Instruction/ maintenance manual of the product IM725 Lincoln Electric
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SP- 135 PLUS OPERA TOR’S MANUAL IM725 December, 2001 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thought- ful operation on your part.
SP-135 PLUS FOR ENGINE powered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors.
SP-135 PLUS ii SAFETY ii ARC RA YS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87.
SP-135 PLUS FOR ELECTRICALL Y powered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer ’ s recommendations.
SP-135 PLUS iv SAFETY iv PR É CA UTIONS DE S Û RET É Pour votre propre protection lire et observer toutes les instructions et les pr é cautions de s û ret é specifiques qui parraissent dans ce manuel aussi bien que les pr é cautions de s û ret é g é n é rales suiv- antes: S û ret é Pour Soudage A L ’ Arc 1.
SP-135 PLUS Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment.
vi vi SP-135 PLUS T ABLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications ..........................................................
A-1 A-1 INST ALLA TION SP-135 PLUS Fuse or Output Mode Input Voltage Breaker Size Input Amps Extension Cord Three Conductor #14 AWG RATED 115V/60Hz 20 Amp 20 (2.1 mm 2 ) or Larger for up to 25 feet (7.6m) Three Conductor #12 AWG MAXIMUM 115V/60Hz 25 Amp 25 (3.
A-2 A-2 INST ALLA TION SP-135 PLUS Read entire installation section before starting installation. SAFETY PRECA UTIONS IDENTIFY AND LOCA TE COMPONENTS If you have not already done so, unpack the SP-135 PLUS from its carton and remove all packing material around the SP-135 PLUS.
A-3 A-3 INST ALLA TION SP-135 PLUS SELECT SUIT ABLE LOCA TION Locate the welder in a dry location where there is free circulation of clean air into the louvers in the back and out the front of the unit.
A-4 SP-135 PLUS A-4 INST ALLA TION 3. Route the cable under and around the back of the Wire Feed Gearbox (6). 4. For GMAW Only: Refer to Figure A.2. As deliv- ered, the SP-135 PLUS is wired for positive polari- ty. This is the appropriate configuration for the Gas Metal Arc Welding (GMAW) process.
A-5 A-5 INST ALLA TION SP-135 PLUS 3. Attach the flow regulator to the cylinder valve and tighten the union nut securely with a wrench. The flow regulator for carbon dioxide must have a plas- tic washer seated in the fitting that attaches to the cylinder to prevent leakage.
A-6 A-6 INST ALLA TION SP-135 PLUS CODE REQUIREMENTS FOR INPUT CONNECTIONS This welding machine must be connected to power source in accordance with applicable elec- trical codes.
SP-135 PLUS B-1 B-1 OPERA TION Read entire Operation section before operating the SP-135 PLUS. ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrode with skin or wet clothing. Insulate yourself from work and ground. • Always wear dry insulating gloves.
B-2 SP-135 PLUS B-2 OPERA TION GENERAL DESCRIPTION The SP-135 PLUS is a complete semiautomatic con- stant voltage DC arc welding machine. Included is a solid state controlled, single phase constant voltage transformer/ rectifier power source and a wire feeder for feeding solid steel electrode and cored electrode.
SP-135 PLUS B-3 B-3 OPERA TION FIGURE B.1a 4. Circuit Breaker – Protects machine from damage if maximum output is exceeded. Button will extend out when tripped (Manual reset). Refer to Figure B.1b. 5. Gun Trigger - Activates welding output, wire feed, and gas solenoid operation.
B-4 B-4 OPERA TION FIGURE B.3 Friction Brake Adjustment With wire spool installed on the spindle shaft and the wing nut loose, turn the spool by hand while slowly tightening the wing nut until a light drag is felt. Tighten the wing nut an additional 1/4 turn.
SP-135 PLUS B-5 B-5 OPERA TION Shielding Gas When using the GMAW process, a cylinder of shield- ing gas, must be obtained. Refer to the ACCES- SORIES section for more information about selecting gas cylinders for use with the SP-135 PLUS. 1. For CO 2 , open the cylinder very slowly.
B-6 SP-135 PLUS B-6 OPERA TION 9. To stop welding, release the gun trigger and then pull the gun away from the work after the arc goes out. 10. When no more welding is to be done, close valve on gas cylinder (if used), momentarily operate gun trigger to release gas pressure, and turn off the SP-135 PLUS.
SP-135 PLUS B-7 B-7 OPERA TION O VERLO AD PRO TECTION Output Overload The SP-135 PLUS is equipped with a circuit breaker which protects the machine from potential damage from excessive output current. The circuit breaker but- ton will extend out when tripped.
B-8 SP-135 PLUS B-8 LEARNING T O WELD LEARNING T O WELD No one can learn to weld simply by reading about it. Skill comes only with practice. The following pages will help the inexperienced operator to understand weld- ing and develop this skill.
SP-135 PLUS B-9 B-9 LEARNING T O WELD The “ arc stream ” is seen in the middle of the picture. This is the electric arc created by the electric current flowing through the space between the end of the wire electrode and the base metal. The temperature of this arc is about 6000 ° F, which is more than enough to melt metal.
B-10 SP-135 PLUS B-10 LEARNING T O WELD For GMAW (MIG) Process 1. Is most of my welding performed on 16 gauge and lighter materials? 2. Can I afford the extra expense, space, and lack of portability required for gas cylinders and gas sup- ply? 3.
SP-135 PLUS B-11 B-11 LEARNING T O WELD FIGURE B.12 Penetration Unless a weld penetrates close to 100% of the metal thickness, a butt weld will be weaker than the material welded together. In the example shown in Figure B.13, the total weld is only half the thickness of the material thus the weld is only approximately half as strong as the metal.
B-12 SP-135 PLUS B-12 LEARNING T O WELD FIGURE B.16 Vertical-down Welding Refer to Figure B.17 Vertical-down welds are applied at a fast pace. These welds are therefore shallow and narrow and, as such, are excellent for sheet metal. Vertical-down welds may be applied to 5/32 ” (3.
SP-135 PLUS B-13 B-13 LEARNING T O WELD ARC RAYS can burn eyes and skin. When using an open arc process, it Is necessary to use correct eye, head and body protection. Protect yourself and others, read “ ARC RAYS can burn ” at the front of this manual.
B-14 SP-135 PLUS B-14 LEARNING T O WELD Mild Steel 16 gauge or 1/16 inch (1.6 mm) Electrode 0.035" (0.9 mm) NR-211-MP Innershield Wire Voltage Setting “ V ” E Wire Feed Speed “ o|o ” 2 For the SP-135 PLUS, use the follo wing: Helpful Hints 1.
SP-135 PLUS B-15 B-15 LEARNING T O WELD MA CHINE SET UP FOR THE GMA W (MIG) PROCESS 1. See PROCESS GUIDELINES in the OPERATION section for selection of welding wire and shielding gas, and for range of metal thicknesses that can be welded. 2. See the Application Guide on the inside of wire feed section door for information on setting the controls.
Helpful Hints 1. For general welding, it is not necessary to weave the arc, neither forward or backward nor sideways. Weld along at a steady pace. You will find it easier.
SP-135 PLUS B-17 B-17 LEARNING T O WELD 4. After you strike the arc, practice the correct electri- cal stickout. Learn to distinguish it by its sound. 5. When you are sure that you can hold the correct electrical stickout, with a smooth “ crackling ” arc, start moving.
SP-135 PLUS B-18 B-18 LEARNING T O WELD Proper Gun Handling Most feeding problems are caused by improper han- dling of the gun cable or electrodes. 1. Do not kink or pull the gun around sharp corners 2. Keep the gun cable as straight as practical when welding.
B-19 B-19 APPLICA TION CHART SP-135 PLUS.
C-1 C-1 SP-135 PLUS A CCESSORIES 4 . KP666-035C Knurled Drive Roll (optional) — Reversible Drive Roll with double knurled grooves for .035 (0.9 mm) cored electrode.
C-2 C-2 SP-135 PLUS A CCESSORIES INNERSHIELD (FCA W) CONVERSION Several changes are needed to convert the unit for operation with the Innershield (FCAW) process. The K549-1 Innershield Kit includes all the necessary accessories for this conversion and are provided for this purpose.
SP-135 PLUS MAINTENANCE SAFETY PRECA UTIONS ELECTRIC SHOCK can kill. • Disconnect input power by removing plug from receptacle before working inside SP-135 PLUS. Use only grounded recep- tacle. Do not touch electrically “ hot ” parts inside SP-135 PLUS.
D-2 SP-135 PLUS D-2 MAINTENANCE GUN AND CABLE MAINTENANCE FOR MA GNUM ™ 100L GUN Gun Cable Cleaning Clean cable liner after using approximately 300 lbs (136 kg) of solid wire or 50 lbs (23 kg) of flux-cored wire. Remove the cable from the wire feeder and lay it out straight on the floor.
D-3 SP-135 PLUS D-3 MAINTENANCE COMPONENT REPLA CEMENT PR OCEDURES CHANGING THE CONT A CT TIP 1. Unplug or turn power switch to Off “ O ” position. 2. Refer to Figure D.2. Remove the gas nozzle from the gun by unscrewing counter-clockwise. 3. Remove the existing contact tip from the gun by unscrewing counter-clockwise.
D-4 GUN HANDLE P ARTS The gun handle consists of two halves that are held together with a collar on each end. To open up the handle, turn the collars approximately 60 degrees counter-clockwise until the collar reaches a stop. Then pull the collar off the gun handle.
SP-135 PLUS If machine case sides and top are removed, the case front must be supported. Failure to do this could result in mechanical or electrical damage to the SP-135 PLUS.
E-2 SP-135 PLUS E-2 TR OUBLESHOO TING Observe Safety Guidelines detailed in the beginning of this manual. TR OUBLESHOO TING GUIDE PROBLEMS (SYMPT OMS) Major physical or electrical damage is evident. No wire feed, weld output or gas flow when gun trigger is pulled.
SP-135 PLUS E-3 E-3 TR OUBLESHOO TING Observe Safety Guidelines detailed in the beginning of this manual. TR OUBLESHOO TING GUIDE PROBLEMS (SYMPT OMS) No wire feed when gun trigger is pulled. Fan runs, gas flows and machine has correct open circuit voltage (28 vdc maximum) – weld output.
E-4 SP-135 PLUS E-4 TR OUBLESHOO TING Observe Safety Guidelines detailed in the beginning of this manual. TR OUBLESHOO TING GUIDE PROBLEMS (SYMPT OMS) Arc is unstable – Poor starting POSSIBLE AREAS OF MISADJUSTMENT(S) 1. Check for correct input voltage to machine – 115 vac.
F-1 SP-135 PLUS F-1 WIRING DIA GRAMS M19922 L1 L2 31 32 531 TO GROUND PER NATIONAL ELECTRICAL CODE S1 SWITCH 202 201 D1 D3 D2 D4 204 204 204 203 203 203 C1 59,000 f 40V 203 204 - + OUTPUT CHOKE GUN CA.
SP-135 PLUS NO TES.
Now A vailable...12th Edition The Procedure Handbook of Ar c W elding With over 500,000 copies of previous editions published since 1933, the Procedure Handbook is considered by many to be the “ Bible ” of the arc welding industry. This printing will go fast so don ’ t delay.
W ARNING A VISO DE PRECA UCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
W ARNING A VISO DE PRECA UCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRU ES DO F ABRICANTE P ARA ESTE EQUIP AMENTO E AS PAR TES DE USO, E SIGA AS PR TICAS DE SEGURAN A DO EMPREGADOR.
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An important point after buying a device Lincoln Electric IM725 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Lincoln Electric IM725 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Lincoln Electric IM725 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Lincoln Electric IM725 you will learn all the available features of the product, as well as information on its operation. The information that you get Lincoln Electric IM725 will certainly help you make a decision on the purchase.
If you already are a holder of Lincoln Electric IM725, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Lincoln Electric IM725.
However, one of the most important roles played by the user manual is to help in solving problems with Lincoln Electric IM725. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Lincoln Electric IM725 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
