope probes connected at machine output ter-

minals. Positive probe to (+) terminal, negative probe
to (–) terminal.
SP-100
ABNORMAL OPEN CIRCUIT VOLTAGE WAVEFORM
C1
0
volts
10 volts 20 ms
This is NOT the typical output voltage waveform. The SCOPE SETTINGS
output capacitor was disconnected from the circuit.
Note the increased ripple in the waveform. This condi- Volts/Div ........................................................10/Div
tion simulates the faulty output filter capacitor. Each Horizontal Sweep .....................................20 ms/Div
vertical division represents 10 volts and that each hor-
izontal division represents 20 milliseconds in time. Coupling .............................................................DC
Trigger..........................................................Internal
Note: Scope probes connected at machine output ter-
minals. Positive probe to (+) terminal, negative probe
to (–) terminal.
SP-100
FAN BLADE AND MOTOR FIGURE F.2

REMOVAL
PROCEDURE DESCRIPTION
The following procedure will aid in the removal and

replacement of the fan blade and/or fan motor. It will
also provide reasonable access to the output diode
heat sinks.
TOOLS REQUIRED
● 5/16” nutdriver or socket wrench
● 7/16” open end wrench
● Phillips head screwdriver FIGURE F.3
Gas Solenoid
● Needle nose pliers
PROCEDURE
1. Using the 5/16” nut driver, remove the three self-
tapping screws holding the fan bracket to the rear
panel.
Refer to Figure F-2.
2. Remove the two aluminum transformer secondary

leads from the diode heat sinks.
Note: When reassembling, use Dow 340 Heat

Sink Compound on connection surfaces.
3. Remove three large black leads and one small FIGURE F.4
blue lead from the large choke lead. Thermostat
4. Remove leads #211 and #212 from the thermostat

located on the diode heat sink.
5. Remove the four leads from the fan motor noting

their positions. (TWO LEADS ON CODES
BELOW 9794.)
6. Remove the three wires connected to the input

receptacle. Note lead placement and connections.
(L1, L2, and green ground lead.)
Diodes
7. Remove the four self tapping screws holding the
line cord and input receptacle to the back panel.
8. Remove input receptacle. 12. Slide the blade from the motor shaft, taking note
of blade placement on motor shaft. (Shaft
9. Remove the two Phillips head screws holding the Indented approximately 0.10” from blade hub) -–
gas solenoid to the center baffle – See Figure F.3. Figure F.4.
10. Remove the gas solenoid and set aside. 13. Remove the two Phillips head screws holding the
motor to the bracket. Remove the motor.
11. Lift up the rectifier fan motor bracket assembly
and support it near the top of the machine. This 14. If the output diodes are to be removed, the leads
should provide access to the fan blade and motor. must be removed from the diodes and the heat
SP-100
WIRE DRIVE ASSEMBLY REMOVAL FIGURE F.5
PROCEDURE DESCRIPTION
The following procedure will aid in the removal of the

entire wire drive unit for possible motor or gear box
replacement.
TOOLS REQUIRED
● Phillips head screwdriver
● Needle nose pliers 1
● Knife or side cutters
● Screwdriver (slot head)
Two plastic fastener buttons attach the Connector Block to the

PROCEDURE
Front Panel at these points. To remove the Connector Block, cut

Refer to Figure F.5. the heads off of the two fastener buttons.
1A. FOR CODES ABOVE 10000 FIGURE F.6

Cut heads off of two plastic fastener buttons locat-
ed on the front panel. (Order new fastener buttons
– Part No. T14659-3)
1B. FOR CODES BELOW 10000

Remove two flat head screws holding conductor
block to front panel.
2. Remove gas hose from Connector block.
3. Remove cable running from output terminal to

Connector block (1).
4. With 5116’’ nutdriver, remove mounting screw at

rear of wire drive assembly.
FIGURE F.7
5. With 5/16” nutdriver, remove screw holding the
front panel to the case bottom. Carefully move
front panel forward 1/2”.
6. Carefully slide out wire drive unit until motor leads

are visible. Using needle nose pliers, remove
motor leads, taking note of lead positions.
7. Remove wire drive unit from machine.
MOTOR REMOVAL PROCEDURE

Refer to Figure F.6
Note: Slight resistance as rear housing is separated from the front
is caused by the bearing, which will remain attached to the front
1. Remove one Phillips head screw connecting front
housing.
to rear housing (1).
2. Using 1/4” nutdriver, remove two 8-32X1” thread 3. Remove motor with rear housing.
forming screws connecting front to rear housing
(2). 4. Remove two screws holding motor to rear hous-
ing.
Refer to Figure F-7
5. Separate motor from rear housing.
SP-100
RETEST AFTER REPAIR

Should a machine under test be rejected for any reason requiring the removal of any mechani-
cal part that could affect the machine’s electrical characteristics, or if any electrical components
are repaired or replaced, the machine must be retested.
MAIN TRANSFORMER SECONDARY VOLTAGES
TEST POINTS VOLTAGES
LEADS #201 – #202 2-20 vac Dependent on arc voltage control

Located on Output Diode Heat Sinks. setting (min. to max.)
INPUT AMPS AT RATED OUTPUT
INPUT AMPS (AC) @ OUTPUT (DC)
20 amps 90 amps @ 18 vdc
OPEN CIRCUIT VOLTAGES
TEST POINTS VOLTAGES
OUTPUT TERMINALS 10 to 27 vdc Dependent on arc voltage

control setting (min. to max.)
WIRE SPEED RANGE
50 to 400 in /min. Dependent on wire speed control setting

(1,2 to 10,2 m/min.)
12/95 SP-100
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-15
SP-100
NOTES:
TABLE OF CONTENTS Section G
– ELECTRICAL DIAGRAMS SECTION –
Electrical Diagrams ........................................................................................Section G

SP-100 Wiring Diagram (codes 9794 and above)................................................G-2
SP-100 Wiring Diagram (codes below 9794) ........................................................G-3
Control PC Board (G1842) Components...............................................................G-4
Control PC Board (G2314) Components...............................................................G-6
Machine Schematic (codes 9794 and above) .......................................................G-8
Machine Schematic (below code 9794) ................................................................G-9
SP-100
SP 100 WIRING DIAGRAM

G-2
SP-100
Do not operate with covers removed.
Disconnect input power by unplugging

ARC VOLTAGE power cord before servicing
CONTROL P.C. BOARD 5K
Do not touch electrically live parts
R1
7 7
Only qualified persons should install, use or
205 207
HIGH VOLTAGE
service this machine.
can kill
32A 32A 206
*
GAS ( J2 )
SOLENOID
*
( J1 )
WIRE SPEED
N.C.
5K
R2
531 31A 1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 10
208 203 GUN TRIGGER THERMOSTAT
209 212 (MOUNTED TO

32 206 539 204 203 213 208 DIODE HEATSINK)
207 205 541 203 209 211
211
213
TO GROUND (W)
FAN
PER NATIONAL 539
MOTOR
ELECTRICAL CODE WIRE FEED MOTOR
204 +
541
203 (B)
OUTPUT CHOKE
24 VAC
L2 L1 AUX WDG.
204
CIRCUIT
+
S1 BREAKER 31A 531 204
D1
ON-OFF
D2 204 GUN CABLE
SWITCH 31 202
+ CONDUCTOR
N.A. N.D. 59,000 f
BLOCK
N.D. C1 40V
N.C.
203
32 201
T1
N.B., N.D.
WIRING DIAGRAMS
D4
SP-100 WIRING DIAGRAM: CODES 9794 and Above
D3 203
TO
203 - WORK
*
CONNECTOR CAVITY NUMBER

J1 J2
NOTES: 1 2 3 1 2 3 4 5 ELECTRICAL SYMBOLS PER E1537

N.A. DIODES D1 & D3 ARE MOUNTED ON THE OUTSIDE HEATSINK.
LEAD COLOR CODE:
N.B. DIODES D2 & D4 ARE MOUNTED ON THE INSIDE HEATSINK,
4 5 6 6 7 8 9 10
WHICH IS CLOSEST TO THE CENTER PANEL.
B-BLACK W-WHITE
N.C. COMPONENT VIEWED FROM REAR. LATCH LATCH
N.D. BOLTED ALUMINUM CONNECTIONS REQUIRE JOINT COMPOUND.
CAVITY NUMBERING SEQUENCE
SEE OPERATING MANUAL WHEN REATTACHING.
(COMPONENT SIDE OF BOARD) 11-12-93K
M16576
CLEVELAND, OHIO U.S.A.
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is
pasted inside the machine on one of the enclosure panels.
M15427
N.A. DIODES D1 & D3 ARE MOUNTED ON THE N.C. COMPONENT VIEWED FROM REAR.
ELECTRICAL SYMBOLS PER E1537
OUTSIDE HEATSINK.
N.D. BOLTED ALUMINUM CONNECTIONS REQUIRE JOINT
N.B. DIODES D2 & D4 ARE MOUNTED ON THE COMPOUND. SEE OPERATING MANUAL WHEN LEAD COLOR CODE:
INSIDE HEATSINK, WHICH IS CLOSEST TO THE REATTACHING.
CENTER PANEL. B-BLACK
W-WHITE
*
CONNECTOR CAVITY NUMBER
J1 J2
ARC VOLTAGE 1 2 3 1 2 3 4 5
CONTROL P.C. BOARD N.C.
5K
R1
HI 4 5 6 6 7 8 9 10
205 207
LATCH LATCH
7 7 206 CAVITY NUMBERING SEQUENCE

GAS ( COMPONENT SIDE OF BOARD )
SOLENOID LO
32A 32A
*
( J2 )
*
( J1 )
WIRE SPEED
N.C.
5K
R2
531 31A 1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 10
208 203 GUN TRIGGER THERMOSTAT (MOUNTED TO
DIODE HEATSINK)
209 212
32 206 539 204 203 213 208
207 205 541 203 209 211
211
213
(W)
539
FAN WIRE FEED MOTOR

MOTOR
541
+
(B)
204
OUTPUT CHOKE
SP-100 WIRING DIAGRAM: CODES Below 9794
L2 L1 203
WIRING DIAGRAMS
204
S1
31 32 CIRCUIT 31A 531
+
ON-OFF BREAKER 204
D1
SWITCH
D2 204 GUN CABLE
31 202
CONDUCTOR
N.A. N.D. 59,000 mf
N.C. N.D. BLOCK
C1 40V
TO GROUND 203
PER NATIONAL 201
32
ELECTRICAL CODE T1
N.B.
D4
D3 203
TO
203 - WORK
SP WELDERS
WIRING DIAGRAM
M 15427
8-1-91D
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels.
G-3
SP-100
G-4 ELECTRICAL DIAGRAMS
CONTROL P.C. BOARD G1842
A
NOTE: Lincoln Electric assumes no responsibility for liabilities resulting from board level troubleshooting. PC Board
repairs will invalidate your factory warranty. This Printed Circuit Board schematic is provided for reference
only. It may not be totally applicable to your machine’s specific PC board version. This diagram is intended
to provide general information regarding PC board function. Lincoln Electric discourages board level trou-
bleshooting and repair since it may compromise the quality of the design and may result in Danger to the
Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.
SP-100
ELECTRICAL DIAGRAMS G-5

Item Identification Item Identification
SCR1, SCR2 SCR & HEATSINK ASBLY R45 RESISTOR-MF, 1/4W, 18.2K, 1%
X4 C-VOLT REG, FIXED, 3-T, (+), 1A, 15V R28, R31, R47, R49 RESISTOR-MF, 1/4W, 2.21K, 1%
C4, C9, C11, C12, C13, CAPACITOR-CEMO, .022, 50V, 20% R12, R38, R39, R60, RESISTOR-MF, 1/4W, 22.1K, 1%
C14, C16, C20, C21, R61
C24, C26 R75 RESISTOR-MF, 1/4W, 267, 1%
J1 CONNECTOR, MOLEX, MINI, PCB, R22 RESISTOR-MF, 1/4W, 267K, 1%
6-PIN R46, R78, R79, R80 RESISTOR-MF, 1/4W, 3.32K, 1%
C5 CAPACITOR-ALEL, 150, 50V, +150/-10% R21, R35 RESISTOR-MF, 1/4W, 33.2K, 1%
D1 D2 D3, D4, D5, DIODE-AXLDS, 1A, 400V R44 RESISTOR-MF, 1/4W, 392K, 1%
D6 D7 D8, D9, D11, R11 RESISTOR-MF, 1/4W, 4.75K, 1%
D12, D13, D14 D17, R10, R62 RESISTOR-MF, 1/4W, 47.5K, 1%
D18, D19, D20, D21 R23, R24 RESISTOR-MF, 1/4W, 562, 1%
R32, R33 RESISTOR-WW, 15W, 80, 5%, SQ R17, R25, R29, R30 RESISTOR-MF, 1/4W, 56.2K, 1%
C19 CAPACITOR-TAEL, 1.8, 20V, 10% R76 RESISTOR-MF, 1/4W, 681, 1%
C6, C17 CAPACITOR-TAEL, 4.7, 35V, 10% R19, R65 RESISTOR-MF, 1/4W, 6.81K, 1%
C15 CAPACITOR-TAEL, 18, 15V, 10% R14, R20 RESISTOR-MF, 1/4W, 68.1K, 1%
C8, C10, C18 CAPACITOR-TAEL, 1.0, 35V, 10% R13 RESISTOR-MF, 1/4W, 82.5K, 1%
C23 CAPACITOR-ALEL, 3300, 50V, +30/-10% Q7 TRANSISTOR-PMF, T220, 6A, 100V,
OCI1, OCI2 OPTOCOUPLER-TRIAC DRIVER, 3023 IRF9520
TRI1 TRIAC-T220, 6A, 400V, 2500D X1, X2, X3 C-OP-AMP, QUAD, GEN-PURPOSE,
J2 CONNECTOR, MOLEX, MINI, PCB, 224N
10-PIN Q1, Q6 TRANSISTOR-N, T226, 0.5A, 300V,
C7 CAPACITOR-PEF, 0.1,100V, 10% MPS-A42
C22 CAPACITOR-PEF, 0.22, 100V, 10% R37, R83 RESISTOR-MF, 1/4W, 2.00K, 1%
C1, C25 CAPACITOR-CD, .0047/.005, 1400V, R34, R81, R82 RESISTOR-MF, 1/4W, 3.01K, 1%
20% R56 TRIMMER-ST, 1/2W, 10K, 10%, LINEAR
C2, C3, C27 CAPACITOR-PEF, 0.1, 400V, 1o% R6 RESISTOR-WW, 5W, 25, 5%, SQ
DZ3 ZENER DIODE-1W, 16V, 5%, 1N4745A R1 RESISTOR-WW, 5W, 150, 5%, SQ
DZ1 ZENER DIODE-1W, 10V, 5%, 1N4740A
DZ4 ZENER DIODE-1W, 43V, 5%, 1N4755A
DZ2 ZENER DIODE-1W, 5.1V, 5%, 1N4733A
Q2, Q3, Q4, Q5 TRANSISTOR-N, T226, 0.5A, 40V,
2N4401
D15, D16 DIODE-AXLDS, 3A, 200V, 1N54o2
D10 DIODE-AXLDS, 0.15A, 75W, 1N914

B31A, B531 CONNECTOR, TAB, QC, VERTICAL, 1/4
B7, B32 CONNECTOR, TAB, QC, VERTICAL,
3/16
R69, R72 RESISTOR-WW, 5W, 0.5, 5%, SQ
R5 RESISTOR-MF, 1/4W, 100, 1%
R2, R4, R8, R26, R27, RESISTOR-MF, 1/4W, 1.00K, 1%

R41, R48, R51, R55,
R58, R70
R50, R57, R53, R54, RESISTOR-MF, 1/4W, 10.0K, 1%
R71, R73, R74
R42, R52, R53, R54, RESISTOR-MF, 1/4W,10.0K, 1%
R59
R43 RESISTOR-MF, 1/4W, 1.00M, %
R15, R16, R18 RESISTOR-MF, 1/4W, 1.30K, 1%
R36, R63, R64, R67 RESISTOR-MF, 1/4W, 15.0K, 1%
repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not avail-
able from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages
board level troubleshooting and repair since it may compromise the quality of the design and may result in
danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the
machine.
SP-100
G-6 ELECTRICAL DIAGRAMS

C16
A
A
A
repairs will invalidate your factory warranty. This Printed Circuit Board schematic is provided for reference
only. It may not be totally applicable to your machine’s specific PC board version. This diagram is intended
to provide general information regarding PC board function. Lincoln Electric discourages board level trou-
bleshooting and repair since it may compromise the quality of the design and may result in Danger to the
Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.
SP-100

Item Identification Item Identification
SCR1, SCR2 SCR 81 HEATSINK ASBLY R45 RESISTOR-MF, 1/4W, 18.2K, 1%

X4 C-VOLT REG, FIXED, 3-T, (+),1A, 15V R28, R31, R47, R49 RESISTOR-MF, 1/4W, 2.21 K, 1%
C4, C9, C11, C12, C13, CAPACITOR-CEMO, .022, 50V, 20% R12, R38, R39, R60, RESISTOR-MF, 1/4W, 22.1K, 1%
C14, C16, C20, C21, R61
C24, C26 R75 RESISTOR-MF, 1/4W, 267,1 %
J1 CONNECTOR, MOLEX, MINI, PCB, R22 RESISTOR-MF, 1/4W, 267K, 1%
6-PIN R46, R78, R79, R80 RESISTOR-MF, 1/4W, 3.32K, 1%
C5 CAPACITOR-ALEL, 150, 50V, +150/ R21 RESISTOR-MF, 1/4W, 33.2K, 1%
–10% R35 RESISTOR-MF, 1/4W, 39.2K, 1%
D1, D2, D3, D4, D5, D6, DIODE-AXLDS, 1A, 400V R44 RESISTOR-MF, 1/4W, 392K, 1%
D7, D8, D9, D11 , D12, R11 RESISTOR-MF, 1/4W, 4.75K, 1%
D13, D14, D17, D18, R10 RESISTOR-MF, 1/4W, 47.5K, 1%
D19, D20, D21 R62 RESISTOR-MF, 1/4W, 47.5,1%
R32, R33 RESISTOR-WW, 15W, 80,5%, SQ R23, R24 RESISTOR-MF, 1/4W, 562,1%
C19 CAPACITOR-TAEL, 1.8, 20V, 10% R17, R25, R29, R30 RESISTOR-MF, 1/4W, 56.2K, 1%
C6, C17 CAPACITOR-TAEL, 4.7, 35V, 10% R76 RESISTOR-MF, 1 /4W, 681 ,1 %
C15 CAPACITOR-TAEL, 18,15V, 10% R19, R65 RESISTOR-MF, 1/4W, 6.81K, 1%
C8, C10, C18 CAPACITOR-TAEL, 1.0, 35V, 10% R14, R20 RESISTOR-MF, 1/4W, 68.1K, 1%
C23 CAPACITOR-ALEL, 3300, 50V, +30/-10% R13 RESISTOR-MF, 1/4W, 82.5K, 1%
OCI1 OCI2 OPTOCOUPLER-TRIAC DRIVER, 3023 Q7 TRANSISTOR-PMF, T220, 6A, 100V,
TRI1 TRIAC-T220, 6A, 400V, 2500D IRF9520
J2 CONNECTOR, MOLEX, MINI, PCB, X1 , X2, X3 C-OP-AMP, OUAD, GEN-PURPOSE,
10-PIN 224N
C7 CAPACITOR-PEF, 0.1,100V, 10% Q1, Q6 TRANSISTOR-N, T226, 0.5A, 300V,
C22 CAPACITOR-PEF, 0.22, 100V, 10% MPS-A42
C1, C25 CAPACITOR-CD, .0047/.005, 1400V, R37, R83 RESISTOR-MF, 1/4W, 2.00K, 1%
20% R34, R81, R82 RESISTOR-MF, 1/4W, 3.01K, 1%
C2 C3 C27 CAPACITOR-PEF, 0.1, 400V, 10% R56 TRIMMER-ST, 1/2W, 10K, 10%,
DZ3 ZENER DIODE-1W, 16V, 5%,1N4745A LINEAR
DZ1 ZENER DIODE-1W, 10V, 5%,1N4740A R6 RESISTOR-WW, 5W, 25, 5%, SQ
DZ4 ZENER DIODE-1W, 43V, 5%,1N4755A R1 RESISTOR-WW, 5W, 150, 5%, SQ
DZ2 ZENER DIODE-1W, 5.1V, 5%,1N4733A
Q2, Q3, Q4, Q5 TRANSISTOR-N, T226, 0.5A, 40V,
2N4401
D15, D16 DIODE-AXLDS, 3A, 200V, 1N5402

D10 DIODE-AXLDS, 0.15A, 75V, 1N914
B31 A, B531 CONNECTOR, TAB, QC, VERTICAL,
1/4
B7, B32 CONNECTOR, TAB, QC, VERTICAL,
3/16
R69, R72 RESISTOR-WW, 5W, 0.5,5%, SQ
R2, R4, R8, R26, R27, RESISTOR-MF, 1/4W, 1.00K, 1%
R41, R48, R51, R55,
R58, R70
R50, R57, R66, R68, RESISTOR-MF, 1/4W, 10.0K, 1%
R71, R73, R74
R42, R52, R53, R54, RESISTOR-MF, 1/4W, 100K, 1%
R55
R43 RESISTOR-MF, 1/4W, 1.00M, %
R15, R16, R18 RESISTOR-MF, 1/4W, 1.30K, 1%
R3 RESISTOR-MF, 1/4W, 150,1%
R36, R63, R64, R67 RESISTOR-MF, 1/4W, 15.0K, 1%
repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not avail-
able from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages
board level troubleshooting and repair since it may compromise the quality of the design and may result in
danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the
machine.
SP-100
MACHINE SCHEMATIC: Codes 9794 and Above

POWER SUPPLY SOURCE POINT

S1 ON-OFF
EARTH GROUND CONNECTION

SWITCH OUTPUT
L2 32 32
CHOKE
VOLTAGE NET
COMMON CONNECTION
SP 100 CONTROL
FRAME CONNECTION
P1
DZ-4
LAST NO. USED
D1 D2
P2 J2
SCHEMATIC
85A 85A 4 204
3
300V 300V
8552
C25
C- 27
T1
R- 83
D- 21
FAN MOTOR + C1 C22 WELDING
10-22-93L
J1
80 80 POWER
115VAC .22
SUPPLY
W/ 24V
R33
R32
.0047 15W 15W OUTPUT
AUX WDG 59K 100V
115VAC 1400VDC
D3 D4 40V
LABELS
125VAC
L
60 HZ 531
C1 .0047 C2 85A 85A P2 J2
25
R1
R6
1400V 300V 300V 3
5W 203
125VAC .1 150
C3 400V 5W
LEAD COLOR CODE

.1 SCR1
31A
L1 31 31A 400V 2 1
W - WHITE
B - BLACK
UNLESS OTHERWISE SPECIFIED)
30A +15V
CIRCUIT 55A 3
UNLESS OTHERWISE SPECIFIED)

BREAKER 600V
GND 1 2
(UNLESS OTHERWISE SPECIFIED)

3.01K
R82
3 SCR2 3.01K 3.01K
R34
R81
D1
10
D2
P1 P1
6 2 +15V
J2
J2
J1 J1
R2 R4 9
SCR
MFD ( .022/50V
1.00K 1.00K
6
1
1/4W
GENERAL INFORMATION
FIRING 211
15.0K
R67
C4
6 OCI2 THERMOSTAT
100
C21 Q4
R5
212 R74 600mA
1A, 400V
D18 D19
RESISTORS = Ohms (
TRIGGER 40V
6
3
S2 10K
SWITCH
CAPACITORS =
MT1 4 Q3
J1
G
2500D 213 600mA MOTOR
32
STOP
DIODES =
TRI1 40V
4
1
R3
MT2 8
LATCH
1.00K
R8
150
C27
J2
.1
GAS SOLENOID +15V
GAS 400V
CONTROL 4 OCI1
SOLENOID
120VAC
R66
R83
2K 2K
R37
3.32K 3.32K 3.32K
R79
10K
R80
R78
10K
R68
3A
D16
R64
7 6 OVERCURRENT 15.0K
OSCILLATOR 200V
NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE
SHUTDOWN
3
WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY

Q1 +15V D17
+15V
500mA 1
X3
VOLTAGE 300V
C26 2
REGULATOR D13
R41
R63
1.00K 15.0K
D8 C14 .5
MC7815CTDS
R69
5W
+15V SUPPLY
R65
SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE

D3 D4 +15V
C20 6.81K
R35
39.2K
R38
24VAC 22.1K
X4
IN OUT
D7 2 13 PWM
ERROR
D5 D6 C5 C6 Q2
GND 1 10 AMP 14
R10
47.5K 150 4.7 X2 R39 600mA X3 R61 DZ3 C23

40V +15V
50V 35V 3 8 12
R70
1.00K 16V 3300
22.1K X3 22.1K 10K
R71
R36
15.0K 1W 50V
9
R60
22.1K 1
10K Q7
R57
+15V R59
6A
4.75K 203 100K 100V 2 203 203
R11
Q6
DZ4
500mA
R19 43V
300V
5
R12 R13 WELD CW 1W
R58
X2 6.81K D12 1.00K C19
10K
R56
7 C8 1.8
22.1K 82.5K Q5
1.0 20V
BURNBACK 6 600mA
267K 35V
R22
D9 LOW
40V
TRIM D14
2
SAWTOOTH SET
+15V
47.5
R62
1 5
X1 R14 PWM
NUMBER.
3 7 HIGH
R55
68.1K X1 1.00K
TRIM
R76
C7 681
6
+15V .1 SET
DZ1 D10
NOTES :
100V
R15
R20
10V 68.1K
R53
R18
1W 1N914 1.3K 1.3K 6
N.A.
.15A X3
100K 7
75V
R16 J2 100K R50 R51
R54
R52 MOTOR 5
R23
1
562
1.3K 10 100K VOLTAGE C18 10K 1.00K
GAS 1
D11 FEEDBACK 1.0 J2
SOLENOID 13
R48
208 1.00K
WIRE 35V
J1 CONTROL SCR
14 1
R21
R17 FIRING 33.2K SPEED X2 R49

2 OCI1 209
4 5K J2 12
R2
56.2K 2 OCI2 7 R42 2.21K B 541
2W SPEED
100K C16 SET
R47
205 2.21K WIRE D15
203 R73 FEED 3A

ARC 206 J1 C24 10
200V
5 MOTOR X2 MOTOR
10K
R1
VOLTS 6
CURRENT 8
9 C17
5K R25 FEEDBACK
J2 9 4.7 W 539
2W 207 8
C9 56.2K X1 35V
10 2
1 ARC VOLTAGE
R46
ERROR AMPLIFIER R44 R45 3.32K J2
J1
204 392K 18.2K
+15V C15
18
R43
1.00M
15V
R24
562
.5
R72
ARC VOLTAGE 5W
R26
1.00K D20 D21

FEEDBACK
+15V 4 4 4 R75
12
R28 267
14
2.21K X1 R29
C11 X1 C12 X2 C13 X3
13
C10 56.2K
1.0 203
R27
1.00K
LM224 LM224 LM224
35V
R30
R31
2.21K
56.2K
L
11 11 11
8552
DZ2
5.1V
1W
NOTE: This machine schedmatic is provided for reference only and may not be totally applicable to every code covered
in this manual.
SP-100
MACHINE SCHEMATIC: Codes Below 9794

ON-OFF 32
COMMON CONNECTION
SWITCH
S1
FRAME CONNECTION
OUTPUT
CHOKE
L2 32
P1
FAN D1 D2 P2 J2
MOTOR 85A 85A 4 204
d (f . 0 2 2 / 5 0 V U N L E S S O T H E R W I S E S P E C I F I E D )
115VAC 115AC 3
SP 100 WELDERS
300V 300V WELDING
T1
NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE
C1 C22
WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY

60 HZ J1 80 80 POWER
RESISTORS = Ohms (1/4W UNLESS OTHERWISE SPECIFIED)

R32
R33
31A C25 .22
EARTH GROUND CONNECTION

15W 15W OUTPUT
SCHEMATIC
.0047 100V
B31A 59K
L1 31 1400V 40V
D3 D4
DIODES = 1A, 400V (UNLESS OTHERWISE SPECIFIED)
7619
B531 85A 85A 203
P2 J2
30A
R1 300V 300V 3
7-27-90J
CIRCUIT
SCR1 120
BREAKER C2
.1 55A 2W
TO GND.
SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE
L
400V 600V R69
LABELS
+15V D16
2 1
.5
3A 5W
200V 5%
POWER SUPPLY SOURCE POINT

+15V
ELECTRICAL SYMBOLS PER E-1537

3
GENERAL INFORMATION
15.0K
R67
1 2
VOLTAGE NET
Q4
C1 R74
3
SCR2 2N4123
R34
.0047 1.00K
55A 10K
27 1400V MOTOR
R6
600V
2W Q3 STOP
D1 D2 2N4123
CAPACITORS =
J2
SUPPLY
C3 R2 R4 9
.1 SCR
1000 1000
+15V
400V 1/2W 1/2W FIRING 211
6 OCI2 R66
THERMOSTAT
D18 D19
C21 10K 10K
R68
C4
R64
S2 TRIGGER 15.0K
R5 4 OSCILLATOR
SWITCH
B32A 100 213 3
D17
1K 1/2W
LAST NO. USED

R3 1
1/2W 8
X3
R8
150 2
DZ4
TP2
GAS SOLENOID 1/2W J2
R63
10K 150V 15.0K
CONTROL
R7
2W OVERCURRENT
GAS 45J 4 OCI1 Q1
D 21
R 75
SHUTDOWN
(connector cavity representations)

SOLENOID TRI1 300V R65
C
120VAC 2500D 500mA
C20 6.81K
R37
1.00K
NUMBER.
6
B7
+15V +15V
ERROR 13
PWM
AMP
10 14
C26 X3 R61
8 12
NOTES :
VOLTAGE X3 22.1K
24VAC 9
REGULATOR C14
R41
1.00K
+15V SUPPLY D8 D13
MC7815CTDS
N.A.
R35
T1
R38
39.2K 22.1K
D3 D4 +15V R59
1 3 2 2
24V 100K
4
Q2
R9 X4 1 1
X2 R39 200mA
R60
IN OUT 22.1K
5 27 D7 3 30V
2
6 22.1K
D5 D6 1/2W C5 C6 3
R36
R58
1.00K
R10
GND 15.0K
47.5K 150 4.7 C19
50V 35V
1.8
20V
DZ3 C23
10K
3300
R71
16V
R70
1.00K
D14 1W 50V
3
+15V 1
203
4.75K
R11
+15V Q6 Q7
R19 500mA 6A 2
5 203 203
R12 R13 300V 100V
X2 6.81K D12
7 C8
22.1K 82.5K
BURNBACK 1.0 Q5 DZ4

6
267K 35V 10K
R22
R57
2N4123 43V
D9 1/2W
CW 1W
2 SAWTOOTH
+15V
R40
1 5
X1 R14 PWM 2K
3 47.5
R62
3 7 10K
68.1K X1 1/2W 2
R53
R56
C7
6
1
+15V .1 CW 100K
DZ1 100V 1
R15
R20
10V 68.1K
R18
500mW D10 1.3K 1.3K 6

2 1N914 X3
R52 7
R16 J2 R50 R51

100K
R55
R54
SCR 1.00K
100K 5
R23
1
562 FIRING
1.3K 10
MOTOR C18 10K 1.00K
1
D11 VOLTAGE 1.0 J2
208 13
R48
1.00K
FEEDBACK 35V
J1 OCI2
14 1
R21
2 OCI1 R17 33.2K WIRE 5K X2 R49

209 J2
4 SPEED 12
SPEED D15
R2
56.2K 2 2W 7 R42 2.21K B 541
SET 3A
GAS 100K C16
R47
205 2.21K WIRE 200V
SOLENOID
CONTROL 203 R73 FEED
ARC 206 J1 10
5 C24 X2 MOTOR
R1
VOLTS 6 MOTOR 10K

8
9 LOAD CURRENT
5K R25 C17
J2 9 W 539
2W FEEDBACK
207 8 4.7
C9 56.2K X1
35V
10 2
1 ARC VOLTAGE R44 R45
ERROR AMPLIFIER J2
J1 392K 18.2K
R46
3.32K
204 C15
+15V
18
R43
1.00M R72
15V
.5
R24
562
5W
ARC VOLTAGE 1%
R26
1.00K D20 D21

FEEDBACK
+15V 4 4 4 R75
12 203
R28 267
14
2.21K X1 R29
C11 X1 C12 X2 C13 X3 1 3 1 5
13
C10 56.2K
1.0
R27
1.00K
LM224 LM224 LM224 LEAD COLOR CODE
35V
R30
R31
2.21K
56.2K B - BLACK
L
GENERAL INFORMATION
11 11 11
W - WHITE
7619
CAPACITORS = MFD/VOLT (.022/50V,UNLESS OTHERWISE SPECIFIED)

4 6 6 10 RESISTORS = OHMS (1/4WATT,UNLESS OTHERWISE SPECIFIED)
DZ2
DIODES = 1A/400V (UNLESS OTHERWISE SPECIFIED)
5.1V LATCH J1 J2
500mW
= COMMON CONNECTION
CONNECTOR CAVITY NUMBERING SEQUENCE
= SOURCE POINT CIRCUIT LOCATION
(VIEWED FROM COMPONENT SIDE OF BOARD)
NOTE: This machine schedmatic is provided for reference only and may not be totally applicable to every code covered
in this manual.
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RETURN TO MAIN INDEX

Safety Depends on You

proper installation ... and thought-

NOT INSTALL, OPERATE OR

ARC WELDING can be hazardous.

ELECTRIC SHOCK can ARC RAYS can burn.

open arc welding. Headshield and filter lens

fumes and gases away from the breathing zone. When

3.e. Also see item 7b.

WELDING SPARKS can CYLINDER may explode

8.c. Exposure to EMF fields in welding may have other health

vaporizing on contact with hot engine parts

____________________________________________________ Mar. ‘93

7.e. In some cases it may be necessary to remove safety

guards to perform required maintenance. Remove

7.g. To prevent accidentally starting gasoline engines while

7.h. To avoid scalding, do not remove the

5. Toujours porter des lunettes de sécurité dans la zone de

2. Dans le cas de travail au dessus du niveau du sol, se pro-

MASTER TABLE OF CONTENTS FOR ALL SECTIONS

Theory of Operation ........................................................................................Section E

Troubleshooting and Repair...........................................................................Section F

SP-100 Parts Manual ........................................................................................Appendix

Gun Installation ...............................................................................................A-4

TECHNICAL SPECIFICATIONS – SP-100

Rated DC Output: 0 - 90 amps 28 N/A

RECOMMENDED INPUT CABLE AND FUSE SIZES

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

CSA 115V/60Hz 15 Amp 12 15 Amp, 125V, (3.3 mm2)

Read entire installation section before starting FIGURE A.1

• The SP-100 power switch is to be in the

IDENTIFY AND LOCATE 3a

2. Gun and cable assembly(1)

3. Literature envelope which contains:

4. 10 ft (3,0 m) work cable.

(1) Gun is ready to feed .025" (0.6 mm) diameter wire

(also .023 and .024 diameter wire).

Each machine must be placed on a secure, level sur- Work Cable

FIGURE A.4 CAUTION

Refer to Figure A.5

When using the GMAW process, a cylinder of carbon

WARNING tighten the union nut securely with a wrench. The

1. Chain the cylinder to a wall or other stationary sup-

2. With the cylinder securely installed, remove the Power

BE SURE TO KEEP YOUR FACE AWAY FROM THE

Never stand directly in front of or behind the flow

CODE REQUIREMENTS FOR INPUT REQUIREMENTS FOR MAXIMUM OUTPUT

REQUIREMENTS FOR RATED OUTPUT

A power cord with a 15 amp, 125 volt, three prong

The rated output with this installation is 90 amps, 18

Shielding Gas .......................................................................................................B-5

Read entire operation section before

FUMES AND GASES can be

WELDING SPARKS can

ARC RAYS can burn eyes

Observe all safety information throughout

feed .023-.025” (0,6- 0,9 mm) diameter wire.

RECOMMENDED PROCESSES LIMITATIONS

OPERATIONAL FEATURES AND 1. Power ON/OFF Switch —