Lincoln Electric SAM400, SAM650 manual Toggle Switch, Contactor, Electrode Polarity Switch

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OPERATION

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c.Be sure the wire feeder is properly set for constant or variable voltage as appropri- ate.

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.

Auxiliary power available for wire feeder operation is described under “Auxiliary Power” in this section of the manual. To operate the SAM contactor, connect the appropriate wire feeder control circuit to close the circuit from #2 to #4 on the SAM terminal strip.

TOGGLE SWITCH

This switch is located on the front of the control panel at the top of the nameplate. Set the switch to “Variable Voltage” or “Constant Voltage” as appropriate for the welding process to be used. See Control Panel operat- ing illustrations in this section of the manual.

CONTACTOR

The output contactor is automatically in the welding cir- cuit when the machine is properly connected to a Lincoln® wire feeder through the “Connect to Auto. Equipment” stud. It closes only when the wire feeder is welding. The contactor is not in the welding circuit when using the ‘Stick’ stud.

ELECTRODE POLARITY SWITCH

Select electrode negative (straight) or electrode posi- tive (reverse) polarity as needed. On the SAM-400, this switch must also be set for either constant or vari- able voltage welding as appropriate.

CAUTION

DO NOT SWITCH WHILE WELDING.

CURRENT AND VOLTAGE CONTROLS

Constant Voltage Welding

The SAM-400 “Current Control” is NOT in the circuit when the ‘Electrode Polarity’ switch is set for constant voltage welding.

Set the open circuit voltage (OCV) needed for the par- ticular application with the “Constant Voltage Control” located to the left of the nameplate. Adjust the final welding voltage with either the wire feeder voltage con- trol or the “Portable Field Control”. Set the welding cur- rent with “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. The Low Range Feature provides a two-position manual switch which allows the operator to set his machine for normal welding or for low voltage welding. Factory installed only.

On the SAM650 connect the “Tap” lead inside the machine to the appropriate “Innershield” stud for”Min. (Flat) Slope.” “Med. Slope” or “Max. Slope”. Low voltage (below 20 volts) low current welding often requires “Max. Slope” to adjust the weld metal droplet size for minimum spatter and to control puddle fluidity and bead shape. Innershield and other spray transfer type processes generally operate with “Med. Slope”.

A Hot Start circuit on all models operates automatical- ly whenever the toggle switch is set on “Constant Voltage.” It increases the open circuit voltage by sev- eral volts until the arc is established -- then the voltage automatically drops to normal welding voltage. When the wire feeder is started before the arc is started, the voltmeter indicates a voltage several volts higher than welding voltage. To read actual welding voltage, the arc must be established.

Constant Voltage Welding With Variable Inductance Control: SAM-400 Only.

Variable inductance or slope control is usually desir- able for low voltage (below 20 volts) applications and is sometimes useful in other constant voltage jobs.

To introduce this control into the circuit, set the “Electrode Polarity” switch to “Variable Voltage” and the toggle switch to “Constant Voltage”. Then the “Current Control” acts as the variable inductance control. Normally this control must be kept within the 8 to 1 o’clock range.

SAM400 & 650

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Contents IM568 Safety SAM400Electric Shock can kill Welding Sparks can cause fire or explosion Précautions DE Sûreté Sûreté Pour Soudage a L’ArcThank You Table of Contents HEIGHT1 Width Depth Weight InstallationTechnical Specifications SAM400 Technical Specifications SAM650 Height Width Depth WeightSpark Arrester Installation PrecautionsProduct Description Machine GroundingWelder Location PRE-OPERATION ServiceOutput Cables Operation Operating PrecautionsAdditional Safety Precautions Pipe ThawingPortable Field Control Connection Welder Controls FUNCTION/OPERATIONOutput Studs Mounting on LN-7Contactor Toggle SwitchElectrode Polarity Switch Current and Voltage ControlsTo Set The Controls -- Submerged Arc Variable Voltage WeldingTo Set The Controls -- Stick Welding SAM400 Controls Operation SAM650 Controls Operation Starting Instructions Auxiliary PowerDuty Cycle BREAK-IN PeriodAccessories Periodic Maintenance MaintenanceRoutine Maintenance Bearing MaintenanceCooling System Commutator and Brush MaintenanceContactor Maintenance APR97Troubleshooting HOW to USE Troubleshooting GuideSymptoms Course of Action Function ProblemsLoss of Output in Both Modes of Operation Control Boards. Note a Pg. E-2 Recommended Diode Test Procedure SCR Bridge PC Board Test ProcedureControl PC Board Calibration Ground Tests SAM400 Machine Wiring Diagram LOW Voltage OptionWiring Diagrams SAM650 Machine Wiring DiagramSAM400 Engine Wiring Diagram Maintenance Instructions Daily ChecksSAM650 Engine Wiring Diagram TerminalDimension Print SAM400 and SAM650 Perkins Engine Welders Dimension PrintBasic Course $700.00Precaucion Aviso DE Warranty Repair Statement of Warranty To Obtain Warranty CoverageWarranty Period Warranty Costs

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.
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