Lincoln Electric SAM650, SAM400 User Manual

SAM400 & 650 PERKINS DIESEL ENGINE DRIVEN
MULTI-PROCESS DC ARC WELDING POWER SOURCES
OPERATOR’S MANUAL
Sales and Service through Subsidiaries and Distributors Worldwide
22801 St. Clair Ave. Cleveland, Ohio 44117-1199 U.S.A.Tel.(216) 481-8100
World's Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors
IM568
April, 1997
Supersedes IM247-D
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 thoughtful opera­tion on your part. DO NOT
INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT.
And, most importantly, think before you act and be careful.
RETURN TO MAIN MENU
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SAFETY
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SAM400 & 650
FOR ENGINE powered equipment.
1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running.
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1.b.Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors.
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1.c. Do not add the fuel near an open flame weld-
ing arc or when the engine is running. Stop the engine and allow it to cool before refuel­ing to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting. Do not spill fuel when filling tank. If fuel is spilled, wipe it up and do not start engine until fumes have been eliminated.
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1.d. Keep all equipment safety guards, covers and
devices in position and in good repair.Keep hands, hair, clothing and tools away from V­belts, gears, fans and all other moving parts when starting, operating or repairing equip­ment.
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1.e. In some cases it may be necessary to remove safety guards to perform required maintenance. Remove guards only when necessary and replace them when the maintenance requiring their removal is complete. Always use the greatest care when working near moving parts.
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1.f. Do not put your hands near the engine fan.Do not attempt to override the governor or idler by pushing on the throttle con­trol rods while the engine is running.
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1.g. To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work, disconnect the spark plug wires, distributor cap or magneto wire as appropriate.
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following saf ety highlights.For additional saf ety inf ormation, it is strongly recommended that you pur­chase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety”booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
WARNING
Mar ‘95
ELECTRIC AND MAGNETIC FIELDS may be dangerous
2.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines
2.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physician before welding.
2.c. Exposure to EMF fields in welding may have other health effects which are now not known.
2.d. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:
2.d.1.
Route the electrode and work cables together - Secure them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
2.d.5. Do not work next to welding power source.
1.h. To avoid scalding, do not remove the radiator pressure cap when the engine is hot.
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents are known to the State of California to cause can­cer, birth defects, and other reproductive harm.
The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.
The Above For Diesel Engines
The Above For Gasoline Engines
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SAFETY
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SAM400 & 650
ARC RAYS can burn.
4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant material to protect your skin and that of your helpers from the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammable screening and/or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal.
ELECTRIC SHOCK can kill.
3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” par ts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands.
3.b. Insulate yourself from work and ground using dry insulation. Make certain the insulation is large enough to cover your full area of physical contact with work and ground.
In addition to the normal safety precautions, if welding must be performed under electrically hazardous conditions (in damp locations or while wearing wet clothing; on metal structures such as floors, gratings or scaffolds; when in cramped positions such as sitting, kneeling or lying, if there is a high risk of unavoidable or accidental contact with the workpiece or ground) use the following equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head, nozzle or semiautomatic welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical connection with the metal being welded. The connection should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical (earth) ground.
3.f.
Maintain the electrode holder, work clamp, welding cable and welding machine in good, safe operating condition.Replace damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders.
3.i. When working above floor level, use a safety belt to protect yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
FUMES AND GASES can be dangerous.
5.a.Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases.When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
welding with electrodes which require special ventilation such as stainless or hard facing (see instructions on container or MSDS) or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes, keep exposure as low as possible and below Threshold Limit Values (TLV) using local exhaust or mechanical ventilation. In confined spaces or in some circumstances, outdoors, a respirator may be required. Additional precautions are also required when welding on galvanized steel.
5.b.
Do not weld in locations near chlorinated hydrocarbon
vapors coming from degreasing, cleaning or spraying operations. The heat and rays of the arc can react with solvent vapors
to form phosgene, a highly toxic gas, and other irritating products.
5.c. Shielding gases used for arc welding can displace air and cause injury or death. Always use enough ventilation, especially in confined areas, to insure breathing air is safe.
5.d. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the material safety data sheet (MSDS) and follow your employer’s safety practices. MSDS forms are available from your welding distributor or from the manufacturer.
5.e. Also see item 1.b.
Mar ‘95
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SAFETY
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SAM400 & 650
FOR ELECTRICALLY powered equipment.
8.a.Turn off input power using the disconnect switch at the fuse box before working on the equipment.
8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations.
8.c. Ground the equipment in accordance with the U.S. National Electrical Code and the manufacturer’s recommendations.
CYLINDER may explode if damaged.
7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely chained to an undercarriage or fixed support.
7.c. Cylinders should be located:
•Away from areas where they may be struck or subjected to
physical damage.
• A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other electrically “hot” par ts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use.
7.g. Read and follow the instructions on compressed gas cylinders, associated equipment, and CGA publication P-l, “Precautions for Safe Handling of Compressed Gases in Cylinders,” available from the Compressed Gas Association 1235 Jefferson Davis Highway, Arlington, VA 22202.
Mar ‘95
WELDING SPARKS can cause fire or explosion.
6.a.
Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
the welding sparks from starting a fire.
Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily available.
6.b. Where compressed gases are to be used at the job site, special precautions should be used to prevent hazardous situations. Refer to “Safety in Welding and Cutting” (ANSI Standard Z49.1) and the operating information for the equipment being used.
6.c. When not welding, make certain no part of the electrode circuit is touching the work or ground. Accidental contact can cause overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside. They can cause an explosion even
though
they have been “cleaned”. For information, purchase “Recommended Safe Practices for the
Preparation
for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances”, AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or welding.They may explode.
6.f.
Sparks and spatter are thrown from the welding arc. Wear oil free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes and a cap over your hair. Wear ear plugs when welding out of position or in confined places. Always wear safety glasses with side shields when in a welding area.
6.g. Connect the work cable to the work as close to the welding area as practical. Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains, crane cables or other alternate circuits. This can create fire hazards or overheat lifting chains or cables until they fail.
6.h. Also see item 1.c.
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SAFETY
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SAM400 & 650
PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv­antes:
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours tout contact entre les parties sous tension et la peau nue ou les vétements mouillés. Porter des gants secs et sans trous pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher met­allique ou des grilles metalliques, principalement dans les positions assis ou couché pour lesquelles une grande partie du corps peut être en contact avec la masse.
c.Maintenir le porte-électrode, la pince de masse, le câble de
soudage et la machine à souder en bon et sûr état defonc­tionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à soud­er parce que la tension entre les deux pinces peut être le total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions pour le porte-électrode s’applicuent aussi au pistolet de soudage.
2. Dans le cas de travail au dessus du niv eau du sol, se protéger contre les chutes dans le cas ou on recoit un choc. Ne jamais enrouler le câble-électrode autour de n’importe quelle partie du corps.
3. Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du ray­onnement de l’arc et des projections quand on soude ou quand on regarde l’arc.
b.Porter des vêtements convenables afin de protéger la peau
de soudeur et des aides contre le rayonnement de l‘arc.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de l’arc de soudage.Se protéger avec des vêtements de protection libres de l’huile, tels que les gants en cuir, chemise épaisse, pan­talons 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. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque d’incendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de la masse. Un court-circuit accidental peut provoquer un échauffement et un risque d’incendie.
8. S’assurer que la masse est connectée le plus prés possible de la zone de travail qu’il est pratique de le faire. Si on place la masse sur la charpente de la construction ou d’autres endroits éloignés de la zone de travail, on augmente le risque de voir passer le courant de soudage par les chaines de levage, câbles de grue, ou autres circuits. Cela peut provoquer des risques d’incendie ou d’echauffement des chaines et des câbles jusqu’à ce qu’ils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage. Ceci est particuliérement important pour le soudage de tôles galvanisées plombées, ou cadmiées ou tout autre métal qui produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant d’opérations de dégraissage, nettoyage ou pistolage. La chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs du solvant pour produire du phosgéne (gas fortement toxique) ou autres produits irritants.
11.Pour obtenir de plus amples renseignements sur la sûreté, voir le code “Code for safety in welding and cutting” CSA Standard W 117.2-1974.
PRÉCAUTIONS DE SÛRETÉ POUR LES MACHINES À SOUDER À TRANSFORMATEUR ET À REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code de l’électricité et aux recommendations du fabricant. Le dispositif de montage ou la piece à souder doit être branché à une bonne mise à la terre.
2. Autant que possible, I’installation et l’entretien du poste seront effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la debranch­er à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur place.
Mar.‘93
SAM400 & 650
Thank You
for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you!
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection. The level of seriousness to be applied to each is explained below:
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.
This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.
CAUTION
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier.Consequently, Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received.
Please record your equipment identification information below f or future reference.This information can be found 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 information you have recorded above.
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TABLE OF CONTENTS
SAM400 & 650
vi
Page
Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
Product Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
Installation Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
Spark Arrester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
Machine Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
Additional Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
Pre-Operation Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
Output Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
Welder Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section B
Operating Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Pipe Thawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Additional Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Engine Controls: Function/Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Welder Controls: Function/Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
Starting Welders with Dead Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-9
Auxiliary Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-9
Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-9
Starting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-9
Break-In Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-9
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section C
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section D
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section E
Diode Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-6
SCR Bridge PC Board Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-6
Control PC Board Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-7
Ground Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-8
Wiring Diagrams and Dimension Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section F
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Appendix
A-1
INSTALLATION
SAM400 & 650
A-1
TECHNICAL SPECIFICATIONS - SAM400
Make/Model Description Speed (RPM) Displacement Starting Capacities
System
Perkins 4 cylinder High Idle 1790 236 cu. in
12VDC batteries
Fuel: 22.5 gal.
4.236 Diesel 63 HP @ Low Idle 1100 (3.87 L)
(2
) & Starter 85.1 L
Engine 1725 RPM Full Load 1725
Bore x Stroke Oil: 8.5 Qts.
8.04 L
3.875” x 5.00”
(98.4 mm x 127.0mm) Coolant: 3.2 gal.
12.11 L
INPUT - DIESEL ENGINE
RATED OUTPUT - WELDER
HEIGHT
1
WIDTH DEPTH WEIGHT
50.13 in. 27.12 in. 83.00 in. 2163 lbs.
1273.3 mm 688.9 mm 2108.2 mm 981.1 kg
OUTPUT - WELDER AND GENERATOR
Duty Cycle Welding Output Volts at Rated Amps
60% (NEMA) 400 amps 36 volts 60% (Lincoln Plus) 400 amps 40 volts
Welding Range Open Circuit Voltage Auxiliary Power
60 - 500 Amps 17 - 45 OCV 120/240 VAC CV Current Range
(excluding hot start voltage)
2kVA, 60 Hz. 80 - 500 60 - 95 OCV 100% Duty Cycle VV Current Range
PHYSICAL DIMENSIONS
1. Add 15.4” (391.2 mm) for optional muffler.
A-2
INSTALLATION
SAM400 & 650
A-2
TECHNICAL SPECIFICATIONS - SAM650
Make/Model Description Speed (RPM) Displacement Starting Capacities
System
Perkins 6 cylinder High Idle 1790 365 cu. in
12VDC batteries
Fuel: 22.5 gal.
1006-6 Diesel 93 HP @ Low Idle 1200 (5.98 L)
(2)
& Starter 85.1 L
Engine 1730 RPM Full Load 1750
Bore x Stroke Oil: 14.0 Qts.
13.24 L
3.937” x 5.00”
(100mm x 127mm) Coolant: 5.5 gal.
20.8 L
INPUT - DIESEL ENGINE
RATED OUTPUT - WELDER
HEIGHT WIDTH DEPTH WEIGHT
56.7 in. 27.12 in. 88.75 in. 2800 lbs.
1440.2 mm 688.9 mm 2254.2 mm 1270.1 kg
OUTPUT - WELDER AND GENERATOR
Duty Cycle Welding Output Volts at Rated Amps
80% (NEMA) 650 Amps 44 volts 60%(NEMA) 725 Amps 44 volts 80%(Lincoln Plus) 650 Amps 50 volts 60%(Lincoln Plus) 725 Amps 50 volts
Welding Range Open Circuit Voltage Auxiliary Power
80 - 815 Amps 18 - 50 OCV 120/240 VAC CV Current Range
(excluding hot start voltage)
2kVA, 60 Hz. 80 - 815 45 - 90 OCV 100% Duty Cycle VV Current Range
PHYSICAL DIMENSIONS
A-3
INSTALLATION
SAM400 & 650
A-3
PRODUCT DESCRIPTION
The SAM engine welders are multi-purpose welding machines. They are designed to be used on all open arc or submerged arc processes within the rating of the unit.
The machine is designed to be used with the following automatic equipment: LN-7, LN-8, LN-9, LN-22, LN­23P (with Adapter Kit), LN-25, NA-3, LT-7, or LT-56. It can be used with most other equipment whose power requirements do not exceed the rating of the machine.
The SAM machines have two types of output charac­teristics; a variable voltage output characteristic for stick and submerged arc welding and also constant voltage characteristics for Innershield® plus both dip­transfer and spray-transfer processes.
INSTALLATION PRECAUTIONS
SPARK ARRESTER
Some federal, state or local laws may require that diesel engines be equipped with exhaust spark arresters when they are operated in certain locations where unarrested sparks may present a fire hazard. The standard mufflers included with these welders do not qualify as spark arresters. When required by local regulations suitable spark arresters must be installed and properly maintained.
An incorrect arrester may lead to damage of the engine or its performance. Contact the engine manufacturer for specific recommendations.
MACHINE GROUNDING
The 1984 National Electrical Code does not require this machine to be grounded under normal operating circumstances.
Some state, local or other codes or unusual operating circumstances may require the machine frame to be grounded. It is recommended that you determine the extent to which such requirements may apply to your particular situation and follow them explicitly. A machine grounding stud marked with the symbol is provided on the welding generator frame foot.
In general, if the machine is to be grounded it should be connected with a #8 or larger copper wire to a solid
earth ground such as a metal water pipe going into the ground for at least ten feet and having no insulated joints, or to the metal framework of a building which has been effectively grounded.The National Electrical Code lists a number of alternate means of grounding electrical equipment.
ADDITIONAL SAFETY PRECAUTIONS FALLING EQUIPMENT can cause injury.
Do not lift this machine using lift
bale if it is equipped with a heavy accessory such as trailer or gas cylinder.
Lift only with equipment of adequate lifting
capacity.
Be sure machine is stable when lifting.
The recommended undercarriage for use with this equipment for in-plant and yard towing by a vehicle is Lincoln’s K767-1. If the user adapts a non-Lincoln undercarriage, he must assume responsibility that the method of attachment and usage does not result in a safety hazard nor damage the welding equipment. Some of the factors to be considered are as follows:
1. Design capacity of undercarriage vs. weight of Lincoln equipment and likely additional attach­ments.
2. Proper support of, and attachment to, the base of the welding equipment so there will be no undue stress to the framework.
3. Proper placement of the equipment on the under­carriage to insure stability side to side and front to back when being moved and when standing b y itself while being operated or serviced.
4. Typical conditions of use, i.e., travel speed; rough­ness of surface on which the undercarriage will be operated; environmental conditions; likely mainte­nance.
5. Conformance with federal, state and local laws.
(1)
WARNING
CAUTION
(1)
Consult applicable federal, state and local laws regarding specific requirements for use on public highways.
A-4
INSTALLATION
A-4 PRE-OPERATION SERVICE
Oil: This unit is supplied from the factory with the
engine crankcase filled with a high quality 10W30 oil. This oil should be acceptable for most typical ambient temperatures. Consult the Engine Operation Manual for specific recommendations. Upon receipt of the welder, check the dipstick to be sure the oil is at the "full" mark. DO NOT OVERFILL.
Fuel: Fill the fuel tank with the grade of diesel fuel rec­ommended in the engine Instruction Manual. Open the fuel feed valve on the sediment bowl by turning the handle counterclockwise.
Cooling System:The cooling system has been filled at the factory with a 50-50 mixture of ethylene glycol antifreeze and water. Check the radiator level and add a 50-50 solution as needed. (See Engine Manual or antifreeze container for alternate antifreeze recom­mendation.)
Battery: Remove the insulating cap from the negative battery terminal. Replace and tighten negative battery cable terminal. NOTE: This machine is furnished with wet charged batteries; if unused for several months, the batteries may require a booster charge. Be sure to use the correct polarity when charging the batteries.
GASES FROM BATTERY can explode.
Keep sparks, flame and cigarettes
away from battery.
To prevent EXPLOSION when:
INSTALLING A NEW BATTERY — disconnect
negative cable from old battery first and connect to new battery last.
CONNECTING A BATTERY CHARGER —
remove battery from welder by disconnecting negative cable first, then positive cable and battery clamp.When reinstalling, connect negative cable last. Keep well ventilated.
USING A BOOSTER — connect positive lead to
battery first then connect negative lead to neg­ative battery lead at engine foot.
BATTERY ACID can burn eyes and skin.
Wear gloves and eye protection
and be careful when working near battery.
Follow instructions printed on battery.
IMPORTANT: To prevent ELECTRICAL DAMAGE WHEN:
a) Installing new batteries. b) Using a booster.
Use correct polarity — Negative Ground. To prevent BATTERY BUCKLING, tighten nuts on bat-
teries only until snug. DO NOT OVERTIGHTEN.
Muffler: On SAM650 units: Screw the muffler into the
exhaust flange and tighten.
On SAM400 units with the optional noise control muffler: Attach the muffler with the
supplied hardware.
The engine and welder controls were properly set at the factory and should require no adjusting when received.
OUTPUT CABLES
With the engine off, connect the electrode and work cables to the studs provided. These connections should be checked periodically and tightened if neces­sary .When welding at a considerable distance from the welder, be sure you use ample size welding cables.
Listed below are copper cable sizes recommended for the rated current and duty cycle.Lengths stipulated are the distance from the welder to work and back to the welder again. Cable sizes are increased for greater lengths primarily for the purpose of minimizing cable voltage drop.
WELDER LOCATION
The welder should be located to provide an unrestrict­ed flow of clean, cool air to the cooling air inlets (lou­vered panel and below side doors) and to avoid heat­ed air coming out the radiator of the welder recirculat­ing back to the cooling air inlets.Also, locate the welder so that engine fumes are properly exhausted.
SAM400 & 650
WARNING
%
Cable Sizes For Combined Lengths
Duty
Of Electrode And Work Cables
Amps Cycle 0-100 ft. 100-200 ft. 200-250 ft.
650 60 3/0 2-2/0 2-3/0 650 80 2-1/0 2-2/0 2-3/0 400 60 2/0 3/0 4/0
B-1
OPERATION
B-1 OPERATING PRECAUTIONS
Do not attempt to use this equipment until you have thoroughly read the engine manufacturer’s manual supplied with your welder. It includes important safety precautions, detailed engine starting, operating and maintenance instructions, and parts lists.
PIPE THA WING
PIPE THAWING can result in fire or explosion.
Only connect welder across
FROZEN section of CONTINUOUS METAL PIPE.
While thawing, remove any ground leads con-
nected to Frozen pipe.
Turn welder on AFTER cables are connected to
pipe.Turn off when done.
IMPORTANT: DO NOT USE A WELDER TO THAW A
PIPE BEFORE REVIEWING LINCOLN BULLETIN E695.1 (dated May 1987 or later).This bulletin may be obtained from your local Lincoln distributor or by writ­ing directly to Lincoln Electric at the address on the back of this manual.
ADDITIONAL SAFETY PRECAUTIONS
Always operate the welder with the hinged doors closed as these provide maximum protection from moving parts and insure proper cooling air flow.
Read carefully the Safety Precautions page in the Instruction Manual before operating this machine. Always follow these and any other safety procedures included in this manual and in the engine instruction manual.
ENGINE CONTROLS: FUNCTION/OPERATION
IGNITION SWITCH
When placed in the “ON”position, this switch energizes the fuel solenoid. When placed in the “OFF” position, the flow of fuel to the injection pump is stopped to shut down the engine.
SPEED CONTROL LEVER
Manually allows the engine to run at its high idle speed controlled by the governor or at the factory set low idle speed. When welding or using auxiliary power the speed control lever must be in the “RUN” position. To reduce the engine to low idle speed when not welding or not using auxiliary power place the speed control lever in the “IDLE” position notch.
ENGINE TEMPERA TURE GAUGE
Displays the coolant temperature in the engine block.
OIL PRESSURE GAUGE
Displays the oil pressure to the engine. When the engine starts running, watch for the oil pressure to build up.If no pressure shows within 30 seconds, stop the engine and consult the engine instruction manual.
BATTERY CHARGING AMMETER
Displays the current going from the charging alternator into the batteries.It is normal for charging current to be high (above 15 amps) after starting or when the batter­ies are ‘low’ on charge.
ENGINE HOUR METER (Factory Installed Optional Feature)
The optional engine hour meter records the total run­ning time on the engine in hours.It can be used to keep a record of maintenance on the engine and or welder.
ENGINE PROTECTION SYSTEM
The engine protection system shuts down the engine under high coolant temperature or low oil pressure conditions by allowing the fuel solenoid valve to close.
SAM400 & 650
WARNING
WARNING
B-2
OPERATION
B-2 WELDER CONTROLS:
FUNCTION/OPERATION
PORTABLE FIELD CONTROL CONNECTION
A “Por table Field Control” complete with 25’ leads is shipped with each SAM welder.
A “Por table Field Control” is
not required
for proper operation of the SAM welder when connected to an LN-8, LN-9, NA-3, NA-5, LT-7, or LT-56 wire feeder. With other wire feeders and when stick electrode weld­ing, the “Por table Field Control”
must be installed
or
the SAM cannot produce its full open circuit voltage. When installed the “Portable Field Control” is a fine
voltage adjustment when using the SAM as a constant voltage power source. It is a fine current adjustment when using the SAM as a variable voltage power source.
The “Portable Field Control” can be mounted on the SAM or wherever con venient for the welding operation. When using an LN-4, LN-5, LN-6 or LN-7 wire feeder, the control should normally be mounted on the wire feeder. Specific mounting instr uctions are given below.
After mounting, connect the “Portable Field Control” leads to #75 and #76 on the SAM terminal strip locat­ed behind the lower cover panel directly belo w the con­trol panel on the SAM400 or behind the right front hinged door on the SAM650. Connect the green lead of the “Portable Field Control” to the grounding stud marked with the symbol located near the terminal strips.
MOUNTING ON LN-4 (Discontinued)
1. Place the “Portable Field Control” on the vertical
front panel of the LN-4 on the wire reel side (next to the rheostat panel) and mark the location of the mounting slots.
2. Drill two holes in the panel and mount the control
using #10 sheet metal screws.
3. Route the leads with the LN-4 control cable back to
the power source.
MOUNTING ON LN-5 OR LN-6 (Discontinued)
1. Remove the knob from the upper rheostat on the
wire feeder control panel.
2. Be sure the appropriate wire feeder nameplate -
“Constant Voltage” or “ Variable Voltage “ - is in
place.
3. Remove the two screws on the top end of the wire feeder nameplate.
4. Position the “Por table Field Control” mounting slots over these holes and replace the screws.
5. Route the leads with the LN-5 or LN-6 control cable back to the power source.
MOUNTING ON LN-7
1. Remove the top screws on the side of the LN-7 con­trol box cover. (This is the left side when facing the nameplate).
2. Position the “Por table Field Control” on the side of the control box with the mounting slots over these holes and replace the screws.
3. Route the leads with the LN-7 control cable back to the power source.
OUTPUT STUDS
With the Engine OFF connect the work cable to the “To Work” stud.
A. For Stick Electrode Welding
1. Connect the electrode cable to the “Stick”stud and the work cable to the “To Work” stud. Connect the “TAP” lead in the SAM650 to the appropriate stud to adjust current and the arc characteristics as described under “Current and V oltage Controls.”
2. Install the “Portable Field Control”.
B. Automatic or Semiautomatic Welding
For all automatic welding processes, connect the welding power cable from the wire feeder to the “Connect to Auto. Equipment” stud. Connect the “TAP” lead in the SAM650 to the appropriate stud to adjust current and the arc characteristics as described under “Current and Voltage Controls.”
1. LN-7, LN-8, LN-9, NA-3, NA-5, LT-7 and LT­56 Wire Feeders.
a. Make the connections exactly as speci-
fied on the connection wiring diagram included in the wire feeder Instruction Manual.
b. Install the “Por table Field Control” when
using an LN-7.
SAM400 & 650
B-3
OPERATION
B-3
c. Be sure the wire feeder is properly set for
constant or variable voltage as appropri­ate.
2. ML-2, ML-3, MN-1, LN-4, LN-5 and LN-6 Wire Feeders
This power source can be used with these obsolete wire feeders. Write to the factory for specific connections.
3. Other Wire Feeders
This power source can be used with wire feeders manufactured by other companies. The connection must be determined by the customer for the specific equipment being used.
Auxiliary power available for wire feeder operation is described under “Auxiliary Power” in this section of the manual. To operate the SAM contactor, connect the appropriate wire feeder control circuit to close the circuit from #2 to #4 on the SAM terminal strip.
TOGGLE SWITCH
This switch is located on the front of the control panel at the top of the nameplate. Set the switch to “Variable Voltage” or “Constant Voltage” as appropriate for the welding process to be used.See Control Panel operat­ing illustrations in this section of the manual.
CONTACTOR
The output contactor is automatically in the welding cir­cuit when the machine is properly connected to a Lincoln® wire feeder through the “Connect to Auto. Equipment” stud. It closes only when the wire feeder is welding. The contactor is not in the welding circuit when using the ‘Stick’ stud.
ELECTRODE POLARITY SWITCH
Select electrode negative (straight) or electrode posi­tive (reverse) polarity as needed. On the SAM-400, this switch must also be set for either constant or vari­able voltage welding as appropriate.
DO NOT SWITCH WHILE WELDING.
CURRENT AND VOLTAGE CONTROLS
Constant V oltage W elding
The SAM-400 “Current Control” is NOT in the circuit when the ‘Electrode Polarity’ switch is set for constant voltage welding.
Set the open circuit voltage (OCV) needed for the par­ticular application with the “Constant Voltage Control” located to the left of the nameplate. Adjust the final welding voltage with either the wire feeder voltage con­trol or the “P ortable Field Control”. Set the welding cur­rent with “Amps” or “Wire Feed Speed” control on the wire feeder.
Low Range Feature (SAM400 K1279-1 only) -­Extends the output voltage range of the SAM400 welder down to 12 volts for constant voltage welding. The maximum output current is not to exceed the rat­ing of the machine. The Low Range Feature provides a two-position manual switch which allows the oper ator to set his machine for normal welding or for low v oltage welding. Factory installed only.
On the SAM650 connect the “Tap” lead inside the machine to the appropriate “Innershield” stud for”Min. (Flat) Slope.”“Med. Slope” or “Max.Slope”.Low voltage (below 20 volts) low current welding often requires “Max. Slope” to adjust the weld metal droplet size for minimum spatter and to control puddle fluidity and bead shape. Innershield and other spray transfer type processes generally operate with “Med.Slope”.
A Hot Start circuit on all models operates automatical­ly whenever the toggle switch is set on “Constant Voltage.” It increases the open circuit voltage by sev­eral volts until the arc is established -- then the voltage automatically drops to normal welding voltage. When the wire feeder is started before the arc is started, the voltmeter indicates a voltage several volts higher than welding voltage. To read actual welding voltage, the arc must be established.
Constant V oltage Welding With V ariable Inductance Control: SAM-400 Only.
Variable inductance or slope control is usually desir­able for low voltage (below 20 volts) applications and is sometimes useful in other constant voltage jobs.
To introduce this control into the circuit, set the “Electrode Polarity”switch to “Variable Voltage” and the toggle switch to “Constant Voltage”. Then the “Current Control” acts as the variable inductance control. Normally this control must be kept within the 8 to 1 o’clock range.
SAM400 & 650
CAUTION
B-4
OPERATION
B-4
Set the welding current and voltage as described under “Constant V oltage W elding”above.
Variab le V oltage W elding
The SAM400 “Current Control” provides the major adjustment of current. It has two calibrated scales; the one gives maximum and the other minimum current available at any given setting.
DO NOT ADJUST THE “CURRENT CONTROL”
WHEN WELDING.
The SAM650 “Tap” lead inside the machine and the series of five “Sub Arc & Stick”studs provide the major adjustment of welding current. Generally connect the “Tap” lead to the stud with the lowest current range that still provides the desired current.
The “Variable Voltage Control” to the left of the name­plate on all models is both the open circuit voltage con­trol and a fine adjustment. The wire feeder current con­trol and the “Por table Field Control” provide the same function as the “Variable Voltage Control.”
To Set The Controls -- Stick Welding
a. Make the coarse setting of welding heat with the
SAM400 “Current Control” or the SAM650 “Tap’”lead.
b. Adjust for the desired arc characteristics with the
“Variable Voltage Control”. For a soft arc desired for most welding keep this control between 7 and High. For a more digging arc, set it lower.
c. If remote control is NOT desired leave the
“Portable Field Control”on “High”. For remote con­trol, leave the “Variable Voltage Control” near “High” and make the adjustments described in paragraph “b” above with the “Portable Field Control”. Remember, increasing either the “Variable Voltage Control” or “Portable Field Control” setting also increases the current.
To Set The Controls -- Submerg ed Arc
a. The open circuit voltage (OCV) is generally not
critical in submerged arc welding. Therefore, the “Variable Voltage Control” can usually be left between 7 and “High”-- no future adjustments are needed.
b. Set SAM400 “Current Control” so the calibration
on the higher scale is a little above the current desired. Set the SAM650 “Tap” lead to the stud with the lowest current range that still provides the desired current.
c. Make the final current adjustment with either the
wire feeder current control or the “Portable Field Control”. Set the arc voltage with the wire feeder control.
Consult the following illustrations for examples of how to set the machine.
SAM400 & 650
CAUTION
B-5
OPERATION
B-5
SAM400 Controls
SAM400 & 650
B-6
OPERATION
B-6
SAM400 & 650
SAM400 Controls
B-7
OPERATION
B-7
SAM400 & 650
SAM650 Controls
B-8
OPERATION
B-8
SAM400 & 650
SAM650 Controls
B-9
OPERATION
B-9 ST AR TING WELDERS WITH DEAD BA TTERIES
DO NOT attempt to star t a SAM engine driven welder
by driving the welding generator as a starter motor using the output of another welder. In addition to the possibility of damaging the machines, starting a SAM engine welder without using its starting circuit elimi­nates the operation of the flashing circuit. This can cause the generator to fail to produce any output.
AUXILIARY POWER
An alternator generates 2 KVA of 120/240 v olt 60 Hertz AC power. It is available either from #31 and #32 on the terminal strip or from the receptacles on the Control Panel. Be careful not to overload this circuit.
The auxiliary power receptacle should only be used with three wire grounded type plugs or approved dou­ble insulated tools with two wire plugs.
The alternator is protected by thermostats and fuses.
DUTY CYCLE
Duty cycle is based on a ten minute period and opera­tion in an ambient temperature of 104°F(40°C).
The SAM400 is NEMA rated at 60% duty cycle. The SAM650 is NEMA rated at 80% duty cycle. Duty cycle is based on a ten minute period. Therefore, a 60% duty cycle welder can be operated at nameplate rated out­put for 6 minutes (8 minutes for 80% duty cycle) out of every 10 minute period without overheating.
The auxiliary power can be used continuously (100% duty cycle) within its rated current capacities.
STARTING INSTRUCTIONS
Be sure all Pre-Operation Maintenance has been per­formed. (See Installation Section of this manual.)
To start the engine, set the speed control lever in the “RUN”position. Place ignition toggle switch in the “ON” position. Push in the engine protection system reset button (if so equipped). Engage the starter button. When the engine starts running, obser ve the oil pres­sure. If no pressure shows within 30 seconds, stop the engine and consult the engine operating manual. To stop the engine, place the ignition toggle switch in the “OFF” position.
When an engine is started for the first time, some of the oil will be needed to fill the passages of the lubricating system. Therefore, on initial starting, run the engine for
about five minutes and then stop the engine and recheck the oil. If the level is down, fill to the full mark again.The engine controls were properly set at the fac­tory and should require no adjusting when received.
For added safety always operate the welder with the doors closed. Further, leaving the doors open changes the designed air flow and may cause overheating.
Cold Weather Starting
Never use any other starting aids, such as ether, when using the “Thermostart” system.
When overnight temperatures are between 10°F (­12°C) and freezing, use the standard “Thermostart” starting system installed on all engines. Follow the instructions on the start panel nameplate and in the engine manual shipped with the welder. With fully charged batteries and the proper weight oil, the “Thermostart” system operates satisfactorily even down to about 0°F (-18°C).
If the engine must be frequently started below 10°F (-12°C), it may be desirable to remove the “Thermostart” and install the optional ether star ter kit. Installation and operating instructions are included in the kit. Use ether starting only when required because excessive use shortens engine life.
BREAK-IN PERIOD
The engine used to supply power for your welder is a heavy duty, industrial engine. It is designed and built for rugged use. It is very normal for any engine to use small quantities of oil until the break-in is accom­plished. Check the oil level twice a day during the break-in period (about 200 running hours).
IMPORTANT: IN ORDER TO ACCOMPLISH THIS BREAK-IN, THE UNIT SHOULD BE SUBJECTED TO HEAVY LOADS, WITHIN THE RATING OF THE MACHINE. AVOID LONG IDLE RUNNING PERIODS.
SAM400 & 650
WARNING
C-1
ACCESSORIES
C-1
K799 Hi-Freq™ - Provides high frequency plus a gas
valve for TIG welding. A water valve is available as an option. Requires 115 volt AC input. Cannot be used with optional meters connected, or in constant voltage mode. (Limited to 250A - 60% Duty Cycle).
K802-D Power Plug Kit - For SAM welders with stan­dard 2KVA of AC auxiliary power. Kit includes male plugs for each auxiliary receptacle.
K805-1 Ether Start Kit - Injects ether for starting aid. Recommended only when engines are frequently started at temperatures under 10°F (-12°C). Ether cylinder is not included.
K767-1 Undercarriage - A 4-wheel steerable under­carriage for in-plant and yard towing
1
with E78-14 load range (B) tubeless tires. Mounts directly to welder base.
1
For highway use, consult applicable federal, state and local laws regarding
possible requirements for brakes, lights, fenders, etc.
Linc-Thaw™ - Includes meter and fuse to protect the welder when thawing frozen water pipes. (L2964-[ ] Specify SAM400 or SAM650)
K704(SAM400 only) Standard Accessory Kit -
Includes electrode and work cables, headshield, work clamp and electrode holder.
K865(SAM400 only) Engine Hour Meter Kit -
(Standard on K1279-1). Keeps track of how long engine has been operated. Useful for following recom­mended maintenance schedules on machine.
SAM400 & 650
D-1
MAINTENANCE
D-1
ELECTRIC SHOCK can kill.
Do not touch electrically live parts
such as output terminals or inter­nal wiring
ENGINE EXHAUST can kill.
Use in open, well ventilated areas
or vent exhaust outside
MOVING PARTS can injure.
Do not operate with doors open or
guards off
Stop engine before servicing
Keep away from moving parts
Remove guards only when necessary and
replace when work requiring removal is com­plete.
Only qualified personnel should install, use, or
service this equipment.
ROUTINE MAINTENANCE
At the end of each day’s welding, refill the fuel tank to minimize moisture condensation in the tank. Also, run­ning out of fuel tends to draw dirt into the fuel system. Check the crankcase oil level.
If the fuel supply runs out while the fuel pump is oper­ating, air may be entrapped in the fuel distribution sys­tem. If this happens, bleeding of the fuel system may be necessary. See the engine instruction manual.
AIR FILTER
SAM650 only:
The air filter element is a dry car tridge type. It can be cleaned and re-used; however, damaged elements should not be washed or re-used. Remove loose dirt from element with compressed air or water hose direct­ed from inside out.Compressed Air: 100 psi maximum. The filter should never be removed while the engine is running.
SAM400 only:
Inspect the oil bath air filter daily - more often in dusty conditions. When necessary clean and fill the oil bath. The filter should never be removed while the engine is running.
PERIODIC MAINTENANCE
1. Blow out the welder and controls with an air hose at least once every two months. In particularly dirty locations, this cleaning may be necessary once a week. Use low pressure air to avoid driving dirt into the insulation.
2. The SAM400 current control reactor brushes are self-lubricating and should not be greased.Keep the contacts clean. This control should be moved from maximum to minimum daily to prevent the controls from sticking.
3. See the engine Instruction Manual for periodic engine maintenance information. Change the crankcase oil at regular intervals using the proper grade of oil as recommended in the engine operat­ing manual. Change the oil filter in accordance with the instructions in the engine operating manual. When the filter is changed add one quart of oil to the crankcase to replace the oil held in the filter dur­ing operation.
4. Belts tend to loosen after the first 30 or 40 hours of operation. Check the cooling fan belt and tighten if necessary. DO NOT OVER TIGHTEN.
BEARING MAINTENANCE
This welder is equipped with a double-shielded ball bearing having sufficient grease to last indefinitely under normal service. Where the welder is used con­stantly or in excessively dirty locations, it may be nec­essary to add one-half ounce of grease per year.A pad of grease one inch wide, one inch long and one inch high weighs approximately one-half ounce. Over greasing is far worse than insufficient greasing.
When greasing the bearings, keep all dirt out of the area. Wipe the fittings completely clean and use clean equipment. More bearing failures are caused by dirt introduced during greasing than from insufficient grease.
SAM400 & 650
WARNING
D-2
MAINTENANCE
D-2
COMMUTATOR AND BRUSH MAINTENANCE
Uncovered rotating equipment can be dangerous. Use care so your hands, hair, clothing or tools do not catch in the rotating parts. Protect yourself from particles that may be thrown out by the rotat­ing armature when stoning the commutator.
The generator brushes are properly adjusted when the welder is shipped.They require no particular attention. DO NOT SHIFT THE BRUSHES or adjust the rocker setting.
Shifting of the brushes may result in:
- Change in machine output
- Commutator Damage
- Excessive brush wear
Periodically inspect the commutator, slip rings and brushes by removing the covers. DO NOT remove or replace these covers while the machine is running.
Commutators and slip rings require little attention. However, if they are black or appear uneven, have them cleaned by an experienced maintenance man using fine sandpaper or a commutator stone. Never use emery cloth or paper for this purpose.
NOTE: If the welder is used in dirty or dusty locations, or if the welder is not used for prolonged periods of time, it may be necessary to clean the commutator and slip rings more often.
Replace brushes when they wear within 1/4" of the pig­tail. A complete set of replacement brushes should be kept on hand.Lincoln brushes have a curved face to fit the commutator. Have an experienced maintenance man seat these brushes by lightly stoning the commu­tator as the armature rotates at full speed until contact is made across the full face of the brushes. After ston­ing, blow out the dust with low pressure air.
To seat the slip ring brushes, position the brushes in place. Then slide one end of a piece of fine sandpaper between slip rings and brushes with the coarse side against the brushes. With slight additional finger pres­sure on top of the brushes, pull the sandpaper around the circumference of the rings, in direction of rotation only - until brushes seat properly. In addition, stone slip ring with a fine stone. Brushes must be seated 100%.
Arcing or excessive e xciter brush wear indicates a pos­sible misaligned shaft. Have an authorized Field Service Shop check and realign the shaft.
COOLING SYSTEM
The SAM welders are equipped with a pressure radia­tor. Keep the radiator cap tight to prevent loss of coolant. Clean and flush the cooling system periodi­cally to prevent clogging the passage and overheating the engine. When antifreeze is needed, always use the permanent type.
CONTACTOR MAINTENANCE
Where the output contactor is operated frequently when tacking or making short welds, turn the engine off and inspect the contactor every three months:
1. be sure the mating surfaces of silver contacts are not worn and all make contact at approximately the same time.
2. Make sure the springs and holders are not broken or out of adjustment. Approximate spring com­pression after making contact is 1/8”. Less than 1/16” compression indicates worn contacts that should be replaced.
3. Make sure the moving contact or other moving parts are not binding.
4. Check interlock contacts and springs. Be sure mounting screws are tight.
SAM400 & 650
WARNING
APR97
E-1
TROUBLESHOOTING
E-1
SAM400 & 650
If for any reason you do not understand the test procedures or are unab le to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three-step procedure listed below.
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled “PROBLEM (SYMPTOMS)”. This column describes pos­sible symptoms that the machine may exhib­it. Find the listing 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.
If you do not understand or are unable to perform the Recommended Course of Action safely, contact you local Lincoln Authorized Field Service Facility.
HO W 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 and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
__________________________________________________________________________
WARNING
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts such as output terminals or internal wiring.
ENGINE EXHAUST can kill.
• Use in open, well ventilated areas or vent exhaust outside.
MOVING PARTS can injure.
• Do not operate with doors open or guards off.
• Stop engine before servicing.
• Keep away from moving parts.
• Remove guards only when necessary and replace when work requiring removal is complete.
• Only qualified personnel should install, use or service this equipment.
E-2
TROUBLESHOOTING
E-2
SAM400 & 650
Observe all Safety Guidelines detailed throughout this manual
If for any reason you do not understand the test procedures or are unab le to perform the tests/repairs safely, contact your Local
Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
FUNCTION PROBLEMS
PROBLEMS
(SYMPTOMS)
POSSIBLE CAUSE
RECOMMENDED
COURSE OF ACTION
LOSS OF OUTPUT IN ONE MODE ONLY (Constant or Variable Voltage Positions) (For loss in both modes see the following pages)
These items functioning properly:
1. Alternator
2. Silicon Controlled Rectifier (SCR) Assembly
3. Control Board #1
4. Generator
1. Test for shorted diode on Three Phase Bridge.
2. Test for failure of Control Board #2.
3. Test for Defective Toggle Switch, Rheostat or Open Circuit
1. Check diodes D7, D8, D9, D10, D11. (See Diode Test Procedure)
2. a) Turn machine off. b) Put toggle switch in mode in
question. c) Remove Control Board #2. d) Tur n voltage control and
portable field control to mini-
mum. e) Start the machine.
f) If generator builds up, install
new Control Board #2 (Note
A); if it does not build up,
proceed to Step 3.
3. a) Turn machine off. b) Remove Control Board #1 c) Put toggle switch in the
mode in question.
d) Tur n voltage control to maxi-
mum.
e) Check continuity of the tog-
gle switch and voltage con­trol. (Note B).
1)V ariable Voltage Position Check continuity from Pin #76 to Pin #204 on Control Board #1 connector. Meter should read a short circuit.
2)Constant V oltage Position Check continuity from Pin #76 to Pin #207 on Control Board #1 connec­tor. Meter should read a short circuit.
NOTE A:If at any time either of the Control (PC) boards is replaced, follow the calibration procedure outlined later in this sec-
tion under “Control P.C. Board Calibration Procedure”. The open circuit voltage will be out of range if trimmers are
not properly set. If both trimmers are set at minimum, the machine might lose excitation. NOTE B:When making continuity checks, use the 1K (X1000) or next higher range. NOTE C:Do not replace PC boards without following outlined procedure for indicated trouble -- damage may result due to
other defective parts.
E-3
TROUBLESHOOTING
E-3
SAM400 & 650
Observe all Safety Guidelines detailed throughout this manual
If for any reason you do not understand the test procedures or are unab le to perform the tests/repairs safely, contact your Local
Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
FUNCTION PROBLEMS
PROBLEMS
(SYMPTOMS)
POSSIBLE CAUSE
RECOMMENDED
COURSE OF ACTION
LOSS OF OUTPUT IN BOTH MODES OF OPERATION
(Constant and Variable Voltage Positions)
Test Alternator Rotor Voltage (80­90 Volts DC) Lead #222 to #1
1. If rotor voltage present go to Step 9. If no rotor voltage go to Step 2.
2. Lightly sand slip rings and reseat brush­es.
3. Flash rotor fields.
a) Turn machine off.
b) Use a 12 to 24 volt battery. c) Apply voltage for 15 seconds, negative
lead to #1, positive lead to #222 at alter­nator terminal strip. CAUTION: Wrong polarity may dam-
age diodes.
4. Jumper leads #75 to #222 -- replace alternator thermostats if this produces output.
5. Continuity check - (Note B Pg.E-2).
a) Remove rotor brushes. b) Disconnect #212 and #214 from alterna-
tor terminal strip.
c) Remove all leads from #1 and #2 on con-
trol box terminal strip.
d) Remove both Control Boards. e)
Check continuity from #214 to #1 and #212 to #1 with the positive lead on #214 and #212. This should read about 27,000 ohms. If shorted, check C-7 for a short. If all right, check D5 and D6. See Procedure
6. SCR Bridge Check.-See Procedure
7. Three phase bridge rectifier check.
a) Remove leads from three phase bridge
rectifier assembly and check diodes (D7 ­D8 - D9 - D10 - D11 - D12) See Procedure
8.
Alternator continuity check - (Note B Pg. E-2).
a) Disconnect lead #212 and #214 and
check winding for continuity.
b) Remove one rotor brush, check continuity
of rotor field. NOTE: Checking resistance of rotor field
may cancel residual magnetism in the rotor iron. Repeat Step 3, "Flash Rotor Fields".
9. If Rotor Voltage is present check voltage between lead #75 and Pin #227 at the rear of Control Board #2 connector. (Approximately 15 to 22 volts DC.)
E-4
TROUBLESHOOTING
E-4
SAM400 & 650
Observe all Safety Guidelines detailed throughout this manual
If for any reason you do not understand the test procedures or are unab le to perform the tests/repairs safely, contact your Local
Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
FUNCTION PROBLEMS
PROBLEMS
(SYMPTOMS)
POSSIBLE CAUSE
RECOMMENDED
COURSE OF ACTION
Output without control - one mode only
(Constant or Variable Voltage)
Output without control - both modes
(Constant and Variable Voltage)
SCR Bridge Test (See Procedure)
Continuity test. (Note B Pg. E-2).
10. Voltage higher than 22 volts DC. a) If between 22 and 100 volts, replace both
Control Boards. (Note A Pg. E-2).
b) If voltage is greater than 100 volts:
1)
Check diode D-4 for a short. See Procedure
2)Replace both Control Boards but only if voltage between Pin #75 and #227 is less than 100 volts DC.
11. Voltage less than 15 volts DC, replace Control Board #1. (Note A Pg. E-2).
12. Voltage within limits.
a) Check SCR Bridge. See Procedure b) Check generator field coil resistance.
1)Disconnect blue and brown field coil
leads. Resistance should be about 10 ohms.
c)
Replace Control Board #1. (Note A Pg. E-2).
d) Check Control Board #2 by following Step
2, Pg E-2.
If bridge tests good proceed to next step.
1. Turn machine off.
2. Remove both Control Boards.
3. Place electrode polarity switch in con­stant voltage positive position.
4. Toggle switch to mode in question.
5. Check continuity of the following (Note B Pg. E-2):
a) Constant Voltage
1)Work to Pin #217 of the connector for
Control Board #2.
2)Pin #203 of the connector for Control
Board #2 to Pin #216 of the connector for Control Board #1.
3)Between corresponding numbers of the
connectors for both Control Boards, Pin #75, 216 and 227.
b) Variable Voltage
1)Blue field lead to Pin #201 of the con-
nector for Control Board #2.
2)Pin #202 of the connector for Control
Board #2 to Pin #216 of the connector for Control Board #1.
3)Between corresponding pins of the
connectors of both Control Boards, Pin #75, 216 and 227.
E-5
TROUBLESHOOTING
E-5
SAM400 & 650
Observe all Safety Guidelines detailed throughout this manual
If for any reason you do not understand the test procedures or are unab le to perform the tests/repairs safely, contact your Local
Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
FUNCTION PROBLEMS
PROBLEMS
(SYMPTOMS)
POSSIBLE CAUSE
RECOMMENDED
COURSE OF ACTION
Output without control ­one mode
Output without control - both modes
Output low in both modes - open circuit voltage low (CV and VV positions)
Arc difficult to start in CV position using low current and voltage (Characterized by large droplets, low frequency transfer)
Continuity test. (Note B Pg. E-2).
Test rotor voltage (80-90 volts DC)
Test alternator outputs (22-24 volts DC)
1.Make continuity test outlined in Step 3, on page E-2 except turn voltage con­trol from maximum (0 ohms) to mini­mum (10,000 ohms).
2.
Replace Control Board #2. (Note A Pg. E-2).
l. Replace Control Board #2
2.
Replace Control Board #1. (Note A Pg. E-2).
1.Rotor Voltage less than 80-90 volts DC
a)Check Diodes D1 - D2 - D5 -D6.See
Procedure.
b)Check SCR Bridge. See Procedure.
c)Check resistance of rotor fields.
Normal value about 14 ohms.
2.Rotor V oltage Within Limits
a)Check SCR Bridge. See Procedure. b)Check generator field coil resis-
tance.
1)Disconnect blue and brown field coil leads. Nor mal value about 10 ohms. One field coil open - 20 ohms. Both field coils open - infinite resistance.
1.Set polarity switch in electrode positive position.
2.Check voltage between work stud and positive alternator lead connected to input side of line contactor.
a)Within Limits
Check contactor contacts.
b)Less than 22-24 volts DC
Check three phase bridge recti­fier diodes D7 - D8 -D9 -D10 ­D11 -D12. See Procedure.
E-6
TROUBLESHOOTING
E-6 DIODE TEST PROCEDURE
Figure E.1
1. Isolate the diode in question from the remainder of the circuit and determine its polarity from the wiring diagram and Figure E.1.
2. Establish the polarity of the ohmmeter leads.
3. Connect the ohmmeter across the diode in question as illustrated in Figures E.2 and E.3 below. Note polarity of ohmmeter in reference to diode.
A SHORTED DIODE will indicate equally low resistance in both directions.
AN OPEN DIODE will have infinite or high resistance in both directions.
A GOOD DIODE will have a re v erse resistance much higher than forward resistance.
Figure E.2
Figure E.3
SCR BRIDGE PC BOARD TEST PROCEDURE
THE SCR BRIDGE SHOULD BE CHECKED BEFORE INSTALLING NEW CONTROL BOARD. COMPONENTS ON THE NEW CONTROL BOARD COULD BE DAMAGED BY A DEFECTIVE SCR BRIDGE.
1. Visually inspect the board for obvious failures.
2. Remove all leads from the terminal strip of the SCR Bridge PC Board.
3. Check C5 and C6 for a short. Read the resistance between terminals 210 and 214 for C5, and between ter­minals 212 and 213 for C6.
4. Check SCR1 and SCR2. For SCR1, attach the (-) ohm­meter lead to the "Brn" Terminal. Place the (+) lead first on Ter minal 210 and then on Terminal 214 and record the resistance of each. To check SCR2, keep the (-) lead on the Brn terminal and with the (+) lead on Terminal 212 and then on Terminal 214 record the resistances read. Reverse the leads and repeat the above tests. The sec­ond resistance values should all be higher than those recorded first. The ohmmeter should be set in its highest range or in "Auto Range".
5. Check D1 and D2. Place the (-) lead on Terminal 75, and place the (+) lead on Ter minal 214 for D1. Keeping the (­) lead on Ter minal 75, attach the (+) lead to Terminal 212 to test D2. This tests the diodes in the "forward" direction. Reverse the leads and repeat the pre vious test. This tests the diodes in the "reverse" direction. The resistance val­ues in the reverse direction should all be higher than those in the forward direction.
6. Test D3 and R28. Connect the (+) lead to the Brn Terminal and the (-) lead to the 75 Terminal and record the resistance. Reverse the meter leads to test the diode in the reverse direction. The resistance in the reverse direc­tion should be higher than it is in the forward direction.
a) If your ohmmeter has a "Diode Test Range"
( ), use that range for this test. Otherwise use "Auto Range" or the lowest range that pro­duces a meter reading.
b) If D3 is open (or you are using too high a range
on the ohmmeter) you will read only the value of R28 (about 1200 ohms) in both directions. If D3 is shorted, you will read zero ohms or a very low resistance in both directions.
7. If the board fails any of the tests, replace it.
SAM400 & 650
CAUTION
Standard Polarity Reverse Polarity
Conventional Current Flow
Anode
Symbol Symbol
Cathode
AnodeCathode
Conventional Current Flow
OHMMETER
+
Anode
i
-
Cathode
Forward Resistance Low
OHMMETER
-
Anode
Reverse Resistance Low
i
+
Cathode
E-7
TROUBLESHOOTING
E-7 CONTROL PC BOARD CALIBRATION
THE SCR BRIDGE SHOULD BE CHECKED BEFORE INSTALLING A NEW CONTROL BOARD. COMPONENTS ON THE NEW CONTROL BOARD COULD BE DAMAGED BY A DEFECTIVE SCR BRIDGE.
NOTE: Before the PC Boards can be calibrated the
machine must be "hot". That is, it should be run approximately one hour at maximum O.C.V. with all covers on the generator.
Factory replacement Control PC Boards are preset and should require only minor adjustment if any.
1. Before any calibrations are made, the engine speed must be correct. Check the engine speed as fol­lows:
a) Set toggle switch to variable voltage. b) Set variable voltage control and portable
field control to high.
c) Allow engine to warm up for approximately
15 minutes.
d) Using an accurate tachometer, check high
idle engine speed. It must be within limits given on the nameplate. Adjust governor only if absolutely necessary. To obtain an accurate speed setting, the unit must be generating its maximum open circuit voltage (Step A.3 below). If no voltage is being gen­erated, this trouble must be first corrected before final speed setting is obtained.
MAX MIN Constant
-1- -2- Voltage Tr immers
MAX MIN Variable
-3- -4- Voltage Tr immers
A. V ariable Voltage
1. Place toggle switch in variable voltage posi­tion.
2. Turn variable voltage control and portable field control to high.
3. Set Trimmer #3 so that OCV is 95±1 volts DC on SAM400 machines or 89±1 volts for SAM650 machines.
4. Turn variable voltage rheostat and por table field control to low.
5. Set Trimmer #4 so that OCV is 65±1 volts
DC on SAM400 machines or 45±1 volts for SAM650 machines. Recheck to make sure readings fall within limits. Trimmer #4 set­ting is dependent on Trimmer #3.
B. Constant Voltage
1. Place toggle switch in constant voltage position.
2. Turn constant voltage rheostat and portable field control to high.
3. Set Trimmer #1 so that OCV is 60±1 volts DC on SAM400 machines or 68±1 volts for SAM650 machines.
4. Turn constant voltage rheostat and portable field control to low.
5. Set Trimmer #2 so that OCV is 21± 0.5 volts DC on SAM400 machines or 22±0.5 volts for SAM650 machines. Recheck to make sure readings fall within limits. Trimmer #2 setting is dependent on Trimmer #1.
SAM400 & 650
CAUTION
E-8
TROUBLESHOOTING
E-8 GROUND TESTS
This machine is equipped with solid-state electronic components which can be damaged if subjected to a ground test or a megger test without observing special precautions as outlined here:
A. Prior to the ground test always turn the engine off
and remove the two Printed Circuit boards mounted on the rear of the welder control panel. For access remove the welder roof and the metal enclosures over the PC boards. Remove one screw from the smaller board and two screws from the larger board and pull each board straight out from the connector block. There are no wires to disconnect.
B. Connect the following jumpers:
1. Welding generator frame to base.
2. Across D13 (#232 to #1)
3. Across D14 (#234 to #75).
C. Place jumpers across the following points, see
wiring diagram.
1. Across the voltmeter terminals if the unit is so equipped.
2. Positive side of SCR bridge (#75) to #214 on the SCR bridge located on the rear panel of the control box.
3. Positive side of SCR bridge (#75) to #212 on the SCR bridge.
4. Across C5 on the SCR bridge.
5. Negative side of the SCR bridge (brown generator field lead) to #214 on the SCR bridge.
6. Negative side of the SCR bridge to #212 on the SCR bridge.
7. Across C6 on the SCR bridge.
8. #1 on the two diode aluminum finned heat sink to #212 on the SCR bridge.
9. #1 on the two diode aluminum finned heat sink to #213 on the SCR bridge.
10. #2 on the base of D4, single diode mount­ed on copper heat sink to #75 on SCR bridge.
11. Across each of the three-phase bridge diodes, jumper from the heat sink across the diode on all six diodes.
NOTE: All jumpers must be as short as possible
SAM400 & 650
CAUTION
F-1
WIRING DIAGRAMS
SAM400 & 650
F-1
SAM400 MACHINE WIRING DIAGRAM
NOTE:This diagram is for reference only. It may not be accurate for all machines covered by this manual. The
specific diagram for a particular code is pasted inside the machine on one of the enclosure panels.
9
8
7
12
S3
11
10
LOW VOLTAGE OPTION
OPEN BOLTED CONNECTION AT 7, 8 AND 9 AT ALTERNATOR.
INSULATE EACH CONNECTION SEPARATELY.
CONNECT LEADS BELOW TO RESPECTIVE STATOR LEADS.
SWITCH S3, IS SHOWN
IN THE "NORMAL" RANGE
THE VOLTAGE RANGE
POSITON AND AS VIEWED
FROM THE REAR OF THE
SWITCH.
212
U
R21
75
75
-
VM
+
207
208
219
204
­+
AM
220
115V POWER
GROUND SCREW
G
G
G
230
229
230V POWER
WORK
RECEPTACLE
F1
N.A.
RECEPTACLE
STICK
AUTOMATIC
21
N.O.
LS1
CIRCUIT
2
2B
218 TO 219
OMIT JUMPERS
FROM
D6
214
D5
201
77
76
213
BOARD #1
TO P.C.
217
N.A.
U
N.O. CIRCUIT
2
2A
2B TO 2
2A TO 2B
214
214
1
75
214
210
F2
LS2
R30
N.C. CIRCUIT
218
219
STRIP AND
ON TERMINAL
P.
BRIDG
210
1
VOLTAGE
VARIABLE
227
216
212
WHITE
TERMINAL
31
S3 - VOLTAGE RANGE SWITCH
LS2 - LIMIT SWITCH (LOW VOLTAGE)
LS1 - LIMIT SWITCH (NORMAL VOLTAGE)
218
219
CONNECT THESE
LEADS TO
TERMINAL STRIPS.
C.BD.
E
BROWN
75
212
213
214
75
212
220
R19
204
1
CONTROL
CONSTANT
1
227
202
75
216
32
33
32
2
+
10CR
10CR
R30- 1000 OHMS (2W)
75
210
212
213
75
N
207
219
R20
CONTROL
VOLTAGE
201
217
203
BOARD #2
TO P.C.
31
N
-1+ A
LEAD BLOCK
-
75
223
223
207
208
4-22-94
L9603
TERMINAL
GROUNDING
U - BLUE
N - BROWN
W - WHITE
LEAD COLOR CODING
WITHOUT LOW VOLTAGE OPTION.)
WITH LOW VOLTAGE OPTION SEE INSERT
INTERNALLY ON LATEST MACHINES
ABOVE. (THESE CONNECTIONS ARE MADE
10, 11 AND 12 SEPARATELY. FOR UNITS
LEADS 7, 8 AND 9 TOGETHER AND
INSULATE CONNECTION. INSULATE LEADS
D13
C9
1
75
C4
2CR 8CR
32
216
202
217
+
219
219
216
220
218
R29
203
76
3
4
4 1
S1
FRONT
5
75
1
R24
1
75
75
31
5
6
2
3
218
S2
2
4
-
3
BACK 2
C10
9CR
D14
234
232
7CR
C8
222
R22
222
76
5 1
224
67
4. FOR NORMAL VOLTAGE WELDING, CONNECT
CIRCUIT DIAGRAM
SEE BATTERY
-
+
235
233
224
SEE
C
#4
NOTE
NOTES
9
CONTROL, CONNECT A JUMPER ACROSS
TERMINALS #75 AND *77.
TO TERMINALS #75 AND #76.
1. CONNECT PORTABLE FIELD CONTROL
-
D11
D10
D7
+
8
11
7
3. WHEN NOT USING LINCOLN EQUIPMENT,
2. WHEN NOT USING PORTABLE FIELD
D12
D8
D9
A
B
10
12
31
33
32
C4
77
76
75
2B 2A
218
219
214
32
1
212
2
31
-+
FIELD
ROTATING
75
222
67
NEG. SLIP
RING IS
21
LEGEND
ELECTRICAL SYMBOLS PER E1537
N.A. CENTER TERMINAL OF FUSE HOLDER.
CONNECT GUN TRIGGER TO #C-4 AND
#2 TO OPERATE CONTACTOR.
ALTERNATOR
PILOT RELAY
REED SWITCH
ENERGIZING RELAY
HOT START RELAY
S-78 CONTACTOR
POLARITY SWITCH
TOGGLE SWITCH
2CR
7CR
8CR
9CR
S2
100
0.5
10K POT.
10K POT.
R19
R20
R21
R22
100 A.
1 A.
100 A.
100 A.
D10
D11
D12
D13
100
500
R24
10 AMP
1 A.
F1
D14
10CR
R29
LAMINATION
NEAREST
S1
20 AMP
F2
100 A.
D9
6.0 MFD
.022 MFD
16 A.
C9
C10D5D6
16 A.
100 A.
100 A.
D7
D8
1.0 MFD
C8
SPECIFIC VALUES OF
NUMBERED COMPONENTS
F-2
WIRING DIAGRAMS
F-2
SAM400 & 650
NOTE:This diagram is for reference only. It may not be accurate for all machines covered by this manual. The
specific diagram for a particular code is pasted inside the machine on one of the enclosure panels.
SAM650 MACHINE WIRING DIAGRAM
4-22-94
L9606
210
212
N
207
207
CONTROL
INNERSHIELD
217
N
224
223
208
207
C4
2CR 8CR
32
75
216
202
220
203
216
219
FRONT
1
219
75
4
1
76
P.
C.BD.
BRIDG
E
BROWN
75
214
210
214
214
D6
1
D5
1
201
77
220
76
213
BOARD #1
TO P.C.
STICK
75
212
227
214
210
75
212
U
R21
75
75
-
VM
+
208
207
219
­+
AM
204
217
214
75
R19
CONTROL
1
216
204
216
213
220
227
TO P.C.
212
212
1
201
202
75
BOARD #2
213
75
R20
203
D15
D13
R22
D14
CIRCUIT DIAGRAM
SEE BATTERY
234
232
-
+
NOTES
235
233
7CR
31
C8
222
222
75
D10
D7
CONTROL, CONNECT A JUMPER ACROSS
TERMINALS #75 AND *77.
TO TERMINALS #75 AND #76.
1. CONNECT PORTABLE FIELD CONTROL
2. WHEN NOT USING PORTABLE FIELD
LEAD COLOR CODING
-
D11
D12
B
A
C
D8
+
FIELD
ROTATING
#2 TO OPERATE CONTACTOR.
CONNECT GUN TRIGGER TO #C4 AND
3. WHEN NOT USING LINCOLN EQUIPMENT,
U - BLUE
N - BROWN
W - WHITE
D9
ALTERNATOR
ELECTRICAL SYMBOLS PER E1537
N.A. CENTER TERMINAL OF FUSE HOLDER.
C9
1
75
1
R24
75
231
6
5
S1
2
3
S2
BACK
GROUND SCREW
GGG
229
115V POWER
230
RECEPTACLE
230V POWER
WORK
RECEPTACLE
F1
N.A.
10CR
STICK
AUTOMATIC
CONNECT TAP
F2
31
LEAD TO DESIRED
OUTPUT TERMINAL
33
N.A.
WHITE
TERMINAL
31
32
32
31
223
10CR
75
MIN. SLOPE, INNERSHIELD
217
224
N
U
(-)(+)
I 1234
-
A
5
MIN TO 140, STICK
217
31
33
32
C10
75
77
R29
9CR
21
LEAD BLOCK
GENERATOR
130 TO 225, SUBMERGED ARC, OR STICK
210 TO 330, SUBMERGED ARC, OR STICK
300 TO 575, SUBMERGED ARC, MAX. SLOPE, INNERSHIELD
450 TO MAX., SUBMERGED ARC, MED. SLOPE, INNERSHIELD
214
75 76 77 C4 32 31 2
67 21
1
75
222
212
NEAREST
NEG. SLIP
RING IS
HOT START RELAY
REED SWITCH
(2 REQ'D)
S-78 CONTACTOR
8CR
9CR
10CR
OF NUMBERED COMPONENTS
100
500
0.5
10K POT.
20 AMP
10 AMP
1 AMP
10K POT.
R19
R20
R21
R22
F1
D15
1.0 MFD
6.0 MFD
LEGEND - SPECIFIC VALUES
C8
C9
R24
F2
.022 MFD
16 A.
16 A.
100 A.
100 A.
100 A.
D8
D9
C10D5D6D7D10
LAMINATION
PILOT RELAY
100
POLARITY SWITCH
ENERGIZING RELAY
TOGGLE SWITCH
2CR
7CR
R29S1S2
1 A.
100 A.
1 A.
100 A.
100 A.
D11
D12
D13
D14
SAM400 & 650
F-3
WIRING DIAGRAMS
F-3
NOTE:This diagram is for reference only. It may not be accurate for all machines covered by this manual. The
specific diagram for a particular code is pasted inside the machine on one of the enclosure panels.
SAM400 ENGINE WIRING DIAGRAM
GENERAL MAINTENANCE INSTRUCTIONS FOR ENGINE DRIVEN ARC WELDING POWER SOURCES
WARNING:
MOVING
PARTS
CAN INJURE
Have only qualified personnel perform
maintenance work.
Turn the engine or input power OFF before
maintenance work unless the maintenance work requires it to be running.
Keep hands, hair, clothing and tools away
from moving parts, and insure all guards or covers are replaced after servicing.
MAINTENANCE INSTRUCTIONS
DAILY CHECKS:
- Electrode and work connections are tight.
- Rotate the current control twice to clean contacts.
- All equipment in serviceable condition.
- Engine oil, coolant, air cleaner and fuel strainer are at
proper operating level and clean.
AS REQUIRED:
- Blow dust from the machine using clean low pressure air.
- Clean commutators or slip rings with fine sandpaper­NOT EMERY CLOTH. See the Operating Manual for instructions.
- Replace brushes before the pigtail is within 1/ 4" of the commutator.
See the Operating Manual for instructions.
- Grease may be added to bearings no more than once a year. See
the Operating Manual for instructions.
TO FLASHING DIODE
(SAE UNITS ONLY)
ALTERNATOR
+
-
ENGINE HOUR METER
(OPTIONAL)
FUEL SHUT OFF VALVE
THERMOSTART
AMMETER
EXC
+
B
Y
IGNITION
SWITCH
FUEL INJECTION PUMP
-
+
START
S
STARTING
MOTOR
COLD TERMINAL
(SAM UNITS
}
-
THERMOSTART
IGNITER
TO CR7
ONLY)
-
+
+
M16879 4-3-92A
SAM400 & 650
F-4
WIRING DIAGRAMS
F-4
NOTE:This diagram is for reference only. It may not be accurate for all machines covered by this manual. The
specific diagram for a particular code is pasted inside the machine on one of the enclosure panels.
SAM650 ENGINE WIRING DIAGRAM
NOT EMERY CLOTH. See the
XB-RW
S22668
from moving parts, and insure all guards or
covers are replaced after servicing.
- Have only qualified personnel perform
maintenance work.
- Keep hands, hair, clothing and tools away
- Turn the engine or input power OFF before
maintenance work unless the maintenance work
WARNING:
GENERAL MAINTENANCE INSTRUCTIONS FOR ENGINE
AND MOTOR DRIVEN ARC WELDING POWER SOURCES
IGNITER
THERMOSTART
-
+
ENGINE HOUR METER
Y Y
requires it to be running.
PARTS
MOVING
CAN INJURE
COLD
COLD
TERMINAL
TERMINAL
START
THERMOSTART
Y
-
+
B
G
MAINTENANCE INSTRUCTIONS
TO CR7
}
}
AMMETER
- All equipment in serviceable condition.
- Welding cable connections are tight.
- Engine oil, coolant, air cleaner and fuel
strainer are at proper operating level and
clean.
DAILY CHECKS:
AS REQUIRED:
+
-
-
IGNITION
+
SWITCH
RELAY
ENGINE
PROTECTION
- Blow dust from the machine using clean low
FUSE
(SFE 14)
sandpaper-
pressure air.
- Clean commutators or slip rings with fine
Operating Manual for instructions.
- Replace brushes before the pigtail is within
1/4" of the commutator. See the Operating
Manual for instructions.
ENGINE GROUND
S
MOTOR
STARTING
G
OFF VALVE
FUEL SHUT
SB
NC
NO G
+
IND
ALTERNATOR
SWITCH (N.C.)
OIL PRESSURE
TEMPERATURE GAGE
FUEL INJECTION PUMP
SAM400 & 650
F-5
DIMENSION PRINT
F-5
5.75
(SAM650 Only)
8.12
8.90
3.00
.88
7-28-95E
M8869-23,-25
**
A
B
C
69.75
*
44.50
F
D
83.00
F
77.00
Height of SAM650
Muffler Installed
Additional Muffler
28.00
DIMENSION PRINT - SAM400 AND SAM650 PERKINS ENGINE WELDERS
19.80
for SAM400 Perkins
Only.
11.00
39.69
50.13
6.00
E
.59 x 1.10 Slots
**
*
24.50
22.14
.81 Dia. Holes
.69 Dia. Holes
*
27.12
22.00
81.25
63.06 38.50 25.95
SAM400
SAM650 56.38 41.00 23.88
E
D
C
B
A
Now Available...12th Edition The Procedure Handbook of Arc Welding
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 industr y.
This printing will go fast so don’t delay. Place your order now using the coupon below.
The hardbound book contains over 750 pages of welding inf or­mation, techniques and procedures. Much of this material has never been included in any other book.
A must for all welders, supervisors, engineers and designers.Many welding instructors will want to use the book as a reference for all students b y taking advantage of the low quan­tity discount prices which include shipping by 4th class parcel post.
$15.00 postage paid U.S.A. Mainland
How To Read Shop Drawings
The book contains the latest information and application data on the American Welding Society Standard Welding Symbols.Detailed discussion tells how engineers and drafts­men use the “short-cut” language of symbols to pass on assembly and welding information to shop personnel.
Practical exercises and examples develop the reader’s
ability to visualize mechanically drawn objects as they will appear in their assembled form.
187 pages with more than 100 illustrations. Size 8-1/2” x
11”
Durable, cloth-covered board binding.
$4.50 postage paid U.S.A.
Mainland
New Lessons in Arc Welding
Lessons, simply written, cover manipulatory techniques; machine and electrode characteristics;related subjects, such as distortion; and supplemental information on arc welding applications, speeds and costs.Practice materials, ex ercises, questions and answers are suggested for each lesson.
528 pages, well illustrated, 6” x 9” size, bound in simulated, gold embossed leather.
$5.00 postage paid U.S.A.
Mainland
Need Welding Training?
The Lincoln Electric Company operates the oldest and most respected Arc Welding School in the United States at its corporate
headquarters in Cleveland, Ohio.Over 100,000 students have graduated. Tuition is low and the training is “hands on”
For details write: Lincoln Welding School
22801 St. Clair Ave. Cleveland, Ohio 44117-1199.
and ask for bulletin ED-80 or call 216-383-2259 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 4th Class Book Rate for U.S.A. Mainland Only. Please allow up to 4 weeks for delivery. UPS Shipping for North America Only. All prepaid orders that request UPS shipment please add:
$5.00 For order value up to $49.99 $10.00 For order value between $50.00 & $99.99 $15.00 For order value between $100.00 & $149.00
For North America invoiced orders over $50.00 & credit card orders, if UPS is requested, it will be invoiced or charged to you at cost. Outside U.S.A. Mainland order must be prepaid in U.S. Funds.Please add $2.00 per book for surface mail or $15.00 per book for air parcel post shipment. METHOD OF PAYMENT: (Sorry, No C.O.D. Orders)
CHECK ONE:
Name: _______________________________________________
Please Invoice (only if order is over $50.00)
Address: _______________________________________________
Check or Money Order Enclosed, U.S. Funds only
_______________________________________________
Credit Card - Telephone: _______________________________________________
Signature as it appears on Charge Card:
Account No.
|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_| Exp Date |_|_| |_|_|
______________________
Month Year
USE THIS FORM TO ORDER:
Order from: BOOK DIVISION,The Lincoln Electric Company, 22801 St. Clair Avenue,Cleveland, Ohio 44117-1199
BOOKS OR FREE INFORMATIVE CATALOGS Telephone: 216-383-2211 or, for fastest service, FAX this completed form to: 216-361-5901.
Lincoln Welding School Titles: Price Code Quantity Cost
(ED-80)
New Lessons in Arc Welding $5.00 L
Seminar Information Procedure Handbook “Twelfth Edition” $15.00 PH
(ED-45)
How to Read Shop Drawings $4.50 H
Educational Video Information Incentive Management $5.00 IM
(ED-93)
A New Approach to Industrial Economics $5.00 NA James F. Lincoln Arc Welding The American Century of John C. Lincoln $5.00 AC Foundation Book Information Welding Preheat Calculator $3.00 WC-8
(JFLF-515)
Pipe Welding Charts $4.50 ED-89
SUB TOT AL
Additional Shipping Costs if any
TOTAL COST
VISA
®
MasterCardMasterCard
®
SAM400 & 650
WARNING
AVISO DE
PRECAUCION
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 BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES 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 A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER­STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
Do not touch 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 moja­da.
Aislese del trabajo y de la tierra.
Ne laissez ni la peau ni des vête-
ments mouillés entrer en contact avec des pièces sous tension.
Isolez-vous du travail et de la terre.
Berühren Sie keine stromführenden
Teile oder Elektroden mit Ihrem Körper oder feuchter Kleidung!
Isolieren Sie sich von den
Elektroden und dem Erdboden!
Não toque partes elétricas e elec-
trodos com a pele ou roupa molha­da.
Isole-se da peça e terra.
Keep flammable materials away.
Mantenga el material combustible
fuera del área de trabajo.
Gardez à l’écart de tout matériel
inflammable.
Entfernen Sie brennbarres Material!
Mantenha inflamáveis bem guarda-
dos.
Wear eye, ear and body protection.
Protéjase los ojos, los oídos y el
cuerpo.
Protégez vos yeux, vos oreilles et
votre corps.
Tragen Sie Augen-, Ohren- und Kör-
perschutz!
Use proteção para a vista, ouvido e
corpo.
SAM400 & 650
WARNING
AVISO DE
PRECAUCION
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 AS PRÁTICAS 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 los
humos. Utilice ventilación o aspiración para gases.
Gardez la tête à l’écart des fumées.
Utilisez un ventilateur ou un aspira-
teur pour ôter les fumées des zones de travail.
Vermeiden Sie das Einatmen von
Schweibrauch!
Sorgen Sie für gute Be- und
Entlüftung 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 máquina
antes de iniciar cualquier servicio.
Débranchez le courant avant l’entre-
tien.
Strom vor Wartungsarbeiten
abschalten! (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 or
guards off.
No operar con panel abierto o
guardas quitadas.
N’opérez pas avec les panneaux
ouverts ou avec les dispositifs de protection enlevés.
Anlage nie ohne Schutzgehäuse
oder Innenschutzverkleidung in Betrieb setzen!
Mantenha-se afastado das partes
moventes.
Não opere com os paineis abertos
ou guardas removidas.
• Sales and Service through Subsidiaries and Distributors Worldwide •
22801 St. Clair Ave. Cleveland, Ohio 44117-1199 U.S.A.Tel. 216-481-8100
World's Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors
STATEMENT OF WARRANTY:
The Lincoln Electric Company (Lincoln) warrants to the original purchaser (end-user) of new equipment that it will be free of defects in workmanship and material.
This warranty is void if Lincoln finds that the equipment has been subjected to improper care or abnormal operation.
WARRANTY PERIOD:
All warranty periods date from the date of shipment to the original purchaser and are as follows:
Three Y ears:
Transformer Welders Motor-generator Welders Inverter Welders Automatic Wire Feeders Semiautomatic Wire Feeders Plasma-cutting Power Source Engine Driven Welders (except engine and engine accessories) with operating speed under 2,000 RPM
Tw o Y ears:
Engine Driven Welders (except engine, engine accessories and Power-Arc 4000 generator/welders) with operating speed over 2,000 RPM
All engine and engine accessories are warranted by the engine or engine accessory manufacturer and are not cov­ered by this warranty.
One Y ear:
Equipment not listed above such as gun and cable assem­blies, water coolers, FAS TRAK or MIG-TRAK equipment, air compressor on the SAE400 WELD’N AIR, Power-Arc 4000 generator/welders, Wire Feed Module (Factory Installed) and field-installed optional equipment.
TO OBTAIN WARRANTY COVERAGE:
You are required to notify Lincoln Electric, your Lincoln Distributor, Lincoln Service Center or Field Service Shop of any defect within the warranty period.Written notification is recommended.
WARRANTY REPAIR:
If Lincoln's inspection of the equipment confirms the exis­tence of a defect covered by this warranty, the defect will be corrected by repair or replacement at Lincoln's option.
WARRANTY COSTS:
You must bear the cost of shipping the equipment to a Lincoln Service Center or Field Service Shop as well as return shipment to you from that location.
IMPORT ANT W ARRANTY LIMIT A TIONS:
Lincoln will not accept responsibility for repairs made without its authorization.
• Lincoln shall not be liable for consequential damages (such as loss of business, etc.) caused by the defect or reasonable delay in correcting the defect.
• Lincoln's liability under this warranty shall not exceed the cost of correcting the defect.
• This written warranty is the only express warranty pro­vided by Lincoln with respect to its products.Warranties implied by law such as the Warranty of Merchantability are limited to the duration of this limited warranty for the equipment involved.
LIMITED W ARRANTY
April, ‘97
WARRANTY SUPERSEDED
SEE IMWS 1
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WARRANTY
WARRANTY
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INCLUDING: PARTS
R
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