Lincoln Electric SAM650, SAM400 manual PRE-OPERATION Service, Output Cables, Welder Location

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INSTALLATION

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PRE-OPERATION SERVICE

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.

Fuel: Fill the fuel tank with the grade of diesel fuel rec- ommended in the engine Instruction Manual. Open the fuel feed valve on the sediment bowl by turning the handle counterclockwise.

Cooling System:The cooling system has been filled at the factory with a 50-50 mixture of ethylene glycol antifreeze and water. Check the radiator level and add a 50-50 solution as needed. (See Engine Manual or antifreeze container for alternate antifreeze recom- mendation.)

Battery: Remove the insulating cap from the negative battery terminal. Replace and tighten negative battery cable terminal. NOTE: This machine is furnished with wet charged batteries; if unused for several months, the batteries may require a booster charge. Be sure to use the correct polarity when charging the batteries.

WARNING

GASES FROM BATTERY can explode.

Keep sparks, flame and cigarettes away from battery.

To prevent EXPLOSION when:

INSTALLING A NEW BATTERY — disconnect negative cable from old battery first and connect to new battery last.

CONNECTING A BATTERY CHARGER — remove battery from welder by disconnecting negative cable first, then positive cable and battery clamp. When reinstalling, connect negative cable last. Keep well ventilated.

USING A BOOSTER — connect positive lead to battery 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- teries only until snug. 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.

OUTPUT CABLES

With the engine off, connect the electrode and work cables to the studs provided. These connections should be checked periodically and tightened if neces- sary. When welding at a considerable distance from the welder, be sure you use ample size welding cables.

Listed below are copper cable sizes recommended for the rated current and duty cycle. Lengths stipulated are the distance from the welder to work and back to the welder again. Cable sizes are increased for greater lengths primarily for the purpose of minimizing cable voltage drop.

 

%

Cable Sizes For Combined Lengths

 

Of Electrode And Work Cables

 

Duty

Amps

Cycle

0-100 ft.

100-200 ft.

200-250 ft.

 

 

 

 

 

650

60

3/0

2-2/0

2-3/0

650

80

2-1/0

2-2/0

2-3/0

400

60

2/0

3/0

4/0

WELDER LOCATION

The welder should be located to provide an unrestrict- ed flow of clean, cool air to the cooling air inlets (lou- vered panel and below side doors) and to avoid heat- ed air coming out the radiator of the welder recirculat- ing back to the cooling air inlets. Also, locate the welder so that engine fumes are properly exhausted.

SAM400 & 650

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Contents IM568 SAM400 SafetyElectric Shock can kill Welding Sparks can cause fire or explosion Sûreté Pour Soudage a L’Arc Précautions DE SûretéThank You Table of Contents HEIGHT1 Width Depth Weight InstallationTechnical Specifications SAM400 Height Width Depth Weight Technical Specifications SAM650Machine Grounding Installation PrecautionsProduct Description Spark ArresterWelder Location PRE-OPERATION ServiceOutput Cables Pipe Thawing Operating PrecautionsAdditional Safety Precautions OperationMounting on LN-7 Welder Controls FUNCTION/OPERATIONOutput Studs Portable Field Control ConnectionCurrent and Voltage Controls Toggle SwitchElectrode Polarity Switch ContactorTo Set The Controls -- Submerged Arc Variable Voltage WeldingTo Set The Controls -- Stick Welding SAM400 Controls Operation SAM650 Controls Operation BREAK-IN Period Auxiliary PowerDuty Cycle Starting InstructionsAccessories Bearing Maintenance MaintenanceRoutine Maintenance Periodic MaintenanceAPR97 Commutator and Brush MaintenanceContactor Maintenance Cooling SystemHOW to USE Troubleshooting Guide TroubleshootingFunction Problems Symptoms Course of ActionLoss of Output in Both Modes of Operation Control Boards. Note a Pg. E-2 Recommended SCR Bridge PC Board Test Procedure Diode Test ProcedureControl PC Board Calibration Ground Tests LOW Voltage Option SAM400 Machine Wiring DiagramSAM650 Machine Wiring Diagram Wiring DiagramsMaintenance Instructions Daily Checks SAM400 Engine Wiring DiagramTerminal SAM650 Engine Wiring DiagramDimension Print Dimension Print SAM400 and SAM650 Perkins Engine Welders$700.00 Basic CoursePrecaucion Aviso DE Warranty Costs Statement of Warranty To Obtain Warranty CoverageWarranty Period Warranty Repair

SAM650, SAM400 specifications

Lincoln Electric has long been synonymous with welding excellence, and its SAM series of advanced welding machines, including the SAM400 and SAM650, epitomizes this commitment to quality and innovation. These models are designed to meet the demands of diverse industrial applications while ensuring ease of use, efficiency, and precision.

The SAM400 is a robust multiprocess welding system that supports MIG, TIG, Stick, and Flux-Cored welding techniques. It features a powerful 400 Amp output, suitable for heavy-duty applications and capable of handling materials such as steel, stainless steel, and aluminum. The machine incorporates advanced inverter technology, resulting in a compact design that significantly reduces the weight while enhancing portability. Furthermore, the SAM400 includes intuitive digital controls, allowing operators to easily adjust settings for optimal performance. Its PAS (Power Adapter System) compatibility enables users to seamlessly integrate different power sources, greatly enhancing its versatility.

On the other hand, the SAM650 takes it a step further, boasting a maximum output of 650 Amps. This model is particularly favored in industries requiring high deposition rates, such as shipbuilding and heavy fabrication. Like the SAM400, the SAM650 features multiprocess capabilities but adds enhanced control mechanisms, such as advanced waveform technology, which allows for better arc stability and reduced spatter. This ensures cleaner welds and, ultimately, a superior finish. Additionally, the SAM650 is equipped with Lincoln Electric's proprietary welding technology, including the Arc Control and Hot Start features that enhance user experience by providing smoother starts and consistent performance, even in challenging conditions.

Both machines come with integrated wire feeders that allow for easy adjustments and quick material changes, offering increased productivity on the job site. Their rugged design and durable construction ensure long-lasting performance, even in the harshest environments.

In conclusion, the Lincoln Electric SAM400 and SAM650 welding systems are trailblazers in the field of welding technology. With their powerful output, advanced features, and user-friendly interfaces, these machines cater to the needs of professionals looking for reliability and efficiency in their welding applications. Whether for small shops or large-scale industrial operations, the SAM400 and SAM650 deliver the performance and versatility that fabricators and welders depend on.