IM710 SP -170 T - Lincoln Electric · PDF fileARC RAYS can burn. 4.a. Use a shield with the...

SP-170 T

OPERATOR’S MANUAL

IM710October, 2001

Safety Depends on YouLincoln arc welding and cuttingequipment is designed and builtwith safety in mind. However, youroverall safety can be increased byproper installation ... and thought-ful operation on your part. DONOT INSTALL, OPERATE ORREPAIR THIS EQUIPMENTWITHOUT READING THISMANUAL AND THE SAFETYPRECAUTIONS CONTAINEDTHROUGHOUT. And, mostimportantly, think before you actand be careful.

For use with machine Code Numbers 10842

• 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 •

Date of Purchase:Serial Number:Code Number:Model:Where Purchased:

Copyright © 2001 Lincoln Global Inc.Made exclusive for Australia

This manual covers equipment which is no longer in production by The Lincoln Electric Co. Speci�cations and availability of optional features may have changed.

iSAFETYi

SP-170T

FOR ENGINEpowered equipment.

1.a. Turn the engine off before troubleshooting and maintenancework unless the maintenance work requires it to be running.

____________________________________________________1.b. Operate engines in open, well-ventilated

areas or vent the engine exhaustfumes 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 beforerefueling to prevent spilled fuel from vapor-izing on contact with hot engine parts andigniting. Do not spill fuel when filling tank. Iffuel is spilled, wipe it up and do not startengine until fumes have been eliminated.

____________________________________________________1.d. Keep all equipment safety guards, covers

and devices in posit ion and in goodrepair.Keep hands, hair, clothing and toolsaway from V-belts, gears, fans and allother moving parts when starting, operatingor repairing equipment.

____________________________________________________

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.

For more detailed information it is strongly recommended that you purchase a copy of "Safety in Welding and Cutting - ANSIStandard Z49.1" and WTIA Technical Note 7. All WTIA publications and ANSI/AWS Standards are available from theWelding Technology Institute of Australia, PO Box 6165 Silverwater NSW 2128. For copies of various Australian Standardscontact your local S.A.A. office.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES AREPERFORMED ONLY BY QUALIFIED INDIVIDUALS.

WARNING

1.h. To avoid scalding, do not remove theradiator pressure cap when the engine ishot.

1.e. In some cases it may be necessary to remove safetyguards to perform required maintenance. Removeguards only when necessary and replace them when themaintenance requiring their removal is complete.Always use the greatest care when working near movingparts.

___________________________________________________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 controlrods while the engine is running.

___________________________________________________1.g. To prevent accidentally starting gasoline engines while

turning the engine or welding generator during maintenancework, disconnect the spark plug wires, distributor cap ormagneto wire as appropriate.

Oct ‘00

iiSAFETYii

SP-170T

2.i.4 Connect the work cable to the work piece as close aspossible to the area being welded. (This is also a goodpractice to eliminate a common problem on welding - apoor work connection.

2.i.5 Do not work next to the welding power source.

ADDITIONAL PRECAUTIONS FORWELDERS WITH PACEMAKERS

2.j. There is no question that the fields in arc welding can interferewith a pacemakers function. Generally the interference doesnot permanently damage the pacemaker. Once the wearerleaves the arc welding environment or stops welding, the pace-maker returns to normal functioning. The welding arc has littleor no effect on the operation of some pacemakers, especiallydesigns that are bi-polar or designed to filter out such interfer-ence.

2.k. For a welder or anyone working around electrical equipmentthe selection of a pacemaker is very important. Get a doctor’sadvice about which pacemaker is the least sensitive to inter-ference from welding while still being medically suitable.

2.l. In addition to the normal safety precautions, the following addi-tional procedures should be adopted by welders with pacemak-ers.

2.l.1 Use gas welding when the application is suitable.

2.l.2 Use the lowest current setting appropriate for the applica-tion. Do not exceed 400 amps. Low current (75-200amps) direct current (DC) welding should be used if arcwelding is necessary. Do not TIG weld with high frequen-cy.

2.l.3 Do not use repeated, short welds. Wait about ten sec-onds between stopping one weld and starting the next.When having difficulty starting an electrode, do not re-strike the rod repeatedly.

2.l.4 If you feel light headed, dizzy or faint, immediately stopwelding. Lay the electrode holder down so that it does notcontact the work and move away from any welding beingperformed. Arrange your work in advance so that, if youbecome dizzy and drop the electrode holder it will not fallon your body or strike the work.

2.l.5 Do not work on a ladder or other elevated position or in acramped, confined place.

2.l.6 Do not work alone. Work only in the presence of an indi-vidual who understands these precautions and the possi-ble effect welding may have on your pacemaker.

2.l.7 Do not work near spot welding equipment.

2.l.8 If you have a pacemaker and wish to continue arc weld-ing, discuss this and any other questions you may havewith your physician and follow his or her advice. The doc-tor may wish to contact the pacemaker manufacturer for arecommendation. As mentioned before, the design of thepacemaker significantly affects the degree to which it issubject to interference from a welding circuit. Do not relyon the fact that you know another welder with a pacemak-er who has welded for years without experiencing a prob-lem.That welder and his or her pacemaker may be quitedifferent from you and your pacemaker.

ELECTRIC AND MAGNETIC FIELDSmay 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, andwelders having a pacemaker should consult their physicianbefore welding.

2.c. Exposure to EMF fields in welding may have other healtheffects which are now not known.

2.d. All welders should follow safe practices that minimize theirexposure to electric and magnetic fields (EMF).

2.e. For welders wearing implanted pacemakers, safe weldingpractices are particularly important and additional proceduresshould be followed by those who have decided to continue toweld. (Hopefully in keeping with a doctor’s advice).

2.f. The following procedures will not eliminate exposure to EMF orthe possibility of arc welding having an effect on a pacemaker,however if followed, they will significantly reduce exposure toelectric and magnetic fields. Electric and magnetic fields arecreated any time electric current flows through a conductor,however it is not clear whether such exposure affects oneshealth.

2.g. Some researchers have reported that exposure to EMF maycause leukemia or other illnesses. These claims originallyarose in relation to high voltage electric power lines and arevery much in dispute in the medical and scientific arena, how-ever the best advice is to minimize your exposure to EMF toprotect your health should doctors eventually decide there is arisk.

2.h. There are four fundamental facts about EMF:2.h.1 With direct current (DC), the field strength is relatively

constant and does not change.

2.h.2 With alternating current (AC), the field strength constant-ly changes.

2.h.3 The greater the current flow, i.e. the higher the amps,the stronger the field created by the current

2.h.4 The closer the conductor or electrical device is to thebody the greater the exposure to the field.

MINIMIZE EXPOSURE TO EMF

2.i. All welders should use the following procedures to minimizeEMF exposure:2.i.1 Route electrode or gun and work cables together. Secure

them with tape if possible.

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

2.i.3 Do not place your body between the electrode and workcables. If your electrode cable is on your right side thework cable should also be on your right side.

Oct ‘00

iiiSAFETYiii

SP-170T

ARC RAYS can burn.4.a. Use a shield with the proper filter and cover

plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistantmaterial to protect your skin and that of your helpers fromthe arc rays.

4.c. Protect other nearby personnel with suitable, non-flammablescreening and/or warn them not to watch the arc nor exposethemselves to the arc rays or to hot spatter or metal.

ELECTRIC SHOCK cankill.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 bareskin 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 fullarea of physical contact with work and ground.

In addition to the normal safety precautions, if weldingmust be performed under electrically hazardousconditions (in damp locations or while wearing wetclothing; on metal structures such as floors, gratings orscaffolds; when in cramped positions such as sitting,kneeling or lying, if there is a high risk of unavoidable oraccidental contact with the workpiece or ground) usethe 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 semiautomaticwelding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electricalconnection with the metal being welded. The connectionshould 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 andwelding machine in good, safe operating condition. Replacedamaged insulation.

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

3.h. Never simultaneously touch electrically “hot” parts ofelectrode holders connected to two welders because voltagebetween the two can be the total of the open circuit voltageof both welders.

3.i. When working above floor level, use a safety belt to protectyourself from a fall should you get a shock.

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

FUMES AND GASEScan be dangerous.5.a. Welding may produce fumes and gases

hazardous to health. Avoid breathing thesefumes and gases.When welding, keepyour head out of the fume. Use enoughventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. Whenwelding with electrodes which require specialventilation such as stainless or hard facing (seeinstructions on container or MSDS) or on lead orcadmium plated steel and other metals or coatingswhich produce highly toxic fumes, keep exposure aslow as possible and below Threshold Limit Values (TLV)using local exhaust or mechanical ventilation. Inconfined spaces or in some circumstances, outdoors, arespirator may be required. Additional precautions arealso required when welding on galvanized steel.

5.b. Do not weld in locations near chlorinated hydrocarbon vaporscoming from degreasing, cleaning or spraying operations.The heat and rays of the arc can react with solvent vapors toform phosgene, a highly toxic gas, and other irritating prod-ucts.

5.c. Shielding gases used for arc welding can displace air andcause 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 thisequipment and the consumables to be used, including thematerial safety data sheet (MSDS) and follow youremployer’s safety practices. MSDS forms are available fromyour welding distributor or from the manufacturer.

5.e. Also see item 1.b.

Mar ‘95

ivSAFETYiv

SP-170T

FOR ELECTRICALLYpowered equipment.

8.a. Turn off input power using the disconnectswitch at the fuse box before working onthe equipment.

8.b. Install equipment in accordance with the NationalElectrical Code, all local codes and the manufacturer’srecommendations.

8.c. Ground the equipment in accordance with the NationalElectrical Code and the manufacturer’s recommendations.

CYLINDER may explodeif damaged.7.a. Use only compressed gas cylinders

containing the correct shielding gas for theprocess used and properly operatingregulators designed for the gas and

pressure used. All hoses, fittings, etc. should be suitable forthe application and maintained in good condition.

7.b. Always keep cylinders in an upright position securelychained to an undercarriage or fixed support.

7.c. Cylinders should be located:• Away from areas where they may be struck or subjected tophysical damage.

• A safe distance from arc welding or cutting operations andany other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any otherelectrically “hot” parts to touch a cylinder.

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

7.f. Valve protection caps should always be in place and handtight except when the cylinder is in use or connected foruse.

7.g. Read and follow the instructions on compressed gascylinders, associated equipment, and CGA publication P-l,“Precautions for Safe Handling of Compressed Gases inCylinders,” available from the Compressed Gas Association1235 Jefferson Davis Highway, Arlington, VA 22202.

Mar ‘95

WELDING SPARKS cancause fire or explosion.6.a. Remove fire hazards from the welding area.

If this is not possible, cover them to preventthe welding sparks from starting a fire.Remember that welding sparks and hot

materials from welding can easily go through small cracksand openings to adjacent areas. Avoid welding nearhydraulic 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 hazardoussituations. Refer to “Safety in Welding and Cutting” (ANSIStandard Z49.1) and the operating information for theequipment being used.

6.c. When not welding, make certain no part of the electrodecircuit is touching the work or ground. Accidental contactcan cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until theproper steps have been taken to insure that such procedureswill not cause flammable or toxic vapors from substancesinside. They can cause an explosion even though they havebeen “cleaned”. For information, purchase “RecommendedSafe Practices for the Preparation for Welding and Cutting ofContainers and Piping That Have Held HazardousSubstances”, AWS F4.1 from the American Welding Society(see address above).

6.e. Vent hollow castings or containers before heating, cutting orwelding. They may explode.

6.f. Sparks and spatter are thrown from the welding arc. Wear oilfree protective garments such as leather gloves, heavy shirt,cuffless trousers, high shoes and a cap over your hair. Wearear plugs when welding out of position or in confined places.Always wear safety glasses with side shields when in awelding area.

6.g. Connect the work cable to the work as close to the weldingarea as practical. Work cables connected to the buildingframework or other locations away from the welding areaincrease the possibility of the welding current passingthrough lifting chains, crane cables or other alternate cir-cuits. This can create fire hazards or overheat lifting chainsor cables until they fail.

6.h. Also see item 1.c.

SAFETY vv

INSTRUCTIONS FOR ELECTRO-MAGNETIC COMPATIBILITYConformanceProducts displaying the C-Tick mark are in conformity withAustralian/New Zealand requirements for ElectromagneticCompatibility (EMC) according to standard (emission) AS/NZS3652 "Electromagnetic Compatibility – Arc WeldingEquipment".

Products displaying the CE mark are in conformity withEuropean Community Council Directive 89/336/EEC require-ments for EMC by implementing EN50199 "ElectromagneticCompatibility (EMC) – Product standard for arc welding equip-ment".

Products are:• For use with other Lincoln Electric/LiquidArc equipment. • Designed for industrial and professional use.

IntroductionAll electrical equipment generates small amounts of electromagnet-ic emission. Electrical emission may be transmitted through powerlines or radiated through space, similar to a radio transmitter. Whenemissions are received by other equipment, electrical interferencemay result. Electrical emissions may effect many kinds of electricalequipment: other nearby welding equipment, radio and TV trans-mitters and receivers, numerical controlled machines, telephonesystems, computers, etc. Be aware that interference may resultand extra precautions may be required when a welding powersource is used in a domestic establishment.

Installation and UseThe purchaser/user is responsible for installing and using the weld-ing equipment according to the manufacturer’s instructions. If elec-tromagnetic disturbances are detected then it shall be the responsi-bility of the purchaser/user of the welding equipment to resolve thesituation with the technical assistance of the manufacturer. In somecases this remedial action may be as simple as earthing (ground-ing) the welding circuit (see note below). In other cases it couldinvolve constructing an electromagnetic screen enclosing thepower source and the work complete with associated input filters.In all cases electromagnetic disturbances must be reduced to thepoint where they are no longer troublesome.

Note: The welding circuit may or may not be earthed for safety rea-sons according to national codes. Changing the earthing arrange-ments should only be authorized by a person who is competent toassess whether the changes increase the risk of injury, eg. byallowing parallel welding current return paths which may damagethe earth circuits of other equipment.

Assessment of AreaBefore installing welding equipment the purchaser/user shall makean assessment of potential problems in the surrounding area.

The following shall be taken into account:

• Other supply cables, control cables, signalling and telephonecables above, below and adjacent to the welding equipment;

• Radio and television transmitters and receivers;

• Computer and other control equipment;

• Safety critical safety equipment, eg. guarding of industrialequipment;

• The health of people around, eg. the use of pacemakers andhearing aids;

• Equipment used for calibration or measurement;

• The immunity of other equipment in the environment. Thepurchaser/user shall ensure that other equipment being usedin the environment is compatible. This may require additionalprotection measures;

• The time of the day that welding or other activities are to becarried out.

The size of the surrounding area to be considered will depend onthe structure of the building and other activities that are takingplace. The surrounding area may extend beyond the boundaries ofthe premises.

Methods of Reducing Emissions

Mains SupplyWelding equipment should be connected to the mains supplyaccording to the manufacturer’s recommendations.If interferenceoccurs, it may be necessary to take additional precautions such asfiltering the mains supply. Consideration should be given to shield-ing the supply cable of permanently installed welding equipment inmetallic conduit or equivalent. Shielding should be electrically con-tinuous throughout its length. The shielding should be connected tothe welding power source so that good electrical contact is main-tained between the conduit and the welding power source enclo-sure.

Maintenance of the Welding EquipmentThe welding equipment should be routinely maintained accordingto the manufacturer’s recommendations. All access and servicedoors and covers should be closed and properly fastened when thewelding equipment is in operation. The welding equipment shouldnot be modified in any way except for those changes and adjust-ment covered in the manufacturer’s instructions. In particular, thespark gaps of arc initiation and stabilizing devices should be adjust-ed and maintained according to the manufacturer’s recommenda-tions.

Welding CablesThe welding cables should be kept as short as possible and shouldbe positioned close together, running at or close to the floor level.

Equipotential BondingBonding of all metallic components in the welding installation andadjacent to it should be considered. However, metallic componentsbonded to the work piece will increase the risk that the operatorcould receive a shock by touching these metallic components andthe electrode at the same time. The operator should be insulatedfrom all such bonded metallic components.

Earthing of the workpieceWhere the workpiece is not bonded to earth for electrical safety,nor connected to earth because of its size and position, eg. ship’shull or building steelwork, a connection bonding the workpiece toearth may reduce emissions in some, but not all instances. Careshould be taken to prevent the earthing of work pieces increasingthe risk of injury to users, or damage to other electrical equipment.Where necessary, the connection of the workpiece to earth shouldbe made by direct connection to the workpiece, but in some coun-tries where direct connection is not permitted, the bonding shouldbe achieved by suitable capacitance, selected according to nationalregulations.

Screening and ShieldingSelective screening and shielding of other cables and equipment inthe surrounding area may alleviate problems of interference.Screening of the entire welding installation may be considered forspecial applications.

Portions of the preceding text are extracted from:• Australian/New Zealand standard AS/NZS 3652. Permission to

reproduce has been granted by Standards Australia andStandards New Zealand. For further explanation, readers shouldbe referred to the standard itself.

• British Standards Institution standard BS EN 50199:1995.Reproduced with permission of BSI under license number2000SK0631. Complete standards can be obtained from BSICustomer Services, 389 Chiswick High Road, London W4 4AL.United Kingdom. (Tel +44 (0) 20 8996 9001).

Copyright of above text is property of Standards Australia,Standards New Zealand and British Standards Institution.Permission to reproduce the text must be obtained.

JAN ‘01

SP-170T

Thank You for selecting a QUALITY product by Lincoln Electric. We want youto 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 ithandy 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:

WARNINGThis statement appears where the information must be followed exactly to avoid serious personal injury orloss of life.

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

CAUTION

Please Examine Carton and Equipment For Damage ImmediatelyWhen this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claimsfor material damaged in shipment must be made by the purchaser against the transportation company at thetime the shipment is received.

Please record your equipment identification information below for future reference. This information can befound on your machine nameplate.

Model Name & Number _____________________________________

Code & Serial Number _____________________________________

Date of Purchase _____________________________________

Whenever you request replacement parts for or information on this equipment always supply the informationyou have recorded above.

vivi

vii vii TABLE OF CONTENTS

Page

Installation .......................................................................................................Section ATechnical Specifications ........................................................................................A-1Identify and Locate Components ...........................................................................A-2Select Suitable Location ........................................................................................A-3

Stacking ..........................................................................................................A-3Tilting...............................................................................................................A-3

Output Connections...............................................................................................A-3Work Clamp Installation ..................................................................................A-3Work Cable Installation ...................................................................................A-4

Gun Installation......................................................................................................A-4Connecting Gun Cable to the SP-170T...........................................................A-4

Gas Connection.....................................................................................................A-4Input Connections..................................................................................................A-5Electrical Input Connection for Rated Output ........................................................A-6

Line Cord Connection .....................................................................................A-6

Operation .........................................................................................................Section BSafety Precautions ................................................................................................B-1General Description ...............................................................................................B-1

Recommended Processess ............................................................................B-1Optional Features and Controls ......................................................................B-1

Design Features and Advantages .........................................................................B-1Welding Capability .................................................................................................B-2Limitations..............................................................................................................B-2Controls and Settings ............................................................................................B-2Welding Operations ...............................................................................................B-3

Sequence of Operations .................................................................................B-3 Wire Loading ..............................................................................................B-3Friction Brake Adjustments ........................................................................B-3Wire Threading...........................................................................................B-4Making a Weld ...........................................................................................B-5Cleaning Tip and Nozzle ............................................................................B-5

Process Guidelines................................................................................................B-5Changing Over to Feed Other Wire Sizes .............................................................B-6Welding with GMAW..............................................................................................B-6Welding with FCAW...............................................................................................B-6

Learning to Weld .......................................................................................................B-7Overload Protection...............................................................................................B-7

Output Overload..............................................................................................B-7Thermal Protection..........................................................................................B-7Electronic Wire Drive Motor Protection ...........................................................B-7

Learning to Weld....................................................................................................B-7The Arc-Welding Circuit ..................................................................................B-7The Self-Shielded FCAW Welding Arc............................................................B-8The GMAW (MIG) Welding Arc.......................................................................B-8Process Selection ...........................................................................................B-9

For GMAW (MIG) Process .........................................................................B-9For FCAW (Innershield) Process ...............................................................B-9

Common Metals ..............................................................................................B-9Joints Types and Positions .............................................................................B-9

Butt Welds..................................................................................................B-9Penetration...............................................................................................B-10Fillet Welds...............................................................................................B-10

SP-170T

viiiviiiTABLE OF CONTENTS

PageLearning to Weld (Continues) ......................................................................................------

Welding in a Vertical Position........................................................................B-10Vertical-up and Overhead Welding .........................................................B-10Vertical-down Welding ............................................................................B-11

Machine Set Up for the Self-Shielded FCAW Process .................................B-11Welding Techniques for the Self-Shielded FCAW Process ..........................B-11

The Correct Welding Position .................................................................B-11The Correct Way to Strick an Arc............................................................B-12The Correct Electrical Stick Out ..............................................................B-12The Correct Welding Speed....................................................................B-12

Helpful Hints..................................................................................................B-13Practice .........................................................................................................B-13Machine Set Up for the GMAW (MIG) Process.............................................B-14Welding Techniques for the GMAW (MIG) Process......................................B-14

The Correct Welding Position .................................................................B-14The Correct Way to Strick an Arc............................................................B-14The Correct Electrical Stick Out ..............................................................B-15The Correct Welding Speed....................................................................B-15

Helpful Hints..................................................................................................B-15Practice .........................................................................................................B-15Troblreshooting Welds ..................................................................................B-16

To Eliminate Porosity .............................................................................B-16To Eliminate a Ropy Convex Bead ........................................................B-16To Reduce Spatter .................................................................................B-16To Correct Poor Penetration ..................................................................B-16If Arc Blow Occurs..................................................................................B-16To Eliminate Stubbing ............................................................................B-16Proper Gun Handling .............................................................................B-17

Application Chart .....................................................................................................B-18

Maintenance ....................................................................................................Section DSafety Precautions ................................................................................................D-1Routine Maintenance.............................................................................................D-1

Wire Feed Compartment.................................................................................D-1Fan Motor........................................................................................................D-1Wire Reel Spindle ...........................................................................................D-1Gun and Cable................................................................................................D-1

Gun Cable Cleaning................................................................................D-1Contact Tips, Nozzles, and Gun Tubes ..................................................D-1

Component Replacement Procedures ..................................................................D-2Changing the Contact Tip ...............................................................................D-2Changing Drive Roll ........................................................................................D-2Changing Liner................................................................................................D-3Gun Handle Parts ...........................................................................................D-3

Ground Test Procedure.........................................................................................D-4

Troubleshooting ..............................................................................................Section ESafety Precautions.................................................................................................E-1How to Use Troubleshooting Guide.......................................................................E-1Troubleshooting Guide.............................................................................E-2 thru E-4

Wiring Diagrams ..............................................................................................Section FSP-170T Wiring Diagram.......................................................................................F-1

SP-170T Parts .......................................................................................P259,P202,P189

A-1 A-1 INSTALLATION

Fuse orOutput Mode Input Voltage Breaker Size Input Amps Power Cord

RATED 240V/50Hz 25 Super Lag 12.7 15Amp, 240V,Three Pin Plug

TECHNICAL SPECIFICATIONS – SP-170TINPUT – SINGLE PHASE ONLY

RATED OUTPUT

OUTPUT

RECOMMENDED INPUT CABLE AND FUSE SIZES

Height Width Depth Weight305 mm 248 mm 419 mm 25.9 kg

PHYSICAL DIMENSIONS

Standard Voltage/Frequency AS1966.1240V/50Hz Rated Input Current

12.7 Amps

Duty Cycle Amps Volts at Rated Amperes20% 130 20

Welding Current Range Maximum Open Circuit Voltage Auxiliary PowerRated DC Output: 30 – 170 amps 33 N/A

SP-170T

A-2 INSTALLATIONRead entire installation section before startinginstallation.

SAFETY PRECAUTIONS

IDENTIFY AND LOCATE COMPONENTS

If you have not already done so, unpack the SP-170Tfrom its carton and remove all packing materialaround the SP-170T. Remove the following looseitems from the carton (see Figure A.1):

1. SP-170T

2. Gun and cable assembly(1)

3. Literature and miscellaneous including:

a) This operating manual

b) A separate .030" (0.8 mm) contact tip

c) Hex key wrench for removal of drive roll.

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

5. Work clamp.

6. Adjustable mixed-Gas Regulator & Hose.

(1) The gun is ready to feed .023" – .025" (0.6 mm)diameter wire.

ELECTRIC SHOCK can kill.

• Only qualified personnel should performthis installation.

• Only personnel that have read and under-stood the SP-170T Operating Manualshould install and operate this equipment.

• Machine must be plugged into a receptaclewhich is grounded per any national, localor other applicable electrical codes.

• The SP-170T power switch is to be in theOFF (“O”) position when installing workcable and gun and when connecting powercord to input power.

WARNING

FIGURE A.1

A-2

SP-170T

12

3

4

5

SP-170T

WELDING AMP RANGE

WELDING AMP RANGE

25-125 25-125

6

A-3 INSTALLATIONSELECT SUITABLE LOCATION

Locate the welder in a dry location where there is freecirculation of clean air into the louvers in the back andout the front of the unit. A location that minimizes theamount of smoke and dirt drawn into the rear louversreduces the chance of dirt accumulation that can blockair passages and cause overheating.

STACKING

SP-170T’s cannot be stacked.

TILTING

Each machine must be placed on a secure, level sur-face, either directly or on the recommended cart. Themachine 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.

7. Cable Hanger.

8. Thumbscrew.

Work Clamp Installation

Attach the work clamp per the following: Refer toFigure A-3.

SP-170 T

1 2

EWELDING AMP RANGEWELDING AMP RANGE 30-70 30-70

45

8

3 6 7

+

-

9

10

FIGURE A.3

1. Insert the work cable terminal lug with the largerhole through the strain relief hole in the work clampas shown above.

2. Fasten securely with the bolt and nut provided.

FIGURE A.2

A-3

SP-170T

A-4 A-4 INSTALLATIONWork Cable Installation


1. Open the wire feed section door on the right side ofthe SP-170T.

2. Pass the end of the work cable that has the termi-nal lug with the smaller hole through the WorkCable Access Hole (1) in the case front.

3. Route the cable under and around the back of theWire Feed Gearbox (6).

4. For GMAW Only: Refer to Figure A.2. As deliv-ered, the machine is connected for positive elec-trode polarity. This is the appropriate configurationfor the GMAW (MIG) process. To complete installa-tion, use the provided wing nut to connect the workcable’s terminal lug to the negative (–) output ter-minal (5) located above the Wire Feed Gearbox(6). Make sure that both wing nuts are tight.

5. For Innershield Only: Refer to Figure A.4. To wirefor negative polarity (required for the Innershieldprocess), connect the short cable attached to theconnector block (1) to the negative (–) output termi-nal (2) and the work cable (3) to the positive (+) ter-minal (4).

FIGURE A.4

NOTE: If .035" or .045" (0.9 mm or 1.2 mm)Innershield flux-cored wire is to be used, the appropri-ate Innershield kit is required.

Connecting Gun Cable to the SP-170T

1. Refer to Figure A.2. Unplug the machine or turnpower switch to the OFF “O” position.

2. Pass the insulated terminals of the gun trigger con-trol leads, one at a time, through the Gun Cableand Control Lead Access Slot (2) in the case front.The leads are to be routed up the inside of thecase front, behind the gas line.

3. Insert the connector on the gun conductor cablethrough the Gun Cable Access Hole (2) in theSP-170T case front. Make sure the connector is allthe way in the brass connector block to obtainproper gas flow. If the gun connector will not fullyinsert, unscrew the thumbscrew on the connectorblock a few turns. Rotate the connector so controlleads are on the underside and tighten theThumbscrew on the connector block.

4. Connect the gun trigger control lead terminals tothe two insulated 1/4" (6,4 mm) tab terminal con-nector bushings located above the “Gun TriggerConnection” decal in the wire feed section (4).Either lead can go to either connector.

If the gun trigger switch being used is other thanthat supplied, the switch must be a normally open,momentary switch. The terminals of the switchmust be insulated from the welding circuit.Malfunction of the SP-170T may result if thisswitch shorts to the SP-170T welding output cir-cuit or is common to any electrical circuit otherthan the SP-170T trigger circuit.

GAS CONNECTION

The SP-170T is supplied with a mixed gas Regulatorand a 3m gas hose. A cylinder of an appropriateshielding gas must be obtained from your gas distribu-tor.

CAUTION

GUN INSTALLATION

As shipped from the factory, the SP-170T gun is readyto feed .023" – .025"(.6mm) solid wire. If .030" (0.8mm) solid wire is to be used, change the contact tip tothe appropriate size.

2

43

1

SP-170T

A-5 INSTALLATION

BE SURE TO KEEP YOUR FACE AWAY FROM THEVALVE OUTLET WHEN “CRACKING” THE VALVE.Never stand directly in front of or behind the flowregulator when opening the cylinder valve. Alwaysstand to one side.

3. Attach the flow regulator to the cylinder valve andtighten the union nut securely with a wrench..

4. Refer to Figure A.6. Attach one end of inlet gashose to the outlet fitting of the flow regulator andtighten the union nut securely with a wrench.Connect the other end to the SP-170T GasSolenoid Inlet Fitting (5/8-18 female threads — forCGA — 032 fitting). Make certain the gas hose isnot kinked or twisted.

5. Reinstall case side before connecting input power.

INPUT CONNECTIONS

FIGURE A.6


CYLINDER may explode if dam-aged. Keep cylinder upright andchained to support

• Keep cylinder away from areaswhere it may be damaged.

• Never lift welder with cylinderattached.

• Never allow welding electrode totouch cylinder.

• Keep cylinder away from weldingor other live electrical circuits.

BUILDUP OF SHIELDING GAS mayharm health or kill.

• Shut off shielding gas supplywhen not in use.

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 earthground. Refer to Figure A.5.

FIGURE A.5

2. With the cylinder securely installed, remove thecylinder cap. Stand to one side away from the out-let and open the cylinder valve very slightly for aninstant. This blows away any dust or dirt which mayhave accumulated in the valve outlet.

WARNING

Cylinder Valve

Gas Hose

Flow Regulator

WARNING

WARNING

POWER INPUTCABLE

GAS SOLENOIDINLET FITTING

A-5

SP-170T

A-6 INSTALLATIONELECTRICAL INPUT CONNECTIONFOR RATED OUTPUT


• Disconnect input power byremoving plug from receptaclebefore working inside SP-170T.

• Use only grounded receptacle.

• Do not touch electrically “hot”parts inside SP-170T.

• Have qualified personnel do themaintenance and troubleshootingwork.

Line Cord Connection

A three conductor line cord with a 15 amp, 240 volt,three pin plug is factory installed. Connect this plug toa mating grounded receptacle which is connected toan appropriate power supply per the Wiring Rules andany applicable local codes.

This welding machine must be connected to apower source in accordance with applicable elec-trical codes.

If there is any question about the installationmeeting applicable electrical code requirements,consult a qualified electrician.

WARNING

WARNING

A-6

SP-170T

B-1 OPERATIONGENERAL DESCRIPTIONThe SP-170T is a complete semiautomatic constantvoltage DC portable arc welder. Included is a tap-switch controlled, single phase constant voltage trans-former/rectifier power source and a wire feeder withwelding gun for feeding .023" (0.6 mm) through .030"(0.8 mm) solid steel electrode. Optional kits are avail-able for .035" (0.9 mm) and .045" (1.2 mm)Innershield® NR-211-MP.It is ideally suited for individuals having access to 240volts 50 Hz AC input power and want the ease of use,quality and dependability of both gas metal arc weld-ing or GMAW (also known as MIG welding) and theInnershield® process (self-shielded flux-cored orFCAW). A convenient chart is mounted inside the wirefeed section door for setting welding procedures for 24gauge (.60 mm) through 5/16" (8.0 mm) mild steel.The machine is rugged and reliable and has designedfor dependable service and long life.

RECOMMENDED PROCESSES

The SP-170T can be used for welding mild steel usingthe GMAW, single pass, process which requires asupply of shielding gas or it can be used for the self-shielded, Innershield® process (FCAW).

OPERATIONAL FEATURES AND CONTROLS

The SP-170T has the following controls as standard:Power ON/OFF Switch, Voltage Control, Wire SpeedControl, Trigger Switch, and a Circuit Breaker.

DESIGN FEATURES AND ADVANTAGES• “Cold electrode” until gun trigger is pressed for an

added measure of safety.

* Overload protection — incorporates both a thermo-stat and a circuit breaker.

• Quality wire drive with electronic overload protection.

• “Quick Release” idle roll pressure arm is easilyadjusted.

• Reversible, dual groove drive roll, shipped ready tofeed .023"/.025" (0.6 mm) diameter wire. The driveroll is easily reversed to feed .030" (0.8 mm) diame-ter solid wire and .035" (0.9 mm) flux-cored diameterwire. Optional drive roll included in .045" (1.2 mm)Innershield® welding kit must be installed to feed.045" (1.2 mm) flux-cored wire.

• No external shielding gas is required when used withLincoln Innershield .035” (0.9mm) NR-211-MP elctrode.

• Spindle accommodates both 8 in. (200 mm) diameterand 4 in. (100 mm) diameter spools of wire.

B-1

SP-170T

SAFETY PRECAUTIONS

ELECTRIC SHOCK can kill.• Do not touch electrically live

parts or electrode with skin orwet clothing. Insulate yourselffrom work and ground.

• Always wear dry insulatinggloves.

FUMES AND GASES can bedangerous.• Keep your head out of fumes.

• Use ventilation or exhaust toremove fumes from breathingzone.

WELDING SPARKS cancause fire or explosion.• Keep flammable material away.

• Do not weld on closed contain-ers.

ARC RAYS can burn eyesand skin.• Wear eye, ear and body protec-

tion.

See additional warning information atfront of this opeerator’s manual.

WARNING

B-2 B-2 OPERATIONWELDING CAPABILITYThe SP-170T is rated at 130 amps, 20 volts, at 20%duty cycle on a ten minute basis. It is capable of high-er output currents at lower duty cycles. .

LIMITATIONSArc Gouging cannot be performed with the SP-170T.The SP-170T is not recommended for pipe thawing orTIG welding.

CONTROLS AND SETTINGSRefer to Figure B.1a.

1. Power ON/OFF Switch —When the power is on thefan motor will run and air willbe exhausted out the louversin the front of the machine.The welding output and wirefeeder remain off until thegun trigger is pressed.

2. Voltage Control — A 5-posi-tion tap selector switch givesfull range adjustment ofpower source output voltage.Do not switch while welding.

3. Wire Speed Control —Controls the wire feed speedfrom 50 – 400 in/min (1.2 –10.2 m/min). The control canbe preset on the dial to thesetting specified on the SP-170T Application Chartlocated on the inside of thewire feed section door.

4. Circuit Breaker – Protects machine from damage ifmaximum output is exceeded. Button will extendout when tripped (Manual reset).Refer to Figure B-1b.

OFF

ON

ARC VOLTS

WIRE SPEED

4

FIGURE B.1a

FIGURE B.1b

SP-170 T

3

2

1

4

+

-

SP-170T

B-3 OPERATIONWELDING OPERATIONS

SEQUENCE OF OPERATION

Wire LoadingRefer to Figure B.2 and B.3.The machine power switch should be turned to theOFF (“O”) position before working inside the wire feedenclosure.

The machine is shipped from the factory ready to feed8” (200 mm) diameter spools [2.2” (56 mm) max.width]. These spools fit on a 2” (50 mm) diameterspindle that has a built-in adjustable friction brake toprevent overrun of the spool and excess slack in thewire.Note:When loading and removing the 8” Spools makesure that the wing nut (inside the wire spool spindlehub) is turned 90° from the wire spool spindle lockingtab. If the wing nut is positioned in line with the lockingtab, the tab cannot be depressed to load or unloadthe wire spool.

Load an 8” (200 mm) diameter spool on the wire spoolspindle 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 theshaft 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 mounteddirectly on the 5/8” (16 mm) diameter shaft and held inplace with the previously removed hardware. Alsomake certain the start end of the wire, which may pro-trude through the side of the spool does not contactany metallic case parts.

Some spools can have the start wire protrudingfrom the side of the spool. This must be insulatedfrom internal metal components otherwise electri-cal grounding faults will result and the machinewill be seriously damaged.------------------------------------------------------------------------Friction Brake AdjustmentsWith wire spool installed on the spindle shaft and thewing nut loose, turn the spool by hand while slowlytightening the wing nut until a light drag is felt. Tightenthe wing nut an additional 1/4 turn.

Note: When properly adjusted, the brake should pro-vide only enough drag to prevent overrun of the spooland excess slack in the wire. Too much drag mayresult in wire feeding problems, and may cause pre-mature wear of wire drive system components.

FIGURE B.2

FIGURE B.3

Wire Spool must be pushed all the way on the spindle so that thespindle’s tab will hold it in place. The Wire Spool will rotate clock-wise when wire is dereeled.

8” Wire Spool

To Wire Drive

Wire Spool Spindle

Be sure that this stud engagesthe hole in the wire spool.

Wire Spindle Shaft 4" Wire Spool

Wing Nut and Spacer

To wire drive

CAUTION

B-3

SP-170T

B-4 B-4 OPERATIONWire Threading Refer to Figure B.4

1. Release the Spring Loaded Pressure Arm (1) rotatethe Idle Roll Arm (2) away from the Wire Feed DriveRoll (3). Ensure that the groove size in the feedingposition on the drive roll matches the wire size beingused. See Maintenance section for further information.

2. Carefully detach the end of the wire from the spool. Toprevent the spool from unwinding, maintain tension onthe wire until after step 5.

3. Cut the bent portion of wire off and straighten the first4” (100 mm).

4. Thread the wire through the ingoing guide tube (4),over the drive roll (3), and into the outgoing guide tube(5).

5. Close the idle roll arm (2) and latch the spring loadedpressure arm (1) in place. Rotate the spool counter-clockwise if required to take up extra slack in the wire.

6. The idle roll pressure adjustment wing nut is factoryset to approximately five full turns from where thewingnut first engages the threads of the pressurearm (1). Iffeeding problems occur because the wire is flattenedexcessively, turn the pressure adjustment counter-clockwise to reduce distortion of the wire. Slightly lesspressure may be required when using 0.023 – 0.025"(0,6 mm) wire. If the drive roll slips while feeding wire,the pressure should be increased until the wire feedsproperly.

When inching the welding wire, the drive rolls, thegun connector block and the gun contact tip are elec-trically energized relative to work and ground andremain energized for several seconds after the guntrigger is released.

7. Refer to Figure B.5. Remove gas nozzle and contacttip from end of gun.

8. Turn the SP-170T ON (“I”).

9. Straighten the gun cable assembly.

10. Depress the gun trigger switch and feed weldingwire through the gun and cable. (Point gun awayfrom yourself and others while feeding wire.)Release gun trigger after wire appears at end ofgun.

11. Turn the SP-170T OFF (“O”).

12. Replace contact tip and gas nozzle.

13. Refer to Figure B-6. Cut the wire off 1/4” – 3/8” (6– 10 mm) from the end of the tip. The SP-170T isnow ready to weld.

WARNING

FIGURE B.4

The Wire Drive Feed Roll canaccommodate two wire sizes byflipping the wire drive feed rollover.

FIGURE B.5

Gun Handle

Gas Diffuser/Contact Tip

Gas Nozzle

1

2

345

SP-170T

B-5 B-5 OPERATION

Making A Weld1. See “Process Guidelines” in this section for selec-

tion of welding wire and shielding gas and forrange of metal thicknesses that can be welded.

2. See the Application chart on the inside of the wirefeed compartment door for information on settingthe SP-170T controls. Refer to Table B.1 for alu-minum and stainless wire.

3. Set the Voltage (“V”) and Wire Speed (“olo’”) con-trols to the settings suggested for the welding wireand base metal thickness being used, refer to

3. Applications chart on the inside of the wire drivecompartment door.

4. Check that the polarity is correct for the weldingwire being used and that the gas supply, ifrequired, is turned on.

5. When using Innershield electrode, remove the gasnozzle and install the gasless nozzle. This willimprove visibility of the arc and protect the gas dif-fuser from weld spatter. Refer to the MAINTE-NANCE section for details on nozzle replacement.

6. Refer to Figure B.7. Connect work clamp to metalto be welded. Work clamp must make good elec-trical contact to the workpiece. The workpiecemust also be grounded as stated in “Arc WeldingSafety Precautions” in the beginning of this manu-al.

7. Position gun over joint. End of wire may be lightlytouching the work.

8. Lower welding helmet, close gun trigger, andbegin welding. Hold the gun so the contact tip towork distance is about 3/8 inch (10 mm).

9. To stop welding, release the gun trigger and thenpull the gun away from the work after the arc goesout.

FIGURE B.6

10. When no more welding is to be done, close valveon gas cylinder (if used), momentarily operate guntrigger to release gas pressure, and turn off theSP-170T.

Cleaning Tip And NozzleClean the contact tip and nozzle to avoid arc bridgingbetween the nozzle and contact tip which can result ina shorted nozzle, poor welds and an overheated gun.Hint: Anti-stick spray or gel, available from a weldingsupply distributor, may reduce buildup and aid in spat-ter removal.

PROCESS GUIDELINES

The SP-170T can be used for welding mild steel usingthe GMAW, single pass, process which requires asupply of shielding gas or it can be used for the self-shielded, Innershield® process (FCAW).

The recommended gases and electrodes for GMAWare welding grade CO2 gas or an argon-CO2 blendedgas (75 to 80% argon and 25 to 20% CO2) and .025"(0.6 mm) diameter Lincoln L-56 mild-steel weldingwire, supplied on 12-1/2 lb (5 kg) spools. The blendedgas is recommended for welding on heavier steel, 14gauge (2.0 mm), for example.

The recommended electrode for the self-shieldedprocess is Lincoln Innershield® NR-211-MP on 10 lb(4.5 kg) spools. This electrode is available as .035"(0.9 mm) and .045" (1.2 mm) NR-211-MP for all posi-tion welding of 18 gauge (1.2 mm) through 5/16" (8.0mm) steel. Thickness of 1/4" (6.4 mm) and 5/16" (7.9mm) require multiple passes. both wire sizes can alsobe used for the welding of galvanized coated sheetmetal.

3/8" – 1/2" Electrical Stickout(10-12 mm)

Contact Tip

Wire Electrode

FIGURE B.7

SP-100T

WORKPIECE

GUN CABLE

ARC

WORK CLAMP

SP-170T

B-6 B-6 OPERATIONThe SP-170T is suitable for .035"(0.9mm) aluminumwire and .023"–.035"(0.6-0.9mm) stainless wire. Referto Table B.1 for recommended procedure settings.(Requires K664-2 Aluminum - Stainless Feeding Kit.)

It is important when changing between weldingwith steel wire and aluminum to exchange feedingcomponents due to the lubricant applied to steelwire. Failure to do so may result in contaminatedwelds when welding aluminum.------------------------------------------------------------------------

TABLE B.1 — SP-170T WELDING PROCEDURES

CHANGING MACHINE OVER TOFEED OTHER WIRE SIZES

The SP-170T is shipped from the factory ready to feed0.023” – .025" (0.6 mm) diameter wire. To operate theSP-170T with other sizes of wire, it is necessary tochange the contact tip and change the drive roll overto other sizes. Refer to Changing the Contact Tip andChanging the Drive Roll, in the MAINTENANCE sec-tion, for specific information on these procedures.

WELDING WITH GMAW (MIG)

Shielding GasWhen using the GMAW process, install a gas regula-tor and hose kit.

• For CO2, open the cylinder very slowly. For argon-mixed gas, open cylinder valve slowly a fraction of aturn. When the cylinder pressure gauge pointerstops moving, open the valve fully.

• 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 positionor in a drafty location.

• Keep the cylinder valve closed, except when usingthe SP-170T. When finished welding:

• Close the cylinder valve to stop gas flow.

• Depress the gun trigger briefly to release thepressure in the gas hose.

• Turn off the SP-170T.

WELDING WITH FCAW (Innershield)

When using the FCAW process, the correct drive rolland electrode polarity must be used. See Work CableInstallation in INSTALLATION section for changing thepolarity.Use optional Innershield welding kit K549-1 (for 0.9mm) or K549-2 (for 1.2 mm), as appropriate.

• K549-1 0.9mm (.035”) Innershield® Welding Kit—Includes a contact tip, a gasless nozzle and a 0.9-1.2mm cable liner to permit the Magnum™ 100L gunand cable to use 0.9mm diameter flux-cored elec-trode. The fitting on the end of the liner is stencilledwith the maximum rated wiresize (.045”/1.2mm). Alsoincluded is a spool of 0.9mm Innershield® NR-211-MP.

• K549-2 1.2mm (.045”) Innershield® Welding Kit—Includes a contact tip, a gasless nozzle and a 0.9-1.2mm cable liner to permit Magnum™ 100L gunand cable to use 1.2mm diameter flux-cored elec-trode. The fitting on the end of the liner is stencilledwith the maximum rated wire size (.045”/1.2mm).Also included is a spool of 1.2mm Innershield® NR-211-MP and a knurled drive roll.

Several changes are needed to convert the unit foroperation with the Innershield (FCAW) process. TheK549-1 or K549-2 Innershield Kits include all the nec-essary accessories for this conversion and are provid-ed for this purpose. The following conversions shouldbe made using the contents of this kit:

• Change the output polarity to DC(-). See “WorkCable Installation” in Installation Section for details.

• Install proper drive roll for wire size selected. See“Changing Drive Roll” in Maintenance Section fordetails.

• Install the proper gun liner and tip for the wire sizeselected. See “Component Replacement” in theMaintenance Section for details.

• Remove gas nozzle (if installed) and install gasless-nozzle. To remove, simply unscrew.

• Load wire into machine and thread into gun andcable per “Welding Wire Loading” section.

Shielding Voltage/Wire SpeedProcess Welding Wire Gas 16 ga 14 ga 12 ga 10 ga 3/16

MIG DC+ .035 Dia 100% Argon A-5 B6.5 C-8 D-8.5 E-104043/5356Aluminum Wire

MIG DC+ .023 Dia 98% Argon/ A-4 B-6 C-8 — —308L Stainless 2% OxygenSteel Wire

MIG DC+ .030 Dia 98% Argon/ B-3.5 C-6.5 D-7 E-8 E-9308L Stainless 2% OxygenSteel Wire

MIG DC+ .035 Dia 98% Argon/ B-2.5 C-4 D-6 E-8 E-8308L Stainless 2% OxygenSteel Wire

CAUTION

SP-170T

Fumes and slag generated fromInnershield type electrodes recom-mended for use with this weldingmachine can be toxic.

• Avoid contact with eyes and skin.

• Do not take internally.

• Keep out of reach of children.

• Follow all safety precautionsfound in this operating manual.

B-7 B-7 LEARNING TO WELD

WARNING

OVERLOAD PROTECTION

OUTPUT OVERLOADThe SP-170T is equipped with a circuit breaker whichprotects the machine from damage if a severe over-load occurs. The circuit breaker button will extend outwhen tripped. The circuit breaker must be manuallyreset.

THERMAL PROTECTIONThe SP-170T has a rated output duty cycle of 30%. Ifthe duty cycle is exceeded, a thermal protector willshut off the output until the machine cools to a rea-sonable operating temperature. This is an automaticfunction of the SP-170T and does not require userintervention. The fan continues to run during cooling.

ELECTRONIC WIRE DRIVE MOTORPROTECTIONThe SP-170T has built-in protection for wire drivemotor overload.

LEARNING TO WELD

No one can learn to weld simply by reading about it.Skill comes only with practice. The following pageswill help the inexperienced operator to understandwelding and develop this skill. For more detailed infor-mation, order a copy of “New Lessons in Arc Welding”listed at the end of this manual.

Electronic Components

HingesBearings

THE ARC-WELDING CIRCUITThe operator’s knowledge of arc welding must gobeyond the arc itself. The operator must know how tocontrol the arc, and this requires a knowledge of thewelding circuit and the equipment that provides theelectric current used in the arc. Figure B.7 illustratesthe welding circuit for a typical welding machine. Thecircuit begins where the gun cable is attached to thewelding machine. Current flows through the guncable, gun, and contact tip, to the wire and across thearc. On the work side of the arc, current flows throughthe base metal to the work cable and back to thewelding machine. This circuit must be complete forthe current to flow.

This machine’s welding circuit has a voltage output of33 volts DC maximum. This voltage is quite low and isonly present when the gun triggers depressed.

To weld, the work clamp must be tightly connected toclean base metal. Remove paint, rust, dirt or oil asnecessary and connect the work clamp as close aspossible to the area you wish to weld. This helps pre-vent current from going through an unwanted path.Avoid allowing the welding circuit to pass throughhinges, bearings, electronic components, or similardevices that can be damaged. See Figure B.8. Alwaysdisconnect electrical devices before welding uponthem.

FIGURE B.8

The gun and cable assembly is held by the operatorwho guides the automatically fed wire along the joint,maintaining a contact tip to work distance of about 3/8to 1/2 inch (10 – 12 mm). This is called electricalstickout. This electrical stickout (ESO) must be prop-erly maintained by the operator. The electric arc ismade in the gap between the work and the tip end ofa small diameter wire. When the power source isproperly set, the arc gap is maintained automatically.

Arc welding is a manual skill requiring a steady hand,good physical condition, and good eyesight. Theoperator controls the welding arc, and, therefore, thequality of the weld made.

SP-170T

B-8 B-8 LEARNING TO WELDTHE SELF-SHIELDED FCAW WELDINGARC

Figure B.9 illustrates the action taking place in the selfshielded FCAW (Innershield) welding arc. It closelyresembles what is actually seen while welding.

FIGURE B.9

The “arc stream” is seen in the middle of the picture.This is the electric arc created by the electric currentflowing through the space between the end of the wireelectrode and the base metal. The temperature of thisarc is about 6000°F, which is more than enough tomelt metal. The arc is very bright, as well as hot, andcannot be looked at with the naked eye without riskingpainful injury. The very dark lens, specif icallydesigned for arc welding must be used with the handor face shield whenever viewing the arc.

The arc melts the base metal and actually digs into itmuch as water through a nozzle on a garden hosedigs into the earth. The molten metal forms a moltenpool or crater and tends to flow away from the arc. Asit moves away from the arc, it cools and solidifies.The function of the Innershield cored wire electrode ismuch more than simply to carry current to the arc. Thewire core is composed of fluxes and/or alloying ingre-dients around which a steel sheath has been formed.It is simply a stick electrode turned inside out in a con-tinuous wire form.

The cored wire melts in the arc and tiny droplets ofmolten metal shoot across the arc into the moltenpool. The wire sheath provides additional filler metalfor the joint to fill the groove or gap between the twopieces of base metal.

The core materials also melt or burn in the arc andperform several functions. They make the arc stead-ier, provide a shield of smoke-like gas around the arcto keep oxygen and nitrogen in the air away from themolten metal, and provide a flux for the molten pool.The flux picks up impurities and forms the protectiveslag on top of the weld during cooling.

After running a weld bead, the slag may be removedwith a chipping hammer and wire brush. Thisimproves appearance and allows for inspection of thefinished weld.

Since machine size and output characteristics limit thesize and type of wire electrode which can be used,Lincoln 0.035" and 0.045" (0.9 and 1.2 mm) NR-211-MP Innershield electrode is recommended for Self-Shielded Flux Cored Arc Welding with this machine.

THE GMAW (MIG) WELDING ARC

Figure B.10 illustrates the GMAW (MIG) welding arc.Solid wire does not contain fluxes or ingredients toform its own shielding and no slag forms to protect themolten weld metal. For this reason, a continuous evenflow of shielding gas is needed to protect the moltenweld metal from atmospheric contaminants such asoxygen and nitrogen. Shielding gas is suppliedthrough the gun and cable assembly, through the gasnozzle and into the welding zone.

When comparing the GMAW and FCAW processes,you can see that the principal difference between thetwo lies in the type of shielding used. GMAW uses gasfor shielding, thus we have Gas Metal Arc Welding.FCAW uses the melting or burning of the core ingredi-ents for shielding, and is thus termed Self-ShieldedFlux Cored Arc Welding.

The recommended wire for Gas Metal Arc Welding(MIG) is Lincolnweld 0.025” (0.6 mm) L-56 electrode.Lincolnweld” L-56 is capable of welding a wide rangeof mild steels in all positions, however, more skill isrequired for out-of-position welding with the GMAWprocess.

FIGURE B.10

Gas nozzle

Shielding gasSolid wireelectrode

Base metalWeld metal

Burning of core materialsinside wire electroderesults in shield of gas.

Arc Stream

Cored Wire

Protective Slag

Weld Metal

SP-170T

B-9 B-9 LEARNING TO WELDPROCESS SELECTION

By gaining knowledge of the differences between thetwo processes, you will be able to select the bestprocess for the job you have at hand. In selecting aprocess, you should consider:

For GMAW (MIG) Process1. Is most of my welding performed on 16 gauge and

lighter materials?

2. Can I afford the extra expense, space, and lack ofportability 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 questionsGMAW may be the process for you. If you haveanswered no to any of the above questions, then youshould consider using the FCAW process.

For FCAW (Innershield) Process1. Do I want simplicity and portability?

2. Will welding be performed outdoors or under windyconditions?

3. Do I require good all position welding capability?

4. Will most welding be performed on 16 gauge andheavier, somewhat rusty or dirty materials?

5. Weld must be cleaned prior to painting.

COMMON METALS

Most metals found around the farm, small shop orhome are low carbon steel, sometimes referred to asmild steel. Typical items made with this type of steelinclude most sheet metal, plate, pipe and rolledshapes such as channels and angle irons. This type ofsteel can usually be easily welded without special pre-cautions. Some steels, however, contain higher car-bon levels or other alloys and are more difficult toweld. Basically, if a magnet sticks to the metal andyou can easily cut the metal with a file, chances aregood that the metal is mild steel and that you will beable to weld the material. In addition, aluminum andstainless steel can be welded using the K664-1Aluminum Welding Kit. For further information onidentifying various types of steels and other metals,and for proper procedures for welding them, we againsuggest you purchase a copy of “New Lessons in ArcWelding”.

Regardless of the type of metal being welded, in orderto get a quality weld, it is important that the metal isfree of oil, paint, rust or other contaminants.

JOINT TYPES AND POSITIONS

Five types of welding joints are: Butt Welds, FilletWelds, Lap Welds, Edge Welds and Corner Welds.See Figure B.11.

Of these, the Butt Weld and Fillet Weld are the twomost common welds.

FIGURE B.11

Butt WeldsPlace two plates side by side, leaving a space approx-imately one half the thickness of the metal betweenthem in order to get deeper penetration.

Securely clamp or tack weld the plates at both ends,otherwise the heat will cause the plates to move apart.See Figure B.12.

Now weld the two plates together. Weld from left toright (if right handed). Point the wire electrode down inthe crack between the two plates, keeping the gunslightly tilted in the direction of travel. Watch themolten metal to be sure it distributes itself evenly onboth edges and in between the plates. This is referedto as the “pull technique”. On thin gauge sheet metal,use the “push technique”. See “Welding Techniquesfor GMAW (MIG) Process”.

Butt weld Lap weld

Edge weld Fillet weld Corner weld

SP-170T


FIGURE B.12PenetrationUnless a weld penetrates close to 100% of the metalthickness, a butt weld will be weaker than the materialwelded together. In the example shown in FigureB.13, the total weld is only half the thickness of thematerial thus the weld is only approximately half asstrong as the metal.

FIGURE B.13

FIGURE B.14

In the example shown in Figure B.14, the joint hasbeen welded so that 100% penetration could beachieved. The weld, if properly made, is as strong asor stronger than the original metal.

Fillet WeldsWhen welding fillet welds, it is very important to holdthe wire electrode at a 45° angle between the twosides or the metal will not distribute itself evenly. Thegun nozzle is generally formed at an angle to facilitatethis. See Figure B.15.

FIGURE B.15

Welding In The Vertical Position

Welding in the vertical position can be done either ver-tical-up or vertical-down. Vertical-up is used whenevera larger, stronger weld is desired. Vertical-down isused primarily on sheet metal 5/32” (3.9 mm) andunder for fast, low penetrating welds.

Use of this unit on thicker materials than recom-mended may result in poor welds. The welds may“look” good, but may just be “sitting” on top, ofthe plate. This is called “Cold Casting” and willresult in weld failure.

Vertical-up And Overhead WeldingThe problem, when welding vertical-up, is to put themolten metal where it is wanted and make it staythere. If too much molten metal is deposited, gravitywill pull it downwards and make it “drip”. Therefore, acertain technique has to be followed.

When welding out-of-position, run stringer beads.Don’t whip, break the arc, move out of the puddle, ormove too fast in any direction. Use Wire Feed Speed(WFS) in the low portion of the range. The generaltechnique and proper gun angle is illustrated in FigureB.16.

Generally, keep the electrode nearly perpendicular tothe joint as illustrated. The maximum angle above per-pendicular may be required if porosity becomes aproblem.

45°

WARNING

SP-170T


FIGURE B.16

Vertical-down WeldingRefer to Figure B.17 Vertical-down welds are appliedat a fast pace. These welds are therefore shallow andnarrow and, as such, are excellent for sheet metal.Vertical-down welds may be applied to 5/32” (3.9 mm)and lighter material.

Use stringer beads and tip the gun in the direction oftravel so the arc force helps hold the molten metal inthe joint. Move as fast as possible consistent withdesired bead shape.

The important thing is to continue lowering the entirearm as the weld is made so the angle of the gun doesnot change. Move the electrode wire fast enough thatthe slag does not catch up with the arc. Vertical-downwelding gives thin, shallow welds. It should not beused on heavy material where large welds arerequired.

FIGURE B.17

PROPER GUN ANGLEFOR GMAW PROCESSWELDING IN THE VERTICAL UP POSITION

PROPER GUN ANGLEFOR FCAW PROCESSWELDING IN THE VERTICAL UP POSITION

MACHINE SET UP FOR THE SELF-SHIELDED FCAW PROCESS

• See PROCESS GUIDELINES in the OPERATIONsection for selection of welding wire and shieldinggas, and for range of metal thicknesses that can bewelded.

• See the Application Guide on the inside of wirefeed section door for information on setting thecontrols.

• Set the “Voltage” and “Wire Speed” controls to thesettings suggested on the Application Guide for thewelding wire and base metal thickness being used.The voltage control is marked “V” and the wire feedspeed is marked ‘’olo.’’

• Check that the polarity is correct for the weldingwire being used. Set the polarity for DC(–) whenwelding with NR-211-MP Innershield electrode.See Work Cable Installation in the INSTALLATIONsection for instructions on changing polarity.

• When using Innershield electrode, the gasless noz-zle may be used instead of a gas nozzle to improvevisibility of the arc.

• Connect work clamp to metal to be welded. Workclamp must make good electrical contact to thework piece. The work piece must also be groundedas stated in the “Arc Welding Safety Precautions”at the beginning of this manual.

WELDING TECHNIQUES FOR THE SELF-SHIELDED FCAW PROCESS

Four simple manipulations are of prime importancewhen welding. With complete mastery of the four,welding will be easy. They are as follows:

• The Correct Welding PositionFigure B.11 illustrates the correct welding positionfor right handed people. (For left handed people, itis the opposite.)

Hold the gun (of the gun and cable assembly) inyour right hand and hold the shield with your lefthand. (Left handers simply do the opposite.)

When using the FCAW Process, weld from left toright (if you are right handed). This enables you toclearly see what you are doing. (Left handers dothe opposite.) Tilt the gun toward the direction oftravel holding the electrode at an angle as shownin Figure B.18.

SP-170T


ARC RAYS can burn eyes and skin.

When using an open arc process, itIs necessary to use correct eye,head and body protection.

Protect yourself and others, read“ARC RAYS can burn” at the frontof this manual.

• The Correct Way To Strike An Arc• Be sure the work clamp makes good electrical

contact to the work.

• Position gun over joint. End of wire may belightly touching the work.

• Position face shield to protect face and eyes,close gun trigger, and begin welding. Hold thegun so that the contact tip to work distance isabout 3/8 to 1/2 inch (10 – 12 mm).

• To stop welding, release the gun trigger andthe pull the gun away from the work after thearc goes out.

• A ball may form at the tip end of the wire afterwelding. For easier restrikes (with Innershieldwire) the ball may be removed by feeding out afew inches of wire and simply bending the wireback and forth until it breaks off.

• When no more welding is to be done, turn offthe machine.

• The Correct Electrical Stickout (ESO)The electrical stickout (ESO) is the distance fromthe end of the contact tip to the end of the wire.

See Figure B.19.

Once the arc has been established, maintainingthe correct ESO becomes extremely important.The ESO should be approximately 3/8 to 1/2 inch(10 to 12 mm) long.

FIGURE B.20

FIGURE B.18

WARNINGFIGURE B.19

3/8 – 1/2” (10 – 12 mm)Electrical Stickout (ESO)

Contact Tip

Wire Electrode

Solidifying ridge

Molten puddle

The easiest way to tell whether the ESO is the cor-rect length is by listening to its sound. The correctESO has a distinctive “crackling” sound, very muchlike eggs frying in a pan. A long ESO has a hollow,blowing or hissing sound. If the ESO is too short,you may stick the contact tip or nozzle to the weldpuddle and/or fuse the wire to the contact tip.

• The Correct Welding SpeedThe important thing to watch while welding is thepuddle of molten metal right behind the arc. SeeFigure B.20. Do not watch the arc itself. It is theappearance of the puddle and the ridge where themolten puddle solidifies that indicates correct weld-ing speed. The ridge should be approximately 3/8”(10 mm) behind the wire electrode.

Most beginners tend to weld too fast, resulting in athin uneven, “wormy” looking bead. They are notwatching the molten metal.

SP-170T

B-13 B-13 LEARNING TO WELDHelpful Hints

• For general welding, it is not necessary to weavethe arc, neither forward or backward nor sideways.Weld along at a steady pace. You will find it easier.

• When welding on thin plate, you will find that youwill have to increase the welding speed, where aswhen welding on heavy plate, it is necessary to gomore slowly in order to get good penetration.

• When welding sheet metal 16 gauge (1.5 mm) andlighter, heat buildup may cause part warpage andburn through. One way to eliminate these problemsis to use the back-stepping method illustrated inFigure B.21.

FIGURE B.21

Practice

The best way of getting practice in the four skills thatenable you to maintain:

• Correct welding position

• Correct way to strike an arc

• Correct electrical stickout

• Correct welding speed

is to perform the following exercise.

Refer to Figure B.22.

• Learn to strike an arc by positioning the gun overthe joint and touching the wire to the work.

• Position face shield to protect face and eyes.

• Depress gun trigger, hold gun so contact tip towork distance is about 3/8 to 1/2 inch (10 to 12mm) and the gun is at proper angle.

• After you strike the arc, practice the correct electri-cal stickout. Learn to distinguish it by its sound.

• When you are sure that you can hold the correctelectrical stickout, with a smooth “crackling” arcstart moving. Look at the molten puddle constantly,and look at the “ridge” where the metal solidifies.

• Run beads on a flat plate. Run them parallel to thetop edge (the edge farthest away from you). Thisgives you practice in running straight welds, andalso gives you an easy way to check yourprogress. The 10th weld will look considerably bet-ter than the first weld. By constantly checking onyour mistakes and your progress, welding will soonbe a matter of routine.

First weld from A to B; then from C to A; thenfrom D to C; then from E to D, and so on.

B A C D E

Back-Stepping

FIGURE B.22

ContactTip

Gun Angle

ESO

SP-170T

WELD BEAD(REPRESENTATION)

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” A

Wire Feed Speed “o|o” 1.5

For the SP-170T, use the following:

B-14 B-14 LEARNING TO WELDMACHINE SET UP FOR THE GMAW (MIG)PROCESS

• See PROCESS GUIDELINES in the OPERATIONsection for selection of welding wire and shieldinggas, and for range of metal thicknesses that can bewelded.

• See the Application Guide on the inside of wirefeed section door for information on setting thecontrols.

• Set the “Voltage” and “Wire Speed” controls to thesettings suggested on the Application Guide for thewelding wire and base metal thickness being used.The voltage control is marked “V” and the wire feedspeed is marked ‘’olo.’’

• Check that the polarity is correct for the weldingwire being used. Set the polarity for DC(+) whenwelding with the GMAW (MIG) process. See WorkCable Installation in the INSTALLATION section forinstructions for changing polarity.

• Check that the gas nozzle and proper size linerand contact tip are being used and that the gassupply is turned on. If adjustable, set for 15 to 20cubic feet per hour (7 to 10 l/min.) under normalconditions, increase to as high as 35 CFH (17I/min.) under drafty (slightly windy) conditions.

• Connect work clamp to metal to be welded. Workclamp must make good electrical contact to thework piece. The work piece must also be groundedas stated in the “Arc Welding Safety Precautions”at the beginning of this manual.

WELDING TECHNIQUES FOR THE GMAW(MIG) PROCESS

Four simple manipulations are of prime importancewhen welding. With complete mastery of the four,welding will be easy. They are as follows:

• The Correct Welding PositionFigure B.23 illustrates the correct welding positionfor right handed people. (For left handed people, itis the opposite.)

When GMAW (MIG) welding on sheet metal, it isimportant to use the “forehand” push technique.

Hold the gun (of the gun and cable assembly) inyour right hand and hold the shield with your lefthand. (Left handers simply do the opposite.)

FIGURE B.23

When using the GMAW process on light gauge mater-ial, weld from right to left (if you are right handed).This results in a colder weld and has less tendency forburn through.

• The Correct Way To Strike An Arc

ARC RAYS can burn eyes and skin.

When using an open arc process, itIs necessary to use correct eye,head and body protection.

Protect yourself and others, read“ARC RAYS can burn” at the frontof this manual.

• Be sure the work clamp makes good electrical con-tact to the work.

• Position gun over joint. End of wire may be lightlytouching the work.

• Position face shield to protect face and eyes, closegun trigger, and begin welding. Hold the gun sothat the contact tip to work distance is about 3/8 to1/2 inch (10 – 12 mm).

• To stop welding, release the gun trigger and pullthe gun away from the work after the arc goes out.

• A ball may form at the tip end of the wire afterwelding. For easier restrikes, the ball may beremoved by feeding out a few inches of wire andcutting off the end of the wire with wire cutters.

• When no more welding is to be done, close thevalve on the gas cylinder, momentarily operate thegun trigger to release gas pressure, then turn offthe machine.

WARNING

SP-170T

Helpful Hints

• For general welding, it is not necessary to weavethe arc, neither forward or backward nor sideways.Weld along at a steady pace. You will find it easier.

• When welding on thin plate, you will find that youwill have to increase the welding speed, whereaswhen welding on heavy plate, it is necessary to gomore slowly in order to get good penetration.

• When welding sheet metal 16 gauge (1.5 mm) andlighter, heat buildup may cause part warpage andburn through. One way to eliminate these problemsis to use the back-stepping method illustrated inFigure B.21.

Practice

The best way of getting practice in the four skills thatenable you to maintain:

• Correct welding position

• Correct way to strike an arc

• Correct electrical stickout

• Correct welding speed

is to perform the following exercise.

Refer to Figure B.22.

• Learn to strike an arc by positioning the gun overthe joint and touching the wire to the work.

• Position face shield to protect face and eyes.

• Depress gun trigger, hold gun so contact tip towork distance Is about 3/8 to 1/2 inch (10 to 12mm) and the gun is at proper angle.

Mild Steel 16 gauge or 1/16 inch(1.6 mm)

Electrode Lincolnweld 0.025 (0.6 mm) L-56electrode

CO2

Voltage Setting “V” C

Wire Feed Speed “o|o” 4

For the SP-170-T, use the following:


FIGURE B.24

• The Correct Electrical Stickout (ESO)The electrical stickout (ESO) is the distance fromthe end of the contact tip to the end of the wire.See Figure B.24.

Once the arc has been established, maintainingthe correct ESO becomes extremely important.The ESO should be approximately 3/8 to 1/2 inch(10 to 12 mm) long.

The easiest way to tell whether the ESO is the cor-rect length is by listening to its sound. The correctESO has a distinctive “crackling” sound, very muchlike eggs frying in a pan. A long ESO has a hollow,blowing or hissing sound. If the ESO is too short,you may stick the contact tip or nozzle to the weldpuddle and/or fuse the wire to the contact tip.

• The Correct Welding SpeedThe important thing to watch while welding is thepuddle of molten metal right behind the arc. SeeFigure B.25. Do not watch the arc itself. It is theappearance of the puddle and the ridge where themolten Puddle solidifies that indicates correct weld-ing speed. The ridge should be approximately 3/8”(10 mm) behind the wire electrode.

Most beginners tend to weld too fast, resulting in athin, uneven, “wormy” looking bead. They are notwatching the molten metal.

FIGURE B.25

Contact Tip

Wire Electrode

ESO

Molten puddle

Base metalWeld metal ridge

SP-170T

B-16 B-16 LEARNING TO WELD• After you strike the arc, practice the correct electri-

cal stickout. Learn to distinguish it by its sound.

• When you are sure that you can hold the correctelectrical stickout, with a smooth “crackling” arc,start moving. Look at the molten puddle constantly,

• Run beads on a flat plate. Run them parallel to thetop edge (the edge farthest away from you). Thisgives you practice in running straight welds, andalso gives you an easy way to check yourprogress. The 10th weld will look considerably bet-ter than the first weld. By constantly checking onyour mistakes and your progress, welding will soonbe a matter of routine.

TROUBLESHOOTING WELDSGood welds have excellent appearance.

To Eliminate Porosity (in order of importance):

• Turn on gas supply, if used

• Decrease voltage.

• Increase stickout.

• Increase WFS (wire feed speed).

• Decrease drag angle.

• Decrease travel speed.

NOTE: Always be sure the joint is free from moisture,oil, rust, paint or other contaminants.

To Eliminate a Ropy Convex Bead(in order of importance):

• Increase voltage

• Decrease stickout.

• Decrease WFS (wire feed speed.



• Check for correct gas, if used.

To Reduce Spatter (in order of importance):

• Increase voltage.

• Increase drag angle.





To Correct Poor Penetration (in order of impor-tance):



• Increase voltage.

• Decrease speed.



If Arc Blow Occurs (in order of importance):

NOTE: Try different ground connection locationsbefore adjusting procedures.


• Increase stickout.

• Decrease voltage.

• Decrease WFS (wire feed speed.


To Eliminate Stubbing* (in order of importance):

• Increase voltage

• Decrease WFS (wire feed speed)

• Decrease stickout

• Increase drag angle

* Stubbing occurs when the electrode drives throughthe molten puddle and hits the bottom plate tendingto push the gun up.

SP-170T


SP-170T

Proper Gun Handling

Most feeding problems are caused by improper han-dling of the gun cable or electrodes.

• Do not kink or pull the gun around sharp corners

• Keep the gun cable as straight as practical whenwelding.

• Do not allow dolly wheels or trucks to run over thecables.

• Keep the cable clean.

• Innershield electrode has proper surface lubrica-tion. Use only clean, rust-free electrode.

• Replace contact tip when it becomes worn or theend is fused or deformed.

B-18 B-18 APPLICATION CHART

SP-170T

D-1

GUN AND CABLE MAINTENANCE

FOR MAGNUM™ 100L GUN

Gun Cable CleaningClean cable liner after using approximately 300 lbs(136 kg) of solid wire or 50 lbs (23 kg) of flux-coredwire. Remove the cable from the wire feeder and lay itout straight on the floor. Remove the contact tip fromthe gun. Using low pressure air, gently blow out thecable liner from the gas diffuser end.

Excessive pressure at the start may cause the dirtto form a plug.

Flex the cable over its entire length and again blowout the cable. Repeat this procedure until no furtherdirt comes out.

Contact Tips, Nozzles, and Gun Tubes• Dirt can accumulate in the contact tip hole and

restrict wire feeding. After each spool of wire isused, remove the contact tip and clean it by push-ing a short piece of wire through the tip repeatedly.Use the wire as a reamer to remove dirt that maybe adhering to the wall of the hole through the tip.

• Replace worn contact tips as required. A variableor “hunting” arc is a typical symptom of a worn con-tact tip. To install a new tip, choose the correct sizecontact tip for the electrode being used (wire size isstenciled on the side of the contact tip) and screw itsnugly into the gas diffuser.

• Remove spatter from inside of gas nozzle and fromtip after each 10 minutes of arc time or as required.

• Be sure the gas nozzle is fully screwed onto thediffuser for gas shielded processes. For theInnershield® process, the gasless nozzle should bescrewed onto the diffuser.

CAUTION

D-1 MAINTENANCE

SAFETY PRECAUTIONS


• Disconnect input power byremoving plug from receptaclebefore working inside SP-170T.Use only grounded receptacle. Donot touch electrically “hot” partsinside SP-170T.

• Have qualified personnel do themaintenance and trouble shoot-ing work.

ROUTINE MAINTENANCE

POWER SOURCE COMPARTMENTIn extremely dusty locations, dirt may clog the air pas-sages causing the welder to run hot. Blow dirt out ofthe welder with low pressure air at regular intervals toeliminate excessive dirt and dust build-up on internalparts.

WIRE FEED COMPARTMENT

• When necessary, vacuum accumulated dirt fromgearbox and wire feed section.

• Occasionally inspect the incoming guide tube andclean inside diameter if necessary.

• Motor and gearbox have lifetime lubrication andrequire no maintenance.

FAN MOTOR

Has lifetime lubrication — requires no maintenance.

WIRE REEL SPINDLE

Requires no maintenance. Do not lubricate shaft.

WARNING

SP-170T

D-2D-2 MAINTENANCE

COMPONENT REPLACEMENT PROCEDURES

CHANGING THE CONTACT TIP

1. Refer to Figure D.2. Remove the gas nozzle fromthe gun by unscrewing counter-clockwise.

2. Remove the existing contact tip from the gun byunscrewing counter-clockwise.

3. Insert and hand tighten desired contact tip.

4. Replace gas nozzle.

CHANGING DRIVE ROLL

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-coredsteel electrode. As shipped, the drive roll is installed inthe .023"-.025" (0.6 mm) position.

If .030"/.035" (0.8/0.9 mm) wire is to be used, thedrive roll must be reversed as follows:

1. Connect the machine to its rated input power perinstructions in Installation section.

2. Release the spring-loaded pressure arm and lift theidle 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 driveunit with the trigger switch until the drive roll setscrew is facing up.

When inching the welding wire, the drive rolls,gun connector block, and gun contact tip areenergized relative to work and ground and remainenergized 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" (2.0mm) hex wrench supplied.

7. Remove the drive roll, flip over and reinstall with the.030/.035" (0.8/0.9 mm) groove (the larger groove)closest to the gearbox.

8. Push a length of straightened welding wire throughthe wire feeder guide tubes and adjust the positionof the drive roll so that the groove is centered onthe wire. Make certain the set screw is located onthe flat portion of the shaft and tighten.

CAUTION

3

2

1

SP-170T

GUN HANDLE PARTS

The gun handle consists of two halves that are heldtogether with a collar on each end. To open up thehandle, turn the collars approximately 60 degreescounter-clockwise until the collar reaches a stop. Thenpull the collar off the gun handle. If the collars are diffi-cult to turn, position the gun handle against a corner,place a screwdriver against the tab on the collar andgive the screwdriver a sharp blow to turn the collarpast an internal locking rib. See Figure D-3.

FIGURE D.3

➣

Counter-clockwise

D-3 D-3 MAINTENANCE

CHANGING LINER

NOTICE: The variation in cable lengths prevents theinterchangeability of liners. Once a liner has been cutfor a particular gun, it should not be installed in anoth-er gun unless it can meet the liner cutoff lengthrequirement. Refer to Figure D.2.

1. Remove the gas nozzle from the gun by unscrew-ing counter-clockwise.

2. Remove the existing contact tip from the gun byunscrewing counter-clockwise.

3. Remove the gas diffuser from the gun tube byunscrewing counter-clockwise.

4. Lay the gun and cable out straight on a flat surface.Loosen the set screw located in the brass connec-tor at the wire feeder end of the cable. Pull the linerout of the cable.

5. Insert a new untrimmed liner into the connector endof the cable. Be sure the liner bushing is stenciledappropriately for the wire size being used.

6. Fully seat the liner bushing into the connector.Tighten the set screw on the brass cable connec-tor. At this time, the gas diffuser should not beinstalled onto the end of the gun tube.

7. With the gas nozzle and diffuser removed from thegun tube, be sure the cable is straight, and thentrim the liner to the length shown in the Figure D.2.Remove any burrs from the end of the liner.

1-1/4 (31.8 mm)Liner Trim Length

Gas Diffuser

Gas Nozzle orGasless Nozzle

Set Screw Brass CableConnector

Liner Assembly (Liner bushing to be sealed tightagainst brass cable connector)

FIGURE D.2Liner trim length

8. Screw the gas diffuser onto the end of the gun tubeand securely tighten.

9. Replace the contact tip and nozzle.

SP-170T

D-4D-4 GROUND TEST PROCEDURE

WARNING ELECTRIC SHOCK can kill

WARNING: This procedure is only suitable for applica-tions using DC mega testers up to 500V.

Note: This procedure is for ‘machines as built’ manymodifications could have taken place over the life of aparticular machine, so details of this procedure mayneed to be ‘adjusted’ to suit these modifications.

For prompt service contact your local authorisedLincoln Field Service shop.

The insulation resistance values listed below are fromAustralian Standard AS1966.1.

• Disconnect input power by removing plug from mainssupply.

• Remove welding leads (gun and work lead) from themachine before any tests are carried out.

• Remove plug from PCB, install a shorting socket intothe harness plug. (The shorting socket is to have pins4 & 5 jumpered together and all other pins jumperedtogether separately and insulated.)

• Connect a shorting jumper across the connections tothe capacitor and from the capacitor to each rectifierheat sink plate.

• Set power switch to ‘on’ position.• Input circuit test: Connect one lead of the mega tester

to the frame of the machine and the other lead toboth the ‘active’ & ‘neutral’ terminals of the 240Vinput plug. Apply the test. (Minimum resistance 1M•)

• Welding circuit test: Connect one lead of the megatester to the frame of the machine and the other leadto the positive output stud. Apply the test. (Minimumresistance 1M•)

• Auxiliary circuit test: Connect one lead of the megatester to the frame of the machine and the other leadto jumper on pins 4 & 5 in the shorting socket. Applythe test. (Minimum resistance 1M•)

• Input circuit to welding circuit test: Connect one lead-of the mega tester to both the ‘active’ & ‘neutral’ ter-minals of the 240V input plug and the other to thepositive output stud. Apply the test(s). (Minimumresistance 10M•)

• Input circuit to auxiliary circuit test: Connect one lead-of the mega tester to both the ‘active’ & ‘neutral’ ter-minals of the 240V input plug and the other to thejumper on pins 4 & 5 in the shorting socket. Apply thetest. (Minimum resistance 1M•)

• Welding circuit to auxiliary circuit test: Connect one-lead of the mega tester to the positive output studand the other to the jumper on pins 4 & 5 in theshorting socket. Apply the test. (Minimum resistance1M•)

• Wire drive test: Connect one lead of the mega tester-to the positive output stud and the other to the driveroll shaft. Apply the test. (Minimum resistance 1M•)

• Remove all harness shorting plugs and connect allplug and leads to PCB. Remove all shorting jumpers.If any problems are encountered, refer to your near-est authorisedLincoln Field Service Shop.

WARNING

SP-170T

E-1 E-1 TROUBLESHOOTING

This Troubleshooting Guide is provided tohelp you locate and repair possible machinemalfunctions. Simply follow the three-stepprocedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).Look under the column labeled “PROBLEM(SYMPTOMS)”. This column describes pos-sible symptoms that the machine mayexhibit. Find the listing that best describesthe symptom that the machine is exhibiting.

Symptoms are grouped into three main cat-egories: output problems, function prob-lems, welding problems.

Step 2. PERFORM EXTERNAL TESTS.The second column labeled “POSSIBLEAREAS OF MISADJUSTMENT(S)” lists theobvious external possibilities that may con-tribute to the machine symptom. Performthese tests/checks in the order listed. Ingeneral, these tests can be conducted with-out removing the case wrap-around cover.

Step 3. PERFORM COMPONENT TESTS.If you have exhausted all of the recom-mended tests in Step 2, Consult your LocalAuthorized Field Service Facility.

HOW TO USE TROUBLESHOOTING GUIDE

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 andmachine operator and will invalidate your factory warranty. For your safety and to avoidElectrical Shock, please observe all safety notes and precautions detailed throughout this manual.__________________________________________________________________________

WARNING

If for any reason you do not understand the test procedures or are unable to performthe tests safely, contact your LOCAL AUTHORIZED LINCOLN ELECTRIC FIELDSERVICE FACILITY for assistance before you proceed._____________________________________________________________________

CAUTION

SP-170T

E-2 E-2TROUBLESHOOTINGObserve Safety Guidelines

detailed in the beginning of this manual.TROUBLESHOOTING GUIDE

PROBLEMS(SYMPTOMS)

Major physical or electrical damageis evident.

No wire feed, weld output or gasflow when gun trigger is pulled. Fandoes NOT operate.

No wire feed, weld output or gasflow when gun trigger is pulled Fanoperates normally.

POSSIBLE AREAS OFMISADJUSTMENT(S)

NoneContact your local Authorized FieldService Facility.

1. Make sure correct voltage isapplied to the machine. SeeInstallation section, “ElectricalConnections”.

2. Make certain that power switchis in the ON position.

3. Make sure circuit breaker insidewire drive compartment is reset.

1. The thermostat may be trippeddue to overheating. Let machinecool. Weld at lower duty cycle.

2. Check for obstructions in airflow.

3. Check Gun Trigger connections.See Installation section.

4. Gun trigger may be faulty.

RECOMMENDEDCOURSE OF ACTION

If all recommended possible areasof misadjustment have beenchecked and the problem persists,Contact your local LincolnAuthorized Field ServiceFacility.

OUTPUT PROBLEMS

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLOCAL AUTHORIZED LINCOLN ELECTRIC FIELD SERVICE FACILITY for assistance before you proceed.

CAUTION

SP-170T

E-3 E-3 TROUBLESHOOTINGTROUBLESHOOTING GUIDEObserve Safety Guidelines

detailed in the beginning of this manual.

PROBLEMS(SYMPTOMS)

No wire feed when gun trigger ispulled. Fan runs, gas flows andmachine has correct open circuitvoltage (33 vcd maximum) – weldoutput.


1. If the wire drive motor is runningmake sure that the correct driverolls are installed in the machine.

2. Check for clogged cable liner orcontact tip.

3. Check for proper size cable linerand contact tip.



FEEDING PROBLEMS


CAUTION

PROBLEMS(SYMPTOMS)

Low or no gas flow when guntrigger is pulled. Wire feed, weldoutput and fan operate normally.


1. Check gas supply, flow regulatorand gas hoses.

2. Check gun connection tomachine for obstruction or leakyseals.



GAS FLOW PROBLEMS

SP-170T

E-4 E-4 TROUBLESHOOTINGObserve Safety Guidelines

detailed in the beginning of this manual.TROUBLESHOOTING GUIDE


CAUTION

PROBLEMS(SYMPTOMS)

Arc is unstable – Poor starting


1. Check for correct input voltageto machine. See Installation sec-tion, “Electrical InputConnections”.

2. Check for proper electrodepolarity for process.

3. Check gun tip for wear or dam-age and proper size – Replace.

4. Check for proper gas and flowrate for process. (For MIG only.)

5. Check work cable for loose orfaulty connections.

6. Check gun for damage orbreaks.

7. Check for proper drive roll orien-tation and alignment.

8. Check liner for proper size.



WELDING PROBLEMS

SP-170T

F-1 F-1 WIRING DIAGRAMSSP-170T WIRING DIAGRAM: Code 10842

SP

-170

T W

IRIN

G D

IAG

RA

M

10/0

0

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. Thespecific diagram for a particular code is pasted inside the machine on one of the enclosure panels.

SP-170T

WARNING

AVISO DEPRECAUCION

ATTENTION

WARNUNG

ATENÇÃO

Spanish

French

German

Portuguese

Japanese

Chinese

Korean

Arabic

READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BEUSED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.

SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOSCONSUMIBLES 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 AETRE 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 UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

● Do not touch electrically live parts orelectrode with skin or wet clothing.

● Insulate yourself from work andground.

● No toque las partes o los electrodosbajo carga con la piel o ropa moja-da.

● Aislese del trabajo y de la tierra.

● Ne laissez ni la peau ni des vête-ments mouillés entrer en contactavec des pièces sous tension.

● Isolez-vous du travail et de la terre.

● Berühren Sie keine stromführendenTeile oder Elektroden mit IhremKörper oder feuchter Kleidung!

● Isolieren Sie sich von denElektroden und dem Erdboden!

● Não toque partes elétricas e elec-trodos com a pele ou roupa molha-da.

● Isole-se da peça e terra.

● Keep flammable materials away.

● Mantenga el material combustiblefuera del área de trabajo.

● Gardez à l’écart de tout matérielinflammable.

● Entfernen Sie brennbarres Material!

● Mantenha inflamáveis bem guarda-dos.

● Wear eye, ear and body protection.

● Protéjase los ojos, los oídos y elcuerpo.

● Protégez vos yeux, vos oreilles etvotre corps.

● Tragen Sie Augen-, Ohren- und Kör-perschutz!

● Use proteção para a vista, ouvido ecorpo.

WARNING

AVISO DEPRECAUCION

ATTENTION

WARNUNG

ATENÇÃO

Spanish

French

German

Portuguese

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA ASPRÁTICAS DE SEGURANÇA DO EMPREGADOR.

● Keep your head out of fumes.● Use ventilation or exhaust to

remove fumes from breathing zone.

● Los humos fuera de la zona de res-piración.

● Mantenga la cabeza fuera de loshumos. Utilice ventilación oaspiración para gases.

● Gardez la tête à l’écart des fumées.● Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zonesde travail.

● Vermeiden Sie das Einatmen vonSchweibrauch!

● Sorgen Sie für gute Be- undEntlüftung des Arbeitsplatzes!

● Mantenha seu rosto da fumaça.● Use ventilação e exhaustão para

remover fumo da zona respiratória.

● Turn power off before servicing.

● Desconectar el cable de ali-mentación de poder de la máquinaantes de iniciar cualquier servicio.

● Débranchez le courant avant l’entre-tien.

● Strom vor Wartungsarbeitenabschalten! (Netzstrom völlig öff-nen; Maschine anhalten!)

● Não opere com as tampas removidas.● Desligue a corrente antes de fazer

serviço.● Não toque as partes elétricas nuas.

● Do not operate with panel open orguards off.

● No operar con panel abierto oguardas quitadas.

● N’opérez pas avec les panneauxouverts ou avec les dispositifs deprotection enlevés.

● Anlage nie ohne Schutzgehäuseoder Innenschutzverkleidung inBetrieb setzen!

● Mantenha-se afastado das partesmoventes.

● Não opere com os paineis abertosou guardas removidas.

• 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 •

IM710 SP -170 T - Lincoln Electric · PDF fileARC RAYS can burn. 4.a. Use a shield with the...

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