B-2
OPERATION
SA-400I
®
Some arc instability may be experienced with EXX10 electrodes
when trying to operate with long arc techniques at settings at the
lower end of the open circuit voltage range.
DO NOT attempt to set the “Current Range Selector” between the
five points designated on the nameplate.
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These switches have a spring loaded cam which almost elimi-
nates the possibility of setting this switch between the designat-
ed points.
ENGINE BREAK-IN
Lincoln Electric selects high quality, heavy-duty industrial
engines for the portable welding machines we offer. While it is
normal to see a small amount of crankcase oil consumption
during initial operation, excessive oil use, wet stacking (oil or tar
like substance at the exhaust port), or excessive smoke is not
normal.
Larger machines with a capacity of 350 amperes and higher,
which are operated at low or no-load conditions for extended
periods of time are especially susceptible to the conditions
described above. To accomplish successful engine break-in,
most diesel-powered equipment needs only to be run at a
reasonably heavy load within the rating of the welder for some
period of time during the engine’s early life. However, if the
welder is subjected to extensive light loading, occasional
moderate to heavy loading of the engine may sometimes be
necessary. Caution must be observed in correctly loading a
diesel/generator unit.
1. Connect the welder output studs to a suitable resistive load
bank. Note that any attempt to short the output studs by
connecting the welding leads together, direct shorting of the
output studs, or connecting the output leads to a length of
steel will result in catastrophic damage to the generator and
voids the warranty.
2. Set the welder controls for an output current and voltage
within the welder rating and duty cycle. Note that any
attempt to exceed the welder rating or duty cycle for any
period of time will result in catastrophic damage to the
generator and voids the warranty.
3. Periodically shut off the engine and check the crankcase oil
level.
WELDER OPERATION
DUTY CYCLE
The NEMA output rating of the SA-400I
®
is 300 amperes at 32
arc volts on a 60% duty cycle (consult Specifications in this
manual for alternate ratings). Duty cycle is based on a ten
minute period; thus, the welder can be loaded at rated output for
six minutes out of every ten minute period.
CONTROL OF WELDING CURRENT
DO NOT TURN THE “CURRENT RANGE SELECTOR” WHILE
WELDING because the current may arc between the contacts
and damage the switch.
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The “Current Range Selector” provides five overlapping current
ranges. The “Fine Current Adjustment” adjusts the current from
minimum to maximum within each range. Open circuit voltage
is also controlled by the “Fine Current Adjustment” permitting
control of the arc characteristics.
A high open circuit voltage setting provides the soft “buttering”
arc with best resistance to pop-outs preferred for most welding.
To get this characteristic, set the “Current Range Selector” to the
lowest setting that still provides the current you need and set the
“Fine Current Adjustment” near maximum.
For example: to obtain 180 amps and a soft arc, set the
“Current Range Selector” to the 190-120 position and then
adjust the “Fine Current Adjustment” for 180 amps.
When a forceful “digging” arc is required, usually for vertical and
overhead welding, use a higher “Current Range Selector” setting
and lower open circuit voltage.
For example: to obtain 180 amps and a forceful arc, set the
“Current Range Selector” to the 260-170 position and the “Fine
Current Adjustment” setting to get 180 amps.
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or
electrode with skin or wet clothing.
• Insulate yourself from work and ground.
FUMES & GASES can be dangerous.
• Keep your head out of the fumes.
• Use ventilation or exhaust to remove
fumes from breathing zone.
WELDING SPARKS can cause fire or explosion.
• Keep flammable material away.
ARC RAYS can burn.
• Wear eye, ear, and body protection.
WARNING
CAUTION
CAUTION
