Lincoln Electric SAM400 manual Auxiliary Power, Duty Cycle, Starting Instructions, BREAK-IN Period

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OPERATION

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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 elimi- nates the operation of the flashing circuit. This can cause the generator to fail to produce any output.

AUXILIARY POWER

An alternator generates 2 KVA of 120/240 volt 60 Hertz AC power. It is available either from #31 and #32 on the terminal strip or from the receptacles on the Control Panel. Be careful not to overload this circuit.

The auxiliary power receptacle should only be used with three wire grounded type plugs or approved dou- ble insulated tools with two wire plugs.

The alternator is protected by thermostats and fuses.

DUTY CYCLE

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 cycle welder can be operated at nameplate rated out- put for 6 minutes (8 minutes for 80% duty cycle) out of every 10 minute period without overheating.

The auxiliary power can be used continuously (100% duty cycle) within its rated current capacities.

STARTING INSTRUCTIONS

Be sure all Pre-Operation Maintenance has been per- formed. (See Installation Section of this manual.)

To start the engine, set the speed control lever in the “RUN” position. Place ignition toggle switch in the “ON” position. Push in the engine protection system reset button (if so equipped). Engage the starter button. When the engine starts running, observe the oil pres- sure. If no pressure shows within 30 seconds, stop the engine and consult the engine operating manual. To stop the engine, place the ignition toggle switch in the “OFF” position.

When an engine is started for the first time, some of the oil will be needed to fill the passages of the lubricating system. Therefore, on initial starting, run the engine for

about five minutes and then stop the engine and recheck the oil. If the level is down, fill to the full mark again. The engine controls were properly set at the fac- tory and should require no adjusting when received.

For added safety always operate the welder with the doors closed. Further, leaving the doors open changes the designed air flow and may cause overheating.

Cold Weather Starting

WARNING

Never use any other starting aids, such as ether, when using the “Thermostart” system.

When overnight temperatures are between 10°F (- 12°C) and freezing, use the standard “Thermostart” starting system installed on all engines. Follow the instructions on the start panel nameplate and in the engine manual shipped with the welder. With fully charged batteries and the proper weight oil, the “Thermostart” system operates satisfactorily even down to about 0°F (-18°C).

If the engine must be frequently started below 10°F (-12°C), it may be desirable to remove the “Thermostart” and install the optional ether starter kit. Installation and operating instructions are included in the kit. Use ether starting only when required because excessive use shortens engine life.

BREAK-IN PERIOD

The engine used to supply power for your welder is a heavy duty, industrial engine. It is designed and built for rugged use. It is very normal for any engine to use small quantities of oil until the break-in is accom- plished. Check the oil level twice a day during the break-in period (about 200 running hours).

IMPORTANT: IN ORDER TO ACCOMPLISH THIS BREAK-IN, THE UNIT SHOULD BE SUBJECTED TO HEAVY LOADS, WITHIN THE RATING OF THE MACHINE. AVOID LONG IDLE RUNNING PERIODS.

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 WeightInstallation Precautions Product DescriptionSpark Arrester Machine GroundingWelder Location PRE-OPERATION ServiceOutput Cables Operating Precautions Additional Safety PrecautionsOperation Pipe ThawingWelder Controls FUNCTION/OPERATION Output StudsPortable Field Control Connection Mounting on LN-7Toggle Switch Electrode Polarity SwitchContactor Current and Voltage ControlsTo Set The Controls -- Submerged Arc Variable Voltage WeldingTo Set The Controls -- Stick Welding SAM400 Controls Operation SAM650 Controls Operation Auxiliary Power Duty CycleStarting Instructions BREAK-IN PeriodAccessories Maintenance Routine MaintenancePeriodic Maintenance Bearing MaintenanceCommutator and Brush Maintenance Contactor MaintenanceCooling System 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 Statement of Warranty To Obtain Warranty Coverage Warranty PeriodWarranty Repair 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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