Lincoln Electric SAM650, SAM400 manual Symptoms Course of Action, Function Problems

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E-2

 

TROUBLESHOOTING

 

E-2

 

 

 

 

 

 

Observe all Safety Guidelines detailed throughout this manual

 

 

 

 

 

 

 

PROBLEMS

POSSIBLE CAUSE

RECOMMENDED

 

 

(SYMPTOMS)

COURSE OF ACTION

 

 

 

 

 

 

 

 

 

FUNCTION PROBLEMS

LOSS OF OUTPUT IN ONE MODE ONLY

(Constant or Variable Voltage Positions) (For loss in both modes see the following pages)

These items functioning properly:

1.Alternator

2.Silicon Controlled Rectifier (SCR) Assembly

3.Control Board #1

4.Generator

1.Test for shorted diode on Three Phase Bridge.

2.Test for failure of Control Board #2.

3.Test for Defective Toggle Switch, Rheostat or Open Circuit

1.Check diodes D7, D8, D9, D10, D11. (See Diode Test Procedure)

2.a) Turn machine off.

b)Put toggle switch in mode in question.

c)Remove Control Board #2.

d)Turn voltage control and portable field control to mini- mum.

e)Start the machine.

f)If generator builds up, install new Control Board #2 (Note A); if it does not build up, proceed to Step 3.

3.a) Turn machine off.

b)Remove Control Board #1

c)Put toggle switch in the mode in question.

d)Turn voltage control to maxi- mum.

e)Check continuity of the tog- gle switch and voltage con- trol. (Note B).

1)Variable Voltage Position Check continuity from Pin #76 to Pin #204 on Control Board #1 connector. Meter should read a short circuit.

2)Constant Voltage Position Check continuity from Pin #76 to Pin #207 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 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 & 650

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Contents IM568 SAM400 SafetyElectric Shock can kill Welding Sparks can cause fire or explosion Sûreté Pour Soudage a L’Arc Précautions DE SûretéThank You Table of Contents Technical Specifications SAM400 InstallationHEIGHT1 Width Depth Weight Height Width Depth Weight Technical Specifications SAM650Product Description Installation PrecautionsSpark Arrester Machine GroundingOutput Cables PRE-OPERATION ServiceWelder Location Additional Safety Precautions Operating PrecautionsOperation Pipe ThawingOutput Studs Welder Controls FUNCTION/OPERATIONPortable Field Control Connection Mounting on LN-7Electrode Polarity Switch Toggle SwitchContactor Current and Voltage ControlsTo Set The Controls -- Stick Welding Variable Voltage WeldingTo Set The Controls -- Submerged Arc SAM400 Controls Operation SAM650 Controls Operation Duty Cycle Auxiliary PowerStarting Instructions BREAK-IN PeriodAccessories Routine Maintenance MaintenancePeriodic Maintenance Bearing MaintenanceContactor Maintenance Commutator and Brush MaintenanceCooling System APR97HOW to USE Troubleshooting Guide TroubleshootingFunction Problems Symptoms Course of ActionLoss of Output in Both Modes of Operation Control Boards. Note a Pg. E-2 Recommended SCR Bridge PC Board Test Procedure Diode Test ProcedureControl PC Board Calibration Ground Tests LOW Voltage Option SAM400 Machine Wiring DiagramSAM650 Machine Wiring Diagram Wiring DiagramsMaintenance Instructions Daily Checks SAM400 Engine Wiring DiagramTerminal SAM650 Engine Wiring DiagramDimension Print Dimension Print SAM400 and SAM650 Perkins Engine Welders$700.00 Basic CoursePrecaucion Aviso DE Warranty Period Statement of Warranty To Obtain Warranty CoverageWarranty Repair Warranty Costs

SAM650, SAM400 specifications

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

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

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

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

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