B-9
OPERATION
B-9
STARTING WELDERS WITH DEAD BATTERIES
DO NOT attempt to start 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 elimi-
nates 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 volt 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 dou-
ble 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 opera-
tion 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 out-
put 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 per-
formed. (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, observe the oil pres-
sure. 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 fac-
tory 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 starter 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 accom-
plished. 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
