Lincoln Electric SAE-300 manual Welder Operation, Engine bREAK-IN, Stick / TIG Welding

b-2 OPERATION b-2

ENGINE bREAK-IN

Lincoln Electric selects high quality, heavy-duty industrial engines for the portable welding machines we offer. While it is normal to see a small amount of crankcase oil consumption during initial operation, excessive oil use, wet stacking (oil or tar like substance at the exhaust port), or excessive smoke is not normal.

Larger machines with a capacity of 350 amperes and higher, which are operated at low or no-load conditions for extended periods of time are especially susceptible to the conditions described above. To accomplish success- ful engine break-in, most diesel-powered equipment needs only to be run at a reasonably heavy load within the rating of the welder for some period of time during the engine’s early life. However, if the welder is subject- ed to extensive light loading, occasional moderate to heavy loading of the engine may sometimes be neces- sary. Caution must be observed in correctly loading a diesel/generator unit.

1.Connect the welder output studs to a suitable resis- tive load bank. Note that any attempt to short the output studs by connecting the welding leads togeth- er, direct shorting of the output studs, or connecting the output leads to a length of steel will result in cat- astrophic damage to the generator and voids the warranty.

2.Set the welder controls for an output current and voltage within the welder rating and duty cycle. Note that any attempt to exceed the welder rating or duty cycle for any period of time will result in catastrophic damage to the generator and voids the warranty.

3.Periodically shut off the engine and check the crankcase oil level.

WELDER OPERATION

WARNING

ELECTRIC ShOCK can kill.

•Do not touch electrically live parts or electrode with skin or wet clothing.

• Insulate yourself from work and ground.

DuTY CYCLE

The NEMA output rating of the SAE-300® is 300 amperes at 32 arc volts on a 60% duty cycle (consult Specifications in this manual for alternate ratings). Duty cycle is based on a ten minute period; thus, the welder can be loaded at rated output for six minutes out of every ten minute period.

CuRRENT CONTROL

CAuTION

Do not adjust the “Current Control” while welding because this can damage the control.

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The “Coarse Current Control” is the main Current Adjuster. The “Fine Current Control” adjusts the current from mini- mum to maximum. Open circuit voltage is also controlled by the “Fine Current Control” permitting control of the arc char- acteristics.

A high open circuit voltage setting provides the soft “butter- ing” arc with best resistance to pop-outs preferred for most welding. To get this characteristic, set the “Coarse Current Control” to the lowest setting that still provides the current you need and set the “Fine Current Control” near maximum.

When a forceful “digging” arc is required, usually for vertical and overhead welding, use a higher “Coarse Current Control” setting and lower open circuit voltage.

Some arc instability may be experienced with EXX10 elec- trodes when trying to operate with long arc techniques at settings at the lower end of the open circuit voltage range.

STICK / TIG WELDING

Start by setting the right-side Fine Current and OCV control dial to 60, then set the left-side Coarse Current control dial to the desired current using the dial markings as an approxi- mate guideline. Arc characteristics and small changes in output can then be adjusted using the Fine Current and OCV control dial. A K924-4 Remote Control unit can also be used as the Fine Control and OCV control dial.

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FuMES & GASES can be dangerous.

•Keep your head out of the fumes.

•use ventilation or exhaust to remove fumes from breathing zone.

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WELDING SPARKS can cause fire or explosion.

• Keep flammable material away.

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ARC RAYS can burn.

• Wear eye, ear, and body protection.

SELF-ShIELDED FLux-CORED WELDING

(WITh A K623-1 WIRE FEED MODuLE INSTALLED) Start by setting the Wire (CV) / Stick (CC) toggle switch to the Wire (CV) position. Then set the left-side Coarse Current control dial to 270. Now move the Voltage Adjustment dial to the desired voltage. Move the Coarse Current control to the left for a softer arc and to the right for a crisper arc.

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SAE-300®