Lincoln Electric SAM400, SAM650 manual Loss of Output in Both Modes of Operation

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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 MODES OF OPERATION

(Constant and Variable Voltage Positions)

Test Alternator Rotor Voltage (80- 90 Volts DC) Lead #222 to #1

1.If rotor voltage present go to Step 9. If no rotor voltage go to Step 2.

2.Lightly sand slip rings and reseat brush- es.

3.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.

4.Jumper leads #75 to #222 -- 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

6.SCR Bridge Check.-See Procedure

7.Three phase bridge rectifier check.

a)Remove leads from three phase bridge rectifier assembly and check diodes (D7 - D8 - D9 - D10 - D11 - D12) See Procedure

8.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 & 650

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

SAM650, SAM400 specifications

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

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

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

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

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