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SP- 175 Plus OPERA TOR’S MANUAL IM610-A May, 2002 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.
SP-175 PLUS FOR ENGINE powered equipment. 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.
SP-175 PLUS ii SAFETY ii ARC RA YS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87.
SP-125 PLUS FOR ELECTRICALL Y powered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 8 . b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturerʼs recommendations.
SP-175 PLUS iv SAFETY iv PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A LʼArc 1.
SP-175 PLUS Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment.
vi vi SP-175 PLUS T ABLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications ..........................................................
A-1 A-1 INST ALLA TION SP-175 PLUS TECHNICAL SPECIFICA TIONS – SP-175 Plus Fuse or Output Mode Input Voltage Breaker Size Input Amps Power Cord RATED 230V/60Hz 40 Super Lag 21/23 50 Amp, 250V, 208V/.
A-2 A-2 INST ALLA TION SP-175 PLUS Read entire installation section before starting installation. SAFETY PRECAUTIONS IDENTIFY AND LOCA TE 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 .
A-3 A-3 INST ALLA TION SP-175 PLUS SELECT SUIT ABLE LOCA TION Locate the welder in a dry location where there is free circulation of clean air into the louvers in the back and left side and out the front of the unit.
A-4 A-4 INST ALLA TION 3. Route the cable under and around the back of the Wire Feed Gearbox (6). 4. For GMAW Only: Refer to Figure A.2. As deliv- ered, the SP-175 Plus is wired for positive polarity. This is the appropriate configuration for the Gas Metal Arc Welding (GMAW) process.
A-5 A-5 INST ALLA TION SP-175 PLUS 3. Attach the flow regulator to the cylinder valve and tighten the union nut securely with a wrench. The flow regulator for carbon dioxide must have a plas- tic washer seated in the fitting that attaches to the cylinder to prevent leakage.
A-6 A-6 INST ALLA TION Line Cord Connection A 3 conductor line cord with a 50 amp, 250 volt, three- prong plug (NEMA Type 6-50P) is factory installed. Connect this plug to a mating grounded receptacle which is connected to an appropriate power supply per the U.
B-1 SP-175 PLUS B-1 OPERA TION Read entire Operation section before operating the SP-175 Plus. 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.
B-2 B-2 OPERA TION GENERAL DESCRIPTION The SP-175 Plus is a complete semiautomatic constant volt- age DC arc welding machine. Included is a continuous con- trolled, single phase constant voltage transformer/rectifier power source and a wire feeder with welding gun for feeding .
WELDING OPERA T IONS SEQUENCE OF OPERA TION Wire Loading Refer to Figure B.2 and B.3. The machine power switch should be turned to the OFF (“O”) position before working inside the wire feed enclosure. The machine is shipped from the factory ready to feed 8” (200 mm) diameter spools [2.
B-4 SP-175 PLUS B-4 OPERA TION Note: The brake should be adjusted with a spool of wire installed. When properly adjusted it should move freely but not coast. Friction Brake Adjustments 1 . With wire spool installed, check free movement and coast of the spool.
B-5 B-5 OPERA TION 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 gas cylinders for use with the SP-175 Plus. Be sure to observe all cylinder handling and use precau- tions.
B-6 B-6 OPERA TION 9. To stop welding, release the gun trigger and then pull the gun away from the work after the arc goes out. 10. When no more welding is to be done, close valve on gas cylinder (if used), momentarily operate gun trigger to release gas pressure, and turn off the SP-175 Plus.
SP-175 PLUS B-7 OPERA TION 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.
B-8 B-8 LEARNING T O WELD LEARNING TO WELD No one can learn to weld simply by reading about it. Skill comes only with practice. The following pages will help the inexperienced operator to understand weld- ing and develop this skill. For more detailed informa- tion, order a copy of “New Lessons in Arc Welding” listed at the end of this manual.
B-9 SP-175 PLUS B-9 LEARNING T O WELD The “arc stream” is seen in the middle of the picture. This is the electric arc created by the electric current flowing through the space between the end of the wire electrode and the base metal. The temperature of this arc is about 6000°F, which is more than enough to melt metal.
B-10 SP-125 PLUS B-10 LEARNING T O WELD 2. Can I afford the extra expense, space, and lack of portability required for gas cylinders and gas sup- ply? 3. Do I require clean, finished-looking welds? If you have answered yes to all the above questions GMAW may be the process for you.
B-1 1 SP-175 PLUS B-1 1 LEARNING T O WELD FIGURE B.12 Penetration Unless a weld penetrates close to 100% of the metal thickness, a butt weld will be weaker than the material welded together. In the example shown in Figure B.13, the total weld is only half the thickness of the material thus the weld is only approximately half as strong as the metal.
B-12 SP-175 PLUS B-12 LEARNING T O WELD FIGURE B.16 Vertical-down Welding Refer to Figure B.17 Vertical-down welds are applied at a fast pace. These welds are therefore shallow and narrow and, as such, are excellent for sheet metal. Vertical-down welds may be applied to 5/32” (3.
B-13 SP-175 PLUS B-13 LEARNING T O WELD ARC RAYS can burn eyes and skin. When using an open arc process, it Is necessary to use correct eye, head and body protection. Protect yourself and others, read “ARC RAYS can burn” at the front of this manual.
B-14 SP-125 PLUS B-14 LEARNING T O WELD Mild Steel 16 gauge or 1/16 inch (1.6 mm) Electrode 0.035" (0.9 mm) NR-211-MP Innershield Wire Voltage Setting “V” B Wire Feed Speed “o|o” 2 For the SP-175 Plus , use the following: Helpful Hints 1.
B-15 SP-175 PLUS B-15 LEARNING T O WELD MACHINE SET UP FOR THE GMA W (MIG) PROCESS 1. See PROCESS GUIDELINES in the OPERATION section for selection of welding wire and shielding gas, and for range of metal thicknesses that can be welded. 2. See the Application Guide on the inside of wire feed section door for information on setting the controls.
Helpful Hints 1. For general welding, it is not necessary to weave the arc, neither forward or backward nor sideways. Weld along at a steady pace. You will find it easier.
B-17 B-17 LEARNING T O WELD 4. After you strike the arc, practice the correct electri- cal stickout. Learn to distinguish it by its sound. 5. When you are sure that you can hold the correct electrical stickout, with a smooth “crackling” arc, start moving.
B-18 SP-125 PLUS B-18 LEARNING T O WELD Proper Gun Handling Most feeding problems are caused by improper han- dling of the gun cable or electrodes. 1. Do not kink or pull the gun around sharp corners 2. Keep the gun cable as straight as practical when welding.
B-19 B-19 APPLICA TION CHART SP-175 PLUS.
C-1 C-1 SP-175 PLUS ACCESSORIES 6. K695-2 Spot / Stitch Timer Kit — Includes spot timer to control the spot welding arc time, and a stitch timer to control the on/off cycle time of the arc to prevent burnthrough on thin gauge metals. Also includes spot welding nozzle.
C-2 C-2 ACCESSORIES INNERSHIELD (FCA W) CONVERSION Several changes are needed to convert the unit for operation with the Innershield (FCAW) process. The Innershield Kits include all the necessary accessories for this conversion and are provided for this purpose.
MAINTENANCE SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Disconnect input power by remov- ing plug from receptacle before working inside SP-175 Plus . Use only grounded receptacle. Do not touch electrically “hot” parts inside SP-175 Plus . • Have qualified personnel do the maintenance and trouble shooting work.
D-2 SP-175 PLUS D-2 MAINTENANCE GUN AND CABLE MAINTENANCE FOR MAGNUM™ 100L GUN Gun Cable Cleaning Clean cable liner after using approximately 300 lbs (136 kg) of solid wire or 50 lbs (23 kg) of flux-cored wire. Remove the cable from the wire feeder and lay it out straight on the floor.
D-3 D-3 MAINTENANCE COMPONENT REPLACEMENT PROCEDURES CHANGING THE CONT ACT TIP 1. Unplug or turn power switch to Off “O” position. 2. Refer to Figure D.2. Remove the gas nozzle from the gun by unscrewing counter-clockwise. 3. Remove the existing contact tip from the gun by unscrewing counter-clockwise.
D-4 SP-175 PLUS D-4 MAINTENANCE CHANGING LINER 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.
D-5 SP-125 PLUS D-5 MAINTENANCE GUN HANDLE P ARTS 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.
E-1 SP-175 PLUS E-1 TROUBLESHOOTING 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.
E-2 SP-175 PLUS E-2 TROUBLESHOOTING PROBLEMS (SYMPTOMS) Major physical or electrical damage is evident. No wire feed, weld output or gas flow when gun trigger is pulled. Fan does NOT operate. No weld output or wire feed when gun trigger is pulled. Fan runs and gas flows normally.
E-3 SP-175 PLUS E-3 TROUBLESHOOTING 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.
E-4 SP-125 PLUS E-4 TROUBLESHOOTING Observe Safety Guidelines detailed in the beginning of this manual. 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.
F-1 SP-175 PLUS F-1 WIRING DIAGRAMS M19060 L1 L2 31 H2 202 201 D5 D7 D2 D8 204 204 203 203 203 204 - + OUTPUT CHOKE TO WORK ELECTRICAL SYMBOLS PER E1537 CIRCUIT BREAKER 31A 12 3 456 LATCH FAN MOTOR 1 234 LATCH 5 6789 1 0 J1 J2 CAVITY NUMBERING SEQUENCE 12 3 4 56 123 4 5 6 7 89 1 0 7 32A CONTROL P.
NOTES.
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W ARNING AV I S O D E PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
W ARNING AV I S O D E PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA ESTE EQUIP AMENTO E AS P ARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
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