RETURN TO MAIN MENU IM568 SAM400 & 650 PERKINS DIESEL ENGINE DRIVEN MULTI-PROCESS DC ARC WELDING POWER SOURCES 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 operation on your part.
i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. The Above For Diesel Engines The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS.
ii ii SAFETY ELECTRIC SHOCK can kill. ARC RAYS can burn. 3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards. 3.b.
iii iii SAFETY WELDING SPARKS can cause fire or explosion. 6.a. Remove fire hazards from the welding area. If this is not possible, cover them 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.
iv iv SAFETY PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. Les circuits à l’électrode et à la piéce sont sous tension quand la machine à souder est en marche.
v v Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• 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.
vi vi TABLE OF CONTENTS Page Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 Product Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3 Installation Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS - SAM400 INPUT - DIESEL ENGINE Make/Model Description Speed (RPM) Displacement Starting System Capacities Perkins 4.236 Diesel Engine 4 cylinder 63 HP @ 1725 RPM High Idle 1790 Low Idle 1100 Full Load 1725 236 cu. in (3.87 L) 12VDC batteries (2) & Starter Fuel: 22.5 gal. 85.1 L 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.
A-2 A-2 INSTALLATION TECHNICAL SPECIFICATIONS - SAM650 INPUT - DIESEL ENGINE Make/Model Description Speed (RPM) Displacement Starting System Capacities Perkins 1006-6 Diesel Engine 6 cylinder 93 HP @ 1730 RPM High Idle 1790 Low Idle 1200 Full Load 1750 365 cu. in (5.98 L) 12VDC batteries (2) & Starter Fuel: 22.5 gal. 85.1 L Bore x Stroke Oil: 14.0 Qts. 13.24 L 3.937” x 5.00” (100mm x 127mm) Coolant: 5.5 gal. 20.
A-3 A-3 INSTALLATION PRODUCT DESCRIPTION The SAM engine welders are multi-purpose welding machines. They are designed to be used on all open arc or submerged arc processes within the rating of the unit. 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 National Electrical Code lists a number of alternate means of grounding electrical equipment.
A-4 PRE-OPERATION SERVICE IMPORTANT: To prevent ELECTRICAL DAMAGE WHEN: Oil: This unit is supplied from the factory with the engine crankcase filled with a high quality 10W30 oil. This oil should be acceptable for most typical ambient temperatures. Consult the Engine Operation Manual for specific recommendations. Upon receipt of the welder, check the dipstick to be sure the oil is at the "full" mark. DO NOT OVERFILL.
B-1 OPERATION OPERATING PRECAUTIONS B-1 SPEED CONTROL LEVER WARNING Do not attempt to use this equipment until you have thoroughly read the engine manufacturer’s manual supplied with your welder. It includes important safety precautions, detailed engine starting, operating and maintenance instructions, and parts lists. Manually allows the engine to run at its high idle speed controlled by the governor or at the factory set low idle speed.
B-2 B-2 OPERATION WELDER CONTROLS: FUNCTION/OPERATION place. PORTABLE FIELD CONTROL CONNECTION 3. Remove the two screws on the top end of the wire feeder nameplate. A “Portable Field Control” complete with 25’ leads is shipped with each SAM welder. 4. Position the “Portable Field Control” mounting slots over these holes and replace the screws. A “Portable Field Control” is not required for proper operation of the SAM welder when connected to an LN-8, LN-9, NA-3, NA-5, LT-7, or LT-56 wire feeder.
B-3 OPERATION c. Be sure the wire feeder is properly set for constant or variable voltage as appropriate. 2. ML-2, ML-3, MN-1, LN-4, LN-5 and LN-6 Wire Feeders This power source can be used with these obsolete wire feeders. Write to the factory for specific connections. 3. Other Wire Feeders This power source can be used with wire feeders manufactured by other companies. The connection must be determined by the customer for the specific equipment being used.
B-4 OPERATION B-4 To Set The Controls -- Stick Welding Set the welding current and voltage as described under “Constant Voltage Welding” above. Variable Voltage Welding a. Make the coarse setting of welding heat with the SAM400 “Current Control” or the SAM650 “Tap’”lead. The SAM400 “Current Control” provides the major adjustment of current. It has two calibrated scales; the one gives maximum and the other minimum current available at any given setting. b.
B-5 OPERATION SAM400 Controls SAM400 & 650 B-5
B-6 OPERATION SAM400 Controls SAM400 & 650 B-6
B-7 OPERATION SAM650 Controls SAM400 & 650 B-7
B-8 OPERATION SAM650 Controls SAM400 & 650 B-8
B-9 B-9 OPERATION 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 eliminates the operation of the flashing circuit. This can cause the generator to fail to produce any output. about five minutes and then stop the engine and recheck the oil.
C-1 ACCESSORIES K799 Hi-Freq™ - Provides high frequency plus a gas valve for TIG welding. A water valve is available as an option. Requires 115 volt AC input. Cannot be used with optional meters connected, or in constant voltage mode. (Limited to 250A - 60% Duty Cycle). K802-D Power Plug Kit - For SAM welders with standard 2KVA of AC auxiliary power. Kit includes male plugs for each auxiliary receptacle. K805-1 Ether Start Kit - Injects ether for starting aid.
D-1 MAINTENANCE SAM400 only: WARNING ELECTRIC SHOCK can kill. ● D-1 Do not touch electrically live parts such as output terminals or internal wiring Inspect the oil bath air filter daily - more often in dusty conditions. When necessary clean and fill the oil bath. The filter should never be removed while the engine is running. PERIODIC MAINTENANCE ENGINE EXHAUST can kill. ● Use in open, well ventilated areas or vent exhaust outside MOVING PARTS can injure.
D-2 MAINTENANCE COMMUTATOR AND BRUSH MAINTENANCE D-2 Arcing or excessive exciter brush wear indicates a possible misaligned shaft. Have an authorized Field Service Shop check and realign the shaft. WARNING Uncovered rotating equipment can be dangerous. Use care so your hands, hair, clothing or tools do not catch in the rotating parts. Protect yourself from particles that may be thrown out by the rotating armature when stoning the commutator.
E-1 TROUBLESHOOTING E-1 HOW TO USE TROUBLESHOOTING GUIDE WARNING 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.
E-2 E-2 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION FUNCTION PROBLEMS LOSS OF OUTPUT IN ONE MODE ONLY (Constant or Variable Voltage Positions) (For loss in both modes see the following pages) 1. Test for shorted diode on Three Phase Bridge. 1. Check diodes D7, D8, D9, D10, D11. (See Diode Test Procedure) 2. Test for failure of Control Board #2. 2. a) b) These items functioning properly: 1.
E-3 E-3 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION FUNCTION PROBLEMS LOSS OF OUTPUT IN BOTH MODES OF OPERATION Test Alternator Rotor Voltage (8090 Volts DC) Lead #222 to #1 (Constant and Variable Voltage Positions) 1. If rotor voltage present go to Step 9. If no rotor voltage go to Step 2. 2. Lightly sand slip rings and reseat brushes. 3. Flash rotor fields. a) Turn machine off.
E-4 E-4 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION FUNCTION PROBLEMS 10. Voltage higher than 22 volts DC. a) If between 22 and 100 volts, replace both Control Boards. (Note A Pg. E-2). b) If voltage is greater than 100 volts: 1)Check diode D-4 for a short. See Procedure 2)Replace both Control Boards but only if voltage between Pin #75 and #227 is less than 100 volts DC. 11.
E-5 E-5 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION FUNCTION PROBLEMS Output without control one mode Continuity test. (Note B Pg. E-2). 1.Make continuity test outlined in Step 3, on page E-2 except turn voltage control from maximum (0 ohms) to minimum (10,000 ohms). 2.Replace Control Board #2. (Note A Pg. E-2). Output without control both modes l. Replace Control Board #2 2.Replace Control Board #1.
E-6 E-6 TROUBLESHOOTING DIODE TEST PROCEDURE Standard Polarity CAUTION Reverse Polarity Anode Cathode Conventional Current Flow SCR BRIDGE PC BOARD TEST PROCEDURE Cathode THE SCR BRIDGE SHOULD BE CHECKED BEFORE INSTALLING NEW CONTROL BOARD. COMPONENTS ON THE NEW CONTROL BOARD COULD BE DAMAGED BY A DEFECTIVE SCR BRIDGE. Anode Symbol Symbol Conventional Current Flow Figure E.1 1. Visually inspect the board for obvious failures. 2.
E-7 TROUBLESHOOTING CONTROL PC BOARD CALIBRATION DC on SAM400 machines or 45±1 volts for SAM650 machines. Recheck to make sure readings fall within limits. Trimmer #4 setting is dependent on Trimmer #3. CAUTION THE SCR BRIDGE SHOULD BE CHECKED BEFORE INSTALLING A NEW CONTROL BOARD. COMPONENTS ON THE NEW CONTROL BOARD COULD BE DAMAGED BY A DEFECTIVE SCR BRIDGE. B. Constant Voltage NOTE: Before the PC Boards can be calibrated the machine must be "hot".
E-8 TROUBLESHOOTING GROUND TESTS CAUTION This machine is equipped with solid-state electronic components which can be damaged if subjected to a ground test or a megger test without observing special precautions as outlined here: A. Prior to the ground test always turn the engine off and remove the two Printed Circuit boards mounted on the rear of the welder control panel. For access remove the welder roof and the metal enclosures over the PC boards.
75 218 10CR 67 - C8 C9 C10 D5 D6 D7 D8 1.0 MFD 6.0 MFD .022 MFD 16 A. 16 A. 100 A. 100 A. A 1 - + 2 F1 N.A. 230V POWER RECEPTACLE 100 A. 100 A. 100 A. 100 A. 1 A. 1 A. 10 AMP N 31 32 31 G F2 R19 R20 R21 R22 R24 R29 222 75 1 212 214 33 32 31 75 217 S1 S2 2CR 7CR 8CR 9CR 10CR C10 R29 BOARD #1 TO P.C.
SAM400 & 650 450 TO MAX., SUBMERGED ARC, MED. SLOPE, INNERSHIELD MIN. SLOPE, INNERSHIELD A - C8 C9 C10 D5 D6 D7 D8 D9 D10 D11 D12 D13 D14 1.0 MFD 6.0 MFD .022 MFD 16 A. 16 A. 100 A. 100 A. 100 A. 100 A. 100 A. 100 A. 1 A. 1 A.
F-3 F-3 WIRING DIAGRAMS WARNING: Have only qualified personnel perform maintenance work. Turn the engine or input power OFF before maintenance work unless the maintenance work requires it to be running. Keep hands, hair, clothing and tools away from moving parts, and insure all guards or covers are replaced after servicing. MOVING PARTS CAN INJURE MAINTENANCE INSTRUCTIONS DAILY CHECKS: - Electrode and work connections are tight. - Rotate the current control twice to clean contacts.
+ SAM400 & 650 NO NC S TEMPERATURE GAGE G Y B - - MOTOR STARTING S START THERMOSTART FUEL SHUT OFF VALVE G (SFE 14) + - TO CR7 ENGINE GROUND - } COLD TERMINAL THERMOSTART IGNITER GENERAL MAINTENANCE INSTRUCTIONS FOR ENGINE - Keep hands, hair, clothing and tools away from moving parts, and insure all guards or covers are replaced after servicing. - Turn the engine or input power OFF before maintenance work unless the maintenance work requires it to be running. maintenance work.
SAM400 & 650 SAM400 SAM650 27.12 38.50 41.00 B 63.06 56.38 A 23.88 C 25.95 D 81.25 .69 Dia. Holes 77.00 E F 83.00 D M8869-23,-25 7-28-95E .88 3.00 ** .59 x 1.10 Slots * .81 Dia. Holes F 8.90 5.75 (SAM650 Only) 24.50 22.00 11.00 8.12 6.00 39.69 19.80 B 22.14* 50.13 Additional Muffler for SAM400 Perkins Only. C A 44.50* 69.75 ** E 28.
Now Available...12th Edition The Procedure Handbook of Arc Welding New Lessons in Arc Welding This printing will go fast so don’t delay. Place your order now using the coupon below. Lessons, simply written, cover manipulatory techniques; machine and electrode characteristics; related subjects, such as distortion; and supplemental information on arc welding applications, speeds and costs. Practice materials, exercises, questions and answers are suggested for each lesson.
● Do not touch electrically live parts or WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENÇÃO ● Keep flammable materials away. ● Wear eye, ear and body protection. ● Mantenga el material combustible ● Protéjase los ojos, los oídos y el 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 mojada. ● Aislese del trabajo y de la tierra.
● Keep your head out of fumes. ● Use ventilation or exhaust to ● Turn power off before servicing. ● Do not operate with panel open or guards off. remove fumes from breathing zone. ● Los humos fuera de la zona de res- piración. ● Mantenga la cabeza fuera de los humos. Utilice ventilación o aspiración para gases. ● Gardez la tête à l’écart des fumées. ● Utilisez un ventilateur ou un aspira- ● Desconectar el cable de ali- mentación de poder de la máquina antes de iniciar cualquier servicio.
CT URER INCLUDING: PARTS & LABOR RR AN TE S22127-3 ED BY UF WA ACT YEAR WARRANTY AN ENGINE 3 M ▲ ▲▲ ▲▲ ▲ S E P A R A T E LY ▲▲▲▲▲ ▲ C OL CO ▲ IC IC TRR ▲▲▲▲▲ ▲ LLIN IN ▲ ▲ ▲▲ ▲▲ EL ▲ LN LE NE EC LIMITED WARRANTY TO OBTAIN WARRANTY COVERAGE: The Lincoln Electric Company (Lincoln) warrants to the original purchaser (end-user) of new equipment that it will be free of defects in workmanship and material.
