Lincoln Electric SAM650, SAM400 manual Control Boards. Note a Pg. E-2

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E-4

 

TROUBLESHOOTING

 

 

E-4

 

 

 

 

 

 

 

Observe all Safety Guidelines detailed throughout this manual

 

 

 

 

 

 

 

 

PROBLEMS

POSSIBLE CAUSE

 

RECOMMENDED

 

 

(SYMPTOMS)

 

COURSE OF ACTION

 

 

 

 

 

 

 

 

 

 

 

FUNCTION PROBLEMS

 

 

 

 

 

 

 

 

 

 

 

10. Voltage higher than 22 volts DC.

 

 

 

 

a) 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).

1.

Turn machine off.

 

(Constant and Variable Voltage)

 

2.

Remove both Control Boards.

 

 

 

 

3.

Place electrode polarity switch in con-

 

 

 

 

stant voltage positive position.

 

 

 

 

4. Toggle switch to mode in question.

 

 

 

5.

Check continuity of the following

(Note

 

 

 

 

B Pg. E-2):

 

 

 

 

a) 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 Control 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 & 650

Image 27
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 Installation Technical Specifications SAM400HEIGHT1 Width Depth Weight Height Width Depth Weight Technical Specifications SAM650Machine Grounding Installation PrecautionsProduct Description Spark ArresterPRE-OPERATION Service Output CablesWelder Location Pipe Thawing Operating PrecautionsAdditional Safety Precautions OperationMounting on LN-7 Welder Controls FUNCTION/OPERATIONOutput Studs Portable Field Control ConnectionCurrent and Voltage Controls Toggle SwitchElectrode Polarity Switch ContactorVariable Voltage Welding To Set The Controls -- Stick WeldingTo Set The Controls -- Submerged Arc SAM400 Controls Operation SAM650 Controls Operation BREAK-IN Period Auxiliary PowerDuty Cycle Starting InstructionsAccessories Bearing Maintenance MaintenanceRoutine Maintenance Periodic MaintenanceAPR97 Commutator and Brush MaintenanceContactor Maintenance Cooling SystemHOW 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 Costs Statement of Warranty To Obtain Warranty CoverageWarranty Period Warranty Repair

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.