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IM795
SP 170-I March, 2004
For use with machine Code Numbers : 10982; 10983
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 © 2004 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
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
4.c. Protect other nearby personnel with suitable, non-flammable
area of physical contact with work and ground.
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
In addition to the normal safety precautions, if welding
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
iii iii
SAFETY
CYLINDER may explode
WELDING SPARKS can
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
iv iv
SAFETY
zones où l’on pique le laitier.
PRÉCAUTIONS DE SÛRETÉ
6. Eloigner les matériaux inflammables ou les recouvrir afin de
Pour votre propre protection lire et observer toutes les instructions
prévenir tout risque d’incendie dû aux étincelles.
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv-
7. Quand on ne soude pas, poser la pince à une endroit isolé de
antes:
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
8. S’assurer que la masse est connectée le plus prés possible
de la zone de travail qu’il est pratique de le faire. Si on place
a. Les circuits à l’électrode et à la piéce sont sous tension
la masse sur la charpente de la construction ou d’autres
quand la machine à souder est en marche. Eviter toujours
endroits éloignés de la zone de travail, on augmente le risque
tout contact entre les parties sous tension et la peau nue
de voir passer le courant de soudage par les chaines de lev-
ou les vétements mouillés. Porter des gants secs et sans
age, câbles de grue, ou autres circuits. Cela peut provoquer
trous pour isoler les mains.
des risques d’incendie ou d’echauffement des chaines et des
b. Faire trés attention de bien s’isoler de la masse quand on
câbles jusqu’� ce qu’ils se rompent.
soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
9. Assurer une ventilation suffisante dans la zone de soudage.
les positions assis ou couché pour lesquelles une grande
Ceci est particuliérement important pour le soudage de tôles
partie du corps peut être en contact avec la masse.
galvanisées plombées, ou cadmiées ou tout autre métal qui
c. Maintenir le porte-électrode, la pince de masse, le câble
produit des fumeés toxiques.
de soudage et la machine à souder en bon et sûr état
defonctionnement.
10. Ne pas souder en présence de vapeurs de chlore provenant
d.Ne jamais plonger le porte-électrode dans l’eau pour le
d’opérations de dégraissage, nettoyage ou pistolage. La
refroidir.
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
e. Ne jamais toucher simultanément les parties sous tension
du solvant pour produire du phosgéne (gas fortement toxique)
des porte-électrodes connectés à deux machines à souder
ou autres produits irritants.
parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
11. Pour obtenir de plus amples renseignements sur la sûreté,
f. Si on utilise la machine à souder comme une source de
voir le code “Code for safety in welding and cutting� CSA
courant pour soudage semi-automatique, ces precautions
Standard W 117.2-1974.
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
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
PRÉCAUTIONS DE SÛRETÉ POUR
enrouler le câble-électrode autour de n’importe quelle partie
LES MACHINES À SOUDER À
du corps.
TRANSFORMATEUR ET À
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
REDRESSEUR
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du ray- 1. Relier à la terre le chassis du poste conformement au code de
onnement de l’arc et des projections quand on soude ou l’électricité et aux recommendations du fabricant. Le dispositif
quand on regarde l’arc. de montage ou la piece à souder doit être branché à une
b. Porter des vêtements convenables afin de protéger la bonne mise à la terre.
peau de soudeur et des aides contre le rayonnement de
l‘arc. 2. Autant que possible, I’installation et l’entretien du poste seront
c. Protéger l’autre personnel travaillant à proximité au effectués par un électricien qualifié.
soudage à l’aide d’écrans appropriés et non-inflammables.
3. Avant de faires des travaux à l’interieur de poste, la debranch-
4. Des gouttes de laitier en fusion sont émises de l’arc de er 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, pan- 4. Garder tous les couvercles et dispositifs de sûreté à leur
talons sans revers, et chaussures montantes. place.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
Mar. �93
v v
SAFETY
vi vi
SAFETY
vii vii
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.
viii viii
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
Work Clamp Installation ..................................................................................A-3
Work Cable Installation ...................................................................................A-3
Gun Installation......................................................................................................A-4
Gas Connection .....................................................................................................A-4
Input Connections..................................................................................................A-5
Line Cord Connection ............................................................................................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
Wire Loading ...................................................................................................B-3
Wire Threading................................................................................................B-4
Making a Weld ................................................................................................B-5
Process Guidelines................................................................................................B-5
Chaning Over to Feed Other Wire Sizes ...............................................................B-6
Welding with GMAW..............................................................................................B-6
Welding with FCAW...............................................................................................B-6
Overload Protection ...............................................................................................B-6
Application Chart ...................................................................................................B-7
Accessories .....................................................................................................Section C
Accessories ...........................................................................................................C-1
Replacement Parts ................................................................................................C-2
Maintenance ....................................................................................................Section D
Safety Precautions ................................................................................................D-1
Routine Maintenance.............................................................................................D-1
Gun and Cable Maintenance.................................................................................D-2
Configuration of Components in Wire Feeding System.........................................D-2
Component Replacement Procedures ..................................................................D-2
Troubleshooting ..............................................................................................Section E
Safety Precautions.................................................................................................E-1
How to Use Troubleshooting Guide.......................................................................E-1
Troubleshooting Guide ..........................................................................................E-2
Wiring Diagrams ..............................................................................................Section F
SP 170-I Wiring Diagram .......................................................................................F-1
SP 170-I Parts...............................................................................................P467 Series
Wire Drive Assembly...........................................................................................P189-D
A-1
A-1 INSTALLATION
TECHNICAL SPECIFICATIONS � SP 170-I
INPUT � SINGLE PHASE ONLY
Standard Voltage/Frequency Input Current
230V/50/60Hz 20 Amps � Rated Output
RATED OUTPUT
Duty Cycle Amps Volts at Rated Amperes
25% 125 20.25
60% 85 18.25
100% 70 17.50
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/50/60Hz 30 Super Lag 20 16 Amp, 230V,
Two-Prong International
Cord Set (Supplied)
PHYSICAL DIMENSIONS
Height Width Depth Weight
12.0 in 9.75 in 16.5 in 57 Ibs
305 mm 248 mm 419 mm 25.9 kg
The SP170-I is designed for industrial and professional use
in accordance with the standard EN 60974-1 / IEC 974-1.
SP-170-I
A-2 A-2
INSTALLATION
Read entire installation section before starting
installation.
1 2
SAFETY PRECAUTIONS
E
WARNING WELDI
NG AM
P RA
NGE
SP 1
70 -I
ELECTRIC SHOCK can kill.
� Only qualified personnel should perform
this installation.
� Only personnel that have read and under-
stood the SP 170-I Operating Manual
should install and operate this equipment.
� Machine must be plugged into a receptacle
which is grounded per any national, local
4
or other applicable electrical codes.
� The SP 170-I power switch is to be in the
OFF (“O�) position when installing work
3
cable and gun and when connecting power
cord to input power.
8
6
IDENTIFY AND LOCATE
5
COMPONENTS
If you have not already done so, unpack the SP 170-I
7
from its carton and remove all packing material
around the SP 170-I. Remove the following loose
FIGURE A.1
items from the carton (see Figure A.1):
1. SP 170-I
2. Gun and cable assembly(1)
3. Literature and miscellaneous including:
a) This operating manual
b) Contact tips:
SP 170-I
2 .025� (0.6mm) for solid wire
2 .030� (0.8mm) for solid wire
1 .035� (0.9mm) for cored wire
c) 5/64� (2.0 mm) Hex key wrench for removal of
drive roll.
4. 10 ft (3,0 m) work cable.
5. Work clamp.
6. 14.0 ft (4.3 m) .19� (4.8 mm) dia. gas hose
7. 2- Hose clamps
8. Gas nozzle
The gun is ready to feed .035" (0.9mm) diameter.
(1)
SP 170-I
A-3
A-3 INSTALLATION
3. Connector Block.
SELECT SUITABLE LOCATION
4. Gun Trigger Lead Connectors.
The SP 170-I has an IP21S rating. Locate the welder
in a dry location where there is free circulation of clean
5. Positive (+) and negative (�) output terminals.
air into the louvers in the back and out the front of the
unit. A location that minimizes the amount of smoke
6. Wire Feed Gearbox / Feedplate
and dirt drawn into the rear louvers reduces the
chance of dirt accumulation that can block air pas-
7. Cable Hanger.
sages and cause overheating.
8. Thumbscrew.
STACKING
SP 170-I’s cannot be stacked.
Refer to the Accessories Section for available optional
TILTING equipment.
Each machine must be placed on a secure, level sur- Work Clamp Installation
face, either directly or on the recommended cart. The
machine may topple over if this procedure is not fol- Attach the work clamp per the following: Refer to
lowed. Figure A-3
FIGURE A.3
LIMITATIONS STRAIN RELIEF HOLE
WORK CABLE
The SP 170-I cannot be used for pipe thawing. NUT AND BOLT
MIG welding and flux cored arc welding are the only
processes supported by the SP 170-I
WORK CLAMP
The handle can not be used for transport by crane.
OUTPUT CONNECTIONS 1. Insert the work cable terminal lug with the larger
Refer to Figure A.2. hole through the strain relief hole in the work clamp
as shown above.
1. Work Cable Access Hole.
2. Fasten securely with the bolt and nut provided.
2. Gun Cable and Control Lead Access Hole.
4
E
5
+
8
SP 170 - I
-
6
3 7
1 2
FIGURE A.2
SP 170-I
A-4 A-4
INSTALLATION
Work Cable Installation Connecting Gun Cable to the SP 170-I
Refer to Figure A.2. As shipped the gun is fitted with a liner suitable for all
wire diameters from .025� - .035� (0.6mm - .9mm) and
1. Open the wire feed section door on the right side of has an .035� (0.9mm) contact tip installed.
the SP 170-I.
1. Refer to Figures A.2 and A.4. Unplug the machine
2. Pass the end of the work cable that has the termi- or turn power switch to the OFF “O� position.
nal lug with the smaller hole through the Work
Cable Access Hole (1) in the case front. 2. Pass the insulated terminals of the gun trigger con-
trol leads, one at a time, through the Gun Cable
3. Route the cable under the feedplate (6) and in front and Control Lead Access Slot (A.2-2) in the case
of the Wire Feed Motor. front. The leads are to be routed up the inside of
the case front, behind the gas line.
4. For Innershield Only: Refer to Figure A.2. As
delivered, the machine is connected for negative 3. Insert the connector on the gun conductor cable
electrode polarity. This is the appropriate configu- through the Gun Cable Access Hole (A.2-2) in the
ration for the Innershield process. To complete SP 170-I case front. Make sure the connector is all
installation, use the provided wing nut to connect the way in the brass connector block to obtain
the work cable’s terminal lug to the positive (+) out- proper gas flow. If the gun connector will not fully
put terminal (4) located above the Wire Feed insert, unscrew the thumbscrew on the connector
Gearbox (5). Make sure that both wing nuts are block a few turns. Rotate the connector so control
tight. leads are on the underside and tighten the
Thumbscrew on the connector block.
5. For GMAW Only: Refer to Figure A.4. To wire for
positive polarity (required for the GMAW process), 4. Connect the gun trigger control lead terminals to
connect the short cable attached to the connector the two insulated 1/4" (6,4 mm) tab terminal con-
block (1) to the positive (+) output terminal (4) and nector bushings located above the “Gun Trigger
the work cable (3) to the negative (-) terminal (2). Connection� decal in the wire feed section (A.4).
Either lead can go to either connector.
CAUTION
4
If the gun trigger switch being used is other than
3
that supplied, the switch must be a normally open,
2 momentary switch. The terminals of the switch
must be insulated from the welding circuit.
Malfunction of the SP 170-I may result if this
1
switch shorts to the SP 170-I welding output cir-
cuit or is common to any electrical circuit other
than the SP 170-I trigger circuit.
5
GAS CONNECTION
When using the MIG process, a cylinder of shielding
FIGURE A.4
gas must be obtained. See Table B.1. Additionally a
flow regulator is required. For more information, refer
to the ACCESSORIES section.
GUN INSTALLATION
As shipped from the factory, the SP 170-I gun is ready
to feed .035 Innershield. If other wire is to be used,
change the contact tip to the appropriate size.
SP 170-I
A-5
A-5 INSTALLATION
let and open the cylinder valve very slightly for an
WARNING instant. This blows away any dust or dirt which may
have accumulated in the valve outlet.
CYLINDER may explode if dam-
aged. Keep cylinder upright and
chained to support
WARNING
� Keep cylinder away from areas
where it may be damaged. BE SURE TO KEEP YOUR FACE AWAY FROM THE
VALVE OUTLET WHEN “CRACKING� THE VALVE.
� Never lift welder with cylinder
Never stand directly in front of or behind the flow
attached.
regulator when opening the cylinder valve. Always
� Never allow welding electrode to
stand to one side.
touch cylinder.
� Keep cylinder away from welding
or other live electrical circuits. 3. Attach the flow regulator to the cylinder valve and
tighten the union nut securely with a wrench..
NOTE: If connecting to 100% CO2 cylinder, make
WARNING certain the plastic washer is seated in the fitting
that attaches to the CO2 cylinder.
BUILDUP OF SHIELDING GAS may
harm health or kill.
4. Refer to Figure A.6. Attach one end of inlet gas
� Shut off shielding gas supply hose to the outlet fitting of the flow regulator and
when not in use. tighten the gas line hose clamp. Connect the other
end to the SP 170-I Gas Solenoid Inlet nipple.
� SEE AMERICAN NATIONAL
Make certain the gas hose is not kinked or twisted.
STANDARD Z-49.1, “SAFETY IN
Tighten the gas line hose clamp.
WELDING AND CUTTING� PUB-
LISHED BY THE AMERICAN
WELDING SOCIETY.
INPUT CONNECTIONS
Refer to Figure A.6.
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
ground. Refer to Figure A.5.
Cylinder Valve
Flow Regulator
GAS SOLENOID
INLET NIPPLE
Gas Hose POWER INPUT
CABLE
FIGURE A.6
FIGURE A.5
2. With the cylinder securely installed, remove the
cylinder cap. Stand to one side away from the out-
SP 170-I
A-6 A-6
INSTALLATION
Line Cord Connection
A 3 conductor international cordset with a 16 amp,
230 volt, two-prong plug is factory installed. Connect
this plug to a mating grounded receptacle which is
connected to an appropriate power supply per any
applicable local codes.
Grounding
Type 75°C Wire Fuse
Wire in Conduit, Copper Size
Input Copper Cond. Cond. (Super
Voltage Hertz AWG Size AWG Size Lag)
230 50/60 8 10 40
CONNECT TO A SYSTEM
GROUNDING WIRE. SEE
THE UNITED STATES
NATIONAL ELECTRICAL
CODE AND/OR LOCAL
CODES FOR OTHER
DETAILS AND MEANS FOR
PROPER GROUNDING.
CONNECT TO HOT WIRES
OF A THREE-WIRE SINGLE
PHASE SYSTEM OR TO
ONE PHASE OF A TWO OR
THREE PHASE SYSTEM.
WARNING
This welding machine must be connected to a
power source in accordance with applicable elec-
trical codes.
The National Electrical Code provides standards
for amperage handling capability of supply con-
ductors based on duty cycle of the welding
source.
If there is any question about the installation
meeting applicable electrical code requirements,
consult a qualified electrician.
SP 170-I
B-1
B-1 OPERATION
GENERAL DESCRIPTION
Read entire operation section before
operating the SP 170-I. The SP 170-I is a complete semiautomatic constant
voltage DC portable arc welder. Included is a tap-
switch controlled, single phase constant voltage trans-
WARNING former/rectifier power source and a wire feeder with
welding gun for feeding .025" (0.6 mm) through .030"
ELECTRIC SHOCK can kill. (0.8 mm) solid steel electrode and .035" (0.9 mm)
Innershield® NR-211-MP.
� Do not touch electrically live
parts or electrode with skin or
It is ideally suited for individuals having access to
wet clothing. Insulate yourself
230V 50/60 Hz AC input power and want the ease of
from work and ground.
use, quality and dependability of both gas metal arc
� Always wear dry insulating welding or GMAW (also known as MIG welding) and
gloves. the Innershield® process (self-shielded flux-cored or
FCAW). A convenient chart is mounted inside the wire
feed section door for setting welding procedures for 24
FUMES AND GASES can be gauge (.60 mm) through 5/16" (8.0 mm) mild steel.
The machine is rugged and reliable and is designed
dangerous.
for dependable service and long life.
� Keep your head out of fumes.
� Use ventilation or exhaust to
remove fumes from breathing RECOMMENDED PROCESSES
zone.
The SP 170-I can be used for welding mild steel,
stainless steels and aluminum using the GMAW, sin-
gle pass, process (MIG) which requires a supply of
WELDING SPARKS can
shielding gas or it can be used for the self-shielded,
cause fire or explosion. Innershield® process (FCAW).
� Keep flammable material away.
� Do not weld on closed contain-
OPERATIONAL FEATURES AND
ers.
CONTROLS
The SP 170-I has the following controls as standard:
Power ON/OFF Switch, Voltage Control, Wire Speed
Control, Trigger Switch, and a Circuit Breaker.
ARC RAYS can burn eyes
and skin.
DESIGN FEATURES AND
� Wear eye, ear and body protec-
ADVANTAGES
tion.
G “Cold electrode� until gun trigger is pressed for an
added measure of safety.
G Overload protection � incorporates both a thermo-
stat and a circuit breaker.
Observe all safety information throughout G Quality wire drive with electronic overload protec-
this manual. tion.
G “Quick Release� idle roll pressure arm is easily
adjusted.
G Reversible, dual groove drive roll, shipped ready
to feed .030" (0.8 mm) diameter solid wire or .035"
diameter flux-cored wire. The drive roll is easily
reversed to feed .025" (0.6 mm) diameter solid
wire.
G
SP-170-I
B-2
OPERATION
B-2
G No external shielding gas is required when used 6. Gun Trigger - Activates welding output, wire feed,
with Lincoln Innershield .035� (0,9 mm) NR®-211- and gas solenoid operation. Releasing the trigger
MP electrode. deactivates welding and simultaneously activates
the “burnback� function so that the welding wire
G Spindle accommodates both 8 in. (200 mm) diame-
does not stick in the weld puddle.
ter and 4 in. (100 mm) diameter spools of wire.
FIGURE B.1a
WELDING CAPABILITY
2 3 4
The SP 170-I is rated at 125 amps, 20.25 volts, at 1
25% duty cycle on a ten minute basis. It is capable of
higher output currents at lower duty cycles. Actual
welding outputs will range between 30 and 175 amps
for the recommended processes.
LIMITATIONS E
Arc Gouging cannot be performed with the SP 170-I.
The SP 170-I is not recommended for pipe thawing or
TIG welding.
SP 170 - I
CONTROLS AND SETTINGS
Refer to Figures B.1a
(Items 1 thru 4) FIGURE B.1b
1. Power ON/OFF Switch � When
the power is on the fan motor
will run and air will be exhaust- 5
ed out the louvers in the front of
ON
the machine. The welding out-
put and wire feeder remain off
until the gun trigger is pressed.
2. Voltage Control � A 5-position
OFF
tap selector switch gives full
range adjustment of power
source output voltage. Do not
switch while welding.
ARC VOLTS
3. Wire Speed Control � Controls
the wire feed speed from 50 �
400 in/min (1.3 � 10.2 m/min).
The control can be preset on
6
the dial to the setting specified
WIRE SPEED
on the SP 170-I Application
Chart located on the inside of
the wire feed section door.
4. Temperature Light � Indicates
thermostat has cut the output.
The fan will be running.
Thermostat resets automatical-
ly.
(Refer to Figure B.1b, Items 5,6)
5. Circuit Breaker � Protects machine from damage if
maximum output is exceeded. Button will extend
out when tripped (Manual reset).
SP 170-I
B-3
B-3 OPERATION
WELDING OPERATIONS
SEQUENCE OF OPERATION
Wire Loading
Refer to Figures B.2 and B.3.
4" Wire Spool
Wire Spindle Shaft
The machine power switch should be turned to the
OFF (“O�) position before working inside the wire feed
enclosure.
The welder is shipped from the factory ready to feed
8" (200 mm) diameter spools with 2.2" (56 mm) maxi-
Wing Nut
mum width. These spools fit on a 2" (51 mm) diameter and Spacer
spindle that has a built in, adjustable friction brake to
To Wire Drive
prevent overrun of the spool and excess slack in the
wire.
FIGURE B.3
Note:When loading and removing the 8� Spools make
Friction Brake Adjustment
sure that the wing nut (inside the wire spool spindle
hub) is turned 90° from the wire spool spindle locking
With wire spool installed on the spindle shaft and the
tab. If the wing nut is positioned in line with the locking
wing nut loose, turn the spool by hand while slowly
tab, the tab cannot be depressed to load or unload the
tightening the wing nut until a light drag is felt. Tighten
wire spool.
the wing nut an additional 1/4 turn.
FIGURE B.2
Note: When properly adjusted, the brake should pro-
vide only enough drag to prevent overrun of the spool
Wire Spool Spindle
8� Wire Spool and excess slack in the wire. Too much drag may
result in wire feeding problems, and may cause pre-
mature wear of wire drive system components.
Be sure that this stud engages
the hole in the wire spool.
To Wire Drive
Wire Spool must be pushed all the way on the spindle so that the
spindle’s tab will hold it in place. The Wire Spool will rotate clock-
wise when wire is dereeled.
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-
dle. The spindle can be stored in the wire feed com-
partment. A 4� (100 mm) diameter spool is mounted
directly on the 5/8� (16 mm) diameter shaft and held in
place with the previously removed hardware. Also
make certain the start end of the wire, which may pro-
trude through the side of the spool does not contact
any metallic case parts.
SP 170-I
B-4 B-4
OPERATION
Refer to Figure B.4
1. Release the Spring Loaded Pressure Arm (1)
rotate the Idle Roll Arm (2) away from the Wire
2
Feed Drive Roll (3). Ensure that the groove size
in the feeding position on the drive roll match-
es the wire size being used. This occurs when
the desired groove is located on the inside, toward
1
the feedplate. See Maintenance section for further
4
5
information.
3
2. Carefully detach the end of the wire from the
The Wire Drive Feed Roll can
spool. To prevent the spool from unwinding, main- accommodate two wire sizes by
tain tension on the wire until after step 5. flipping the wire drive feed roll
over.
3. Cut the bent portion of wire off and straighten the
first 4� (100 mm).
FIGURE B.4
4. Thread the wire through the ingoing guide tube
(4), over the drive roll (3), and into the outgoing
guide tube (5). Check the alignment of the wire
over the drive roll groove and adjust if necessary.
If alignment adjustment is necessary use the allen
wrench provided to loosen the drive roll, move it to
Gun Handle
the desired position and then retighten.
Gas Diffuser
5. Close the idle roll arm (2) and latch the spring
Contact Tip
loaded pressure arm (1) in place. Rotate the spool
counterclockwise if required to take up extra slack
in the wire.
Gas Nozzle
6. The idle roll pressure adjustment wing nut is factory
set to approximately five full turns from where the
FIGURE B.5
wing nut first engages the threads of the pressure
arm (1). If feeding problems occur because the wire
7. Refer to Figure B.5. Remove gas nozzle and con-
is flattened excessively, turn the pressure adjust-
tact tip from end of gun.
ment counter-clockwise to reduce distortion of the
wire. Slightly less pressure may be required when
8. Turn the SP 170-I ON (“I�).
using 0.023 � 0.025" (0,6 mm) wire. If the drive roll
slips while feeding wire, the pressure should be
9. Straighten the gun cable assembly.
increased until the wire feeds properly.
10. Depress the gun trigger switch and feed welding
wire through the gun and cable. (Point gun away
WARNING
from yourself and others while feeding wire.)
Release gun trigger after wire appears at end of
When inching the welding wire, the drive rolls, the
gun.
gun connector block and the gun contact tip are
electrically energized relative to work and ground
11. Turn the SP 170-I OFF (“O�).
and remain energized for several seconds after
the gun trigger is released.
12. Replace contact tip and gas nozzle.
13. Refer to Figure B-6. Cut the wire off 3/8� � 1/2� (10
� 12 mm) from the end of the tip. The SP 170-I is
now ready to weld.
SP 170-I
B-5
B-5 OPERATION
Contact Tip SP-170 -I
GUN CABLE
Wire Electrode
3/8" � 1/2" (10 - 12 mm)Contact
Tip To Work Distance(CTWD)
WORKPIECE
ARC
FIGURE B.6
WORK CLAMP
Making A Weld FIGURE B.7
1. See “Process Guidelines� in this section for selec-
tion of welding wire and shielding gas and for 10. When no more welding is to be done, close valve
range of metal thicknesses that can be welded. on gas cylinder (if used), momentarily operate gun
trigger to release gas pressure, and turn off the
2. See the Application chart on the inside of the wire SP 170-I.
feed compartment door for information on setting
the SP 170-I controls. Refer to Table B.1 for alu-
minum and stainless wire. Cleaning Tip And Nozzle
Clean the contact tip and nozzle to avoid arc bridging
3. Set the Voltage (“Vâ€?) and Wire Speed (“olo’â??) con- between the nozzle and contact tip which can result in
trols to the settings suggested for the welding wire a shorted nozzle, poor welds and an overheated gun.
and base metal thickness being used, refer to Hint: Anti-stick spray or gel, available from a welding
3. Applications chart on the inside of the wire drive supply distributor, may reduce buildup and aid in spat-
compartment door. ter removal.
4. Check that the polarity is correct for the welding
wire being used and that the gas supply, if PROCESS GUIDELINES
required, is turned on.
The SP 170-I can be used for welding mild steel,
5. When using Innershield electrode, remove the gas stainless steel and aluminum using the MIG process
nozzle and install a gasless nozzle. This will and also for welding mild steel with the gasless self-
improve visibility of the arc and protect the gas dif- shielded, Innershield® process (FCAW).
fuser from weld spatter. Refer to the MAINTE-
NANCE section for details on nozzle replacement. The recommended gases and electrodes for MIG
(GMAW) are welding grade CO2 gas or an argon-CO2
6. Refer to Figure B.7. Connect work clamp to metal blended gas (75 to 80% argon and 25 to 20% CO2)
to be welded. Work clamp must make good elec- and .025" (0.6 mm) and .030� (0.8mm) diameter
trical contact to the workpiece. The workpiece Lincoln L-56 mild-steel welding wire, supplied on 12-
must also be grounded as stated in “Arc Welding 1/2 lb (5.7 kg) spools. The blended gas is recom-
Safety Precautions� in the beginning of this manu- mended for welding on heavier steel, 14 gauge (2.0
al. mm), for example.
7. Position gun over joint. End of wire may be lightly The recommended electrode for the self-shielded
touching the work. process is Lincoln Innershield® NR-211-MP on 10 lb
(4.5 kg) spools. This electrode is available as .035"
8. Lower welding helmet, close gun trigger, and (0.9 mm) and .045" (1.2 mm) NR-211-MP for all posi-
begin welding. Hold the gun so the contact tip to tion welding of 18 gauge (1.2 mm) through 5/16" (8.0
work distance is about 3/8 inch (10 mm). mm) steel. Thickness of 1/4" (6.4 mm) and 5/16" (7.9
mm) require multiple passes. both wire sizes can also
9. To stop welding, release the gun trigger and then be used for the welding of galvanized coated sheet
pull the gun away from the work after the arc goes metal.
out.
SP 170-I
B-6 B-6
OPERATION
The SP 170-I is suitable for .035" (0.9 mm) aluminum 3. Keep the cylinder valve closed, except when using
wire and .023"� .035" (0.6 - 0.9 mm) stainless wire. the SP 170-I. When finished welding:
Refer to Table B.1 for Recommended Procedure
a) Close the cylinder valve to stop gas flow.
Settings. Aluminum wire requires an Aluminum
b) Depress the gun trigger briefly to release the
Welding kit. See ACCESSORIES section.
pressure in the gas hose.
CAUTION c) Turn off the SP 170-I.
It is important when changing between welding
with steel wire and aluminum to exchange feeding
components due to the lubricant applied to steel
WELDING WITH FCAW (Innershield)
wire. Failure to do so may result in contaminated
welds when welding aluminum.
When using the FCAW process, the correct drive roll
------------------------------------------------------------------------
and electrode polarity must be used. See Work Cable
TABLE B.1 � SP 170-I
Installation in INSTALLATION section for changing the
WELDING PROCEDURES
polarity.
Voltage/Wire Speed
Shielding
Process Welding Wire Gas 22 ga 16 ga 12 ga 1/8� 3/16� 1/4� Innershield welding kits K549-1 (for .035") and K549-2
.035 Dia(0.9mm 100% Argon B-5 B-7 E-9 G-9 I-9 J-10* (for .045") are also available.
4043 Aluminum
Wire
16 ga 14 ga 12 ga 10 ga
MIG DC+
.030 Dia 98% Argon/ A-3 C-6 D-7.5 D-7.5
OVERLOAD PROTECTION
308L Stainless 2% Oxygen
Steel Wire
Output Overload
The SP 170-I is equipped with a circuit breaker which
CHANGING MACHINE OVER TO protects the machine from damage if a severe over-
FEED OTHER WIRE SIZES load occurs. The circuit breaker button will extend out
when tripped. The circuit breaker must be manually
reset.
The SP 170-I is shipped from the factory ready to feed
0.035" (0.9 mm) Innershield diameter wire. To operate
the SP 170-I with other sizes of wire, it maybe neces-
Thermal Protection
sary to change the contact tip and change the drive
The SP 170-I has a rated output duty cycle of 20%. If
roll over to other sizes. Refer to Changing the Contact
the duty cycle is exceeded, a thermal protector will
Tip and Changing the Drive Roll, in the MAINTE-
shut off the output until the machine cools to a reason-
NANCE section, for specific information on these pro-
able operating temperature. This is an automatic func-
cedures.
tion of the SP 170-I and does not require user inter-
vention. The fan continues to run during cooling.
WELDING WITH GMAW (MIG)
Electronic Wire Drive Motor Protection
The SP 170-I has built-in protection for wire drive
Shielding Gas
motor overload.
When using the GMAW process, obtain and install a
gas regulator and hose kit. If using 100% CO2 a CO2
adapter is required, sold separately.
1. For CO2, open the cylinder very slowly. For argon-
mixed gas, open cylinder valve slowly a fraction of
a turn. When the cylinder pressure gauge pointer
stops moving, open the valve fully.
2. If using a regulator with an adjustable flow meter,
close the gun trigger and adjust the flow to give 15
� 20 cubic ft per hour (CFH) (7 � 10 I/min) [use 20
� 25 CFH (10 � 12 I/min) when welding out of
position or in a drafty location.
SP 170-I
B-7
SUGGESTED SETTINGS FOR WELDING
ADJUST FOR OPTIMUM WELDING
FOR STAINLESS STEEL AND ALUMINUM SETTINGS - SEE MANUAL
STEEL THICKNESS
.105 in.
.030 in. .048 in. .075 in. 1/4 in.
.024 in. .135 in.
.036 in. .060 in. 3/16 in. 5/16
SHIELDING 2.5 mm
0.80 mm 1.2 mm 2.0 mm 6.0 mm
1.0 mm 1.6 mm
0.60 mm 3.5 mm 5.0 mm 8.0 mm
PROCESS WELDING WIRE
GAS
CO2 B-2 B-2 B-2 C-3 C-3 D-5 E-7.5
.025 in. (0.6 mm) DIA.
SOLID STEEL WIRE C20 or C25
(7 5 -8 0 % A rg o n , B-4
A-2 A-2 A-2 B-3 C-5 D-6
MIG 2 5 -2 0 % C O 2 )
DC(+)
CO2 B-2 C-3 C-3 D-4 E-6.5
.030 in. (0.8 mm) DIA.
SOLID STEEL WIRE C20 or C25
(7 5 -8 0 % A rg o n , B-3 B-3 C-3 D-5 E-8 E-8
2 5 -2 0 % C O 2 )
.035 in. (0.9 mm) DIA.
INNERSHIELD A-1 A-1 B-2 B-2 C-2.5 D-2.5 D-2.5* D-2.5*
GASLESS NONE
NR®-211-MP
FLUX-CORED
.045 in. (1.2 mm) DIA.
DC(-) INNERSHIELD B-1 C-1.5 E-2.5*
D-2
A-1 B-1 E-2*
C-1.5
NONE
NR®-211-MP
* Multiple passes required
SP-170-I
OUTPUT POLARITY DRIVE ROLL ORIENTATION
ALIGN GROOVE WITH CENTER OF GUIDE TUBES, SECURE DRIVE ROLL WITH SET SCREW CENTERED ON FLAT
MIG DC(+) GASLESS FLUX-CORED DC(-)
MIG
.035 (0.9 mm) DIA.
.030 (0.8 mm) DIA.
.025 (0.6 mm) DIA. .045 (1.2 mm) DIA.
APPLICATION CHART
DC(+) INNERSHIELD NR®-211-MP
SOLID STEEL WIRE
SOLID STEEL WIRE INNERSHIELD NR®-211-MP
-- OR --
EITHER
EITHER
SMALL LARGE GROOVE
LARGE GROOVE
GROOVE GROOVE GROOVE
(BEVEL SIDE)
GASLESS
Optional knurled drive roll for .035 and .045 wire
FLUX-CORED
included in the .045 (1.2 mm) Innershield Kit.
DC(-)
.035/.045 liner and appropriate tip must be installed in gun - see manual.
Be sure to read and understand the warnings on this welding machine and the section on ARC WELDING SAFETY PRECAUTIONS in
the Operating Manual. Because design, fabrication, assembly and welding variables affect the results obtained in applying this type
of information, the serviceability of a product or assembly is the responsibility of the builder/user.
L10732 SP170-I
B-7
C-1
C-1 ACCESSORIES
3. K464 .035" (0.9 mm) Innershield® Welding Kit
OPTIONAL ACCESSORIES
� Includes a contact tip, a gasless nozzle and a
.035/.045" (0.9/1.2 mm) cable liner to permit the
See Maintenance section for instructions on
gun and cable to use .035" (0.9 mm) diameter flux-
installing drive roll, cable liner, contact tip and their
cored electrode. The fitting on the end of the liner
proper configuration.
is stenciled with the maximum rated wire size
(.045"/1.2 mm). Also included is a 10 lb.(4.5 kg.)
1. KP665-045C Drive Roll � Optional � Knurled
spool of .035" (0.9 mm) Innershield® NR-211-MP.
drive roll for feeding .035 - .045� (0.9 - 1.2 mm)
diameter flux-cored electrode.
For use with “Lincoln Electric®� gun (with black
trigger). The end of the brass fitting on the end of
the .035/.045� (0.9/1.2mm) liner is color coded
2. K520 Utility Cart � Designed to transport the
green. (The .023-.030� (0.6-0.8mm) liner is color
Lincoln family of small welders. Has provisions for
coded orange).
mounting a single gas cylinder. Has front casters
and large rear wheels. Handle height is easily
See “Innershield (FCAW) Conversion� in this sec-
adjustable. Bottom tray provided for tools and
tion for installation instructions and MAINTE-
accessories. Easy assembly required; takes less
NANCE section for proper feeding component con-
than 15 minutes.
figuration and installation.
4. K491 .045" (1.2 mm) Innershield® Welding Kit
� Includes a contact tip, a gasless nozzle and a
.035/.045" (0.9/1.2 mm) cable liner to permit the
gun and cable to use .045" (1.2 mm) diameter flux-
cored electrode. The fitting on the end of the liner
is stenciled with the maximum rated wire size
(.045"/1.2 mm). Also included is a 10 lb.(4.5 kg.)
spool of .045" (1.2 mm) Innershield® NR-211-MP
and a knurled drive roll for .035� (0.9mm) and .045�
(1.2mm) wire.
For use with “Lincoln Electric®� gun (with black
trigger). The end of the brass fitting on the end of
the .035/.045� (0.9/1.2mm) liner is color coded
green. (The .023-.030� (0.6-0.8mm) liner is color
coded orange).
See “Innershield (FCAW) Conversion� in this sec-
tion for installation instructions and MAINTE-
NANCE section for proper feeding component con-
figuration and installation.
SP-170-I
C-2 C-2
ACCESSORIES
MIG (GMAW) REPLACEMENT PARTS
CONVERSION
Complete Gun and Cable Assembly (Code 10983)
Several changes are needed to convert the unit for L11951
operation with the MIG (GMAW) process. The follow-
ing conversions should be reviewed before welding Complete Gun and Cable Assembly (Code 10982)
with (GMAW): L8311-5
1. Change the output polarity to DC(+). See “Work
Cable Installation� in Installation section for details.
2. Install proper drive roll for the wire size selected.
See “Changing Drive Roll� in Maintenance section
for details.
3. Install the proper gun liner and tip for the wire size
selected. See “Component Replacement� in
Maintenance section for details.
4. Remove gasless nozzle (if installed) and install gas
nozzle.
5. Load wire into machine and thread into gun and
cable per “Welding Wire Loading� section.
SP 170-I
D-1 D-1
MAINTENANCE
MAINTENANCE
SAFETY PRECAUTIONS
WARNING
ELECTRIC SHOCK can kill.
� Disconnect input power by removing plug
from receptacle before working inside
SP170-I. Use only grounded receptacle. Do
not touch electrically “hot� parts inside
SP 170-I.
� Have qualified personnel do the mainte-
nance and trouble shooting work.
ROUTINE MAINTENANCE
POWER SOURCE COMPARTMENT
In extremely dusty locations, dirt may clog the air passages
causing the welder to run hot. Blow dirt out of the welder with
low pressure air at regular intervals to eliminate excessive dirt
and dust build-up on interval parts.
WIRE FEED COMPARTMENT
1. When necessary, vacuum accumulated dirt from gearbox and
wire feed section.
2. Occasionally inspect the incoming guide tube and clean
inside diameter if necessary.
3. Motor and gearbox have lifetime lubrication and require no
maintenance.
FAN MOTOR
Has lifetime lubrication � requires no maintenance.
WIRE REEL SPINDLE
Requires no maintenance. Do not lubricate shaft.
SP 170-I
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
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 the four screws from the gun handle
and separate the handle halves. (For L8311-5 gun
and cable handle half says magnum 100L.
Flex the cable over its entire length and again blow
Remove both collars from each end of the gun
out the cable. Repeat this procedure until no further
handle and separate the handle halves). Loosen
dirt comes out.
the locking nut holding the gun tube in place
against the gun end cable connector. Unscrew gun
tube from cable connector. To install gun tube,
Contact Tips, Nozzles, and Gun Tubes
screw the locking nut on the gun tube as far as
1. Dirt can accumulate in the contact tip hole and
possible. Then screw the gun tube into the cable
restrict wire feeding. After each spool of wire is
connector until it bottoms. Then unscrew (no more
used, remove the contact tip and clean it by push-
than one turn) the gun tube until its axis is perpen-
ing a short piece of wire through the tip repeatedly.
dicular to the flat sides of the cable connector and
Use the wire as a reamer to remove dirt that may
pointed in the direction of the trigger. Tighten the
be adhering to the wall of the hole through the tip.
locking nut so as to maintain the proper relation-
ship between the gun tube and the cable connec-
tor. Replace the gun handle, trigger and diffuser.
Replace the gas nozzle or gasless nozzle.
CONFIGURATION OF COMPONENTS IN WIRE FEEDING SYSTEM
Contact Tip Cable Liner Drive Roll
Components shipped with KP665-035
SP 170-I* .035� (0.9mm) .025�-.035� 2 Smooth grooves
(0.6-.9mm) Small .025� (0.6mm)
Large .030� (0.8mm)
* If other size wire feeding is desired use the additional Contact Tips shipped loose with your SP 170-I.
� 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-170-I
D-3 D-3
MAINTENANCE
COMPONENT
7. Remove the drive roll, flip over and reinstall with the
REPLACEMENT .023/.025" (0.6mm) groove (the smaller groove)
PROCEDURES closest to the gearbox.
CHANGING THE CONTACT TIP (These 8. Push a length of straightened welding wire through
instructions pertain to the Lincoln Electric® gun. The the wire feeder guide tubes and adjust the position
instructions for the Magnumâ„? 100L gun, are similar of the drive roll so that the groove is centered on
except that the gas nozzle is threaded.) the wire. Make certain the set screw is located on
the flat portion of the shaft and tighten.
1. Refer to Figure D.2a or D.2b. Remove the gas noz-
zle from the gun by pulling and rotating it clockwise FIGURE D.1
off the diffuser. (Threadless slip fit).
2. Remove the existing contact tip from the gun by
gripping it with pliers and twisting counter-clock-
wise. Tip will now slip out of diffuser.
3. Insert new tip into diffuser. Grip it with pliers, push
3
tip into diffuser until it bottoms, then twist clockwise
to tighten.
4. Replace gas nozzle.
2
CHANGING DRIVE ROLL
1
The drive roll has two grooves; one for .023" � .025"
(0.6 mm) solid steel electrode and a larger groove for
.030" (0.8 mm) solid and .035" (0.9 mm) flux-cored
steel electrode. As shipped, the drive roll is installed in
the .030"-.035" (0.8/0.9mm) position.
If .023"/.025" (0.6mm) wire is to be used, the drive roll
must be reversed as follows:
1. Connect the machine to its rated input power per
instructions in Installation section.
2. Release the spring-loaded pressure arm and lift the
idle roll arm away from the drive roll.
3. Turn the power switch to ON (marked “I�).
4. Set the wire speed to minimum and jog the drive
unit with the trigger switch until the drive roll set
screw is facing up.
CAUTION
When inching the welding wire, the drive rolls,
gun connector block, and gun contact tip are
energized relative to work and ground and remain
energized for several seconds after the gun trig-
ger is released.
5. Turn the power switch to OFF (marked “O�).
6. Loosen the drive roll set screw with the 5/64" (2.0
mm) hex wrench supplied.
SP 170-I
D-4 D-4
MAINTENANCE
CHANGING LINER
NOTICE: The variation in cable lengths pre-
vents 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 require-
ment. Refer to Figure D.2a or D.2b.
Gas Diffuser
Contact Tip
1. Remove the gas nozzle from the gun
(threadless slip-fit or threaded).
Gas Nozzle or
Allen Brass Cable
Gasless Nozzle
Head Screw Connector 2. Remove the existing contact tip from the
(Slip-Fit)
gun by twisting counter-clockwise.
3. If the gun is a Magnum 100L Fig D.2b.
Remove the gas diffuser from the gun
Liner Assembly tube by unscrewing counter-clockwise.
(Liner bushing to be seated tight
against brass cable connector)
4. Lay the gun and cable out straight on a
flat surface. Loosen the set screw located
FIGURE D.2a
in the brass connector at the wire feeder
Liner trim length for gun (Lincoln Electric®)
end of the cable. Pull the liner out of the
cable.
5. Insert a new untrimmed liner into the con-
nector end of the cable. Be sure the liner
bushing is stenciled appropriately for the
wire size being used.
6. Fully seat the liner bushing into the con-
1-1/4 (31.8 mm)
nector. Tighten the set screw on the brass
Liner Trim Length
cable connector.
Gas Diffuser
7A. (For Gun Shown in Fig D.2a)
Contact Tip With the torch extended straight out, cut
the liner flush with the end of the diffuser.
Allen Brass Cable
Rotate the gun clockwise until the liner
Head Screw Connector Gas Nozzle or
Gasless Nozzle protrudes out the end of the diffuser
(Threaded)
enough to cut off an additional 2 coils
(approx. 2mm). Rotate the handle back to
the original position.
7B. (For Gun Shown in Fig D.2b)
Liner Assembly
(Liner bushing to be seated tight With the gas nozzle and diffuser removed
against brass cable connector)
from the gun tube, be sure the cable is
straight, and then trim the liner to the
FIGURE D.2b length shown in the Figure D.2b. Remove
Liner trim length for gun (Magnumâ„? 100L)
any burrs from the end of the liner. Screw
the gas diffuser onto the end of the gun
tube and securely tighten.
8. Replace the contact tip and nozzle.
SP 170-I
D-5 D-5
MAINTENANCE
GUN HANDLE PARTS (Magnum 100L)
GUN HANDLE PARTS (Lincoln Electric)
The gun handle consists of two halves that are held
The gun handle consists of two halves that are held
together with a collar on each end. To open up the
together with four screws. To open up the gun handle
handle, turn the collars approximately 60 degrees
assembly, remove the four screws and pry down the
counter-clockwise until the collar reaches a stop. Then
trigger handle half with a screwdriver. See Figure D.3.
pull the collar off the gun handle. If the collars are diffi-
FIGURE D.3
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-4.
Screwdriver
âž?
Counter-clockwise
Cable
FIGURE D.4
SP 170-I
E-1
E-1 TROUBLESHOOTING
HOW TO USE TROUBLESHOOTING GUIDE
WARNING
Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician and
machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical
Shock, please observe all safety notes and precautions detailed throughout this manual.
__________________________________________________________________________
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 Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
SP 170-I
E-2 E-2
TROUBLESHOOTING
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 None
is evident. Contact your local 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. See
does NOT operate. Installation section, “Electrical
Connections�.
2. Make certain that power switch
is in the ON position.
Contact your local Lincoln
3. Make sure circuit breaker is Authorized Field Service Facility.
reset.
No wire feed, weld output or gas 1. The thermostat may be tripped
flow when gun trigger is pulled Fan due to overheating. Let machine
operates normally. cool. Weld at lower duty cycle.
2. Check for obstructions in air
flow.
3. Check Gun Trigger connections.
See Installation section.
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 170-I
E-3
E-3 TROUBLESHOOTING
Observe Safety Guidelines detailed in the beginning of this manual.
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENT(S) 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 make sure that the correct drive
machine has correct open circuit rolls are installed in the machine.
voltage (33 VDC maximum) � weld Contact your local Lincoln
output. 2. Check for clogged cable liner or Authorized Field Service Facility.
contact tip.
3. Check for proper size cable liner
and contact tip.
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. Contact your local Lincoln
output and fan operate normally. Authorized Field Service Facility.
2. Check gun connection to
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 170-I
E-4 E-4
TROUBLESHOOTING
Observe Safety Guidelines detailed in the beginning of this manual.
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
WELDING PROBLEMS
Arc is unstable � Poor starting 1. Check for correct input voltage
to machine. See Installation sec-
tion, “Electrical Input
Connections�.
2. Check for proper electrode
polarity for process.
3. Check gun tip for wear or dam-
age and proper size � Replace.
Contact your local Lincoln
4. Check for proper gas and flow Authorized Field Service Facility.
rate for process. (For MIG only.)
5. Check work cable for loose or
faulty connections.
6. Check gun for damage or
breaks.
7. Check for proper drive roll orien-
tation and alignment.
8. Check liner for proper size.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
LOCAL AUTHORIZED LINCOLN ELECTRIC FIELD SERVICE FACILITY for assistance before you proceed.
SP-170-I
F-1
SP-170-I
WIRING DIAGRAMS
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The
specific diagram for a particular code is pasted inside the machine on one of the enclosure panels.
F-1
NOTES
SP 170-I
NOTES
SP 170-I
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 �
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Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
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