Lincoln Electric SAM400 Operator's Manual
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Lincoln Electric SAM400 Operator's Manual

Lincoln Electric SAM400 Operator's Manual

Perkins diesel engine driven multi-process dc arc welding power sources
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See also: Operating Manual
SAM400 & 650 PERKINS DIESEL ENGINE DRIVEN
MULTI-PROCESS DC ARC WELDING POWER SOURCES
For use with SAM400 machines having Code Numbers: 10140 & 10141
For use with SAM650 machines having Code Number: 10333
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
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.
World's Leader in Welding and Cutting Products
Sales and Service through Subsidiaries and Distributors Worldwide
22801 St. Clair Ave. Cleveland, Ohio 44117-1199 U.S.A. Tel. (216) 481-8100
RETURN TO MAIN MENU
Supersedes IM247-D
NOT
OPERATOR'S MANUAL
Premier Manufacturer of Industrial Motors
IM568
April, 1997

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Summary of Contents for Lincoln Electric SAM400

  • Page 1 SAM400 & 650 PERKINS DIESEL ENGINE DRIVEN MULTI-PROCESS DC ARC WELDING POWER SOURCES For use with SAM400 machines having Code Numbers: 10140 & 10141 For use with SAM650 machines having Code Number: 10333 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind.

  • Page 2: California Proposition 65 Warnings

    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.

  • Page 3: Electric Shock Can Kill

    (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. SAM400 & 650 which require special Mar ‘95...
  • Page 4 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. Mar ‘95 SAM400 & 650 compressed cylinders...
  • Page 5 électricien qualifié. 3. Avant de faires des travaux à l’interieur de poste, la debranch- er à l’interrupteur à la boite de fusibles. 4. Garder tous les couvercles et dispositifs de sûreté à leur place. SAM400 & 650 Mar. ‘93...
  • Page 6 This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment. for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product •••...

  • Page 7: Table Of Contents

    Parts List ............Appendix TABLE OF CONTENTS SAM400 & 650 Page...

  • Page 8: Technical Specifications

    TECHNICAL SPECIFICATIONS - SAM400 Make/Model Description Perkins 4 cylinder 4.236 Diesel 63 HP @ Engine 1725 RPM Duty Cycle Welding Output 60% (NEMA) 400 amps 60% (Lincoln Plus) 400 amps OUTPUT - WELDER AND GENERATOR Welding Range 60 - 500 Amps...
  • Page 9 (excluding hot start voltage) 2kVA, 60 Hz. 45 - 90 OCV 100% Duty Cycle PHYSICAL DIMENSIONS DEPTH 88.75 in. 2254.2 mm SAM400 & 650 Starting Capacities System 12VDC batteries Fuel: 22.5 gal. (2) & Starter 85.1 L Oil: 14.0 Qts.

  • Page 10: Product Description

    5. Conformance with federal, state and local laws. Consult applicable federal, state and local laws regarding specific requirements for use on public highways. SAM400 & 650 WARNING...

  • Page 11: Pre-Operation Service

    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.

  • Page 12: Operating Precautions

    PIPE BEFORE REVIEWING LINCOLN BULLETIN E695.1 (dated May 1987 or later). This bulletin may be obtained from your local Lincoln distributor or by writ- ing directly to Lincoln Electric at the address on the back of this manual. ADDITIONAL SAFETY PRECAUTIONS...

  • Page 13: Welder Controls: Function/Operation

    #75 and #76 on the SAM terminal strip locat- ed behind the lower cover panel directly below the con- trol panel on the SAM400 or behind the right front hinged door on the SAM650. Connect the green lead of the “Portable Field Control”...
  • Page 14 “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 rat- ing of the machine.
  • Page 15 “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.
  • Page 16 OPERATION SAM400 Controls SAM400 & 650...
  • Page 17 OPERATION SAM400 Controls SAM400 & 650...
  • Page 18 OPERATION SAM650 Controls SAM400 & 650...
  • Page 19 OPERATION SAM650 Controls SAM400 & 650...

  • Page 20: Starting Welders With Dead Batteries

    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...

  • Page 21: Accessories

    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 recom- mended maintenance schedules on machine.

  • Page 22: Maintenance

    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.
  • Page 23 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 APR97...

  • Page 24: How To Use Troubleshooting Guide

    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 your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 25 Phase Bridge. 2. Test for failure of Control Board 3. Test for Defective Toggle Switch, Rheostat or Open Circuit CAUTION SAM400 & 650 RECOMMENDED COURSE OF ACTION 1. Check diodes D7, D8, D9, D10, D11. (See Diode Test Procedure) 2. a) Turn machine off.
  • Page 26 POSSIBLE CAUSE FUNCTION PROBLEMS Test Alternator Rotor Voltage (80- 90 Volts DC) Lead #222 to #1 CAUTION SAM400 & 650 RECOMMENDED COURSE OF ACTION 1. If rotor voltage present go to Step 9. If no rotor voltage go to Step 2.
  • Page 27 POSSIBLE CAUSE FUNCTION PROBLEMS SCR Bridge Test (See Procedure) Continuity test. (Note B Pg. E-2). CAUTION SAM400 & 650 RECOMMENDED COURSE OF ACTION 10. Voltage higher than 22 volts DC. a) If between 22 and 100 volts, replace both Control Boards. (Note A Pg. E-2).
  • Page 28 Test rotor voltage (80-90 volts DC) Test alternator outputs (22-24 volts DC) CAUTION SAM400 & 650 RECOMMENDED COURSE OF ACTION 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).

  • Page 29: Diode Test Procedure

    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 ), use that range for this test. Otherwise...

  • Page 30: Control Pc Board Calibration

    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 portable field control to low.

  • Page 31: Ground Tests

    #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 TROUBLESHOOTING SAM400 & 650...
  • Page 32 WIRING DIAGRAMS SAM400 & 650...
  • Page 33 INNERSHIELD INNERSHIELD SLOPE, WIRING DIAGRAMS STICK 140, STICK ARC, SUBMERGED 225, STICK ARC, SUBMERGED 330, INNERSHIELD SLOPE, MAX. ARC, SUBMERGED 575, SLOPE, MED. ARC, SUBMERGED MAX., MIN. SAM400 & 650...

  • Page 34: Wiring Diagrams

    PARTS covers are replaced after servicing. CAN INJURE THERMOSTART (SAE UNITS ONLY) AMMETER START IGNITION SWITCH FUEL INJECTION STARTING PUMP MOTOR SAM400 & 650 THERMOSTART IGNITER COLD TERMINAL TO CR7 (SAM UNITS ONLY) M16879 4-3-92A...
  • Page 35 WIRING DIAGRAMS SAM400 & 650...
  • Page 36 DIMENSION PRINT SAM400 & 650...
  • Page 37 ® ® |_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_| Account No. 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 Lincoln Welding School Titles: (ED-80) New Lessons in Arc Welding Seminar Information Procedure Handbook “Twelfth Edition”...
  • Page 38 Gardez à l’écart de tout matériel inflammable. Entfernen Sie brennbarres Material! Mantenha inflamáveis bem guarda- dos. SAM400 & 650 Wear eye, ear and body protection. Protéjase los ojos, los oídos y el cuerpo. Protégez vos yeux, vos oreilles et votre corps.
  • Page 39 Anlage nie ohne Schutzgehäuse oder Innenschutzverkleidung in Betrieb setzen! Mantenha-se afastado das partes moventes. Não opere com os paineis abertos ou guardas removidas. SAM400 & 650 WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENÇÃO...

  • Page 40: Limited Warranty

    INCLUDING: PARTS & LABOR S22127-3 LIMITED WARRANTY 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:...

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