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IM790
SP-
175 Plus March, 2005
For use with machine Code Numbers 10976
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However, your
overall safety can be increased by
proper installation ... and thought-
ful operation on your part. DO
NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT READING THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and be careful.
OPERATOR’S MANUAL
Copyright © 2005 Lincoln Global Inc.
� World's Leader in Welding and Cutting Products �
� Sales and Service through Subsidiaries and Distributors Worldwide �
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
i i
SAFETY
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
The engine exhaust from this product contains
Diesel engine exhaust and some of its constituents
chemicals known to the State of California to cause
are known to the State of California to cause can-
cancer, birth defects, or other reproductive harm.
cer, birth defects, and other reproductive harm.
The Above For Gasoline Engines
The Above For Diesel Engines
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
purchase 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
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
FOR ENGINE 1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
powered equipment. hot.
1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
1.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.
ELECTRIC AND
MAGNETIC FIELDS
____________________________________________________
may be dangerous
1.c. Do not add the fuel near an open flame
welding arc or when the engine is running.
Stop the engine and allow it to cool before 2.a. Electric current flowing through any conductor causes
refueling to prevent spilled fuel from vaporiz- localized Electric and Magnetic Fields (EMF). Welding
ing on contact with hot engine parts and current creates EMF fields around welding cables and
igniting. Do not spill fuel when filling tank. If welding machines
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated. 2.b. EMF fields may interfere with some pacemakers, and
____________________________________________________ welders having a pacemaker should consult their physician
1.d. Keep all equipment safety guards, covers and devices in before welding.
position and in good repair.Keep hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving 2.c. Exposure to EMF fields in welding may have other health
parts when starting, operating or repairing equipment. effects which are now not known.
____________________________________________________
2.d. All welders should use the following procedures in order to
1.e. In some cases it may be necessary to remove safety
minimize exposure to EMF fields from the welding circuit:
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
2.d.1. Route the electrode and work cables together - Secure
maintenance requiring their removal is complete.
them with tape when possible.
Always use the greatest care when working near moving
parts.
2.d.2. Never coil the electrode lead around your body.
___________________________________________________
1.f. Do not put your hands near the engine fan.
2.d.3. Do not place your body between the electrode and
Do not attempt to override the governor or
idler by pushing on the throttle control rods work cables. If the electrode cable is on your right
while the engine is running. side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while 2.d.5. Do not work next to welding power source.
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate. Mar �95
SP-175 PLUS
ii ii
SAFETY
ARC RAYS can burn.
ELECTRIC SHOCK can
4.a. Use a shield with the proper filter and cover
kill. plates to protect your eyes from sparks and
3.a. The electrode and work (or ground) circuits
the rays of the arc when welding or observing
are electrically “hot� 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. 4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
3.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. 4.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
FUMES AND GASES
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
can be dangerous.
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use 5.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
3.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
3.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
3.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.
5.b. Do not weld in locations near chlorinated hydrocarbon vapors
3.f. Maintain the electrode holder, work clamp, welding cable and
coming from degreasing, cleaning or spraying operations.
welding machine in good, safe operating condition. Replace
The heat and rays of the arc can react with solvent vapors to
damaged insulation.
form phosgene, a highly toxic gas, and other irritating prod-
ucts.
3.g. Never dip the electrode in water for cooling.
5.c. Shielding gases used for arc welding can displace air and
3.h. Never simultaneously touch electrically “hot� parts of
cause injury or death. Always use enough ventilation,
electrode holders connected to two welders because voltage
especially in confined areas, to insure breathing air is safe.
between the two can be the total of the open circuit voltage
of both welders.
5.d. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
3.i. When working above floor level, use a safety belt to protect
material safety data sheet (MSDS) and follow your
yourself from a fall should you get a shock.
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
3.j. Also see Items 6.c. and 8.
5.e. Also see item 1.b.
Mar �95
SP-175 PLUS
iii
iii
SAFETY
WELDING SPARKS can CYLINDER may explode
cause fire or explosion. if damaged.
6.a. Remove fire hazards from the welding area.
7.a. Use only compressed gas cylinders
If this is not possible, cover them to prevent
containing the correct shielding gas for the
the welding sparks from starting a fire.
process used and properly operating
Remember that welding sparks and hot
regulators designed for the gas and
materials from welding can easily go through small cracks
pressure used. All hoses, fittings, etc. should be suitable for
and openings to adjacent areas. Avoid welding near
the application and maintained in good condition.
hydraulic lines. Have a fire extinguisher readily available.
7.b. Always keep cylinders in an upright position securely
6.b. Where compressed gases are to be used at the job site,
chained to an undercarriage or fixed support.
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting� (ANSI
7.c. Cylinders should be located:
Standard Z49.1) and the operating information for the
� Away from areas where they may be struck or subjected to
equipment being used.
physical damage.
6.c. When not welding, make certain no part of the electrode
� A safe distance from arc welding or cutting operations and
circuit is touching the work or ground. Accidental contact
any other source of heat, sparks, or flame.
can cause overheating and create a fire hazard.
7.d. Never allow the electrode, electrode holder or any other
6.d. Do not heat, cut or weld tanks, drums or containers until the
electrically “hot� parts to touch a cylinder.
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
7.e. Keep your head and face away from the cylinder valve outlet
inside. They can cause an explosion even though they have
when opening the cylinder valve.
been “cleaned�. For information, purchase “Recommended
Safe Practices for the Preparation for Welding and Cutting of
7.f. Valve protection caps should always be in place and hand
Containers and Piping That Have Held Hazardous
tight except when the cylinder is in use or connected for
Substances�, AWS F4.1 from the American Welding Society
use.
(see address above).
7.g. Read and follow the instructions on compressed gas
6.e. Vent hollow castings or containers before heating, cutting or
cylinders, associated equipment, and CGA publication P-l,
welding. They may explode.
“Precautions for Safe Handling of Compressed Gases in
Cylinders,� available from the Compressed Gas Association
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
1235 Jefferson Davis Highway, Arlington, VA 22202.
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
FOR ELECTRICALLY
Always wear safety glasses with side shields when in a
powered equipment.
welding area.
6.g. Connect the work cable to the work as close to the welding
8.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
through lifting chains, crane cables or other alternate cir-
8.b. Install equipment in accordance with the U.S. National
cuits. This can create fire hazards or overheat lifting chains
Electrical Code, all local codes and the manufacturer’s
or cables until they fail.
recommendations.
6.h. Also see item 1.c.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Mar �95
SP-125 PLUS
iv iv
SAFETY
PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
7. Quand on ne soude pas, poser la pince à une endroit isolé de
manuel aussi bien que les précautions de sûreté générales suiv-
la masse. Un court-circuit accidental peut provoquer un
antes:
échauffement et un risque d’incendie.
Sûreté Pour Soudage A L’Arc
8. S’assurer que la masse est connectée le plus prés possible
1. Protegez-vous contre la secousse électrique:
de la zone de travail qu’il est pratique de le faire. Si on place
la masse sur la charpente de la construction ou d’autres
a. Les circuits à l’électrode et à la piéce sont sous tension
endroits éloignés de la zone de travail, on augmente le risque
quand la machine à souder est en marche. Eviter toujours
de voir passer le courant de soudage par les chaines de lev-
tout contact entre les parties sous tension et la peau nue
age, câbles de grue, ou autres circuits. Cela peut provoquer
ou les vétements mouillés. Porter des gants secs et sans
des risques d’incendie ou d’echauffement des chaines et des
trous pour isoler les mains.
câbles jusqu’� ce qu’ils se rompent.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher
9. Assurer une ventilation suffisante dans la zone de soudage.
metallique ou des grilles metalliques, principalement dans
Ceci est particuliérement important pour le soudage de tôles
les positions assis ou couché pour lesquelles une grande
galvanisées plombées, ou cadmiées ou tout autre métal qui
partie du corps peut être en contact avec la masse.
produit des fumeés toxiques.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état
10. Ne pas souder en présence de vapeurs de chlore provenant
defonctionnement.
d’opérations de dégraissage, nettoyage ou pistolage. La
d.Ne jamais plonger le porte-électrode dans l’eau pour le
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
refroidir.
du solvant pour produire du phosgéne (gas fortement toxique)
e. Ne jamais toucher simultanément les parties sous tension
ou autres produits irritants.
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le
11. Pour obtenir de plus amples renseignements sur la sûreté,
total de la tension à vide des deux machines.
voir le code “Code for safety in welding and cutting� CSA
f. Si on utilise la machine à souder comme une source de
Standard W 117.2-1974.
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
PRÉCAUTIONS DE SÛRETÉ POUR
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
LES MACHINES À SOUDER À
enrouler le câble-électrode autour de n’importe quelle partie
du corps.
TRANSFORMATEUR ET À
REDRESSEUR
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:
1. Relier à la terre le chassis du poste conformement au code de
a. Utiliser un bon masque avec un verre filtrant approprié
l’électricité et aux recommendations du fabricant. Le dispositif
ainsi qu’un verre blanc afin de se protéger les yeux du ray-
de montage ou la piece à souder doit être branché à une
onnement de l’arc et des projections quand on soude ou
bonne mise à la terre.
quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la
2. Autant que possible, I’installation et l’entretien du poste seront
peau de soudeur et des aides contre le rayonnement de
effectués par un électricien qualifié.
l‘arc.
c. Protéger l’autre personnel travaillant à proximité au
3. Avant de faires des travaux à l’interieur de poste, la debranch-
soudage à l’aide d’écrans appropriés et non-inflammables.
er à l’interrupteur à la boite de fusibles.
4. Des gouttes de laitier en fusion sont émises de l’arc de
4. Garder tous les couvercles et dispositifs de sûreté à leur
soudage. Se protéger avec des vêtements de protection libres
place.
de l’huile, tels que les gants en cuir, chemise épaisse, pan-
talons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de sécurité dans la zone de
Mar. �93
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.
SP-175 PLUS
v v
for selecting a QUALITY product by Lincoln Electric. We want you
Thank You to take pride in operating this Lincoln Electric Company product
•â?¢â?? as much pride as we have in bringing this product to you!
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.
Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.
Product _________________________________________________________________________________
Model Number ___________________________________________________________________________
Code Number or Date Code_________________________________________________________________
Serial Number____________________________________________________________________________
Date Purchased___________________________________________________________________________
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially important when identifying the correct replacement parts.
On-Line Product Registration
- Register your machine with Lincoln Electric either via fax or over the Internet.
� For faxing: Complete the form on the back of the warranty statement included in the literature packet
accompanying this machine and fax the form per the instructions printed on it.
� For On-Line Registration: Go to our WEB SITE at www.lincolnelectric.com. Choose “Quick Links� and then
“Product Registration�. Please complete the form and submit your registration.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or
loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to
this equipment.
SP-175 PLUS
vi
vi
TABLE OF CONTENTS
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-7
Application Chart ...................................................................................................B-8
Accessories .....................................................................................................Section C
Accessories ...........................................................................................................C-1
Replacement Parts ................................................................................................C-2
Maintenance ....................................................................................................Section D
Safety Precautions ................................................................................................D-1
Items Requiring No Maintenance ..........................................................................D-1
Routine and Periodic Maintenance........................................................................D-1
Gun and Cable Maintenance.................................................................................D-2
Configuration of Components in Wire Feeding System.........................................D-2
Component Replacement Procedures ..................................................................D-3
Troubleshooting ..............................................................................................Section E
Safety Precautions.................................................................................................E-1
How To Use Troubleshooting Guide......................................................................E-1
Troubleshooting Guide ..........................................................................................E-2
Wiring Diagrams ..............................................................................................Section F
SP-175 Plus Wiring Diagram ...............................................................................F-1
Parts Lists....................................................................................P460 Series & P202-E
SP-175 PLUS
A-1
INSTALLATION
A-1
TECHNICAL SPECIFICATIONS � SP-175 Plus
INPUT � SINGLE PHASE ONLY
Standard Voltage/Frequency Input Current
230V/60Hz 21 Amps @ Rated Output
208V/60Hz 23 Amps @ Rated Output
RATED OUTPUT
Duty Cycle Current Voltage
30% Duty Cycle @ 230V/60Hz 130 Amps 20 V
25% Duty Cycle @ 208V/60Hz 130 Amps 20 V
OUTPUT
Welding Current Range Maximum Open Circuit Voltage Wire Speed Range
Rated DC Output: 30 � 175 amps 33 50-400IPM (1.3-10.2m/min)
RECOMMENDED INPUT CABLE AND FUSE SIZES
Fuse or
Output Mode Input Voltage Breaker Size Input Amps Power Cord
RATED 230V/60Hz 40 Super Lag 21/23 50 Amp, 250V,
208V/60Hz Three-Prong Plug
(NEMA Type 6-50P)
PHYSICAL DIMENSIONS
Height Width Depth Weight
12.0 in 9.75 in 16.5 in 60 Ibs
305 mm 248 mm 419 mm 27.3 kg
SP-175 PLUS
A-2 INSTALLATION A-2
FIGURE A.1
Read entire installation section before starting
installation.
1
SAFETY PRECAUTIONS 2
WARNING WELD
ING
25-12 AMP RA
NGE
5
SP-1
75 P
lus
ELECTRIC SHOCK can kill.
� Only qualified personnel should perform
this installation.
� Only personnel that have read and under-
stood the SP-175 Plus Operating Manual
should install and operate this equipment.
� Machine must be plugged into a receptacle
which is grounded per any national, local
or other applicable electrical codes. 4
� The SP-175 Plus power switch is to be in
the OFF (“O�) position when installing
3
work cable and gun and when connecting
power cord to input power.
6
IDENTIFY AND LOCATE 5
COMPONENTS
If you have not already done so, unpack the SP-175
Plus from its carton and remove all packing material
around the SP-175 Plus . Remove the following loose
items from the carton (see Figure A.1):
7
1. SP-175 Plus
2. Gun and cable assembly(1)
3. Literature and miscellaneous including:
a) This operating manual
b) A contact tip for .030� (0.8 mm) diameter wire.
c) A contact tip for .035� (0.9 mm) diameter wire.
4. 10 ft (3.0 m) work cable.
5. Work clamp.
6. 2 LB. Sample Spool of Super Arc L-56 .025 MIG
Wire.
7. Adjustable mixed-Gas Regulator & Hose.
For available options and accessories refer to the
accessories section later in this manual.
As shipped from the factory, the SP-175 Plus gun
1)
liner is ready to feed .023� (0.6 mm) -.035 (0.9 mm)
wire. The contact tip is sized for .025� (0.6 mm) wire.
SP-175 PLUS
A-3
INSTALLATION
A-3
Work Clamp Installation
SELECT SUITABLE LOCATION
Attach the work clamp per the following:
Locate the welder in a dry location where there is free
circulation of clean air into the louvers in the back and
1. Unplug the machine or turn the power switch to the
left side and out the front of the unit. A location that
“OFF� position.
minimizes the amount of smoke and dirt drawn into
the louvers reduces the chance of dirt accumulation
2. Insert the work cable terminal lug with the larger
that can block air passages and cause overheating.
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-175 Plus� cannot be stacked.
FIGURE A.3
TILTING
Strain Relief Hole
Each machine must be placed on a secure, level sur-
Work Cable
face, or on a recommended undercarriage. The Nut & Bolt
machine may topple over if this procedure is not fol-
lowed.
OUTPUT CONNECTIONS
Work Clamp
Refer to Figure A.2.
Work Cable Installation
1. Work Cable Access Hole.
2. Gun Cable and Control Lead Access Hole. Refer to Figure A.2.
3. Connector Block.
1. Open the wire feed section door on the right side of
4. Gun Trigger Lead Connectors. the SP-175 Plus .
5. Positive (+) and negative (�) output terminals.
2. Pass the end of the work cable that has the termi-
6. Wire Feed Gearbox and Gun Connector Block nal lug with the smaller hole through the Work
Cable Access Hole (1) in the case front.
7. Cable Clamp
8. Thumbscrew - Secures gun and cable assembly 3. Route the cable under and around the back of the
Wire Feed Gearbox (6).
FIGURE A.2
4
WELDING AMP RANGE
5
25-125
SP-175 Plus +
8
-
1 3 6
2 7
SP-175 PLUS
A-4 A-4
INSTALLATION
The leads are to be routed under the Wire Feed
4. For GMAW Only: Refer to Figure A.2. As deliv- Gearbox (6) and through the Cable Hanger (7) on the
ered, the SP-175 Plus is wired for positive polarity. inner panel.
This is the appropriate configuration for the Gas
Metal Arc Welding (GMAW) process. To complete 3. Insert the connector on the gun conductor cable
installation, use the provided wing nut to connect through the Gun Cable Access Hole (2) in the SP-
the work cable’s terminal lug to the negative (�) 175 Plus case front. Make sure the connector is all
output terminal (5) located above the Wire Feed the way in the metal connector block to obtain
Gearbox (6). Make sure that both wing nuts are proper gas flow. Rotate the connector so control
tight. leads are on the underside and tighten the
Thumbscrew (8) in the connector block.
5. For Innershield Only: Refer to Figure A.4. To wire
for negative polarity, connect the short cable 4. Connect the gun trigger control lead terminals to
attached to the connector block (1) to the negative the two insulated 1/4" (6,4 mm) tab connector
(�) output terminal (2) and the work cable (3) to the bushings located above the “Gun Trigger
positive (+) terminal (4). Connection� decal in the wire feed section (4).
Either lead can go to either connector. Form the
FIGURE A.4 leads so that they are as close as possible to the
inside panel.
CAUTION
3
4
If the gun trigger switch being used is other than
that supplied with the SP-175 Plus, the switch
must be a normally open, momentary switch. The
2 terminals of the switch must be insulated from the
welding circuit. Malfunction of the SP-175 Plus will
result if this switch shorts to the SP-175 Plus
1 welding output circuit or is common to any electri-
cal circuit other than the SP-175 Plus trigger
circuit.
GAS CONNECTION
Refer to Figure A.5
When using the GMAW process, a cylinder of shield-
GUN INSTALLATION
ing gas, must be obtained. For more information about
As shipped from the factory, the SP-175 Plus gun liner
selecting gas cylinders for use with the SP-175 Plus,
is ready to feed 0.023 - 0.035� (0.6 - 0.9 mm) wire. If
refer to the ACCESSORIES section.
0.025� (0.6 mm) or 0.030� (0.8 mm) wire is to be used
install the 0.025� (0.6 mm) or 0.30� (0.8 mm) contact
tip. Refer to the MAINTENANCE section for contact tip
WARNING
installation details. If .035� Flux-Cored wire is to be
used, change the contact tip and nozzle to the appro-
priate types and orient the drive roll to the appropriate
groove size.
Note: If .045� (1.2mm) / innershield Flux-Cored wire is CYLINDER may explode if dam-
to be used, the appropriate Innershield Kit is required. aged. Keep cylinder upright and
chained to support
Connecting Gun Cable to the SP-175 Plus � Keep cylinder away from areas
where it may be damaged.
1. Refer to Figure A.2. Unplug the machine or turn
� Never lift welder with cylinder
power switch to the off “O� position.
attached.
2. Pass the insulated terminals of the gun trigger con- � Never allow welding electrode to
trol leads, one at a time, through the Gun Cable touch cylinder.
and Control Lead Access Slot (2) in the case front.
SP-175 PLUS
A-5
INSTALLATION
A-5
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-
� Keep cylinder away from welding
tic washer seated in the fitting that attaches to the
or other live electrical circuits.
cylinder to prevent leakage.
BUILDUP OF SHIELDING GAS may
harm health or kill. 4. Refer to Figure A.6. Attach one end of inlet gas
hose to the outlet fitting of the flow regulator and
� Shut off shielding gas supply
tighten the union nut securely with a wrench.
when not in use.
Connect the other end to the SP-175 Plus Gas
� SEE AMERICAN NATIONAL
Solenoid Inlet Fitting (5/8-18 female threads � for
STANDARD Z-49.1, “SAFETY IN
CGA � 032 fitting). Make certain the gas hose is
WELDING AND CUTTING� PUB-
not kinked or twisted.
LISHED BY THE AMERICAN
WELDING SOCIETY.
INPUT CONNECTIONS
1. Chain the cylinder to a wall or other stationary sup-
port to prevent the cylinder from falling over. Refer to Figure A.6.
Insulate the cylinder from the work circuit and earth
ground. The SP-175 Plus has two input connections, the
power input cable, and the Gas Solenoid Inlet Fitting.
Both connections are located on the rear of the
Cylinder Valve
Flow Regulator
machine.
FIGURE A.6
Gas Hose
Gas Solenoid
Inlet Fitting
FIGURE A.5
Power
2. With the cylinder securely installed, remove the
Input
cylinder cap. Stand to one side away from the out-
Cable
let and open the cylinder valve very slightly for an
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-175 PLUS
A-6 INSTALLATION A-6
Line Cord Connection ELECTRICAL INPUT CONNECTION FOR
RATED OUTPUT
A 3 conductor line cord with a 50 amp, 250 volt, three-
prong plug (NEMA Type 6-50P) is factory installed.
WARNING
Connect this plug to a mating grounded receptacle
which is connected to an appropriate power supply
per the U.S. National Electric Code and any applicable ELECTRIC SHOCK can kill.
local codes.
� Disconnect input power by removing
plug from receptacle before working
Grounding
inside SP-175 Plus.
Type 75°C Wire Fuse
Wire in Conduit, Copper Size � Use only grounded receptacle.
Input Copper Cond. Cond. (Super
� Do not touch electrically “hot� parts
Voltage Hertz AWG Size AWG Size Lag)
inside SP-175 Plus.
208/230 60 8 10 40
� Have qualified personnel do the main-
CONNECT TO A SYSTEM
tenance and troubleshooting work.
GROUNDING WIRE. SEE
THE UNITED STATES
NATIONAL ELECTRICAL
CODE AND/OR LOCAL
CODES FOR OTHER
230 Volt Input Connection
DETAILS AND MEANS FOR
PROPER GROUNDING.
The SP-175 Plus is shipped from the factory connect-
CONNECT TO HOT WIRES
ed for 230 volt input power. If the welder has been
OF A THREE-WIRE SINGLE
PHASE SYSTEM OR TO reconnected for 208 volt input power and 230 volt
ONE PHASE OF A TWO OR
input is desired, perform the following reconnection
THREE PHASE SYSTEM.
instructions:
1. Disconnect welder from input power and remove
WARNING
case side panel.
This welding machine must be connected to a
2. Remove lead marked “H3� from H1 terminal on the
power source in accordance with applicable elec-
control P.C. Board.
trical codes.
3. Remove tape securing H1 lead to lead sleeving
The National Electrical Code provides standards
and connect H1 lead to H1 terminal on the board.
for amperage handling capability of supply con-
ductors based on duty cycle of the welding
4. Insulate unused H3 lead for 300 volts with electri-
source.
cal tape and secure to lead sleeving.
If there is any question about the installation
5. Reinstall case side before connecting input power.
meeting applicable electrical code requirements,
consult a qualified electrician.
208 Volt Input Connection
1. Disconnect welder from input power and remove
case side.
2. Remove lead marked “H1� from H1 terminal on the
control P.C. Board.
3. Remove tape securing H3 lead to lead sleeving
and connect H3 lead to H1 terminal on the board.
4. Insulate unused H1 lead for 300V with electrical
tape and secure to lead sleeving.
5. Reinstall case side before connecting input power.
SP-175 PLUS
B-1
OPERATION
B-1
Read entire Operation section before
operating the SP-175 Plus.
WARNING
ELECTRIC SHOCK can kill.
� Do not touch electrically live
parts or electrode with skin or
wet clothing. Insulate yourself
from work and ground.
� Always wear dry insulating
gloves.
FUMES AND GASES can be
dangerous.
� Keep your head out of fumes.
� Use ventilation or exhaust to
remove fumes from breathing
zone.
WELDING SPARKS can
cause fire or explosion.
� Keep flammable material away.
� 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-175 PLUS
B-2 B-2
OPERATION
G Reversible, dual groove drive roll. Drive roll will feed
GENERAL DESCRIPTION
.023-.035� (0.6- 0.9 mm) diameter wire.
The SP-175 Plus is a complete semiautomatic constant volt- G Accommodates both 8� (200 mm) diameter and 4� (100
age DC arc welding machine. Included is a continuous con- mm) diameter spools of wire.
trolled, single phase constant voltage transformer/rectifier
G No external shielding gas is required when used with
power source and a wire feeder with welding gun for feeding
Lincoln .035� (0,9 mm) Innershield NR®-211-MP elec-
.023� (0.6 mm) through .035� (0.9 mm) solid steel electrode.
trode.
Optional kits are available for .035� (0.9 mm) and .045� (1.2
G Easy to change polarity. (No tools required)
mm) Innershield® NR-211-MP cored wire and .035� alu-
minum wire.
The SP-175 Plus is ideally suited for individuals having
WELDING CAPABILITY
access to 230 or 208 volt 60 Hz AC input power, and wanti-
ng the ease of use, quality and dependability of both gas
metal arc welding or GMAW (also known as MIG welding) The SP-175 Plus, as shipped, is rated at 130 amps, 20
and the Innershield electrode process (self-shielded flux- volts, at 30% duty cycle on a ten minute basis. It is capable
cored or FCAW). A convenient chart is mounted inside the of higher duty cycles at lower output currents.
wire feed section door for setting welding procedures for 24
gauge (.60 mm) through 5/16� (8.0 mm) mild steel. The SP-
LIMITATIONS
175 Plus is a rugged and reliable machine that has been
designed for dependable service and long life.
Arc Gouging cannot be performed with the SP-175
Plus. The SP-175 Plus is not recommended for pipe
RECOMMENDED PROCESSES thawing or TIG welding.
The SP-175 Plus can be used for welding mild steel using
CONTROLS AND SETTINGS
the GMAW, single pass, process which requires a supply of
shielding gas or it can be used for the self shielded,
Innershield electrode process (FCAW). The SP-175 Plus is Refer to Figures B.1a
configured for use with the GMAW (MIG) process as deliv-
ered from the factory. 1. Power ON/OFF Switch �
When the power is on the
ON
fan motor will run and air will
OPERATIONAL FEATURES AND be exhausted out the louvers
CONTROLS in the front of the machine.
The welding output and wire
The SP-175 Plus has the following controls as standard: feeder remain off until the
OFF
Power ON/OFF Switch, Voltage Control, Wire Speed gun trigger is pressed.
Control, and a Circuit Breaker.
2. Voltage Control � A contin-
uous control that gives full
ON
DESIGN FEATURES AND range adjustment of power
ARC VOLTS
ADVANTAGES source output voltage.
Voltage can be adjusted
while welding.
G Reconnect table for 230 volt or 208 volt single phase 60
ARC VOLTS
Hz input power.
3. Wire Speed Control �
G Solid state output control. Controls the wire feed speed
from 50 � 400 in /min (1.3 �
G WIRE SPEED
“Cold electrode� until gun trigger is pressed for an added
10 m/min). The control can
measure of safety.
be preset on the dial to the
G Overload protection � incorporates both a thermostat setting specified on the SP-
and a circuit breaker. 175 Plus Application Chart
located on the inside of the
G Quality wire drive with electronic overload protection.
wire feed section door. Wire
G Easy-to-set continuous range controls for precise setting speed is not affected when
of arc voltage and wire speed. changes are made in the
voltage control.
G “Quick Release� idle roll pressure arm is easily adjusted.
SP-175 PLUS
B-3
OPERATION
B-3
WELDING OPERATIONS
SEQUENCE OF OPERATION
2
1 Wire Loading
Refer to Figure B.2 and B.3.
WELDING AMP RANGE
25-125
The machine power switch should be turned to the
OFF (“O�) position before working inside the wire feed
3
enclosure.
SP-175 Plus
The machine is shipped from the factory ready to feed
8� (200 mm) diameter spools [2.2� (56 mm) max.
width]. These spools fit on a 2� (50 mm) diameter
spindle that has a built-in adjustable friction brake to
prevent overrun of the spool and excess slack in the
wire.
Note: When loading and removing the 8� Spools
make sure that the wing nut (inside the wire spool
spindle hub) is turned 90° from the wire spool spindle
locking tab. If the wing nut is positioned in line with the
locking tab, the tab cannot be depressed to load or
FIGURE B.1a unload the wire spool.
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 wing nut and spacer at the end of the
shaft and remove the outside plastic wire spool spin-
Refer to Figure B.1b dle. The spindle can be stored in the wire feed com-
partment. A 4� (100 mm) diameter spool is mounted
4. Circuit Breaker � Protects machine from damage if directly on the 5/8� (16 mm) diameter shaft and held in
maximum output is exceeded. Button will extend place with the previously removed hardware. Also
out when tripped (Manual reset). make certain the start end of the wire, which may pro-
trude through the side of the spool does not contact
FIGURE B.1b any metallic case parts.
FIGURE B.2
Wire Spool Spindle
Locking Tab
8� Wire Spool
Be sure that this stud engages
the hole in the wire spool.
Thumb
Screw
To wire drive
Wire Spool must be pushed all the way on the spindle so that the
spindle’s tab will hold it in place. The Wire Spool must rotate clock-
wise when wire is dereeled.
SP-175 PLUS
B-4 B-4
OPERATION
FIGURE B.3 FIGURE B.4
Wire Spindle Shaft 4" Wire Spool
2
1
Wing Nut
4
5
and Spacer
To wire drive
3 The Wire Drive Feed Roll can
accommodate two wire sizes by
flipping the wire drive feed roll
Note: The brake should be adjusted with a spool of over. The sizes are stenciled on
wire installed. When properly adjusted it should the drive roll.
move freely but not coast.
6. The idle roll pressure adjustment wing nut is nor-
mally set for mid-position on the pressure arm
Friction Brake Adjustments
threads. If feeding problems occur because the
wire is flattened excessively, turn the pressure
1. With wire spool installed, check free movement
adjustment counter-clockwise to reduce distortion
and coast of the spool.
of the wire. Slightly less pressure may be required
when using 0.023 � 0.025� (0,6 mm) wire. If the
2. To tighten the brake, turn the wing nut clockwise in
drive roll slips while feeding wire, the pressure
1/4 turn increments until coasting stops.
should be increased until the wire feeds properly.
3. To loosen the brake, turn the wing nut counter-
WARNING
clockwise in 1/4 turn increments until the wire spool
moves freely without coasting.
When inching the welding wire, the drive rolls, the
gun connector block and the gun contact tip are
Wire Threading
always energized relative to work and ground and
Refer to Figure B.4
remain energized several seconds after the gun
trigger is released.
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-
7. Refer to Figure B.5. Remove (unscrew) gas noz-
ciled size on the drive roll matches the wire size
zle and contact tip from end of gun.
being used.
8. Turn the SP-175 Plus ON (“I�).
2. Carefully detach the end of the wire from the
spool. To prevent the spool from unwinding, do
9. Straighten the gun cable assembly.
not release the wire until after step 5.
10. Depress the gun trigger switch and feed welding
3. Cut the bent portion of wire off and straighten the
wire through the gun and cable. (Point gun away
first 4� (100 mm).
from yourself and others while feeding wire.)
Release gun trigger after wire appears at end of
4. Thread the wire through the incoming guide tube
gun.
(4), over the drive roll (3), and into the out-going
guide tube (5).
11. Replace contact tip and gas nozzle.
5. Close the idle roll arm and latch the spring loaded
12. Refer to Figure B-6. Cut the wire off 3/8� � 1/2�
pressure arm (2) in place (now you may release
(10 � 13 mm) from the end of the tip. The SP-175
the welding wire).
Plus is now ready to weld.
SP-175 PLUS
B-5
OPERATION
B-5
FIGURE B.5 FIGURE B.6
Gun Handle
Contact Tip
Gas Diffuser/
Contact Tip Wire Electrode
3/8" � 1/2" Contact Tip to
Gas Nozzle Work Distance (CTWD)
Shielding Gas
When using the GMAW process, a cylinder of shield-
ing gas, must be obtained. Refer to the ACCES-
SORIES section for more information about selecting 4. Check that the polarity is correct for the welding
gas cylinders for use with the SP-175 Plus. Be sure wire being used and that the gas supply, if
to observe all cylinder handling and use precau- required, is turned on.
tions.
5. When using Innershield electrode, remove the gas
nozzle and install the gasless nozzle. This will
1. For CO2, open the cylinder very slowly. For argon- improve visibility of the arc and protect the gas dif-
mixed gas, open cylinder valve slowly a fraction of fuser from weld spatter. Refer to the MAINTE-
a turn. When the cylinder pressure gauge pointer NANCE section for details on nozzle replacement.
stops moving, open the valve fully.
6. Refer to Figure B.7. Connect work clamp to metal
2. If using a regulator with an adjustable flow meter, to be welded. Work clamp must make good elec-
press the gun trigger and adjust the flow to give 15 trical contact to the workpiece. The workpiece
� 20 cubic ft per hour (CFH) (7 � 10 I/min) [use 20 must also be grounded as stated in “Arc Welding
-� 25 CFH (10 � 12 I/min) when welding out of Safety Precautions� in the beginning of this manu-
position or in a drafty location for CO2]. For argon al.
mixed gas, press the gun trigger to release gas
pressure, and adjust the flow to give 25 � 30 CFH 7. Position gun over joint. End of wire may be lightly
(12 � 14 I/min). touching the work.
3. Keep the cylinder valve closed, except when using 8. Lower welding helmet, close gun trigger, and
the SP-175 Plus. When finished welding: begin welding. Hold the gun so the contact tip to
work distance is about 3/8 inch (10 mm).
a) Close the cylinder valve to stop gas flow.
b) Depress the gun trigger briefly to release the
pressure in the gas hose.
FIGURE B.7
c) Turn off the SP-175 Plus.
Making A Weld
1. See Recommended Processes And Equipment
section for selection of welding wire and shielding
gas and for range of metal thicknesses that can be SP-175 Plus
welded.
GUN CABLE
2. See the Application Chart on the inside of wire
feed section door for information on setting the
SP-175 Plus controls.
3. Set the Voltage (“Vâ€?) and Wire Speed (“olo’â??) con- WORKPIECE
trols to the settings suggested for the welding wire ARC
and base metal thickness being used.
WORK CLAMP
SP-175 PLUS
B-6 OPERATION B-6
9. To stop welding, release the gun trigger and then
CAUTION
pull the gun away from the work after the arc goes
It is important when changing between welding
out.
with steel wire and aluminum to exchange feeding
components due to the lubricant applied to steel
10. When no more welding is to be done, close valve
wire. Failure to do so may result in contaminated
on gas cylinder (if used), momentarily operate gun
welds when welding aluminum.
trigger to release gas pressure, and turn off the
------------------------------------------------------------------------
SP-175 Plus.
TABLE B.1 � SP-175 Plus Welding Procedures
Cleaning Tip And Nozzle
Voltage/Wire Speed
Shielding
Clean the contact tip and nozzle to avoid arc bridging
Process Welding Wire Gas 22 ga 16 ga 12 ga 1/8� 3/16� 1/4�
between the nozzle and contact tip which can result in
.035 Dia(0.9mm 100% Argon B-5 B-7 E-9 G-9 I-9 J-10*
a shorted nozzle, poor welds and an overheated gun. 4043 Aluminum
Hint: Anti-stick spray or gel, available from a welding Wire
16 ga 14 ga 12 ga 10 ga
MIG DC+
supply distributor, may reduce buildup and aid in spat-
.030 Dia 98% Argon/ A-3 C-6 D-7.5 D-7.5
ter removal. 308L Stainless 2% Oxygen
Steel Wire
*Test assembly preheated to 250° F.
PROCESS GUIDELINES
CHANGING MACHINE OVER TO
The SP-175 Plus can be used for welding mild steel
FEED OTHER WIRE SIZES
using the GMAW, single pass, process which requires
a supply of shielding gas or it can be used for the self
shielded, Innershield electrode process. The SP-175 Plus is shipped from the factory with a
gun liner ready to feed 0.023-0.035� (0.6-0.9 mm)
The recommended gas and electrode for GMAW is diameter wire. The contact tip is 0.025� (0.6 mm) and
welding grade mixed CO2 and Argon (75-80%) gas the drive roll is set for 0.023�-0.025� (0.6 mm). To
and 0.025� (0 6 mm) diameter Lincoln Super Arc L-56 operate the SP-175 Plus with other sizes of wire, it
mild-steel welding wire. For 14 gauge (2,0 mm) and maybe necessary to change the contact tip, and Gun
thinner CO2, or blended gas is acceptable. A mixed Liner Configuration. Refer to the maintenance section
gas consisting of 75 to 80% Argon and 20 to 25% CO2 for component configuration and replacement proce-
is recommended for welding on heavier gauge [12 dures
gauge (2,5 mm) for example] steel.
The recommended electrode for the self-shielded
WELDING WITH FCAW (Innershield)
process is 0.035� (0,9 mm) diameter Lincoln
Innershield NR-211-MP. This electrode can be used
for all position welding of 20 gauge through 5/16� (1,0 Welding with Innershield requires an Innershield
� 8,0 mm) thick steel [multiple passes are required for Welding Kit. A gasless nozzle is provided in the
1/4� and 5/16� (6,0 and 8,0 mm)]. Innershield Welding Kit. When using Innershield elec-
trode, installing the gasless nozzle will improve visibili-
ty of the arc and protect the gas diffuser from weld
spatter. Additionally included is a gun cable liner to
permit proper feeding of .035� (0,9 mm) Innershield
WARNING wire. Refer to the ACCESSORIES section for details
on obtaining this kit.
Use of the GMAW process with the SP-175 Plus on
thicker materials than 5/16� (8.0 mm) may result in
poor welds. The welds may “look� good, but may
just be “sitting� on top of the plate. This is called
“cold casting� and will result in weld failure.
The SP-175 Plus is suitable for .035" Aluminum wire
and .030"-.035� stainless wire. Refer to Table B.1 for
Recommended Procedure Settings. Aluminum wire
requires an Aluminum Welding kit. See ACCES-
SORIES section.
SP-175 PLUS
B-7
OPERATION
B-7
OVERLOAD PROTECTION
Output Overload
The SP-175 Plus is equipped with a circuit breaker
which protects the machine from potential damage
from excessive output current. The circuit breaker but-
ton will extend out when tripped. The circuit breaker
must be manually reset.
Thermal Protection
The SP-175 Plus duty cycle is exceeded a thermostat
will shut off the output until the machine cools to a nor-
mal operating temperature. This is an automatic func-
tion and is self resetting.
Wire Feed Overload Protection
If the SP-175 Plus has an automatic electronic protec-
tion circuit to protect the wire feed motor. If excessive
motor overload occurs (due to excessive feeding force
jammed drive rolls, or shorted motor leads) the circuit
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-175 PLUS
B-8
APPLICATION CHART
B-8
SP-175 PLUS
C-1 C-1
ACCESSORIES
OPTIONAL ACCESSORIES
1. K520 Utility Cart � Designed to transport the
Lincoln family of small welders. Has provisions for
mounting a single gas cylinder. Has front casters
and large rear wheels. Handle height is easily
adjustable. Bottom tray provided for tools and
accessories. Easy assembly required; takes less
than 15 minutes.
2. K586-1 Deluxe Adjustable Gas Regulator &
Hose Kit
Accommodates CO2 or mixed Gas Cylinders.
3. K663-2 Aluminum Feeding Kit � This kit recom-
mended for welding with .035 Aluminum wire.
Included with this kit are a drive roll, cable liner and
.035 contact tip. It is important when changing
between welding with steel wire and aluminum
to exchange feeding components due to the
lubricant applied to steel wire. Failure to do so
may result in contaminated welds when weld-
ing aluminum.
See Maintenance section for instructions on installing
drive roll, cable liner, contact tip and their proper con-
figuration.
4. K549-1 .035 (0.9 mm) Innershield Welding Kit
Includes a contact tip, a gasless nozzle and a
cable liner to permit the Magnumâ„? 100L gun and
cable to use .030-.035� (0.8-0.9 mm) diameter flux-
cored electrode. Also included is a spool of .035
(0.9 mm) Innershield NR-211-MP.
5. KP666-035c Knurled Drive Roll (optional) --
Reversable Drive Roll with double knurled grooves
for .035 (0.9mm) cored electrode.
6. K549-4 .045� (1.2mm) Innershield Welding Kit
Includes a contact tip, a gasless nozzle, a .045�
(1,2mm) knurled drive roll, acable liner and guide
tubes to permit the Magnumâ„? 100L gun and
cable to use .045� (1.2mm ) diameter flux- cored
electrode. Also included is a spool of .045 (1.2mm)
Innershield NR-211-MP.
SP-175 PLUS
C-2
ACCESSORIES
C-2
Contact Tip .035A� (0.9 mm)
INNERSHIELD (FCAW)
KP2078-1B1 (Aluminum Tip-Mag 100L)
CONVERSION
Liner .023 - .035� (0.6 - 0.9 mm)
Several changes are needed to convert the unit for
KP1937-3
operation with the Innershield (FCAW) process. The
Innershield Kits include all the necessary accessories Liner .035 - .045� (0.9 - 1.2 mm)
for this conversion and are provided for this purpose. KP1937-1
The following conversions should be made using the
Gas Diffuser
contents of a kit:
KP2040-1
1. Change the output polarity to DC(-). See “Work Gas Nozzle
Cable Installation� section for details. KP1938-1
Gas Nozzle-Tip Recessed 3/8� (9.5 mm)
2. Install proper drive roll for the wire size selected.
Opening I.D.
See “Changing Drive Roll� in Maintenance section
KP1942-1
for details.
Gas Nozzle-Tip Recessed 1/2� (12.7 mm)
Opening I.D.
3. Install the proper gun liner* and tip for the wire size
KP1942-2
selected. See “Component Replacement� in
Maintenance section for details.
Gas Nozzle-Tip Recessed 5/8� (15.9 mm)
Opening I.D.
4. Remove gas nozzle (if installed) and install gasless KP1942-3
nozzle. To remove, simply unscrew.
Spot Welding Nozzle
KP1956-1
* The factory installed gun liner will feed .025-.035
(0.6-0.9mm) wire. Gasless Nozzle (Innershield Only)
KP1939-1
REPLACEMENT PARTS
Complete Gun and Cable Assembly
L8311-6 (K530-4)
Contact Tip .025� (0.6 mm)
KP2039-1B1
Contact Tip .030� (0.8 mm)
KP2039-2B1
Contact Tip .035� (0.9 mm)
KP2039-3B1
Contact Tip .045� (1.2 mm)
KP2039-4B1
Contact Tip-Tapered .025� (0.6 mm)
KP2052-1B1
Contact Tip-Tapered .030� (0.8 mm)
KP2052-2B1
Contact Tip-Tapered .035� (0.9 mm)
KP2052-3B1
Contact Tip-Tapered .045� (1.2mm)
KP2052-4B1
SP-175 PLUS
D-1 D-1
MAINTENANCE
AFTER FEEDING 50# OF FLUX CORED
MAINTENANCE
WIRE OR 300# OF SOLID WIRE
SAFETY PRECAUTIONS
� Unplug machine or turn power switch to OFF � “O�
WARNING position. Remove gun and cable from machine.
� Remove gas nozzle and contact tip from gun.
ELECTRIC SHOCK can kill.
� Lay cable out straight - blow out gently into gun end
� Disconnect input power by remov- with compressed air. Bend cable back and forth �
ing plug from receptacle before blow out again � Repeat until clean.
working inside SP-175 Plus . Use
only grounded receptacle. Do not
WARNING
touch electrically “hot� parts
inside SP-175 Plus .
Excessive pressure at start may cause the dirt to
form a plug.
� Have qualified personnel do the
maintenance and trouble shooting
work.
PERIODICALLY AS REQUIRED
� Blow dirt out of the welder with low pressure air to
ITEMS REQUIRING NO
eliminate excessive dirt and dust buildup that could
MAINTENANCE cause welder to run hot.
� Drive Motor and Gearbox � Lifetime lubrication
� Blow dirt out of: Rectifier & Fan Motor Assembly;
� Fan Motor- Lifetime lubrication.
PC Board located on Case Side Assembly; and
� Wire Reel Spindle � Do NOT lubricate shaft.
Center Assembly components.
ROUTINE AND PERIODIC MAINTE- � Vacuum accumulated dirt from gearbox and wire
NANCE feed section.
BEFORE EACH USE � Inspect the incoming guide tube and clean inside
� Check over machine and accessories for any obvious diameter if necessary. Replace when excessively
condition that may prevent safe performance or oper- worn.
ation, repair or replace items as necessary to correct
any abnormal condition. � Replace Contact Tip � when hole is enlarged or
elongated (refer to “CHANGING THE CONTACT
AFTER 5 MINUTES OF WELDING TIP�, in this section).
or when spatter accumulates in nozzle
� Replace gas nozzle.
� Clean nozzle to avoid bridging between nozzle and
� Replace Liner � when wire feeding problems occur
contact tip which results in shorted nozzle, poor welds
and other items have been checked (refer to
and overheated gun. Hint: Anti-stick spray or gel
“CHANGING LINER� procedure in this section).
available from a welding supply supplier may reduce
buildup and aid in spatter removal.
� Replace internal gun handle parts as necessary
AFTER EACH SPOOL OF WIRE FEED (see Procedure at the end of this section).
� Remove contact tip and clean inside diameter with
short piece of wire
� Clean cable liner � when rough and erratic wire feed-
ing occur.
SP-175 PLUS
D-2 D-2
MAINTENANCE
2. Replace worn contact tips as required. A variable
GUN AND CABLE
or “hunting� arc is a typical symptom of a worn con-
MAINTENANCE
tact tip. To install a new tip, choose the correct size
contact tip for the electrode being used (wire size is
FOR MAGNUMâ„? 100L GUN
stenciled on the side of the contact tip) and screw it
snugly into the gas diffuser.
Gun Cable Cleaning
Clean cable liner after using approximately 300 lbs
3. Remove spatter from inside of gas nozzle and from
(136 kg) of solid wire or 50 lbs (23 kg) of flux-cored
tip after each 10 minutes of arc time or as required.
wire. Remove the cable from the wire feeder and lay it
out straight on the floor. Remove the contact tip from
4. Be sure the gas nozzle is fully screwed onto the
the gun. Using low pressure air, gently blow out the
diffuser for gas shielded processes. For the
cable liner from the gas diffuser end.
Innershield® process, the gasless nozzle should
be screwed onto the diffuser.
CAUTION
5. To remove gun tube from gun, remove gas nozzle
Excessive pressure at the start may cause the dirt
or gasless nozzle and remove diffuser from gun
to form a plug.
tube. Remove both collars from each end of the
gun handle and separate the handle halves.
Loosen the locking nut holding the gun tube in
Flex the cable over its entire length and again blow
place against the gun end cable connector.
out the cable. Repeat this procedure until no further
Unscrew gun tube from cable connector. To install
dirt comes out.
gun tube, screw the locking nut on the gun tube as
far as possible. Then screw the gun tube into the
cable connector until it bottoms. Then unscrew (no
Contact Tips, Nozzles, and Gun Tubes
more than one turn) the gun tube until its axis is
1. Dirt can accumulate in the contact tip hole and
perpendicular to the flat sides of the cable connec-
restrict wire feeding. After each spool of wire is
tor and pointed in the direction of the trigger.
used, remove the contact tip and clean it by push-
Tighten the locking nut so as to maintain the proper
ing a short piece of wire through the tip repeatedly.
relationship between the gun tube and the cable
Use the wire as a reamer to remove dirt that may
connector. Replace the gun handle, trigger and dif-
be adhering to the wall of the hole through the tip.
fuser. Replace the gas nozzle or gasless nozzle.
CONFIGURATION OF COMPONENTS IN WIRE FEEDING SYSTEM
Contact Tip Cable Liner Drive Roll
Components shipped with KP2039-1B1 KP1937-3 KP665-035
SP-175 Plus .025� (0.6mm) .030-.035� 2 Smooth grooves
S19726-2&-3(Loose) (0.8-0.9 mm) Small .023-.025� (Stenciled .025)
.030� & .035� Large .030-.035� (Stenciled .030-.035)
K549-1 .035 (0.9mm) KP2039-3B1 KP1937-3 Use Large groove of KP665-035
Innershield Welding Kit .035� (0.9mm) .035 (0.9mm)
K549-4 .045 (1.2mm) KP2039-4B1 KP1937-1 KP1881-3 Knurled .035-.045
Innershield Welding Kit .045� (1.2mm) .045� (1.2mm)
THESE PARTS
S24220 Drive Roll
}
K663-2 .035 (0.9mm) KP2078-1B1 KP1959-1 S24219 Idle Roll NOT SOLD
Aluminum Welding Kit* � .035A (0.9mm) .035� (0.9mm) SEPARATELY
KP666-035C KP1881-2
2 Knurled grooves for .035� (0.9mm)
� If .030 Solid wire feeding is desired obtain an KP2039-2B1 Contact Tip, an KP1937-2 Cable Liner and an M15448 Drive Roll (Smaller Groove).
* It is important when changing between welding with steel wire and aluminum to exchange feeding components due to the lubricant applied to steel wire. Failure
to do so may result in contaminated welds when welding aluminum.
SP-175 PLUS
D-3 D-3
MAINTENANCE
COMPONENT REPLACEMENT
CAUTION
PROCEDURES
When inching the welding wire, the drive rolls,
gun connector block, and gun contact tip are
CHANGING THE CONTACT TIP
energized relative to work and ground and remain
energized for several seconds after the gun trig-
1. Unplug or turn power switch to Off “O� position.
ger is released.
------------------------------------------------------------------------
2. Refer to Figure D.2. Remove the gas nozzle from
the gun by unscrewing counter-clockwise.
4. Remove the drive roll, flip over and reinstall with the
3. Remove the existing contact tip from the gun by
opposite groove closest to the gearbox.
unscrewing counter-clockwise.
NOTE: The stencil of the groove that you want to use
4. Insert and hand tighten desired contact tip.
is marked on the outside of the drive roll
(when installed)
5. Replace gas nozzle.
5. Push a length of straightened welding wire through
CHANGING THE SP-175 Plus FOR USE
the wire feeder guide tubes and reset the Phillips
WITH INNERSHIELD FLUX CORED WIRE
Head screw to secure the drive roll onto the shaft.
� Change The Contact Tip
6. Reapply the spring loaded idle arm tensioner.
� Acquire Innershield Welding Kit (See ACCES-
SORIES section). Note: Feeding .035� Innershield
7. Turn the power “ON� (I) and check the drive roll for
requires nothing extra but feeding will be optimized
slipping when feeding wire. DO NOT OVERTIGHTEN -
with the use of the KP666-035C drive roll.
If necessary, tighten or loosen the spring loaded
idle arm tensioner (2).
1. Refer to Figure D.2. Remove the gas nozzle from
the gun by unscrewing counter-clockwise.
2. Remove the existing contact tip from the gun by
unscrewing counter-clockwise.
3. Insert and hand tighten the contact tip for use with
.035� or .045� (.045� requires a liner change also)
Innershield Flux Cored Wire.
3
4. Replace gas nozzle � The gasless nozzle may be
used instead of the gas nozzle to give improved
visibility of the arc.
2
CHANGING DRIVE ROLL
1
The drive roll, Figure D.1 Item 1, has two grooves; one
for .023" � .025" (0.6mm) solid steel electrode and a larg-
er groove for .030" (0.8mm) solid and .035" (0.9mm) flux-
cored steel electrode. As shipped, the drive roll is
installed in the .023" � .025" (0.6mm) position.
FIGURE D.1
If .030"-.035" (0.9mm) wire is to be used, the drive roll
must be reversed as follows:
1. Turn the power switch to OFF (marked “O�).
2. Release the spring-loaded idle arm tensioner, Figure D.1
Item 2, and lift the idle roll arm, Figure D.1 Item 3, away
from the drive roll.
3. Loosen the Phillips Head screw holding the drive
roll onto the drive shaft. SP-175 PLUS
D-4 D-4
MAINTENANCE
1-1/4 (31.8 mm)
CHANGING LINER
Liner Trim Length
NOTICE: The variation in cable lengths prevents the
interchangeability of liners. Once a liner has been
cut for a particular gun, it should not be installed in
another gun unless it can meet the liner cutoff
length requirement. Refer to Figure D.2.
Gas Diffuser 1. Remove gun and cable assembly from machine.
2. Remove the gas nozzle from the gun by
Gas Nozzle or unscrewing counter-clockwise.
Gasless Nozzle
Set Screw Brass Cable
Connector 3. Remove the existing contact tip from the gun by
unscrewing counter-clockwise.
4. Remove the gas diffuser from the gun tube by
unscrewing counter-clockwise.
Liner Assembly
(Liner bushing to be sealed tight
against brass cable connector)
5. Lay the gun and cable out straight on a flat sur-
face. Loosen the set screw located in the brass
FIGURE D.2
connector at the wire feeder end of the cable.
Liner trim length
Pull the liner out of the cable.
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 connector.
Tighten the set screw on the brass cable con-
nector. 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-175 PLUS
D-5 D-5
MAINTENANCE
GUN HANDLE PARTS
The gun handle consists of two halves that are held
together with a collar on each end. To open up the
handle, turn the collars approximately 60 degrees
counter-clockwise until the collar reaches a stop. Then
pull the collar off the gun handle. If the collars are diffi-
cult to turn, position the gun handle against a corner,
place a screwdriver against the tab on the collar and
give the screwdriver a sharp blow to turn the collar
past an internal locking rib. See Figure D-3.
âž?
Counter-clockwise
FIGURE D.3
SP-175 PLUS
E-1
TROUBLESHOOTING
E-1
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 Step 3. RECOMMENDED COURSE OF ACTION
locate and repair possible machine malfunctions. This column provides a course of action for the
Simply follow the three-step procedure listed below. Possible Cause, generally it states to contact your
local Lincoln Authorized Field Service Facility.
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled “PROBLEM (SYMP- If you do not understand or are unable to perform the
TOMS)�. This column describes possible symptoms Recommended Course of Action safely, contact your
that the machine may exhibit. Find the listing that local Lincoln Authorized Field Service Facility.
best describes the symptom that the machine is
exhibiting.
Step 2. POSSIBLE CAUSE.
The second column labeled “POSSIBLE CAUSE� lists
the obvious external possibilities that may contribute
to the machine symptom.
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.
___________________________________________________________________
CAUTION
If machine case sides and top are removed, the case front must be supported.
Failure to do this could result in mechanical or electrical damage to the SP-175 Plus.
___________________________________________________________________
SP-175 PLUS
E-2 TROUBLESHOOTING E-2
Observe Safety Guidelines detailed in the beginning of this manual.
PROBLEMS POSSIBLE RECOMMENDED
(SYMPTOMS) CAUSE COURSE OF ACTION
OUTPUT PROBLEMS
Major physical or electrical damage Contact your LOCAL LINCOLN
is evident. AUTHORIZED FIELD SERVICE
FACILITY.
No wire feed, weld output or gas 1. Make sure correct voltage is
flow when gun trigger is pulled. Fan applied to the machine (208 or
does NOT operate. 230 VAC 60 Hz.).
2. Make certain that power switch
is in the ON position.
3. Make sure circuit breaker is
reset.
No weld output or wire feed when Contact your LOCAL LINCOLN
gun trigger is pulled. Fan runs and AUTHORIZED FIELD SERVICE
gas flows normally. FACILITY.
No weld output when gun trigger is 1. Arc voltage may be set too low.
pulled. Fan runs, gas flows and
wire feeds normally. 2. Gun tip may be worn � Replace. Contact your local Lincoln
Authorized Field Service Facility.
3. Check for correct input voltage
to machine.
4. Gun or work cable may be
faulty.
No Wire feed, weld output or gas 1. Check the circuit breaker locat-
flow when the gun trigger is pulled. ed in the machine’s wire drive
Fan operates normally. compartment. Reset if tripped.
2. The thermostat may be tripped
due to overheating. Let machine
cool. Weld within the duty cycle
or remove any air obstruction to
machine.
3. Wire feed motor may be over-
loaded. Correct feeding prob-
lem. (Check brake adjustment-
could be to tight)
4. Gun trigger may be faulty.
CAUTION
If for any reason you do not understand the test procedures or are unable to Perform the tests/repairs safely, contact your
LOCAL AUTHORIZED LINCOLN ELECTRIC FIELD SERVICE FACILITY for assistance before you proceed.
SP-175 PLUS
E-3
TROUBLESHOOTING
E-3
Observe Safety Guidelines detailed in the beginning of this manual.
PROBLEMS POSSIBLE RECOMMENDED
(SYMPTOMS) CAUSE COURSE OF ACTION
FEEDING PROBLEMS
No wire feed when gun trigger is 1. If the wire drive motor is running
pulled. Fan runs, gas flows and check to see if the correct wire
machine has correct open circuit is in the machine.
voltage (33 VDC maximum) � weld
output. 2. If the wire drive motor is running
make sure that the correct drive
rolls are installed in the Contact your local Lincoln
machine. Authorized Field Service Facility.
3. Check for clogged cable liner or
feeding problems.
4. Check brake adjustment (could
be too tight).
Wire feed speed motor runs very 1. Make sure that the wire speed
fast. Weld output, gas flow and fan control is not set at maximum.
operate normally.
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
GAS FLOW PROBLEMS
Low or no gas flow when gun 1. Check gas supply, flow regulator
trigger is pulled. Wire feed, weld and gas hoses.
output and fan operate normally. Contact your local Lincoln
2. Check gun connection to Authorized Field Service Facility.
machine for obstruction or leaky
seals.
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.
SP-175 PLUS
E-4
E-4 TROUBLESHOOTING
Observe Safety Guidelines detailed in the beginning of this manual.
PROBLEMS POSSIBLE RECOMMENDED
(SYMPTOMS) CAUSE COURSE OF ACTION
WELDING PROBLEMS
Arc is unstable � Poor starting 1. Check for correct input voltage
to machine � 208 or 230 VAC.
2. Check for proper electrode
polarity for process.
3. Check gun tip for wear or dam- Contact your local Lincoln
age � Replace. Authorized Field Service Facility.
4. Check for proper gas and flow
rate for process.
5. Check work cable for loose or
faulty connections.
6. Check gun for damage or
breaks.
7. Check wire feed to assure
smooth wire feeding (check
brake adjustment).
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.
SP-175 PLUS
F-1
SP-175 PLUS
WIRING DIAGRAMS
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The
F-1
specific diagram for a particular code is pasted inside the machine on one of the enclosure panels.
NOTES
G Do not touch electrically live parts or G Keep flammable materials away. G Wear eye, ear and body protection.
WARNING electrode with skin or wet clothing.
G Insulate yourself from work and
ground.
Spanish
G No toque las partes o los electrodos G Mantenga el material combustible G Protéjase los ojos, los oÃdos y el
AVISO DE bajo carga con la piel o ropa moja- fuera del área de trabajo. cuerpo.
da.
PRECAUCION G Aislese del trabajo y de la tierra.
French G Ne laissez ni la peau ni des vête- G Gardez à l’écart de tout matériel G Protégez vos yeux, vos oreilles et
ments mouillés entrer en contact inflammable. votre corps.
ATTENTION avec des pièces sous tension.
G Isolez-vous du travail et de la terre.
G Berühren Sie keine stromführenden
German G Entfernen Sie brennbarres Material! G Tragen Sie Augen-, Ohren- und Kör-
Teile oder Elektroden mit Ihrem perschutz!
WARNUNG Körper oder feuchter Kleidung!
G Isolieren Sie sich von den
Elektroden und dem Erdboden!
Portuguese
G Não toque partes elétricas e elec- G Mantenha inflamáveis bem guarda- G Use proteção para a vista, ouvido e
trodos com a pele ou roupa molha- dos. corpo.
ATENÇÃO da.
G Isole-se da peça e terra.
Japanese
Chinese
Korean
Arabic
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-
STELLERS. DIE UNFALLVERHÃœTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
G Keep your head out of fumes. G Turn power off before servicing. G Do not operate with panel open or
G Use ventilation or exhaust to
WARNING
guards off.
remove fumes from breathing zone.
Spanish
G Los humos fuera de la zona de res- G Desconectar el cable de ali- G No operar con panel abierto o
AVISO DE
piración. mentación de poder de la máquina guardas quitadas.
G Mantenga la cabeza fuera de los antes de iniciar cualquier servicio.
PRECAUCION
humos. Utilice ventilación o
aspiración para gases.
French
G Débranchez le courant avant l’entre- G N’opérez pas avec les panneaux
G Gardez la tête à l’écart des fumées.
G Utilisez un ventilateur ou un aspira- tien. ouverts ou avec les dispositifs de
ATTENTION
protection enlevés.
teur pour ôter les fumées des zones
de travail.
German
G Strom vor Wartungsarbeiten G Anlage nie ohne Schutzgehäuse
G Vermeiden Sie das Einatmen von
abschalten! (Netzstrom völlig öff- oder Innenschutzverkleidung in
Schweibrauch!
WARNUNG
G Sorgen Sie für gute Be- und nen; Maschine anhalten!) Betrieb setzen!
Entlüftung des Arbeitsplatzes!
Portuguese
G Não opere com as tampas removidas. G Mantenha-se afastado das partes
G Mantenha seu rosto da fumaça.
G Desligue a corrente antes de fazer
G Use ventilação e exhaustão para moventes.
ATENÇÃO
serviço. G Não opere com os paineis abertos
remover fumo da zona respiratória.
G Não toque as partes elétricas nuas. ou guardas removidas.
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÃTICAS DE SEGURANÇA DO EMPREGADOR.
� World's Leader in Welding and Cutting Products �
� Sales and Service through Subsidiaries and Distributors Worldwide �
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
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