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Lincoln Electric SAM650 User's Manual

Contents

1. Section E Diod Test Procedure sex BEER EE REX RET RR EE d aS E 6 SCR Bridge PC Board Test Procedure E 6 Control PC Board Calibration E 7 Ground BEE dE WU DR Rer we e ek eek RE TN a E 8 Wiring Diagrams and Dimension Print Section F Parts List Zu E cles EE RE et sies a ied s Appendix SAM400 8 650 LINCOLN vi A 1 INSTALLATION TECHNICAL SPECIFICATIONS SAM400 INPUT DIESEL ENGINE Make Model Description Speed RPM Displacement Starting Capacities System Fuel 22 5 gal 85 1 L 236 cu in 3 87 L 4 cylinder 63 HP O 1725 RPM High Idle 1790 Low Idle 1100 Full Load 1725 12VDC batteries 2 amp Starter 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 11 L RATED OUTPUT WELDER 60 NEMA 60 Lincoln Plus 400 amps 400 amps 36 volts 40 volts OUTPUT WELDER AND GENERATOR Welding Range Open Circuit Voltage Auxiliary Power 60 500 Amps CV Current Range 80 500 17 45 OCV excluding hot start voltage 60 95 OCV 120 240 VAC 2kVA 60 Hz 100 Duty Cycle VV Current Range PHYSICAL DIMENSIONS HEIGHT WIDTH DEPTH WEIGHT 50 13 in 27 12 in 83 00 in 2163 lbs 1273 3 mm 688 9 mm 2108 2 mm 981 1 kg 1 Add 15 4 391 2 mm for optional muffler SAM
2. repre zez eta L 9018 Qv31 HO1VH3N39 v y H1izevs N n OILS OVE OL NIN MHOILS HO OHV GADYAWENS SZZ OL 0 MOILS HO Ouv GADYAWENS OEE OL OLZ G T3IHSU3NNI 3d01S XVI ouv GIOYSWENS S S OL 00 G I3IHSU3NNI 34018 GSW OH 39H3NANS XVIN OL OSY G 3IHSU3NNI 3d01S NIN ES 8 S d 7 ct Quvog Od OL 7 on N WIRING DIAGRAMS AO anna TOHLNOO MOLLS wun SKM gt HE Ht quvog Od OL WNINHAL Ladino 038830 OL 0v31 _ d L 19NN09 MOLLS Hd N 7 OLLVWOLNY 310V1d303u qoy u3MOd ASLE u3MOd ADEE gt YHOM AAA A AAA A AAA MAHOS ANNOYS INVH9VIG SNIHIM 3NIHOVIN OS9INVS F 2 SAM400 amp 650 LINCOLN F 3 WIRING DIAGRAMS SAM400 ENGINE WIRING DIAGRAM GENERAL MAINTENANCE INSTRUCTIONS FOR ENGINE DRIVEN ARC WELDING POWER SOURCES N WARNING Have only qualified personnel perform maintenance work y Turn the engine or input power OFF before maintenance work unless the maintenance work requires it to be running vw Keep hands
3. Submerged Arc a The open circuit voltage OCV is generally not critical in submerged arc welding Therefore the Variable Voltage Control can usually be left between 7 and High no future adjustments are needed b Set SAM400 Current Control so the calibration on the higher scale is a little above the current desired Set the SAM650 Tap lead to the stud with the lowest current range that still provides the desired current c Make the final current adjustment with either the wire feeder current control or the Portable Field Control Set the arc voltage with the wire feeder control Consult the following illustrations for examples of how to set the machine SAM400 8 650 LINCOLN B 5 OPERATION SAMAOO Controls WELDER CONTROL PANEL Variable Voltage D Set toggle switch on Variable Voltage 2 Set Electrode Polarity to Variable Voltage Positive or Variable Voltage Negative as desired ELECTRODE POLARITY C N STANT 7 A I ot POSITIVE CIRCUIT ELECTRODE WORK CABLE CABLE STUD PANEL PORTABLE WELDER CONTROL PANEL O Set toggle switch on O Variable Voltage Variable Voltage 2 Set electode polarity to Variable Voltage Positive or Variable Voltage Negative Constant Voltage ELECTRODE POLARITY CON STANT gt POSITIVE VARI LOW HIGH ABLE PORTABLE NOT IN CIRCUIT HIGH L
4. Installation Instructions Section A Technical Specifications A 1 Product Description volar A RR ee de EE eee Re EE Ra Rosie A 3 Installation Pr cautions 3 ics WERE usq e k a eH Paes BE exc A RE A 3 Spark Arrester isses ees led REX RS E REED eque n E E RE A 3 Machine Grounding atar wily Gree Se aa A 3 Additional Safety Precautions A 3 Pre Op ration Service EK A 4 Output Cables c etes e eR habue exa pbi eed ad dd A 4 Welder Locations uns roe ee esa be de SER A 4 Operating Instructions Section B Operating Precautions B 1 Pipe LAAWING ee RE a exeat ee GER E ee oe atts B 1 Additional Safety Precautions B 1 Engine Controls Function Operation B 1 Welder Controls Function Operation B 2 Starting Welders with Dead Batteries B 9 Auxillary POWE aa N RR ROB ORE e NL a EO ERK B 9 BASEL B 9 Starting Instructions B 9 Break In Period donnine aclaro at e B 9 Accessories EE E Saee EE lustige sede Section C Maintenance Section D Routine Maintenance D 1 Periodic Maintenance u urus AS ET baha Rhe idees eias D 1 Troubleshooting Guide
5. LINCOLN Y B 7 STICK ELECTRODE WELDING Variable Voltage MIN 130 TO TO 140 225 SUBMERGED ARC WELDING Variable Voltage NOTE For welding with small diameter electrodes at fast travel speeds use nnershield Constant Voltage settings 210 575 max TO 330 max SLOPE OPERATION SAM650 Controls WELDER CONTROL PANEL Variable Voltage Set toggle switch on Variable Voltage Constant 3 Set Electrode Polarity Voltage to Positive or Negative as desired ELECTRODE POLARITY NOT IN CIRCUIT POSITIVE D Connect to Stick stud ELECTRODE CABLE WORK CABLE WELDER CONTROL PANEL Variable Voltage Set toggle switch on Variable Voltage Set Electrode Polarity Constant to Positive or Voltage Negative as desired i ELECTRODE POLARITY NOT IN CIRCUIT org POSITIVE CABLE TO Connect to Auto WIRE FEEDER O ool ol WORK CABLE STUD PANEL SAM400 amp 650 LINCOLN NEGATIVE 4 Connect Tap lead to appropriate 1 of 5 studs for the lowest current range which provides heat desired Use Variable voltage rheostat to adjust exact current and to set OCV for arc characteristics desired Normal Welding range recommended Either set Portable Field Controf to High or use it for remote current adju
6. 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 0 100 ft 100 200 ft 200 250 ft 3 0 2 2 0 2 3 0 2 1 0 2 2 0 2 3 0 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 amp 650 LINCOLN P B 1 OPERATION B 1 OPERATING PRECAUTIONS 44 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 PIPE THAWING 44 WARNING PIPE THAWING can result in fire or g y explosion le Only connect welder across FROZEN section of CONTINUOUS METAL PIPE e While thawing remove any ground leads con nected
7. 100 psi maximum The filter should never be removed while the engine is running SAMA400 only 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 1 Blow out the welder and controls with an air hose at least once every two months In particularly dirty locations this cleaning may be necessary once a week Use low pressure air to avoid driving dirt into the insulation 2 The SAMAOO current control reactor brushes are self lubricating and should not be greased Keep the contacts clean This control should be moved from maximum to minimum daily to prevent the controls from sticking 3 See the engine Instruction Manual for periodic engine maintenance information Change the crankcase oil at regular intervals using the proper grade of oil as recommended in the engine operat ing manual Change the oil filter in accordance with the instructions in the engine operating manual When the filter is changed add one quart of oil to the crankcase to replace the oil held in the filter dur ing operation 4 Belts tend to loosen after the first 30 or 40 hours of operation Check the cooling fan belt and tighten if necessary DO NOT OVER TIGHTEN BEARING MAINTENANCE This welder is equipped with a double shielded ball bearing having sufficient grease to last indefinitely under normal servi
8. Con stant CABLE TO WIRE FEEDER STUD PANEL NEGATIVE LOW HIGH STICK ELECTRODE WELDING Variable Voltage VARI ABLE CURRENT CONTROL DO NOT ADJUST WHEN WELDING e Set Current Control for approximate current desired using the high Scale O Use Variable voltage rheostat to adjust exact current and to set OCV for arc characteristics desired Normal Welding range recommended Either set Portable Field Control to High or use it for remote current adjuster with Variable voltage rheostat near High FIELD CONTROL SUBMERGED ARC WELDING Variable Voltage NOTE For welding with smal diameter electrodes at fast travel speeds use Innershietd Constant Voltage settings CURRENT CONTROL NEGATIVE DO NOT ADJUST WHEN WELDING Set Current Control slightly above current de sired using the high scale Make final current adjustments with either the wire feeder current control or the Portable Field Control Set Variable voltage rheostat between 7 and 10 for high OCV Set arc voltage at the wire feeder FIELD CONTROL SAM400 amp 650 LINCOLN Y B 6 OPERATION B 6 SAMAOO Controls WELDER CONTROL PANEL NERSHIELD AND MOST ad HER OPEN ARC WELDING NOT IN D Set toggle switch on i Constant Voltage Constant Voltage Cl R CU IT Set Electrode Polarity O on Constant Voltage Constan
9. 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 amp 650 LINCOLN B 4 OPERATION B 4 Set the welding current and voltage as described under Constant Voltage Welding above Variable Voltage Welding The SAM400 Current Control provides the major adjustment of current It has two calibrated sca
10. OIL PRESSURE GAUGE Displays the oil pressure to the engine When the engine starts running watch for the oil pressure to build up If no pressure shows within 30 seconds stop the engine and consult the engine instruction manual BATTERY CHARGING AMMETER Displays the current going from the charging alternator into the batteries It is normal for charging current to be high above 15 amps after starting or when the batter ies are low on charge ENGINE HOUR METER Factory Installed Optional Feature The optional engine hour meter records the total run ning time on the engine in hours It can be used to keep a record of maintenance on the engine and or welder ENGINE PROTECTION SYSTEM The engine protection system shuts down the engine under high coolant temperature or low oil pressure conditions by allowing the fuel solenoid valve to close SAM400 8 650 LINCOLN B 2 OPERATION B 2 WELDER CONTROLS FUNCTION OPERATION PORTABLE FIELD CONTROL CONNECTION A Portable Field Control complete with 25 leads is shipped with each SAM welder A Portable Field Control is not required tor 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 With other wire feeders and when stick electrode weld ing the Portable Field Control must be installed or the SAM cannot produce its full open circuit voltage When installed the Portable Field Control is a fine v
11. Ww GASES FROM BATTERY can explode MP e Keep sparks flame and cigarettes away from battery To prevent EXPLOSION when e INSTALLING A NEW BATTERY disconnect negative cable from old battery first and connect to new battery last e 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 e 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 4 e Wear gloves and eye protection and be careful when working near battery e 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
12. hair clothing and tools away MOVING from moving parts and insure all guards or CAN INJURE covers are replaced after servicing MAINTENANCE INSTRUCTIONS DAILY CHECKS Electrode and work connections are tight Rotate the current control twice to clean contacts All equipment in serviceable condition Engine oil coolant air cleaner and fuel strainer are at proper operating level and clean AS REQUIRED Blow dust from the machine using clean low pressure air Clean commutators or slip rings with fine sandpaper NOT EMERY CLOTH See the Operating Manual for instructions Replace brushes before the pigtail is within 1 4 of the commutator See the Operating Manual for instructions Grease may be added to bearings no more than once a year See the Operating Manual for instructions TO FLASHING DIODE SAE UNITS ONLY THERMOSTART EXC AMMETER c et ZN N oos TERMINAL ALTERNATOR 4 TO CR7 Pi IGNITION Z ENGINE HOUR SWITCH METER OPTIONAL FUEL SHUT OFF VALVE N FUEL INJECTION yt PUMP STARTI SAM400 amp 650 LINCOLN amp NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels Sjeued eunsoj oue ay JO suo uo aulyoeu au
13. see wiring diagram 1 Across the voltmeter terminals if the unit is so equipped 2 Positive side of SCR bridge 75 to 214 on the SCR bridge located on the rear panel of the control box 3 Positive side of SCR bridge 75 to 212 on the SCR bridge 4 Across C5 on the SCR bridge 5 Negative side of the SCR bridge brown generator field lead to 214 on the SCR bridge 6 Negative side of the SCR bridge to 212 on the SCR bridge 7 Across C6 on the SCR bridge 8 1 on the two diode aluminum finned heat sink to 212 on the SCR bridge 9 1 on the two diode aluminum finned heat sink to 213 on the SCR bridge 10 2 on the base of D4 single diode mount ed on copper heat sink to 75 on SCR bridge 11 Across each of the three phase bridge diodes jumper from the heat sink across the diode on all six diodes NOTE All jumpers must be as short as possible SAM400 amp 650 LINCOLN F 1 WIRING DIAGRAMS sjoued eunsojoue ay JO euo uo aulyoeu sy episui pajsed si epoo Jejnoned e 104 weiBelp onoeds ay Jenueuu siu Aq pajanoo saulyoeu Je 104 9 e1nooe aq jou Aew y AjUO e2u9J9j81J JO SI ureJBerp siu 3 ON 0961 da Leg HOLIMS 0338 4901 913 d3d SIOSNAS KOHL T3 HOLOVINOD 9 8 56 OH 38N3 40 1VNIINH31 HALN39 VN AVi13H LEWIS LOH HOS A NMOWS N HOLIMS ALIEWIOd ZS Y 3078 n HOLIMS 319901 IS V OAN 01 89 SS ONIGOO 40109 QV31 HOLOVINOO 31VH3dO OL 24 SLNANOdWOO Q3H38INN Via EE ARCUP UA QNv 9 OL
14. 0S9INVS DIMENSION PRINT F 5 F 5 88 c 0O0 Lv E 0044 0022 Sels S6S2 098 s loH EI 69 y SOJOH BIG 18 x SIOIS OL L X 6G xx AIUO OS9NVS el 0S GZS 08 6 Au N Suu OOVINVS 10 1J JjniA EUONIDPY pej e1su Jeun OS9NVS 40 JUBISH SH3Q 13M 3NIOSN3 SND1H4d 0S9WVS NV OOVINVS LNIHd NOISN3WIG V SAM400 amp 650 LINCOLN ELECTRIC Now Available 12th Edition The Procedure Handbook of Arc Welding With over 500 000 copies of previous editions published since 1933 the Procedure Handbook is considered by many to be the Bible of the arc welding industry This printing will go fast so don t delay Place your order now using the coupon below The hardbound book contains over 750 pages of welding infor mation techniques and procedures Much of this material has never been included in any other book A must for all welders supervisors engineers and designers Many welding instructors will want to use the book as a reference for all students by taking advantage of the low quan tity discount prices which include shipping by 4th class parcel post 15 00 postage paid U S A Mainland How To Read Shop Drawings The book contains the latest information and application data on the American Welding Society Standard Welding Symbols Detailed discussion tells how engineers and drafts men use the short cut language of symbols to pass on assembly and welding information to shop per
15. 2 Establish the polarity of the ohmmeter leads 3 Connect the ohmmeter across the diode in question as illustrated in Figures E 2 and E 3 below Note polarity of ohmmeter in reference to diode A SHORTED DIODE will indicate equally low resistance in both directions AN OPEN DIODE will have infinite or high resistance in both directions A GOOD DIODE will have a reverse resistance much higher than forward resistance OHMMETER Forward Resistance Low Figure E 2 Cathode Reverse Resistance Low Figure E 3 SCR BRIDGE PC BOARD TEST PROCEDURE A CAUTION 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 1 Visually inspect the board for obvious failures 2 Remove all leads from the terminal strip of the SCR Bridge PC Board 3 Check C5 and C6 for a short Read the resistance between terminals 210 and 214 for C5 and between ter minals 212 and 213 for C6 4 Check SCR1 and SCR2 For SCR1 attach the ohm meter lead to the Brn Terminal Place the lead first on Terminal 210 and then on Terminal 214 and record the resistance of each To check SCR2 keep the lead on the Brn terminal and with the lead on Terminal 212 and then on Terminal 214 record the resistances read Reverse the leads and repeat the above tests The sec ond resistance values should all be higher than those recorded first The ohmm
16. 7 Z p BE br 635 NTOBRELTFEU ORAR ODER 945 MAIER HER e Sal Siss HS BU EE iss Br BAA nisle e Su HIE Ys ole Juil up gas ell la Quali e A paal Slag ay ASI o wp badly AU laits daad DA daan de Yile MAP Keep flammable materials away e Mantenga el material combustible fuera del rea de trabajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material e Mantenha inflam veis bem guarda dos e Hi VY LL OORATOBETR MMIC U TEE VERA e i DAMM AE RT TEE Nu AI MID Am OS Juro AL Aal a e O Wear eye ear and body protection e Prot jase los ojos los o dos y el cuerpo Prot gez vos yeux vos oreilles et votre corps e Tragen Sie Augen Ohren und K r perschutz e Use protec o para a vista ouvido e corpo e BH HRUBS ISUCREREUCT iD RI TIESSSEGNSBR ex 19 so HSE s ESSAI dis die Je yg usas cil gah ae daan y READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EGUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER S SAFETY PRACTICES SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR LESEN SIE UND B
17. CONTROL LOW VOLTAGE WELDER CONTROL PANEL LOW CURRENT Voltage NOT IN OPEN ARC ancar a o S Es WELDING Connect Tap lead to c Max Slope stud Constant Voltage With Set Electrode Polarity Voltage seer stu Variable Inductance on Positive K Control Negative as desired SAM 300 or SAM 400 recommended for this type welding ELECTRODE POLARITY O POSITIVE o x D Connect to Auto CABLE TO TAP Equip stud WIRE FEEDER nos STUD PANEL SAM400 8 650 LINCOLN 5 Set Constant voltage rheostat for desired OCV Make final voltage adjust ments with either the wire feeder current control or the Portable Field Control 8 Set wire feed speed or current at wire feeder NEGATIVE LOW PORTABLE FIELD HIGH CONTROL B 9 OPERATION B 9 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
18. Lincoln Arc Welding Foundation Book Information JFLF 515 Educational Video Information ED 93 Procedure Handbook Twelfth Editor 1500 PH __ Howto Read Shop Drawings 450 H _ Incentive Management 590 M 1 A New Approach to Industrial Economics 5 00 NA T Welding Preheat Calculator 3 00 WC 8 Pipe Weiding Chans 9450 eos LLL SUBO A ona Shipping Costs if any a A A MOTA COSA LA A a was il Eed LINCOLN WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENC O Japanese it BIR Korean Do not touch electrically live parts or 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 moja da Aislese del trabajo y de la tierra O Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension e Isolez vous du travail et de la terre Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung Isolieren Sie sich von den Elektroden und dem Erdboden N o toque partes el tricas e elec trodos com a pele ou roupa molha da O Isole se da peca e terra C EROEARMR XU HIE 7 RAPER TBRELIE e J T ipp
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20. feeder nameplate 4 Position the Portable Field Control mounting slots over these holes and replace the screws 5 Route the leads with the LN 5 or LN 6 control cable back to the power source MOUNTING ON LN 7 1 Remove the top screws on the side of the LN 7 con trol box cover This is the left side when facing the nameplate 2 Position the Portable Field Control on the side of the control box with the mounting slots over these holes and replace the screws 3 Route the leads with the LN 7 control cable back to the power source OUTPUT STUDS With the Engine OFF connect the work cable to the To Work stud A For Stick Electrode Welding 1 Connect the electrode cable to the Stick stud and the work cable to the To Work stud Connect the TAP lead in the SAM650 to the appropriate stud to adjust current and the arc characteristics as described under Current and Voltage Controls 2 Install the Portable Field Control B Automatic or Semiautomatic Welding For all automatic welding processes connect the welding power cable from the wire feeder to the Connect to Auto Equipment stud Connect the TAP lead in the SAM650 to the appropriate stud to adjust current and the arc characteristics as described under Current and Voltage Controls 1 LN 7 LN 8 LN 9 NA 8 NA 5 LT 7 and LT 56 Wire Feeders a Make the connections exactly as speci fied on the connection wiring diagram included in
21. instructions for this equipment and the consumables to be used including the material safety data sheet MSDS and follow your employer s safety practices MSDS forms are available from your welding distributor or from the manufacturer Mar 95 SAM400 amp 650 LINCOLN Y SAFETY US 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 Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Welding and Cutting ANSI Standard Z49 1 and the operating information for the equipment being used When not welding make certain no part of the electrode circuit is touching the work or ground Accidental contact can cause overheating and create a fire hazard Do not heat cut or weld tanks drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside They can cause an explosion even though they have been cleaned For information purchase Recommended Safe Practices for the Preparation for Welding and Cutti
22. of this limited warranty for the E ed optional equipment equipment involved E re April 97 4 Of shipping the equipment to a E S m LINCOLN amp World s Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors Sales and Service through Subsidiaries and Distributors Worldwide 22801 St Clair Ave Cleveland Ohio 44117 1199 U S A Tel 216 481 8100
23. operated environmental conditions likely mainte nance 5 Conformance with federal state and local laws 1 Consult applicable federal state and local laws regarding specific requirements for use on public highways SAM400 amp 650 LINCOLN amp A 4 INSTALLATION A 4 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 44 WARNING
24. ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques 10 Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants 11 Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 PR CAUTIONS DE S RET POUR LES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR 1 Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place SAM400 8 650 LINCOLN Y V v for selecting a QUALITY product by
25. the calibration procedure outlined later in this sec tion under Control P C Board Calibration Procedure The open circuit voltage will be out of range if trimmers are not properly set If both trimmers are set at minimum the machine might lose excitation NOTE B When making continuity checks use the 1K X1000 or next higher range NOTE C Do not replace PC boards without following outlined procedure for indicated trouble damage may result due to other defective parts CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed SAM400 8 650 LINCOLN B E 3 TROUBLESHOOTING E 3 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE CAUSE RECOMMENDED SYMPTOMS COURSE OF ACTION FUNCTION PROBLEMS LOSS OF OUTPUT IN BOTH Test Alternator Rotor Voltage 80 If rotor voltage present go to Step 9 If MODES OF OPERATION 90 Volts DC Lead 222 to 1 no rotor voltage go to Step 2 Lightly sand slip rings and reseat brush Constant and Variable Voltage es Positions Flash rotor fields a Turn machine off b Use a 12 to 24 volt battery c Apply voltage for 15 seconds negative lead to 1 positive lead to 222 at alter nator terminal strip CAUTION Wrong polarity may dam age diodes Jumper leads 75 to 2
26. the wire feeder Instruction Manual b Install the Portable Field Control when using an LN 7 SAM400 amp 650 LINCOLN B 3 OPERATION B 3 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 amp 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 usin
27. 22 replace alternator thermostats if this produces output 5 Continuity check Note B Pg E 2 a Remove rotor brushes b Disconnect 212 and 214 from alterna tor terminal strip c Remove all leads from 1 and 2 on con trol box terminal strip d Remove both Control Boards e Check continuity from 214 to 1 and 212 to 1 with the positive lead on 214 and 212 This should read about 27 000 ohms If shorted check C 7 for a short If all right check D5 and D6 See Procedure SCR Bridge Check See Procedure Three phase bridge rectifier check Remove leads from three phase bridge rectifier assembly and check diodes D7 D8 D9 D10 D11 D12 See Procedure Alternator continuity check Note B Pg E 2 a Disconnect lead 212 and 214 and check winding for continuity b Remove one rotor brush check continuity of rotor field NOTE Checking resistance of rotor field may cancel residual magnetism in the rotor iron Repeat Step 3 Flash Rotor Fields 9 If Rotor Voltage is present check voltage between lead 75 and Pin 227 at the rear of Control Board 2 connector Approximately 15 to 22 volts DC CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed SAM400 8 650 LINCOLN B E 4 TROUBLESHOOTING E
28. 4 Observe all Safety Guidelines detailed throughout this manual PROBLEMS RECOMMENDED SYMPTOMS pee Senos COURSE OF ACTION FUNCTION PROBLEMS 10 Voltage higher than 22 volts DC 8 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 Voltage less than 15 volts DC replace Control Board 1 Note A Pg E 2 12 Voltage within limits a Check SCR Bridge See Procedure b Check generator field coil resistance 1 Disconnect blue and brown field coil leads Resistance should be about 10 ohms c Replace Control Board 1 Note A Pg E 2 d Check Control Board 2 by following Step 2 Pg E 2 Output without control one mode only SCR Bridge Test See Procedure If bridge tests good proceed to next step Constant or Variable Voltage Output without control both modes Continuity test Note B Pg E 2 Turn machine off Constant and Variable Voltage Remove both Control Boards Place electrode polarity switch in con stant voltage positive position Toggle switch to mode in question Check continuity of the following Note B Pg E 2 8 Constant Voltage 1 Work to Pin 217 of the connector for Control Board 2 2 Pin 203 of the connector for Control Board 2 to Pin 216 of the connector for C
29. 400 8 650 LINCOLN A 2 INSTALLATION A 2 TECHNICAL SPECIFICATIONS SAM650 INPUT DIESEL ENGINE Make Model Description Speed RPM Displacement Starting Capacities System Perkins 6 cylinder High Idle 1790 365 cu in 12VDC batteries Fuel 22 5 gal 1006 6 Diesel 93 HP O Low Idle 1200 5 98 L 2 amp Starter 85 1 L Engine 1730 RPM Full Load 1750 Bore x Stroke Oil 14 0 Qts 13 24 L 3 937 x 5 00 100mm x 127mm Coolant 5 5 gal 20 8L RATED OUTPUT WELDER 8096 NEMA 650 Amps 44 volts 60 NEMA 725 Amps 44 volts 80 Lincoln Plus 650 Amps 50 volts 60 Lincoln Plus 725 Amps 50 volts OUTPUT WELDER AND GENERATOR 80 815 Amps 18 50 OCV 120 240 VAC CV Current Range exeluding hot start vollage 2kVA 60 Hz 80 815 45 90 OCV 100 Duty Cycle VV Current Range PHYSICAL DIMENSIONS WIDTH DEPTH WEIGHT 27 12 in 88 75 in 2800 lbs 1440 2 mm 688 9 mm 2254 2 mm 1270 1 kg SAM400 8 650 LINCOLN A 3 INSTALLATION A 3 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 The machine is designed to be used with the following automatic equipment LN 7 LN 8 LN 9 LN 22 LN 23P with Adapter Kit LN 25 NA 3 LT 7 or LT 56 It can be used with most other equipment whose power requirements do not exceed the rating of the machine The SAM mach
30. EFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER STELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN SAM400 amp 650 LINCOLN gui Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res piraci n e Mantenga la cabeza fuera de los humos Utilice ventilaci n o aspiraci n para gases O Gardez la t te l cart des fum es e Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail e Vermeiden Sie das Einatmen von Schweibrauch e Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes e Mantenha seu rosto da fumaca Use ventilac o e exhaust o para remover fumo da zona respirat ria E1 APSMERTLSICLT F n 9 fsPBHEILTABSSUCFEU Fat in es e RE FA MAH A ARE Sess 2748 BeleHlAlg s Adoses SNE AAS get 71241717114 SEE ASIA Clea ge lue dal al gU Gall bacs jga d aach Jarl Jg GAS ui Mall oe Quad as us Turn power off before servicing Desconectar el cable de ali mentaci n de poder de la m quina antes de iniciar cualquier servicio D branchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine anhalten N o opere com as tampas removidas Desligue a corrente antes de fazer servico N o toque as partes e
31. GED BY A DEFECTIVE SCR BRIDGE NOTE Before the PC Boards can be calibrated the machine must be hot That is it should be run approximately one hour at maximum O C V with all covers on the generator Factory replacement Control PC Boards are preset and should require only minor adjustment if any 1 Before any calibrations are made the engine speed must be correct Check the engine speed as fol lows a Set toggle switch to variable voltage b Set variable voltage control and portable field control to high c Allow engine to warm up for approximately 15 minutes d Using an accurate tachometer check high idle engine speed It must be within limits given on the nameplate Adjust governor only if absolutely necessary To obtain an accurate speed setting the unit must be generating its maximum open circuit voltage Step A 3 below If no voltage is being gen erated this trouble must be first corrected before final speed setting is obtained Constant Voltage Trimmers Variable Voltage Trimmers A Variable Voltage 1 Place toggle switch in variable voltage posi tion 2 Turn variable voltage control and portable field control to high 3 Set Trimmer 3 so that OCV is 95 1 volts DC on SAM400 machines or 89 1 volts for SAM650 machines 4 Turn variable voltage rheostat and portable field control to low 5 Set Trimmer 4 so that OCV is 65 1 volts DC on SAM400 machines or 45 1 volts for SAM650 machines R
32. HADOIL NNO 103NNOO HOIVNH3IAV EA 30 SANTVA 91419348 SE nent es I LN3INdInO3 NIOONIT ONISN LON N3HM SON QN3971 LL ONY 8 4 S WNIINH3LL dS DAN 30VIN 38v SNOLLO3NNOO 3S3HL 3A08Y LHASNI 33S NOLLdO 39V110A MOT HLIM SSOHOY ONT LO3NNOO HIN D SLINN HO4 AT31VHVd3S Z ONY LI OL 01314 318v18Od ONISN LON N3HM gt Sav31 31WINSNI NOLLO3NNOO SLVINSNI 94 ONY S STYNIWHAL OL Jl E bp ONG 83H13901 6 NV 8 2 SQv31 1OH1NOO 01314 318v18Od LOANNOO old LOANNOO SNIQT3M 39VILTOA TWWHON 401 v SALON INVEDVIO LINOHID Au3liva aas vid sde Die se ZEZ ELO H N QuvO8 Le 59018 Qv31 10HLNOO OL Mz SWHO 0001 OEH on la t D HOLIMS 39NVE SOVLTOA ES ANVLSNOO ze 40 B9VLTOA MOT HOLIMS LINI 281 T 39V L10A IVWEON HOLIMS LWIT 1S1 lt d H SdIHLS 1VNINH31 Co S n SE TOHLNOO Ze 3S3H1 LOINN AO IEN ayo ele ONY diel1s DCH ON 2 AVNINH3L NO 3igvigvA IHM e INHO ON ei N z OL 8 we vy UNO m LOZ Se ON y SHAdANT LINO ira zl G
33. HOOTING E 2 Observe all Safety Guidelines detailed throughout this manual PROBLEMS RECOMMENDED SYMPTOMS POSSE GAUSE COURSE OF ACTION FUNCTION PROBLEMS 1 Test for shorted diode on Three Phase Bridge Constant or Variable Voltage Positions For loss in both modes 2 Test for failure of Control Board see the following pages 2 These items functioning properly 1 Alternator 2 Silicon Controlled Rectifier SCR Assembly 8 Control Board 1 4 Generator 3 Test for Defective Toggle Switch Rheostat or Open Circuit 1 Check diodes D7 D8 D9 D10 D11 See Diode Test Procedure Turn machine off Put toggle switch in mode in question Remove Control Board 2 Turn voltage control and portable field control to mini mum Start the machine If generator builds up install new Control Board 2 Note A if it does not build up proceed to Step 3 Turn machine off Remove Control Board 1 Put toggle switch in the mode in question Turn voltage control to maxi mum Check continuity of the tog gle switch and voltage con trol Note B 1 Variable Voltage Position Check continuity from Pin 76 to Pin 4204 on Control Board 1 connector Meter should read a short circuit 2 Constant Voltage Position Check continuity from Pin 76 to Pin 4207 on Control Board 1 connec tor Meter should read a short circuit NOTE A If at any time either of the Control PC boards is replaced follow
34. Lincoln Electric We want you J kont You to take pride in operating this Lincoln Electric Company product see 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 Consequently Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received Please record your equipment identification information below for future reference This information can be found on your machine nameplate Model Name amp Number Code amp Serial Number Date of Purchase Whenever you request replacement parts for or information on this equipment always supply the information you have recorded above Read this Operators Manual completely before attempting to use this equipment Save this manual and keep it handy for quick reference Pay particular attention to the safety instructions we have provided for your protection The level of seriousness to be applied to each is explained below A WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life A CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment SAM400 amp 650 LINCOLN vi TABLE OF CONTENTS Page
35. Meter Kit Standard on K1279 1 Keeps track of how long engine has been operated Useful for following recom mended maintenance schedules on machine SAM400 amp 650 LINCOLN Y D 1 MAINTENANCE D 1 44 WARNING e ELECTRIC SHOCK can kill e Do not touch electrically live parts such as output terminals or inter nal wiring ENGINE EXHAUST can kill e Use in open well ventilated areas or vent exhaust outside MOVING PARTS can injure e Do not operate with doors open or guards off e Stop engine before servicing e Keep away from moving parts e Remove guards only when necessary and replace when work requiring removal is com plete e Only qualified personnel should install use or service this equipment ROUTINE MAINTENANCE At the end of each day s welding refill the fuel tank to minimize moisture condensation in the tank Also run ning out of fuel tends to draw dirt into the fuel system Check the crankcase oil level If the fuel supply runs out while the fuel pump is oper ating air may be entrapped in the fuel distribution sys tem If this happens bleeding of the fuel system may be necessary See the engine instruction manual AIR FILTER SAM650 only The air filter element is a dry cartridge type It can be cleaned and re used however damaged elements should not be washed or re used Remove loose dirt from element with compressed air or water hose direct ed from inside out Compressed Air
36. RETURN TO MAIN MENU SAM400 amp 650 PERKINS DIESEL ENGINE DRIVEN pode MULTI PROLESS DL ARC WELDING POWER SOURCES For use with SAM400 machines having Code Numbers 10140 amp 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 opera tion on your part DO NOT INSTALL OPERATE OR REPAIR This manual covers THIS EQUIPMENT WITHOUT equipment which is READING THIS MANUAL AND obsolete and no longer THE SAFETY PRECAUTIONS in production by The CONTAINED THROUGHOUT Lincoln Electric Co And most importantly think before Specifications and you act and be careful availability of optional features may have changed OPERATOR S MANUAL LINCOLN E World s Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors Sales and Service through Subsidiaries and Distributors Worldwide 22801 St Clair Ave Cleveland Ohio 44117 1199 U S A Tel 216 481 8100 i SAFETY A WARNING A CALIFORNIA PROPOSITION 65 WARNINGS A Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and other reproductive har
37. 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 6096 duty cycle welder can be operated at nameplate rated out put for 6 minutes 8 minutes for 8096 duty cycle out of every 10 minute period without overheating The auxiliary power can be used continuously 10096 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 sta
38. a commutator stone Never use emery cloth or paper for this purpose NOTE If the welder is used in dirty or dusty locations or if the welder is not used for prolonged periods of time it may be necessary to clean the commutator and slip rings more often Replace brushes when they wear within 1 4 of the pig tail A complete set of replacement brushes should be kept on hand Lincoln brushes have a curved face to fit the commutator Have an experienced maintenance man seat these brushes by lightly stoning the commu tator as the armature rotates at full speed until contact is made across the full face of the brushes After ston ing blow out the dust with low pressure air To seat the slip ring brushes position the brushes in place Then slide one end of a piece of fine sandpaper between slip rings and brushes with the coarse side against the brushes With slight additional finger pres sure on top of the brushes pull the sandpaper around the circumference of the rings in direction of rotation only until brushes seat properly In addition stone slip ring with a fine stone Brushes must be seated 100 SAM400 8 650 Arcing or excessive exciter brush wear indicates a pos sible misaligned shaft Have an authorized Field Service Shop check and realign the shaft COOLING SYSTEM The SAM welders are equipped with a pressure radia tor Keep the radiator cap tight to prevent loss of coolant Clean and flush the cooling system period
39. able is on your right Do not put your hands near the engine fan Do not attempt to side the work cable should also be on your right side override the governor or idler by pushing on the throttle con trol rods while the engine is running 2 d 4 Connect the work cable to the workpiece as close as possible to the area being welded To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance 2 d 5 Do not work next to welding power source work disconnect the spark plug wires distributor cap or magneto wire as appropriate SAM400 amp 650 LINCOLN Y SAFETY ii ELECTRIC SHOCK can kill 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 3 b Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground In addition to the normal safety precautions if welding must be performed under electrically hazardous conditions in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying if there is a high risk of unavoidable or accidental contact with the workpiece or ground use the following equipment S
40. butor Lince Ged or Field Service SI rr o be free of defects in workmanship and material any defect eriod Written notificati s recommeg 4 This warranty is void if Lincoln finds that the equipment has y een subjected to improper care or abnormal operation R WARRANTY PERIOD 4 Lipeolg s ection of the equipme jnfirms the exis All warranty periods date from the date of shipment to t detect covered by this ward A the defect will be original purchaser and are as follows y repai Lincoln s option Three Years E RAN Transformer Welders A Motor generator Welders he Inverter Welders Automatic Wire Feeders Semiautomatic Wire Feeders Plasma cutting Power Sourg Engine Driven Welders g accessories with ope er or Field Service Shop as well as you from that location colin will not accept responsibility for repairs made Two Years without its authorization Engine Drive accessories Lincoln shall not be liable for consequential damages such as loss of business etc caused by the defect or reasonable delay in correcting the defect Lincoln s liability under this warranty shall not exceed the cost of correcting the defect gun and cable assem This written warranty is the only express warranty pro or MIG TRAK equipment vided by Lincoln with respect to its products Warranties 40 WELD N AIR Power Arc implied by law such as the Warranty of Merchantability Wire Feed Module Factory are limited to the duration
41. ce Where the welder is used con stantly or in excessively dirty locations it may be nec essary to add one half ounce of grease per year A pad of grease one inch wide one inch long and one inch high weighs approximately one half ounce Over greasing is far worse than insufficient greasing When greasing the bearings keep all dirt out of the area Wipe the fittings completely clean and use clean equipment More bearing failures are caused by dirt introduced during greasing than from insufficient grease SAM400 8 650 LINCOLN 5 D 2 MAINTENANCE D 2 COMMUTATOR AND BRUSH MAINTENANCE 44 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 rotat ing armature when stoning the commutator The generator brushes are properly adjusted when the welder is shipped They require no particular attention DO NOT SHIFT THE BRUSHES or adjust the rocker setting Shifting of the brushes may result in Change in machine output Commutator Damage Excessive brush wear Periodically inspect the commutator slip rings and brushes by removing the covers DO NOT remove or replace these covers while the machine is running Commutators and slip rings require little attention However if they are black or appear uneven have them cleaned by an experienced maintenance man using fine sandpaper or
42. charge check or money order in U S Funds Only IPrices include shipment by 4thClass Book Rate for U S A Mainland Only Please allow up to 4 weeks for delivery luPs Shipping for North America Only All prepaid orders that request UPS shipment please add l 5 00 For order value up to 49 99 l 10 00 I 15 00 l For North America invoiced orders over 50 00 amp credit card orders if UPS is requested it will be invoiced or charged to you at cost Outside U S A Mainland order must be prepaid in U S Funds Please add 2 00 per book for surface mail or 15 00 per book for air parcel post shipment METHOD OF PAYMENT Sorry No C O D Orders Name CHECKONE dde Please Invoice only if order is over 50 00 l Check or Money Order Enclosed U S Funds only I Credit Card o Telephone Vect No MEER dees rd po Exp Date RE AE Signature as it appears on Charge Card l onth Year l USE THIS FORM TO ORDER w OR FREE INFORMATIVE CATALOGS li incoin Welding School Titles I ED 80 For order value between 50 00 amp 99 99 For order value between 100 00 amp 149 00 Order from BOOK DIVISION The Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 Telephone 216 383 2211 or for fastest service FAX this completed form to 216 361 5901 New Lessons in Arc Welding 5 00 Price Code Quantity Cost Y Seminar Information ED 45 James F
43. ck resistance of rotor fields Normal value about 14 ohms 2 Rotor Voltage Within Limits a Check SCR Bridge See Procedure b Check generator field coil resis tance 1 Disconnect blue and brown field coil leads Normal value about 10 ohms One field coil open 20 ohms Both field coils open infinite resistance Arc difficult to start in CV position Test alternator outputs 22 24 1 Set polarity switch in electrode positive using low current and voltage volts DC position Characterized by large droplets low 2 Check voltage between work stud and frequency transfer positive alternator lead connected to input side of line contactor a Within Limits Check contactor contacts b Less than 22 24 volts DC Check three phase bridge recti fier diodes D7 D8 D9 D10 D11 D12 See Procedure CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed SAM400 8 650 LINCOLN B E 6 TROUBLESHOOTING E 6 DIODE TEST PROCEDURE Standard Polarity Reverse Polarity Anode Cathode Cathode Anode Conventional Current Flow Conventional Current Flow Symbol Symbol Figure E 1 1 Isolate the diode in question from the remainder of the circuit and determine its polarity from the wiring diagram and Figure E 1
44. ck 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 8 650 LINCOLN 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 6096 Duty Cycle K802 D Power Plug Kit For SAM welders with stan dard 2KVA of AC auxiliary power Kit includes male plugs for each auxiliary receptacle K805 1 Ether Start Kit Injects ether for starting aid Recommended only when engines are frequently started at temperatures under 10 F 12 C Ether cylinder is not included K767 1 Undercarriage A 4 wheel steerable under carriage for in plant and yard towing with E78 14 load range B tubeless tires Mounts directly to welder base TFor highway use consult applicable federal state and local laws regarding possible requirements for brakes lights fenders etc Linc Thaw Includes meter and fuse to protect the welder when thawing frozen water pipes L2964 Specify SAM400 or SAM650 K704 SAM400 only Standard Accessory Kit Includes electrode and work cables headshield work clamp and electrode holder K865 SAM400 only Engine Hour
45. coup de soliel donc a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du ray onnement de l arc et des projections quand on soude ou quand on regarde l arc b Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc c Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les zones ou l on pique le laitier 6 Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de le faire Si on place la masse sur la charpente de la construction ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de levage c bles de grue
46. e arc rays Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal 3 FUMES AND GASES can be dangerous 5 a Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and below Threshold Limit Values TLV using local exhaust or mechanical ventilation In confined spaces or in some circumstances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating products Shielding gases used for arc welding can displace air and cause injury or death Always use enough ventilation especially in confined areas to insure breathing air is safe Read and understand the manufacturer s
47. echeck to make sure readings fall within limits Trimmer 4 set ting is dependent on Trimmer 3 B Constant Voltage 1 Place toggle switch in constant voltage position 2 Turn constant voltage rheostat and portable field control to high 3 Set Trimmer 1 so that OCV is 6041 volts DC on SAM400 machines or 68 1 volts for SAM650 machines 4 Turn constant voltage rheostat and portable field control to low 5 Set Trimmer 2 so that OCV is 214 0 5 volts DC on SAM400 machines or 22 0 5 volts for SAM650 machines Recheck to make sure readings fall within limits Trimmer 2 setting is dependent on Trimmer 1 SAM400 8 650 LINCOLN 5 E 8 TROUBLESHOOTING E 8 GROUND TESTS A 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 Remove one screw from the smaller board and two screws from the larger board and pull each board straight out from the connector block There are no wires to disconnect B Connect the following jumpers 1 Welding generator frame to base 2 Across D13 232 to 1 3 Across D14 234 to 75 C Place jumpers across the following points
48. emiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot Always be sure the work cable makes a good electrical connection with the metal being welded The connection should be as close as possible to the area being welded Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 Also see item 1 b ARC RAYS can burn 4 a Use a shield with the proper filter and cover E 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 standards Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from th
49. eter should be set in its highest range or in Auto Range 5 Check D1 and D2 Place the lead on Terminal 75 and place the lead on Terminal 214 for D1 Keeping the lead on Terminal 75 attach the lead to Terminal 212 to test D2 This tests the diodes in the forward direction Reverse the leads and repeat the previous test This tests the diodes in the reverse direction The resistance val ues in the reverse direction should all be higher than those in the forward direction 6 Test D3 and R28 Connect the lead to the Brn Terminal and the lead to the 75 Terminal and record the resistance Reverse the meter leads to test the diode in the reverse direction The resistance in the reverse direc tion should be higher than it is in the forward direction a If your ohmmeter has a Diode Test Range KA use that range for this test Otherwise use Auto Range or the lowest range that pro duces a meter reading If D3 is open or you are using too high a range on the ohmmeter you will read only the value of R28 about 1200 ohms in both directions If D3 is shorted you will read zero ohms or a very low resistance in both directions 7 If the board fails any of the tests replace it SAM400 amp 650 LINCOLN 5 E 7 TROUBLESHOOTING E 7 CONTROL PC BOARD CALIBRATION A CAUTION THE SCR BRIDGE SHOULD BE CHECKED BEFORE INSTALLING A NEW CONTROL BOARD COMPONENTS ON THE NEW CONTROL BOARD COULD BE DAMA
50. ez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher met allique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonc tionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines soud er parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se prot ger contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle partie du corps Un coup d arc peut tre plus s v re qu un
51. g 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 44 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
52. i cally to prevent clogging the passage and overheating the engine When antifreeze is needed always use the permanent type CONTACTOR MAINTENANCE Where the output contactor is operated frequently when tacking or making short welds turn the engine off and inspect the contactor every three months 1 be sure the mating surfaces of silver contacts are not worn and all make contact at approximately the same time 2 Make sure the springs and holders are not broken or out of adjustment Approximate spring com pression after making contact is 1 8 Less than 1 16 compression indicates worn contacts that should be replaced 3 Make sure the moving contact or other moving parts are not binding 4 Check interlock contacts and springs Be sure mounting screws are tight APR97 LINCOLN 5 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 This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under
53. ines have two types of output charac teristics a variable voltage output characteristic for stick and submerged arc welding and also constant voltage characteristics for Innershield plus both dip transfer and spray transfer processes INSTALLATION PRECAUTIONS SPARK ARRESTER Some federal state or local laws may require that diesel engines be equipped with exhaust spark arresters when they are operated in certain locations where unarrested sparks may present a fire hazard The standard mufflers included with these welders do not qualify as spark arresters When required by local regulations suitable spark arresters must be installed and properly maintained 44 CAUTION An incorrect arrester may lead to damage of the engine or its performance Contact the engine manufacturer for specific recommendations MACHINE GROUNDING The 1984 National Electrical Code does not require this machine to be grounded under normal operating circumstances Some state local or other codes or unusual operating circumstances may require the machine frame to be grounded lt is recommended that you determine the extent to which such requirements may apply to your particular situation and follow them explicitly A machine grounding stud marked with the symbol is provided on the welding generator frame foot In general if the machine is to be grounded it should be connected with a 8 or larger copper wire to a solid earth ground such as a metal
54. l gt be d HOLIMS izy Ve c 3HL 40 HV3H 3HL WOH Ke Ze O3M3IA SV ANY NOLISOd n 7 MOLLS 39NvH WON JHL NI 310VL1d3038 E 310V1d3038 sy HHOM NMOHS SI ES HOLIMS YAMOd ASIE H3MOd A086 3ONVH 39V L10A IHL NA I 672 AT31V8Vd3S NOLLO3NNOO HOv3 SLVINSNI ke SOV41 YOLVLS 3411934838 OL M0138 SQV31 LO3NNOO HOLVNHALIV LY 6 ON 8 2 1Y NOILO3NNOO 31108 N3dO M3HOS ONNOH9 INVH9VIG SNIHIM ANIHOVIN OOVINVS NOILdO 39WI10A MOT SAM400 amp 650 LINCOLN E sjoued eunsojoue ay JO suo uo aulyoeu au episui pejsed si epoo 1e nonaed e 10 urejBeip oyloeds ou JL enueu siy Aq pajaros saulyoeu e 10 9jenooe eq Jou Aew y AjUO 89U918 91 JO S uiejDeip siu ALON F 2 90961 1 913 ddd SIOBNAS TVOIdLO313 AV 13H 9NIZI943N3 y Av du LOTId H3010H ISNI JO TWNINHAL H31N30 VN RE HOLIMS 319901 NOLLYNINY1 5001 1S3HV3N EG HOLOVINOO 41VH3dO OL 2 ans DAN ONY YO OL HA99IHL NND LO3NNOO 9 034 2 IN3WdIND3 NTOONI DNISN LON N3HM JLIHM M E HOLIMS 0338 Li ANY 9 4 SIVNINHAL NMOU8 N de HOLOVINOO 82 S i SSOHOV HAdINNF Y LO3NNOO 1OHLNOO anig n y AVIS IHVIS LOH H OAN OL 89 0314 318V 80d ONISN LON N3HM NO 40109 Qva gt SIN3NOdWOO Q3H38WnN dO S3nvA 91419348 ONSE 914 ONY 9 4 SIVNINHAL OL SC JOHINOO 01314 318v1HOd LO3NNOO S3LON H WVHDVIG LINOBIO p valve 338 vid DT
55. l tricas nuas e X7TTLA UACNRUD PERK ETBRAT VEE FAITE e HFA ER Au lt phd NM ria gl uz ail e Do not operate with panel open or guards off No operar con panel abierto o guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen e Mantenha se afastado das partes moventes N o opere com os paineis abertos ou guardas removidas O I J 1 3 L EE TREE FT L EUITTF EL e SER HGTBI BUSUR RE ERE EIE Ko exo Yel Mee 45 DRAS hy ats D gal lin Jio Y e Aale Cut Al al gta WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENC O it BR Chinese LEIA E COMPREENDA AS INSTRUC ES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PRATICAS DE SEGURANCA DO EMPREGADOR fBosdoeBBox b5 o0dBmE E BA ETISMUCEFSU TLTRHOR EME Ci TFE o SO EK GE RA DD RIG HI SE LD ol Sol co HARANE SAAD HALO Alea AO LATAS 4 ETEW BHE aa canal Z ll Cat az y Lila Qu gly Clan 05 SO al illai agil y gaai L SAM400 amp 650 LINCOLN amp gui LIMITED WARRANTY STATEMENT OF WARRANTY TO OBTAIN WARRA COV The Lincoln Electric Company Lincoln warrants to the You are required noti Electric your riginal purchaser end user of new equipment that it will Distri
56. les the one gives maximum and the other minimum current available at any given setting A CAUTION DO NOT ADJUST THE CURRENT CONTROL WHEN WELDING The SAM650 Tap lead inside the machine and the series of five Sub Arc amp Stick studs provide the major adjustment of welding current Generally connect the Tap lead to the stud with the lowest current range that still provides the desired current The Variable Voltage Control to the left of the name plate on all models is both the open circuit voltage con trol and a fine adjustment The wire feeder current con trol and the Portable Field Control provide the same function as the Variable Voltage Control To Set The Controls Stick Welding a Make the coarse setting of welding heat with the SAM400 Current Control or the SAM650 Tap lead b Adjust for the desired arc characteristics with the Variable Voltage Control For a soft arc desired for most welding keep this control between 7 and High For a more digging arc set it lower c If remote control is NOT desired leave the Portable Field Control on High For remote con trol leave the Variable Voltage Control near High and make the adjustments described in paragraph b above with the Portable Field Control Remember increasing either the Variable Voltage Control or Portable Field Control setting also increases the current To Set The Controls
57. m cancer birth defects or other reproductive harm The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you pur chase a copy of Safety in Welding amp Cutting ANSI Standard Z49 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is available from the Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS T FOR ENGINE D th To avoid scalding do not remove the radiator pressure cap when the engine is S Ai Ag Pk powered equipment Eeer W for 1 a Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 3 o 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors ELECTRIC AND y MAGNETIC FIELDS 1 c Do not add the fuel near an open flame weld N may be dangerous ing arc or when the engine is running Stop the engine and allow it to cool before refuel 2 8 Electric cur
58. ng of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode Sparks and spatter are thrown from the welding arc Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap over your hair Wear ear plugs when welding out of position or in confined places Always wear safety glasses with side shields when in a welding area Connect the work cable to the work as close to the welding area as practical Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains crane cables or other alternate circuits This can create fire hazards or overheat lifting chains or cables until they fail 6 h Also see item 1 c al CYLINDER may explode if damaged 7 a Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Oylinders should be located Away from areas where they may be struck or subjected t
59. o physical damage A safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication P I Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect Switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations SAM400 amp 650 LINCOLN Y iv SAFETY iv PR CAUTIONS DE S RET Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Proteg
60. oltage adjustment when using the SAM as a constant voltage power source It is a fine current adjustment when using the SAM as a variable voltage power source The Portable Field Control can be mounted on the SAM or wherever convenient for the welding operation When using an LN 4 LN 5 LN 6 or LN 7 wire feeder the control should normally be mounted on the wire feeder Specific mounting instructions are given below After mounting connect the Portable Field Control leads to 75 and 76 on the SAM terminal strip locat ed behind the lower cover panel directly below the con trol panel on the SAMAOO or behind the right front hinged door on the SAM650 Connect the green lead of the Portable Field Control to the grounding stud marked with the symbol e located near the terminal strips MOUNTING ON LN 4 Discontinued 1 Place the Portable Field Control on the vertical front panel of the LN 4 on the wire reel side next to the rheostat panel and mark the location of the mounting slots 2 Drill two holes in the panel and mount the control using 10 sheet metal screws 3 Route the leads with the LN 4 control cable back to the power source MOUNTING ON LN 5 OR LN 6 Discontinued 1 Remove the knob from the upper rheostat on the wire feeder control panel 2 Be sure the appropriate wire feeder nameplate Constant Voltage or Variable Voltage is in place 3 Remove the two screws on the top end of the wire
61. ontrol Board 1 3 Between corresponding numbers of the connectors for both Control Boards Pin 75 216 and 227 b Variable Voltage 1 Blue field lead to Pin 201 of the con nector for Control Board 2 2 Pin 202 of the connector for Control Board 2 to Pin 216 of the connector for Control Board 1 3 Between corresponding pins of the connectors of both Control Boards Pin 75 216 and 227 CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed SAM400 8 650 LINCOLN B E 5 TROUBLESHOOTING E 5 Observe all Safety Guidelines detailed throughout this manual PROBLEMS RECOMMENDED SYMPTOMS POSSE GAUSE COURSE OF ACTION FUNCTION PROBLEMS Output without contro Continuity test Note B Pg E 2 1 Make continuity test outlined in Step 3 one mode on page E 2 except turn voltage con trol from maximum 0 ohms to mini mum 10 000 ohms 2 Replace Control Board 2 Note A Pg E 2 Output without control Replace Control Board 2 both modes 2 Replace Control Board 1 Note A Pg E 2 Output low in both modes Test rotor voltage 80 90 volts DC 1 Rotor Voltage less than 80 90 volts DC open circuit voltage low CV and VV a Check Diodes D1 D2 D5 D6 See positions Procedure b Check SCR Bridge See Procedure c Che
62. rent flowing through any conductor causes ing to prevent spilled fuel from vaporizing on localized Electric and Magnetic Fields EMF Welding contact with hot engine parts and igniting Do current creates EMF fields around welding cables and not spill fuel when filling tank If fuel is spilled welding machines wipe it up and do not start engine until fumes have been eliminated EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician Keep all equipment safety guards covers and before welding devices in position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing equip ment Exposure to EMF fields in welding may have other health effects which are now not known All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit 1 e In some cases it may be necessary to remove safety 2 d 1 Route the electrode and work cables together Secure guards to perform required maintenance Remove them with tape when possible guards only when necessary and replace them when the maintenance requiring their removal is complete 2 d 2 Never coil the electrode lead around your body Always use the greatest care when working near moving parts 2 d 3 Do not place your body between the electrode and work cables If the electrode c
63. rting 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 44 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 Che
64. sonnel Practical exercises and examples develop the reader s ability to visualize mechanically drawn objects as they will appear in their assembled form 187 pages with more than 100 illustrations Size 8 1 2 x 11 Durable cloth covered board binding 4 50 postage paid U S A Mainland New Lessons in Arc Welding 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 528 pages well illustrated 6 x 9 size bound in simulated gold embossed leather 5 00 postage paid U S A Mainland Need Welding Training The Lincoln Electric Company operates the oldest and most respected Arc Welding School in the United States at its corporate headquarters in Cleveland Ohio Over 100 000 students have graduated Tuition is low and the training is hands on Lincoln Welding School 22801 St Clair Ave Cleveland Ohio 44117 1199 For details write and ask for bulletin ED 80 or call 216 383 2259 and ask for the Welding School Registrar Lincoln Welding School BASIC COURSE 700 00 5 weeks of fundamentals There is a 10 discount on all orders of 50 00 or more for shipment at one time to one location lorders of 50 or less before discount or orders outside of North America must be prepaid with
65. ster with Variable voltage rheostat near High NEGATIVE LOW PORTABLE FIELD CONTROL MoN Connect Tap lead to appropriate 1 of 4 studs for lowest current range which provides heat desired B Make final current adjust ments with either the wire feeder current control or the Portable Field Control amp Set Variable voltage rheostat between 7 and 10 for high OCV Set voltage at wire feeder Q N LOW 300 TO 450 TO 130 210 MIN autro ro PORTABLE 225 330 Ges ED SLOPE EQUIP WORK FIELD HIGH SLOPE SLOPE CONTROL B 7 B 8 OPERATION SAM650 Controls INNERSHIELD WELDER CONTROL PANEL AND MOST ries OTHER OPEN AT IN Q Set toggle switch on ARC WELDING CIRCUIT Constant Voltage Q Constant Constant Voltage Set Electrode Polarity Voltage on Positive or Negative as desired ELECTRODE POLARITY POSITIVE D Connect to Auto CABLE TO Equip stud WIRE FEEDER WORK CABLE ud TO E ES STUD PANEL AUTO TO EQUIP WORK 4 Connect Tap lead to appropriate 1 of 3 studs for slope desired Med Slope usually preferred 6 Set Constant voltage rheostat for desired OCV Make final voltage adjust ments with either the wire feeder current control or the Portable Field Control Set wire feed speed or current at wire feeder NEGATIVE O LOW PORTABLE FIELD HIGH
66. t HIGH LOW Positive or Constant Voltage N OT l N Voltage Negative as desired ELECTRODE CIRCUIT POLARITY CON ARI STANT BL e yc CURRENT CONTROL POSITIVE NEGATIVE N N ap No o Z VARI Ei ABLE CABLE TO WORK WIRE FEEDER CABLE Set Constant voltage rheostat for desired OCV Low Make final arc voltage adjustments with either the wire feeder voltage control or the Portable Field Control HIGH Set wire feed speed or current at wire feeder e PORTABLE STUD PANEL FIELD CONTROL WELDER CONTROL PANEL OW VOLTAGE LOW CURRENT voltage OPEN ARC WELDING on Variable Voltage Constant Positive or Variable Voltage STANT ABLE TAN E ENT CURR NOT IN ME nag Constant Voltage With Voltage Negative as di 5 CONTROL POSITIVE NEGATIVE Variable Inductance P Control of DO NOT ADJUST S O Variable Inductance CI R CU IT 2 Set Electrode Polarity Control desired 5 ELECTRODE POLARITY lt o CON VARI DO ei VARI ABLE WHEN WELDING CABLE TO WORK WIRE FEEDER CABLE amp Set Constant voltage rheostat for desired OCV Lan Make final arc voltage adjustments with either the wire feeder voltage control or the Portable Field Control HIGH Set wire feed speed or current at wire feeder 6 Adjust the variable inductance control Current PORTABLE Control as desired in the 8 o clock to 1 o clock STUD PANEL FIELD CONTROL range SAM400 8 650
67. the column labeled PROBLEM SYMPTOMS This column describes pos sible symptoms that the machine may exhib it Find the listing that best describes the symptom that the machine is exhibiting Step 2 POSSIBLE CAUSE The second column labeled POSSIBLE CAUSE lists the obvious external possibili ties that may contribute to the machine symptom Step 3 RECOMMENDED COUHSE OF ACTION This column provides a course of action for the Possible Cause If you do not understand or are unable to perform the Recommended Course of Action safely contact you local Lincoln Authorized Field Service Facility 44 WARNING ELECTRIC SHOCK can kill e Do not touch electrically live parts such as output terminals or internal wiring ENGINE EXHAUST can kill ON Use in open well ventilated areas or vent exhaust outside i Stop engine before servicing 4 MOVING PARTS can injure x Do not operate with doors open or guards off NY gt Keep away from moving parts e Remove guards only when necessary and replace when work requiring removal is complete Only qualified personnel should install use or service this equipment 44 CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed SAM400 8 650 LINCOLN 5 E 2 TROUBLES
68. to Frozen pipe e Turn welder on AFTER cables are connected to pipe Turn off when done IMPORTANT DO NOT USE A WELDER TO THAW A PIPE BEFORE REVIEWING LINCOLN BULLETIN E695 1 dated May 1987 or later This bulletin may be obtained from your local Lincoln distributor or by writ ing directly to Lincoln Electric at the address on the back of this manual ADDITIONAL SAFETY PRECAUTIONS Always operate the welder with the hinged doors closed as these provide maximum protection from moving parts and insure proper cooling air flow Read carefully the Safety Precautions page in the Instruction Manual before operating this machine Always follow these and any other safety procedures included in this manual and in the engine instruction manual ENGINE CONTROLS FUNCTION OPERATION IGNITION SWITCH When placed in the ON position this switch energizes the fuel solenoid When placed in the OFF position the flow of fuel to the injection pump is stopped to shut down the engine SPEED CONTROL LEVER Manually allows the engine to run at its high idle speed controlled by the governor or at the factory set low idle speed When welding or using auxiliary power the speed control lever must be in the RUN position To reduce the engine to low idle speed when not welding or not using auxiliary power place the speed control lever in the IDLE position notch ENGINE TEMPERATURE GAUGE Displays the coolant temperature in the engine block
69. 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 44 WARNING ADDITIONAL SAFETY PRECAUTIONS FALLING EQUIPMENT can cause injury e Do not lift this machine using lift bale if it is equipped with a heavy accessory such as trailer or gas cylinder e Lift only with equipment of adequate lifting capacity e Be sure machine is stable when lifting The recommended undercarriage for use with this equipment for in plant and yard towing by a vehicle is Lincoln s K767 1 If the user adapts a non Lincoln undercarriage he must assume responsibility that the method of attachment and usage does not result in a safety hazard nor damage the welding equipment Some of the factors to be considered are as follows 1 Design capacity of undercarriage vs weight of Lincoln equipment and likely additional attach ments 2 Proper support of and attachment to the base of the welding equipment so there will be no undue stress to the framework 3 Proper placement of the equipment on the under carriage to insure stability side to side and front to back when being moved and when standing by itself while being operated or serviced 4 Typical conditions of use i e travel speed rough ness of surface on which the undercarriage will be

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