Lincoln Electric SAM650 Commutator and Brush Maintenance, Cooling System, Contactor Maintenance

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MAINTENANCE

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COMMUTATOR AND BRUSH MAINTENANCE

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 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%.

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 periodi- 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.

SAM400 & 650

APR97

 

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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 HEIGHT1 Width Depth Weight InstallationTechnical Specifications SAM400 Height Width Depth Weight Technical Specifications SAM650Machine Grounding Installation PrecautionsProduct Description Spark ArresterWelder Location PRE-OPERATION ServiceOutput Cables 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 ContactorTo Set The Controls -- Submerged Arc Variable Voltage WeldingTo Set The Controls -- Stick Welding 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.
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