Lincoln Electric SAM400 Operator'S Manual Download Page 1

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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

For use with SAM400 machines having Code Numbers: 10140 & 10141
For use with SAM650 machines having Code Number: 10333

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 opera-
tion 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.

Summary of Contents for SAM400

Page 1: ...il 1997 For use with SAM400 machines having Code Numbers 10140 10141 For use with SAM650 machines having Code Number 10333 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 opera tion on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPME...

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

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

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

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

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

Page 7: ... 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 ...

Page 8: ...127 0mm Coolant 3 2 gal 12 11 L INPUT DIESEL ENGINE RATED OUTPUT WELDER HEIGHT1 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 Curre...

Page 9: ...oolant 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...

Page 10: ...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 Na...

Page 11: ...ttery first then connect negative lead to neg ative 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...

Page 12: ...osition 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 e...

Page 13: ...he 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 Portable Field Control mounting slots over th...

Page 14: ...tant Voltage Control located to the left of the nameplate Adjust the final welding voltage with either the wire feeder voltage con trol or the Portable Field Control Set the welding cur rent 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 out...

Page 15: ...sired 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 con trol leave the Variable Voltage Control near High and make the adjustments described in paragraph b above with the Portable Field Contro...

Page 16: ...B 5 OPERATION B 5 SAM400 Controls SAM400 650 ...

Page 17: ...B 6 OPERATION B 6 SAM400 650 SAM400 Controls ...

Page 18: ...B 7 OPERATION B 7 SAM400 650 SAM650 Controls ...

Page 19: ...B 8 OPERATION B 8 SAM400 650 SAM650 Controls ...

Page 20: ...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...

Page 21: ...ther cylinder is not included K767 1 Undercarriage A 4 wheel steerable under carriage for in plant and yard towing1 with E78 14 load range B tubeless tires Mounts directly to welder base 1For 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 pipe...

Page 22: ...INTENANCE 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 ...

Page 23: ...il contact is made across the full face of the brushes After ston ing 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 pres sure on top of the brushes pull the sandpaper around the circumference of t...

Page 24: ...ou do not understand or are unable to perform the Recommended Course of Action safely contact you local Lincoln Authorized Field Service Facility HOW 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 yo...

Page 25: ...trol 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 Turn voltage control to maxi mum e Check continuity of the tog gle switch and voltage con trol Note B 1 Variable Voltage Position Check contin...

Page 26: ... 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 ...

Page 27: ...ess 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 bo...

Page 28: ... volts DC 1 Make continuity test outlined in Step 3 on page E 2 except turn voltage con trol from maximum 0 ohms to mini mum 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 ...

Page 29: ...esistances read Reverse the leads and repeat the above tests The sec ond 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 Terminal 214 for D1 Keeping the lead on Terminal 75 attach the lead to Terminal 212 to test D2 This tests the diodes in the for...

Page 30: ...If no voltage is being gen erated this trouble must be first corrected before final speed setting is obtained MAX MIN Constant 1 2 Voltage Trimmers MAX MIN Variable 3 4 Voltage Trimmers A Variable Voltage 1 Place toggle switch in variable voltage posi tion 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 volt...

Page 31: ...oss 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 ...

Page 32: ... 75 217 76 9CR 224 67 TO P C BOARD 1 TO P C BOARD 2 FRONT BACK 2 1 7 2 0 3 2 0 1 2 0 2 2 2 7 2 1 6 2 2 7 2 1 6 2 1 0 2 1 2 2 1 4 2 2 0 2 0 4 2 1 9 2 0 7 2 0 8 2 1 3 7 5 1 7 5 7 7 7 6 217 U F2 N A WHITE TERMINAL LEAD BLOCK A 1 2 31 N 32 33 U N A 32 31 WORK STICK AUTOMATIC 21 GROUND SCREW 10K POT 10K POT 0 5 POLARITY SWITCH ENERGIZING RELAY 230V POWER RECEPTACLE 115V POWER RECEPTACLE 230 229 10CR 22...

Page 33: ...31 2 32 67 21 LEAD COLOR CODING U BLUE N BROWN W WHITE ROTATING FIELD NEG SLIP RING IS NEAREST LAMINATION C B NOTES 1 CONNECT PORTABLE FIELD CONTROL TO TERMINALS 75 AND 76 2 WHEN NOT USING PORTABLE FIELD CONTROL CONNECT A JUMPER ACROSS TERMINALS 75 AND 77 3 WHEN NOT USING LINCOLN EQUIPMENT 2 TO OPERATE CONTACTOR N A CENTER TERMINAL OF FUSE HOLDER 33 31 32 1 75 214 212 222 D10 D7 D11 D12 D8 D9 ALTE...

Page 34: ...EMERY CLOTH See the Operating Manual for instructions Replace brushes before the pigtail is within 1 4 of the commutator Grease may be added to bearings no more than once a year See the Operating Manual for instructions ENGINE HOUR METER OPTIONAL FUEL INJECTION PUMP M16879 4 3 92A GENERAL MAINTENANCE INSTRUCTIONS FOR ENGINE DRIVEN ARC WELDING POWER SOURCES maintenance work Turn the engine or input...

Page 35: ... unless the maintenance work requires it to be running STARTING THERMOSTART THERMOSTART sandpaper NOT EMERY CLOTH See the ALTERNATOR RELAY PROTECTION ENGINE IGNITION SWITCH MAINTENANCE INSTRUCTIONS TO CR7 COLD TERMINAL G G ENGINE GROUND WARNING AND MOTOR DRIVEN ARC WELDING POWER SOURCES Keep hands hair clothing and tools away COLD TERMINAL Y Y IND Engine oil coolant air cleaner and fuel strainer a...

Page 36: ...3 06 38 50 25 95 19 80 Additional Muffler for SAM400 Perkins 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 56 38 41 00 23 88 DIMENSION PRINT SAM400 AND SAM650 PERKINS ENGINE WELDERS M8869 23 25 7 28 95E E 22 00 F 77 00 ...

Page 37: ...lletin 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 ...

Page 38: ...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 moja da 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 Ele...

Page 39: ...e 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 op...

Page 40: ...0 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 conf...

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