Lincoln Electric SP-175 PLUS IM790 Bedienungsanleitung

SP-175 Plus

OPERATOR’S MANUAL

IM790

March, 2005

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.

For use with machine Code Numbers 10976

• 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

• World's Leader in Welding and Cutting Products •

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.

____________________________________________________

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

refueling to prevent spilled fuel from vaporiz-

ing on contact with hot engine parts and

igniting. Do not spill fuel when filling tank. If

fuel is spilled, wipe it up and do not start

engine until fumes have been eliminated.

____________________________________________________

1.d. Keep all equipment safety guards, covers and devices in

position and in good repair.Keep hands, hair, clothing and

tools away from V-belts, gears, fans and all other moving

parts when starting, operating or repairing equipment.

____________________________________________________

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

guards to perform required maintenance. Remove

guards only when necessary and replace them when the

maintenance requiring their removal is complete.

Always use the greatest care when working near moving

parts.

___________________________________________________

1.f. Do not put your hands near the engine fan.

Do not attempt to override the governor or

idler by pushing on the throttle control rods

while the engine is running.

___________________________________________________

1.g. To prevent accidentally starting gasoline engines while

turning the engine or welding generator during maintenance

work, disconnect the spark plug wires, distributor cap or

magneto wire as appropriate.

SAFETY

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.

WARNING

Mar ‘95

ELECTRIC AND

MAGNETIC FIELDS

may be dangerous

2.a. Electric current flowing through any conductor causes

localized Electric and Magnetic Fields (EMF). Welding

current creates EMF fields around welding cables and

welding machines

2.b. EMF fields may interfere with some pacemakers, and

welders having a pacemaker should consult their physician

before welding.

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

effects which are now not known.

2.d. All welders should use the following procedures in order to

minimize exposure to EMF fields from the welding circuit:

2.d.1.

Route the electrode and work cables together - Secure

them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode and

work cables. If the electrode cable is on your right

side, the work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close as

possible to the area being welded.

2.d.5. Do not work next to welding power source.

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

radiator pressure cap when the engine is

hot.

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents

are known to the State of California to cause can-

cer, birth defects, and other reproductive harm.

The engine exhaust from this product contains

chemicals known to the State of California to cause

cancer, birth defects, or other reproductive harm.

The Above For Diesel Engines The Above For Gasoline Engines

SP-175 PLUS

SAFETY

ARC RAYS 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. I standards.

4.b. Use suitable clothing made from durable flame-resistant

material to protect your skin and that of your helpers from

the arc rays.

4.c. Protect other nearby personnel with suitable, non-flammable

screening and/or warn them not to watch the arc nor expose

themselves to the arc rays or to hot spatter or metal.

ELECTRIC SHOCK can

kill.

3.a. The electrode and work (or ground) circuits

are electrically “hot”when the welder is on.

Do not touch these “hot”parts with your bare

skin or wet clothing. Wear dry, hole-free

gloves to insulate hands.

3.b. Insulate yourself from work and ground using dry insulation.

Make certain the insulation is large enough to cover your full

area of physical contact with work and ground.

In addition to the normal safety precautions, if welding

must be performed under electrically hazardous

conditions (in damp locations or while wearing wet

clothing; on metal structures such as floors, gratings or

scaffolds; when in cramped positions such as sitting,

kneeling or lying, if there is a high risk of unavoidable or

accidental contact with the workpiece or ground) use

the following equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode,

electrode reel, welding head, nozzle or semiautomatic

welding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electrical

connection with the metal being welded. The connection

should be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical

(earth) ground.

3.f.

Maintain the electrode holder, work clamp, welding cable and

welding machine in good, safe operating condition. Replace

damaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically “hot”parts of

electrode holders connected to two welders because voltage

between the two can be the total of the open circuit voltage

of both welders.

3.i. When working above floor level, use a safety belt to protect

yourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

FUMES AND GASES

can be dangerous.

5.a.Welding may produce fumes and gases

hazardous to health. Avoid breathing these

fumes and gases.When welding, keep

your head out of the fume. Use enough

ventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. When

welding with electrodes which require special

ventilation such as stainless or hard facing (see

instructions on container or MSDS) or on lead or

cadmium plated steel and other metals or coatings

which produce highly toxic fumes, keep exposure as

low as possible and below Threshold Limit Values (TLV)

using local exhaust or mechanical ventilation. In

confined spaces or in some circumstances, outdoors, a

respirator may be required. Additional precautions are

also required when welding on galvanized steel.

5.b.

Do not weld in locations near chlorinated hydrocarbon

vapors

coming from degreasing, cleaning or spraying operations.

The heat and rays of the arc can react with solvent vapors

form phosgene, a highly toxic gas, and other irritating prod-

ucts.

5.c. Shielding gases used for arc welding can displace air and

cause injury or death. Always use enough ventilation,

especially in confined areas, to insure breathing air is safe.

5.d. Read and understand the manufacturer’s instructions for this

equipment and the consumables to be used, including the

material safety data sheet (MSDS) and follow your

employer’s safety practices. MSDS forms are available from

your welding distributor or from the manufacturer.

5.e. Also see item 1.b.

Mar ‘95

SP-125 PLUS

FOR ELECTRICALLY

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 manufacturer’s

recommendations.

8.c. Ground the equipment in accordance with the U.S. National

Electrical Code and the manufacturer’s recommendations.

CYLINDER may explode

if damaged.

7.a. Use only compressed gas cylinders

containing the correct shielding gas for the

process used and properly operating

regulators designed for the gas and

pressure used. All hoses, fittings, etc. should be suitable for

the application and maintained in good condition.

7.b. Always keep cylinders in an upright position securely

chained to an undercarriage or fixed support.

7.c. Cylinders should be located:

•Away from areas where they may be struck or subjected to

physical damage.

•A safe distance from arc welding or cutting operations and

any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any other

electrically “hot”parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outlet

when opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand

tight except when the cylinder is in use or connected for

use.

7.g. Read and follow the instructions on compressed gas

cylinders, associated equipment, and CGA publication P-l,

“Precautions for Safe Handling of Compressed Gases in

Cylinders,”available from the Compressed Gas Association

1235 Jefferson Davis Highway, Arlington, VA 22202.

iii

SAFETY

iii

Mar ‘95

WELDING SPARKS can

cause fire or explosion.

6.a.

Remove fire hazards from the welding area.

If this is not possible, cover them to prevent

the welding sparks from starting a fire.

Remember that welding sparks and hot

materials from welding can easily go through small cracks

and openings to adjacent areas. Avoid welding near

hydraulic lines. Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site,

special precautions should be used to prevent hazardous

situations. Refer to “Safety in Welding and Cutting”(ANSI

Standard Z49.1) and the operating information for the

equipment being used.

6.c. When not welding, make certain no part of the electrode

circuit is touching the work or ground. Accidental contact

can cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until the

proper steps have been taken to insure that such procedures

will not cause flammable or toxic vapors from substances

inside. They can cause an explosion even

though

they have

been “cleaned”. For information, purchase “Recommended

Safe Practices for the

Preparation

for Welding and Cutting of

Containers and Piping That Have Held Hazardous

Substances”, AWS F4.1 from the American Welding Society

(see address above).

6.e. Vent hollow castings or containers before heating, cutting or

welding. They may explode.

6.f.

Sparks and spatter are thrown from the welding arc. Wear oil

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.

Always wear safety glasses with side shields when in a

welding area.

6.g. Connect the work cable to the work as close to the welding

area as practical. Work cables connected to the building

framework or other locations away from the welding area

increase the possibility of the welding current passing

through lifting chains, crane cables or other alternate cir-

cuits. This can create fire hazards or overheat lifting chains

or cables until they fail.

6.h. Also see item 1.c.

SP-175 PLUS

SAFETY

PRÉCAUTIONS DE SÛRETÉ

Pour votre propre protection lire et observer toutes les instructions

et les précautions de sûretéspecifiques qui parraissent dans ce

manuel aussi bien que les précautions de sûretégénérales suiv-

antes:

SûretéPour Soudage A L’Arc

1. Protegez-vous contre la secousse électrique:

a. Les circuits àl’électrode et àla piéce sont sous tension

quand la machine àsouder est en marche. Eviter toujours

tout contact entre les parties sous tension et la peau nue

ou les vétements mouillés. Porter des gants secs et sans

trous pour isoler les mains.

b. Faire trés attention de bien s’isoler de la masse quand on

soude dans des endroits humides, ou sur un plancher

metallique ou des grilles metalliques, principalement dans

les positions assis ou couchépour lesquelles une grande

partie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câble

de soudage et la machine àsouder en bon et sûrétat

defonctionnement.

d.Ne jamais plonger le porte-électrode dans l’eau pour le

refroidir.

e. Ne jamais toucher simultanément les parties sous tension

des porte-électrodes connectésàdeux machines àsouder

parce que la tension entre les deux pinces peut être le

total de la tension àvide des deux machines.

f. Si on utilise la machine àsouder comme une source de

courant pour soudage semi-automatique, ces precautions

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

enrouler le câble-électrode autour de n’importe quelle partie

du corps.

3. Un coup d’arc peut être plus sévère qu’un coup de soliel,

donc:

a. Utiliser un bon masque avec un verre filtrant approprié

ainsi qu’un verre blanc afin de se protéger les yeux du ray-

onnement de l’arc et des projections quand on soude ou

quand on regarde l’arc.

b. Porter des vêtements convenables afin de protéger la

peau de soudeur et des aides contre le rayonnement de

l‘arc.

c. Protéger l’autre personnel travaillant àproximitéau

soudage àl’aide d’écrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de l’arc de

soudage. Se protéger avec des vêtements de protection libres

de l’huile, tels que les gants en cuir, chemise épaisse, pan-

talons sans revers, et chaussures montantes.

5. Toujours porter des lunettes de sécuritédans la zone de

soudage. Utiliser des lunettes avec écrans lateraux dans les

zones oùl’on pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin de

prévenir tout risque d’incendie dûaux étincelles.

7. Quand on ne soude pas, poser la pince àune endroit isoléde

la masse. Un court-circuit accidental peut provoquer un

échauffement et un risque d’incendie.

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

la masse sur la charpente de la construction ou d’autres

endroits éloignés de la zone de travail, on augmente le risque

de voir passer le courant de soudage par les chaines de lev-

age, câbles de grue, ou autres circuits. Cela peut provoquer

des risques d’incendie ou d’echauffement des chaines et des

câbles jusqu’à ce qu’ils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage.

Ceci est particuliérement important pour le soudage de tôles

galvanisées plombées, ou cadmiées ou tout autre métal qui

produit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenant

d’opérations de dégraissage, nettoyage ou pistolage. La

chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs

du solvant pour produire du phosgéne (gas fortement toxique)

ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté,

voir le code “Code for safety in welding and cutting”CSA

Standard W 117.2-1974.

PRÉCAUTIONS DE SÛRETÉPOUR

LES MACHINES ÀSOUDER À

TRANSFORMATEUR ET À

REDRESSEUR

1. Relier àla terre le chassis du poste conformement au code de

l’électricitéet aux recommendations du fabricant. Le dispositif

de montage ou la piece àsouder doit être branchéàune

bonne mise àla terre.

2. Autant que possible, I’installation et l’entretien du poste seront

effectués par un électricien qualifié.

3. Avant de faires des travaux àl’interieur de poste, la debranch-

er àl’interrupteur àla boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûretéàleur

place.

Mar. ‘93

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. 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.

This statement appears where the information must be followed to avoid minor personal injury or damage to

this equipment.

CAUTION

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.

vi vi

SP-175 PLUS

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

A-1

A-1 INSTALLATION

SP-175 PLUS

TECHNICAL SPECIFICATIONS –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/60Hz Three-Prong Plug

(NEMA Type 6-50P)

INPUT –SINGLE PHASE ONLY

RATED OUTPUT

OUTPUT

RECOMMENDED INPUT CABLE AND FUSE SIZES

Height Width Depth Weight

12.0 in 9.75 in 16.5 in 60 Ibs

305 mm 248 mm 419 mm 27.3 kg

PHYSICAL DIMENSIONS

Standard Voltage/Frequency Input Current

230V/60Hz 21 Amps @ Rated Output

208V/60Hz 23 Amps @ Rated Output

Duty Cycle Current Voltage

30% Duty Cycle @ 230V/60Hz 130 Amps 20 V

25% Duty Cycle @ 208V/60Hz 130 Amps 20 V

Welding Current Range Maximum Open Circuit Voltage Wire Speed Range

Rated DC Output: 30 –175 amps 33 50-400IPM (1.3-10.2m/min)

A-2 A-2

INSTALLATION

SP-175 PLUS

Read entire installation section before starting

installation.

SAFETY PRECAUTIONS

IDENTIFY AND LOCATE

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):

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.

1) As shipped from the factory, the SP-175 Plus gun

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.

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.

•The SP-175 Plus power switch is to be in

the OFF (“O”) position when installing

work cable and gun and when connecting

power cord to input power.

WARNING

FIGURE A.1

SP-175 Plus

WELDING AMP RANGE

25-125

A-3

A-3 INSTALLATION

SP-175 PLUS

SELECT SUITABLE LOCATION

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 location that

minimizes the amount of smoke and dirt drawn into

the louvers reduces the chance of dirt accumulation

that can block air passages and cause overheating.

STACKING

SP-175 Plus’cannot be stacked.

TILTING

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

face, or on a recommended undercarriage. The

machine may topple over if this procedure is not fol-

lowed.

OUTPUT CONNECTIONS

Refer to Figure A.2.

1. Work Cable Access Hole.

2. Gun Cable and Control Lead Access Hole.

3. Connector Block.

4. Gun Trigger Lead Connectors.

5. Positive (+) and negative (–) output terminals.

6. Wire Feed Gearbox and Gun Connector Block

7. Cable Clamp

8. Thumbscrew - Secures gun and cable assembly

Work Clamp Installation

Attach the work clamp per the following:

1. Unplug the machine or turn the power switch to the

“OFF”position.

2. Insert the work cable terminal lug with the larger

hole through the strain relief hole in the work clamp

as shown in Figure A-3.

3. Fasten securely with the bolt and nut provided.

FIGURE A.3

Work Cable Installation

Refer to Figure A.2.

1. Open the wire feed section door on the right side of

the SP-175 Plus .

2. Pass the end of the work cable that has the termi-

nal lug with the smaller hole through the Work

Cable Access Hole (1) in the case front.

3. Route the cable under and around the back of the

Wire Feed Gearbox (6).

Strain Relief Hole

Nut & Bolt

Work Clamp

Work Cable

FIGURE A.2

367

SP-175 Plus

WELDING AMP RANGE

25-125

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