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IM568
SAM400 & 650 PERKINS DIESEL ENGINE DRIVEN
April, 1997
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
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 REPAI
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i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can- chemicals known to the State of California to cause cer, birth defects, and other reproductive harm. cancer, birth defects, or other reproductive harm. The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY
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ii ii SAFETY ELECTRIC SHOCK can kill. ARC RAYS can burn. 3.a. The electrode and work (or ground) circuits 4.a. Use a shield with the proper filter and cover are electrically “hot” when the welder is on. plates to protect your eyes from sparks and Do not touch these “hot” parts with your bare the rays of the arc when welding or observing skin or wet clothing. Wear dry, hole-free open arc welding. Headshield and filter lens gloves to insulate hands. should conform to ANSI Z87. I standards. 3.b. In
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iii iii SAFETY WELDING SPARKS can CYLINDER may explode cause fire or explosion. if damaged. 6.a. Remove fire hazards from the welding area. 7.a.Use only compressed gas cylinders If this is not possible, cover them to prevent containing the correct shielding gas for the the welding sparks from starting a fire. process used and properly operating Remember that welding sparks and hot regulators designed for the gas and materials from welding can easily go through small cracks pressure used. All hos
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iv iv SAFETY PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque d’incendie dû aux étincelles. Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce 7. Quand on ne soude pas, poser la pince à une endroit isolé de manuel aussi bien que les précautions de sûreté générales suiv- la masse. Un court-circuit accidental peut provoquer un antes: échauffement et un risqu
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v v for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• Thank You as much pride as we have in bringing this product to you! 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
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vi vi TABLE OF CONTENTS Page Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 Product Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3 Installation Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS - SAM400 INPUT - DIESEL ENGINE Make/Model Description Speed (RPM) Displacement Starting Capacities System Perkins 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) & Starter 85.1 L Engine 1725 RPM Full Load 1725 Bore x Stroke Oil: 8.5 Qts. 8.04 L 3.875” x 5.00” (98.4 mm x 127.0mm) Coolant: 3.2 gal. 12.11 L RATED OUTPUT - WELDER Duty Cycle Welding Output Volts at Rated Amps 60% (NE
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A-2 A-2 INSTALLATION TECHNICAL SPECIFICATIONS - SAM650 INPUT - DIESEL ENGINE Make/Model Description Speed (RPM) Displacement Starting Capacities System Perkins 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) & Starter 85.1 L Engine 1730 RPM Full Load 1750 Bore x Stroke Oil: 14.0 Qts. 13.24 L 3.937” x 5.00” (100mm x 127mm) Coolant: 5.5 gal. 20.8 L RATED OUTPUT - WELDER Duty Cycle Welding Output Volts at Rated Amps 80% (NEMA
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A-3 A-3 INSTALLATION earth ground such as a metal water pipe going into the PRODUCT DESCRIPTION ground for at least ten feet and having no insulated joints, or to the metal framework of a building which The SAM engine welders are multi-purpose welding has been effectively grounded. The National Electrical machines. They are designed to be used on all open Code lists a number of alternate means of grounding arc or submerged arc processes within the rating of the electrical equipment. unit. The ma
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A-4 A-4 INSTALLATION IMPORTANT: To prevent ELECTRICAL DAMAGE PRE-OPERATION SERVICE WHEN: Oil: This unit is supplied from the factory with the a) Installing new batteries. engine crankcase filled with a high quality 10W30 oil. b) Using a booster. This oil should be acceptable for most typical ambient Use correct polarity — Negative Ground. temperatures. Consult the Engine Operation Manual for specific recommendations. Upon receipt of the To prevent BATTERY BUCKLING, tighten nuts on bat- welder,
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B-1 B-1 OPERATION SPEED CONTROL LEVER OPERATING PRECAUTIONS Manually allows the engine to run at its high idle speed WARNING controlled by the governor or at the factory set low idle speed. When welding or using auxiliary power the Do not attempt to use this equipment until you speed control lever must be in the “RUN” position. To have thoroughly read the engine manufacturer’s reduce the engine to low idle speed when not welding manual supplied with your welder. It includes or not using auxiliar
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B-2 B-2 OPERATION place. WELDER CONTROLS: FUNCTION/OPERATION 3. Remove the two screws on the top end of the wire feeder nameplate. PORTABLE FIELD CONTROL CONNECTION 4. Position the “Portable Field Control” mounting slots A “Portable Field Control” complete with 25’ leads is over these holes and replace the screws. shipped with each SAM welder. 5. Route the leads with the LN-5 or LN-6 control cable A “Portable Field Control” is not required for proper back to the power source. operation of the SA
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B-3 B-3 OPERATION c. Be sure the wire feeder is properly set for CURRENT AND VOLTAGE CONTROLS constant or variable voltage as appropri- ate. Constant Voltage Welding 2. ML-2, ML-3, MN-1, LN-4, LN-5 and LN-6 The SAM-400 “Current Control” is NOT in the circuit Wire Feeders when the ‘Electrode Polarity’ switch is set for constant voltage welding. This power source can be used with these obsolete wire feeders. Write to the factory Set the open circuit voltage (OCV) needed for the par- for specific c
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B-4 B-4 OPERATION To Set The Controls -- Stick Welding Set the welding current and voltage as described under “Constant Voltage Welding” above. a. Make the coarse setting of welding heat with the SAM400 “Current Control” or the SAM650 Variable Voltage Welding “Tap’”lead. The SAM400 “Current Control” provides the major b. Adjust for the desired arc characteristics with the adjustment of current. It has two calibrated scales; the “Variable Voltage Control”. For a soft arc desired one gives maximum
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B-5 B-5 OPERATION SAM400 Controls SAM400 & 650
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B-6 B-6 OPERATION SAM400 Controls SAM400 & 650
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B-7 B-7 OPERATION SAM650 Controls SAM400 & 650
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B-8 B-8 OPERATION SAM650 Controls SAM400 & 650
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B-9 B-9 OPERATION about five minutes and then stop the engine and STARTING WELDERS WITH DEAD BATTERIES recheck the oil. If the level is down, fill to the full mark again. The engine controls were properly set at the fac- DO NOT attempt to start a SAM engine driven welder tory and should require no adjusting when received. by driving the welding generator as a starter motor using the output of another welder. In addition to the For added safety always operate the welder with the possibility of da
