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Lincoln Electric SAM400 manual

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Table of contents for the manual

  • Page 1

    S AM400 & 650 PERKINS DIESEL ENGINE DRIVEN MUL TI-PROCESS DC ARC WELDING PO WER SOURCES OPERA T OR’S MANU AL Sales and Ser vice through Subsidiaries and Distr ibutors Worldwide 22801 St. Clair A ve. Cle veland, Ohio 44117-1199 U .S.A. T el. (216) 481-8100 W orld's Leader in W elding and Cutting Products Premier Manuf acturer of Industr i[...]

  • Page 2

    i SAFETY i SAM400 & 650 FOR ENGINE powered equipment. 1.a. T ur n the engine off bef ore troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b . Operate engines in open, well-v entilated areas or vent the engine e xhaust fumes outdoors. ______________[...]

  • Page 3

    ii SAFETY ii SAM400 & 650 ARC RA YS can burn. 4.a. Use a shield with the proper filter and cov er plates to protect your e yes from sparks and the ra ys of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards. 4.b . Use suitab le clothing made from durab le flame-resistant materi[...]

  • Page 4

    iii SAFETY iii SAM400 & 650 FOR ELECTRICALL Y powered equipment. 8.a. T ur n off input power using the disconnect switch at the fuse bo x before working on the equipment. 8.b . Install equipment in accordance with the U.S . National Electrical Code, all local codes and the manuf acturer’ s recommendations. 8.c. Ground the equipment in accorda[...]

  • Page 5

    iv SAFETY iv SAM400 & 650 PRÉCA UTIONS DE SÛRETÉ P our 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 suiv- antes: Sûreté P our Soudage A L ’Arc 1. Protegez-vous contre la secousse électriq[...]

  • Page 6

    SAM400 & 650 Thank Y ou f or selecting a QU ALITY product by Lincoln Electric. We w ant you to take pride in operating this Lincoln Electric Company product ••• as much pride as we ha ve in bringing this product to y ou! Read this Operators Man ual completely bef ore attempting to use this equipment. Sa v e this manual and k eep it handy [...]

  • Page 7

    vi T ABLE OF CONTENTS SAM400 & 650 vi P age Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A T echnical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 Product Description . . . . . . . . . . . . . . . . .[...]

  • Page 8

    A-1 INST ALLA TION SAM400 & 650 A-1 TECHNICAL SPECIFICA TIONS - SAM400 Make/Model Description Speed (RPM) Displacement Starting Capacities System P erkins 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 ) & Star ter 85.1 L Engine 1725 RPM Full Load 1725 Bore x Stroke Oil: 8[...]

  • Page 9

    A-2 INST ALLA TION SAM400 & 650 A-2 TECHNICAL SPECIFICA TIONS - SAM650 Make/Model Description Speed (RPM) Displacement Starting Capacities System P erkins 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) & Star ter 85.1 L Engine 1730 RPM Full Load 1750 Bore x Stroke Oil: 1[...]

  • Page 10

    A-3 INST ALLA TION SAM400 & 650 A-3 PR ODUCT DESCRIPTION The SAM engine welders are multi-purpose welding machines. The y 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 f ollowing automatic equipment: LN-7, LN-8, LN-9, LN-22, LN- 23P (with Adapter Kit[...]

  • Page 11

    A-4 INST ALLA TION A-4 PRE-OPERA TION SER VICE Oil: This unit is supplied from the f actor y with the engine crankcase filled with a high quality 10W30 oil. This oil should be acceptable f or most typical ambient temperatures . Consult the Engine Operation Manual f or specific recommendations. Upon receipt of the welder , check the dipstic k to be [...]

  • Page 12

    B-1 OPERA TION B-1 OPERA TING PRECA UTIONS Do not attempt to use this equipment until y ou have thor oughly read the engine manufacturer’ s manual supplied with y our welder . It inc ludes important safety precautions, detailed engine starting, operating and maintenance instructions, and parts lists. PIPE THA WING PIPE THA WING can result in fire[...]

  • Page 13

    B-2 OPERA TION B-2 WELDER CONTROLS: FUNCTION/OPERA TION PORT ABLE FIELD CONTROL CONNECTION A “P or table Field Control” complete with 25’ leads is shipped with each SAM welder . A “P or table Field Control” is not required f or proper operation of the SAM welder when connected to an LN-8, LN-9, NA-3, NA-5, L T -7, or L T -56 wire f eeder [...]

  • Page 14

    B-3 OPERA TION B-3 c. Be sure the wire f eeder is properly set for constant or v ariable v oltage as appropri- ate. 2. ML-2, ML-3, MN-1, LN-4, LN-5 and LN-6 Wire F eeders This pow er source can be used with these obsolete wire f eeders. Write to the factory f or specific connections. 3. Other Wire F eeders This pow er source can be used with wire f[...]

  • Page 15

    B-4 OPERA TION B-4 Set the welding current and v oltage as described under “Constant V oltage Welding” abov e . V ariable V oltage Welding The SAM400 “Current Control” pro vides the major adjustment of current. It has two calibrated scales; the one giv es maximum and the other minimum current av ailable at any giv en setting. DO NO T ADJUST[...]

  • Page 16

    B-5 OPERA TION B-5 SAM400 Contr ols SAM400 & 650[...]

  • Page 17

    B-6 OPERA TION B-6 SAM400 & 650 SAM400 Contr ols[...]

  • Page 18

    B-7 OPERA TION B-7 SAM400 & 650 SAM650 Contr ols[...]

  • Page 19

    B-8 OPERA TION B-8 SAM400 & 650 SAM650 Contr ols[...]

  • Page 20

    B-9 OPERA TION B-9 ST ARTING WELDERS WITH DEAD B A TTERIES DO NO T 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 star ting circuit elimi- nates the operation [...]

  • Page 21

    C-1 A CCESSORIES C-1 K799 Hi-Freq™ - Provides high frequency plus a gas valv e for TIG welding. A w ater valv e is av ailable as an option. Requires 115 volt A C input. Cannot be used with optional meters connected, or in constant v oltage mode. (Limited to 250A - 60% Duty Cycle). K802-D P ower Plug Kit - For SAM welders with stan- dard 2KV A of [...]

  • Page 22

    D-1 MAINTENANCE D-1 ELECTRIC SHOCK can kill. ● Do not touch electrically live parts such as output terminals or inter- nal wiring ENGINE EXHA UST can kill. ● Use in open, well ventilated areas or vent exhaust outside MO VING P AR TS can injure. ● Do not operate with doors open or guards off ● Stop engine before servicing ● Keep a way fr o[...]

  • Page 23

    D-2 MAINTENANCE D-2 COMMUT A T OR AND BRUSH MAINTENANCE Uncovered r otating equipment can be dang erous. Use care so y our hands, hair , clothing or tools do not catch in the r otating parts. Protect your self from particles that ma y be thrown out b y the rotat- ing armature when stoning the commutator . The generator brushes are properly adjusted[...]

  • Page 24

    E-1 TR OUBLESHOO TING E-1 SAM400 & 650 If f or any reason y ou do not understand the test procedures or are unab le to perf or m the tests/repairs saf ely , contact your Local Lincoln A uthorized Field Service Facility for technical troub leshooting assistance before y ou proceed. CA UTION This T roubleshooting Guide is pro vided to help you lo[...]

  • Page 25

    E-2 TR OUBLESHOO TING E-2 SAM400 & 650 Obser ve all Saf ety Guidelines detailed throughout this manual If f or any reason y ou do not understand the test procedures or are unab le to perf or m the tests/repairs saf ely , contact your Local Lincoln A uthorized Field Service Facility for technical troub leshooting assistance before y ou proceed. [...]

  • Page 26

    E-3 TR OUBLESHOO TING E-3 SAM400 & 650 Obser ve all Saf ety Guidelines detailed throughout this manual If f or any reason y ou do not understand the test procedures or are unab le to perf or m the tests/repairs saf ely , contact your Local Lincoln A uthorized Field Service Facility for technical troub leshooting assistance before y ou proceed. [...]

  • Page 27

    E-4 TR OUBLESHOO TING E-4 SAM400 & 650 Obser ve all Saf ety Guidelines detailed throughout this manual If f or any reason y ou do not understand the test procedures or are unab le to perf or m the tests/repairs saf ely , contact your Local Lincoln A uthorized Field Service Facility for technical troub leshooting assistance before y ou proceed. [...]

  • Page 28

    E-5 TR OUBLESHOO TING E-5 SAM400 & 650 Obser ve all Saf ety Guidelines detailed throughout this manual If f or any reason y ou do not understand the test procedures or are unab le to perf or m the tests/repairs saf ely , contact your Local Lincoln A uthorized Field Service Facility for technical troub leshooting assistance before y ou proceed. [...]

  • Page 29

    E-6 TR OUBLESHOO TING E-6 DIODE TEST PROCEDURE Figure E.1 1. Isolate the diode in question from the remainder of the circuit and determine its polar ity from the wir ing diagram and Figure E.1. 2. Estab lish 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 po[...]

  • Page 30

    E-7 TR OUBLESHOO TING E-7 CONTROL PC BO ARD CALIBRA TION THE SCR BRIDGE SHOULD BE CHECKED BEFORE INST ALLING A NEW CONTROL BO ARD. COMPONENTS ON THE NEW CONTROL BO ARD COULD BE D AMA GED BY A DEFECTIVE SCR BRIDGE. NO TE: Before the PC Boards can be calibrated the machine must be "hot". That is, it should be run appro ximately one hour at [...]

  • Page 31

    E-8 TR OUBLESHOO TING 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 alwa ys tur n the engine off and remov e the two Printed Circuit boards mounted on the rear of [...]

  • Page 32

    F-1 WIRING DIA GRAMS SAM400 & 650 F-1 4-22-94 L9603 R20 AM VM + - 7CR 232 234 D14 D13 SEE BATTERY CIRCUIT DIAGRAM F1 2CR 7CR 8CR 9CR 10CR C9 C10 D5 D6 D7 D9 D10 D11 D12 D13 D14 R19 R20 R21 R22 R24 PILOT RELAY HOT START RELAY S-78 CONTACTOR REED SWITCH 1.0 MFD 6.0 MFD .022 MFD 16 A. 16 A. 100 A. 100 A. 100 A. 100 A. 100 A. 100 A. 1 A. 1 A. 100 5[...]

  • Page 33

    F-2 WIRING DIA GRAMS F-2 SAM400 & 650 4-22-94 L9606 R20 AM VM + - 7CR 232 234 D14 D13 SEE BATTERY CIRCUIT DIAGRAM F1 2CR 7CR 8CR 9CR 10CR C9 C10 D5 D6 D7 D10 D11 D12 D13 D14 R19 R20 R21 R22 R24 PILOT RELAY HOT START RELAY S-78 CONTACTOR 1.0 MFD 6.0 MFD .022 MFD 16 A. 16 A. 100 A. 100 A. 100 A. 100 A. 100 A. 100 A. 1 A. 1 A. 100 500 R29 S1 S2 F2[...]

  • Page 34

    SAM400 & 650 F-3 WIRING DIA GRAMS F-3 DAILY CHECKS: - Electrode and work connections are tight. - All equipment in serviceable condition. AS REQUIRED: See the Operating Manual for instructions. MOVING PARTS CAN INJURE WARNING: Y B + EXC TO FLASHING DIODE + - IGNITER + - S MOTOR + + - - START AMMETER FUEL SHUT OFF VALVE STARTING THERMOSTART THER[...]

  • Page 35

    SAM400 & 650 F-4 WIRING DIA GRAMS F-4 XB-RW S22668 GENERAL MAINTENANCE INSTRUCTIONS FOR ENGINE AS REQUIRED: - Blow dust from the machine using clean low 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[...]

  • Page 36

    SAM400 & 650 F-5 DIMENSION PRINT F-5 .88 3.00 8.12 5.75 (SAM650 Only) 8.90 83.00 81.25 F 69.75 44.50 * 6.00 39.69 50.13 63.06 38.50 25.95 19.80 Additional Muffler f or SAM400 P er kins Only . 28.00 27.12 24.50 22.14 * E A A B B C C D D 11.00 Height of SAM650 Muffler Installed ** ** * .59 x 1.10 Slots .81 Dia. Holes .69 Dia. Holes SAM400 SAM650 [...]

  • Page 37

    Now A vailable...12th Edition The Procedure Handbook of Ar c W elding With ov er 500,000 copies of previous editions published since 1933, the Procedure Handbook is considered by man y to be the “Bible” of the arc welding industr y . This printing will go fast so don’t dela y . Place your order now using the coupon belo w . The hardbound book[...]

  • Page 38

    SAM400 & 650 W ARNING A VISO DE PRECA UCION A TTENTION W ARNUNG A TENÇÃO Spanish French German P ortuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL F [...]

  • Page 39

    SAM400 & 650 W ARNING A VISO DE PRECA UCION A TTENTION W ARNUNG A TENÇÃO Spanish French German P ortuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE PARA ESTE EQUIP AMENTO E AS PAR TES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust [...]

  • Page 40

    • Sales and Ser vice through Subsidiaries and Distr ibutors Worldwide • 22801 St. Clair A ve. Clev eland, Ohio 44117-1199 U .S.A. T el. 216-481-8100 W orld's Leader in W elding and Cutting Products Premier Manuf acturer of Industr ial Motors ST A TEMENT OF W ARRANTY : The Lincoln Electric Company (Lincoln) warrants to the original purchase[...]