Lincoln Electric SAM400, SAM650 manual Recommended

Page 28

E-5

 

TROUBLESHOOTING

E-5

 

 

 

 

 

 

Observe all Safety Guidelines detailed throughout this manual

 

 

 

 

 

 

PROBLEMS

POSSIBLE CAUSE

RECOMMENDED

 

(SYMPTOMS)

COURSE OF ACTION

 

 

 

 

 

 

 

 

 

FUNCTION PROBLEMS

 

 

 

 

Output without control -

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 -

 

 

l. 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)Check 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 & 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 Technical Specifications SAM400 InstallationHEIGHT1 Width Depth Weight Technical Specifications SAM650 Height Width Depth WeightInstallation Precautions Product DescriptionSpark Arrester Machine GroundingOutput Cables PRE-OPERATION ServiceWelder Location Operating Precautions Additional Safety PrecautionsOperation Pipe ThawingWelder Controls FUNCTION/OPERATION Output StudsPortable Field Control Connection Mounting on LN-7Toggle Switch Electrode Polarity SwitchContactor Current and Voltage ControlsTo Set The Controls -- Stick Welding Variable Voltage WeldingTo Set The Controls -- Submerged Arc SAM400 Controls Operation SAM650 Controls Operation Auxiliary Power Duty CycleStarting Instructions BREAK-IN PeriodAccessories Maintenance Routine MaintenancePeriodic Maintenance Bearing MaintenanceCommutator and Brush Maintenance Contactor MaintenanceCooling System 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 Statement of Warranty To Obtain Warranty Coverage Warranty PeriodWarranty 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.