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Lincoln Electric SP-135 PLUS IM725, Operator'S Manual

The Lincoln Electric SP-135 PLUS IM725 is a versatile welding machine designed for both beginners and professionals. Ensure optimal usage by referring to the comprehensive Operator's Manual, available for free download at 88.208.23.73:8080. Access the manual today and unlock the full potential of your welding experience.

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SP-135 PLUS

TABLE OF CONTENTS

Page

Installation .......................................................................................................Section A

Technical Specifications ........................................................................................A-1
Identify and Locate Components ...........................................................................A-2
Select Suitable Location ........................................................................................A-3
Output Connections ...............................................................................................A-3
Input Connections..................................................................................................A-5
Code Requirements ..............................................................................................A-6

Operation .........................................................................................................Section B

Safety Precautions ................................................................................................B-1
General Description ...............................................................................................B-2

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

Welding Operations ...............................................................................................B-3
Overload Protection ...............................................................................................B-7
Learning to Weld....................................................................................................B-8
Application Chart .................................................................................................B-19

Accessories .....................................................................................................Section C

Accessories ...........................................................................................................C-1
Replacement Parts ................................................................................................C-2

Maintenance ....................................................................................................Section D

Safety Precautions ................................................................................................D-1
Items Requiring No Maintenance ..........................................................................D-1
Routine and Periodic Maintenance........................................................................D-1
Gun and Cable Maintenance.................................................................................D-2
Configuration of Components in Wire Feeding System.........................................D-2
Component Replacement Procedures ..................................................................D-3
Changing Liner ......................................................................................................D-4
Gun Handle Parts ..................................................................................................D-4

Troubleshooting ..............................................................................................Section E

Safety Precautions.................................................................................................E-1
How To Use Troubleshooting Guide......................................................................E-1
Troubleshooting Guide.........................................................................E-2 THRU E-4

Wiring Diagrams ..............................................................................................Section F

SP-135 PLUS Wiring Diagram...............................................................................F-1

Parts Lists ..............................................................................................P 397 & P202-E

Summary of Contents for SP-135 PLUS IM725

Page 1: ...THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT And most importantly think before you act and be careful For use with machine Code Numbers 10868 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 ...

Page 2: ...CEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding Cutting ANSI Standard Z49 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is ...

Page 3: ...electrical earth ground 3 f Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation 3 g Never dip the electrode in water for cooling 3 h Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both wel...

Page 4: ... to prevent the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available 6 b Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in ...

Page 5: ...ropriés et non inflammables 4 Des gouttes de laitier en fusion sont émises de l arc de soudage Se protéger avec des vêtements de protection libres de l huile tels que les gants en cuir chemise épaisse pan talons sans revers et chaussures montantes 5 Toujours porter des lunettes de sécurité dans la zone de soudage Utiliser des lunettes avec écrans lateraux dans les zones où l on pique le laitier 6 ...

Page 6: ...here the information must be followed to avoid minor personal injury or damage to this equipment CAUTION Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped title passes to the purchaser upon receipt by the carrier Consequently Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is r...

Page 7: ... 3 Overload Protection B 7 Learning to Weld B 8 Application Chart B 19 Accessories Section C Accessories C 1 Replacement Parts C 2 Maintenance Section D Safety Precautions D 1 Items Requiring No Maintenance D 1 Routine and Periodic Maintenance D 1 Gun and Cable Maintenance D 2 Configuration of Components in Wire Feeding System D 2 Component Replacement Procedures D 3 Changing Liner D 4 Gun Handle ...

Page 8: ... PLUS INPUT SINGLE PHASE ONLY RATED OUTPUT OUTPUT RECOMMENDED INPUT CABLE AND FUSE SIZES Height Width Depth Weight 12 0 in 9 75 in 16 5 in 54 Ibs 305 mm 248 mm 419 mm 24 3 kg PHYSICAL DIMENSIONS Standard Voltage Frequency Input Current 115V 60Hz 20 Amps Rated Output 115V 60Hz 25 Amps Maximum Output 115V 60Hz 15 Amps CSA Rated output Duty Cycle Amps Volts at Rated Amperes 20 Duty Cycle Rated DC Out...

Page 9: ...Adjustable mixed Gas Regulator Hose For available options and accessories refer to the accessories section later in this manual 1 As shipped from the factory the SP 135 PLUS gun is ready to feed 023 or 025 0 6 mm wire ELECTRIC SHOCK can kill Only qualified personnel should perform this installation Only personnel that have read and under stood the SP 135 PLUS Operating Manual should install and op...

Page 10: ... Lead Connectors 5 Positive and negative output terminals 6 Wire Feed Gearbox and Gun Connector Block 7 Cable Clamp 8 Thumbscrew Secures gun and cable assembly 9 Optional Spot Stitch Timer Kit see Accessories Work Clamp Installation Attach the work clamp per the following 1 Unplug the machine or turn the power switch to the OFF position 2 Insert the work cable terminal lug with the larger hole thr...

Page 11: ... switch being used is other than that supplied with the SP 135 PLUS the switch must be a normally open momentary switch The terminals of the switch must be insulated from the welding circuit Malfunction of the SP 135 PLUS will result if this switch shorts to the SP 135 PLUS welding output circuit or is common to any electri cal circuit other than the SP 135 PLUS trigger circuit GAS CONNECTION Refe...

Page 12: ...are located on the rear of the machine FIGURE A 6 BUILDUP OF SHIELDING GAS may harm health or kill Shut off shielding gas supply when not in use SEE AMERICAN NATIONAL STANDARD Z 49 1 SAFETY IN WELDING AND CUTTING PUB LISHED BY THE AMERICAN WELDING SOCIETY 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 circui...

Page 13: ...e 5 15P is factory installed on the SP 135 PLUS Connect this plug to a mating ground ed receptacle which is connected to a 20 amp branch circuit with a nominal voltage rating of 115 to 125 volts 60 Hertz AC only The rated output with this installation is 90 amps 18 Volts 20 duty cycle 2 minutes of every 10 minutes used for welding Do not connect the SP 135 PLUS to an input power supply with a rate...

Page 14: ...from work and ground Always wear dry insulating gloves FUMES AND GASES can be dangerous Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone WELDING SPARKS can cause fire or explosion Keep flammable material away Do not weld on closed contain ers ARC RAYS can burn eyes and skin Wear eye ear and body protec tion Observe all safety information throughout this ma...

Page 15: ...t and a circuit breaker Quality wire drive with electronic overload protec tion Easy to set continuous range controls for precise setting of arc voltage and wire speed Continuous voltage control Quick Release idle roll pressure arm is easily adjusted Reversible dual groove drive roll Drive roll will feed 023 035 0 6 0 9 mm diameter wire Accommodates both 8 200 mm diameter and 4 100 mm diameter spo...

Page 16: ...G OPERATIONS SEQUENCE OF OPERATION Wire Loading Refer to Figure B 2 AND B3 The machine power switch should be turned to the OFF O position before working inside the wire feed enclosure The machine is shipped from the factory ready to feed 4 100 mm diameter spools A 4 100 mm diameter spool is mounted directly on the 5 8 16 mm diame ter spindle that has a built in adjustable friction brake to preven...

Page 17: ... engages the threads of the pressure arm 1 If feeding problems occur because the wire is flattened excessively turn the pressure adjust ment counter clockwise to reduce distortion of the wire Slightly less pressure 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 feeds properly When inching the welding wir...

Page 18: ...shielding gas and for range of metal thicknesses that can be welded 2 See the Application Chart on the inside of wire feed section door for information on setting the SP 135 PLUS controls 3 Set the Voltage V and Wire Speed olo con trols to the settings suggested for the welding wire and base metal thickness being used FIGURE B 6 FIGURE B 5 Gun Handle Gas Diffuser Contact Tip Gas Nozzle 4 Check tha...

Page 19: ... Welding kit See ACCES SORIES section It is important when changing between welding with steel wire and aluminum to exchange feeding components due to the lubricant applied to steel wire Failure to do so may result in contaminated welds when welding aluminum TABLE B 1 SP 135 PLUS Welding Procedures CHANGING MACHINE OVER TO FEED OTHER WIRE SIZES The SP 135 PLUS is shipped from the factory ready to ...

Page 20: ...put until the machine cools to a normal operating temperature This is an automatic function and is self resetting Wire Feed Overload Protection If the SP 135 PLUS has an automatic electronic pro tection circuit to protect the wire feed motor If exces sive motor overload occurs due to excessive feeding force jammed drive rolls or shorted motor leads the circuit will shut down the wire feed motor an...

Page 21: ...d This helps pre vent current from going through an unwanted path Avoid allowing the welding circuit to pass through hinges bearings electronic components or similar devices that can be damaged See Figure B 8 Always disconnect electrical devices before welding upon them Fumes and slag generated from Innershield type electrodes recom mended for use with this welding machine can be toxic Avoid conta...

Page 22: ...purities and forms the protective slag on top of the weld during cooling After running a weld bead the slag may be removed with a chipping hammer and wire brush This improves appearance and allows for inspection of the finished weld Since machine size and output characteristics limit the size 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 ...

Page 23: ...e good that the metal is mild steel and that you will be able to weld the material In addition aluminum and stainless steel can be welded using the K664 1 Aluminum Welding Kit For further information on identifying various types of steels and other metals and for proper procedures for welding them we again suggest you purchase a copy of New Lessons in Arc Welding Regardless of the type of metal be...

Page 24: ...tical up or vertical down Vertical up is used whenever a larger stronger weld is desired Vertical down is used primarily on sheet metal 5 32 3 9 mm and under 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 of the plate This is called Cold Casting and will result in weld failure Ve...

Page 25: ...s to the settings suggested on the Application Guide for the welding wire and base metal thickness being used The voltage control is marked V and the wire feed speed is marked olo 4 Check that the polarity is correct for the welding wire being used Set the polarity for DC when welding with NR 211 MP Innershield electrode See Work Cable Installation in the INSTALLATION section for instructions on c...

Page 26: ...stickout ESO is the distance from the end of the contact tip to the end of the wire See Figure B 19 Once the arc has been established maintaining the 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 WARNING FIGURE B 19 3 8 1 2 10 12 mm Electrical Stickout ESO Contact Tip Wire Electrode Solidifying ridge Molten puddle T...

Page 27: ... Correct welding speed is to perform the following exercise Refer to Figure B 22 1 Learn to strike an arc by positioning the gun over the joint and touching the wire to the work 2 Position face shield to protect face and eyes 3 Depress gun trigger hold gun so contact tip to work distance is about 3 8 to 1 2 inch 10 to 12 mm and the gun is at proper angle 4 After you strike the arc practice the cor...

Page 28: ...y of the four welding will be easy They are as follows 1 The Correct Welding Position Figure B 23 illustrates the correct welding position for right handed people For left handed people it is the opposite When GMAW MIG welding on sheet metal it is important to use the forehand push technique Hold the gun of the gun and cable assembly in your right hand and hold the shield with your left hand Left ...

Page 29: ...nch 1 6 mm Electrode Lincolnweld 0 025 L 56 electrode CO2 Voltage Setting V G Wire Feed Speed o o 5 For the SP 135 PLUS use the following FIGURE B 24 3 The Correct Electrical Stickout ESO The electrical stickout ESO is the distance from the end of the contact tip to the end of the wire See Figure B 24 Once the arc has been established maintaining the correct ESO becomes extremely important The ESO...

Page 30: ... is free from moisture oil rust paint or other contaminants To Eliminate a Ropy Convex Bead in order of importance 1 Increase voltage 2 Decrease stickout 3 Decrease WFS wire feed speed 4 Decrease travel speed 5 Decrease drag angle 6 Check for correct gas if used To Reduce Spatter in order of importance 1 Increase voltage 2 Increase drag angle 3 Decrease stickout 4 Increase WFS wire feed speed 5 De...

Page 31: ...ot kink or pull the gun around sharp corners 2 Keep the gun cable as straight as practical when welding 3 Do not allow dolly wheels or trucks to run over the cables 4 Keep the cable clean 5 Innershield electrode has proper surface lubrica tion Use only clean rust free electrode 6 Replace contact tip when it becomes worn or the end is fused or deformed ...

Page 32: ...B 19 B 19 APPLICATION CHART SP 135 PLUS ...

Page 33: ... trode Also included is a spool of 035 0 9 mm Innershield NR 211 MP OPTIONAL ACCESSORIES 1 K520 Utility Cart Designed to transport the Lincoln family of small welders Has provisions for mounting a single gas cylinder Has front casters and large rear wheels Handle height is easily adjustable Bottom tray provided for tools and accessories Easy assembly required takes less than 15 minutes 2 K586 1 De...

Page 34: ...intenance section for details 4 Remove gas nozzle if installed and install gasless nozzle To remove simply unscrew REPLACEMENT PARTS Complete Gun and Cable Assembly L8311 6 K530 4 Contact Tip 025 0 6 mm S19726 1 Contact Tip 030 0 8 mm S19726 2 Contact Tip 035 0 9 mm S19726 3 Contact Tip 045 1 2 mm S19726 4 Contact Tip Tapered 025 0 6 mm S20278 1 Contact Tip Tapered 030 0 8 mm S20278 2 Contact Tip ...

Page 35: ...ith short piece of wire Clean cable liner when rough and erratic wire feed ing occur MAINTENANCE D 1 D 1 WARNING AFTER FEEDING 50 OF FLUX CORED WIRE OR 300 OF SOLID WIRE Unplug machine or turn power switch to OFF O position Remove gun and cable from machine Remove gas nozzle and contact tip from gun Lay cable out straight blow out gently into gun end with compressed air Bend cable back and forth b...

Page 36: ...zle or gasless nozzle and remove diffuser from gun tube Remove both collars from each end of the gun handle and separate the handle halves Loosen the locking nut holding the gun tube in place against the gun end cable connector Unscrew gun tube from cable connector To install gun tube screw the locking nut on the gun tube as far as possible Then screw the gun tube into the cable connector until it...

Page 37: ...el electrode As shipped the drive roll is installed in the 023 025 0 6 mm position If 030 035 0 8 0 9 mm wire is to be used the drive roll must be reversed as follows 1 Turn the power switch to OFF marked O 2 Release the spring loaded idle arm tensioner Figure D 1 Item 2 and lift the idle roll arm Figure D 1 Item 3 away from the drive roll 3 Loosen the Phillips Head screw holding the drive roll on...

Page 38: ...le lengths prevents the interchangeability of liners Once a liner has been cut for a particular gun it should not be installed in anoth er gun unless it can meet the liner cutoff length requirement Refer to Figure D 2 1 Remove gun and cable assembly from machine 2 Remove the gas nozzle from the gun by unscrew ing counter clockwise 3 Remove the existing contact tip from the gun by unscrewing counte...

Page 39: ... that best describes the symptom that the machine is exhibiting Step 2 POSSIBLE CAUSE The second column labeled POSSIBLE CAUSE lists the obvious external possibilities that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause generally it states to contact your local Lincoln Authorized Field Service Facility If you...

Page 40: ...e certain that power switch is in the ON position Contact your LOCAL LINCOLN AUTHORIZED FIELD SERVICE FACILITY 1 Arc voltage may be set too low 2 Gun tip may be worn Replace 3 Check for correct input voltage to machine 4 Gun or work cable may be faulty 1 Check the circuit breaker locat ed in the machine s wire drive compartment Reset if tripped 2 The thermostat may be tripped due to overheating Le...

Page 41: ...k for clogged cable liner or feeding problems 1 Make sure that the wire speed control is not set at maximum 1 Wire spool friction brake adjust ment set too tight Check adjust ment of the wire spool friction brake See Friction Brake Adjustment in the OPERA TION section of this manual 2 Idle roll pressure adjustment set too high Check adjustment of the idle roll pressure See Wire Threading in The OP...

Page 42: ...OMMENDED COURSE OF ACTION Contact your local Lincoln Authorized Field Service Facility WELDING PROBLEMS If for any reason you do not understand the test procedures or are unable to Perform the tests repairs safely contact your LOCAL AUTHORIZED LINCOLN ELECTRIC FIELD SERVICE FACILITY for assistance before you proceed CAUTION PROBLEMS SYMPTOMS Low or no gas flow when gun trigger is pulled Wire feed ...

Page 43: ... A DIODES D1 D3 ARE MOUNTED ON THE OUTSIDE HEATSINK N C COMPONENT VIEWED FROM REAR H I G H V O L T A G E c a n k i l l N B DIODES D2 D4 ARE MOUNTED ON THE INSIDE HEATSINK WHICH IS CLOSEST TO THE CENTER PANEL LEAD COLOR CODE B BLACK W WHITE N B N D COMPONENT SIDE OF BOARD N D BOLTED ALUMINUM CONNECTIONS REQUIRE T12837 JOINT COMPOUND DOW CORNING 340 WHEN REATTACHING 4 01 1 2 3 4 5 LATCH J3 5 4 3 2 1...

Page 44: ...SP 135 PLUS NOTES ...

Page 45: ...6 383 2259 and ask for the Welding School Registrar Lincoln Welding School BASIC COURSE 700 00 5 weeks of fundamentals There is a 10 discount on all orders of 50 00 or more for shipment at one time to one location Orders of 50 or less before discount or orders outside of North America must be prepaid with charge check or money order in U S Funds Only Prices include shipment by 4 th Class Book Rate...

Page 46: ...ch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja da Aislese del trabajo y de la tierra Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension Isolez vous du travail et de la terre Ber hren Sie keine stromf hrenden Teile oder Elektr...

Page 47: ...ute Be und Entl ftung des Arbeitsplatzes Mantenha seu rosto da fuma a Use ventila o e exhaust o para remover fumo da zona respirat ria Turn power off before servicing Desconectar el cable de ali mentaci n de poder de la m quina antes de iniciar cualquier servicio D branchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine anhalten N o opere com a...

Page 48: ...s 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 ...

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