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IM309-D
TM
CV ADAPTER
January, 2005
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However,
your overall safety can be
increased by proper installation
... and thoughtful operation on
your part. DO NOT INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT READ-
ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON-
TAINED THROUGHOUT. And,
most importantly, think before you
act and be careful.
OPERATOR’S MANUAL
Copyright © 2005 Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
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SAFETY
ARC RAYS can burn.
ELECTRIC SHOCK can kill.
3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.
4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:
FUMES AND GASES
can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
fumes and gases.When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
fumes and gases away from the breathing zone. When
welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
3.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
5.b. Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors to
form phosgene, a highly toxic gas, and other irritating
products.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.
5.c. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
5.d. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
3.j. Also see Items 6.c. and 8.
5.e. Also see item 1.b.
Mar ‘95
CV ADAPTER
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SAFETY
WELDING SPARKS can
cause fire or explosion.
CYLINDER may explode
if damaged.
6.a. Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
the welding sparks from starting a fire.
Remember that welding sparks and hot
materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.
process used and properly operating
regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.
7.c. Cylinders should be located:
•Away from areas where they may be struck or subjected to
physical damage.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact can
cause overheating and create a fire hazard.
•A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even though they have
been “cleaned”. For information, purchase “Recommended
Safe Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.
FOR ELECTRICALLY
powered equipment.
6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate circuits.
This can create fire hazards or overheat lifting chains or
cables until they fail.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.
6.h. Also see item 1.c.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Mar ‘95
CV ADAPTER
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SAFETY
zones où l’on pique le laitier.
PRÉCAUTIONS DE SÛRETÉ
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv-
antes:
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
8. S’assurer que la masse est connectée le plus prés possible de
la zone de travail qu’il est pratique de le faire. Si on place la
masse sur la charpente de la construction ou d’autres endroits
éloignés de la zone de travail, on augmente le risque de voir
passer le courant de soudage par les chaines de levage,
câbles de grue, ou autres circuits. Cela peut provoquer des
risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher met-
allique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble de
soudage et la machine à souder en bon et sûr état defonc-
tionnement.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à soud-
er parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
11. Pour obtenir de plus amples renseignements sur la sûreté, voir
le code “Code for safety in welding and cutting” CSA Standard
W 117.2-1974.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie
du corps.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du ray-
onnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
l‘arc.
1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
3. Avant de faires des travaux à l’interieur de poste, la debranch-
er à l’interrupteur à la boite de fusibles.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan-
talons sans revers, et chaussures montantes.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
Mar. ‘93
CV ADAPTER
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for selecting a QUALITY product by Lincoln Electric. We want you
to take pride in operating this Lincoln Electric Company product •••
as much pride as we have in bringing this product to you!
Thank You
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the time
the shipment is received.
Please record your equipment identification information below for future reference. This information can be found
on your machine nameplate.
Product _________________________________________________________________________________
Model Number ___________________________________________________________________________
Code Number or Date Code_________________________________________________________________
Serial Number____________________________________________________________________________
Date Purchased___________________________________________________________________________
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially important when identifying the correct replacement parts.
On-Line Product Registration
- Register your machine with Lincoln Electric either via fax or over the Internet.
• For faxing: Complete the form on the back of the warranty statement included in the literature packet
accompanying this machine and fax the form per the instructions printed on it.
• For On-Line Registration: Go to our WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then
“Product Registration”. Please complete the form and submit your registration.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or
loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to
this equipment.
CV ADAPTER
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TABLE OF CONTENTS
Page
General DescriptIon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section B
K384 CV Adapter to SA-200 Engine Welder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
K384 CV Adapter to SA-250 Engine Welder with AC Auxiliary Output. . . . . . . . . . . . . . B-4
K384 CV Adapter to SA-250 Engine Welder with DC Auxiliary Output . . . . . . . . . . . . . B-6
K384 CV Adapter to Classic I Engine Welder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-9
K384 CV Adapter to Classic II Engine Welder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-11
K385-1 Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-12
K385-1 CV Adapter to SAE-300, SAE-400 or SAE-400 WELD’N AIR Engine Welders . . . . . . B-13
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section C
VV or CV Welding (All Power Sources) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
VV Stick Welding (All Power Sources) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
CV Innershield Welding (SA-200 and SA-250) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
CV Innershield Welding (SAE Engine Welders) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section D
Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section E
Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Appendix
CV ADAPTER
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A-1
A-1
GENERAL DESCRIPTION
NOTE: WHEN ENGINE WELDER IS SUPPLIED
WITH A METER, THE AMMETER DOES NOT WORK
WHEN WELDING IN THE CV MODE.
PRODUCT PURPOSE
The CV Adapter can be connected to certain variable
voltage water-cooled engine welders to provide con-
stant voltage output recommended for welding .068
and .072 NR-232, .068 and 5/64 NR-211, 5/64 NS-3M,
Innershield electrodes within the current rating of the
machine used. The unit can also be used for some
other open arc processes depending on the application
and process to be used. With the CV Adapter installed,
the welder can be easily set to operate in either the CV
mode or the standard VV mode.
The CV Adapter will fit any of the following engine
welders:
• SA-200 with electronic idler and FDW DC exciter
(above Code 7240)
• Classic I and II (Below Code 10066)
• SA-250 above Code 7826 and Below code 10066.
Three models have been available, one for SA-200 and SA-
250 welders, one for SAE-300, SAE-400 and SAE-400
WELD’N AIR engine welders and one for SAE-350 engine
welders.
• SAE-300 and SAE-400 without Remote Control
option and with 115V FDW DC exciter, 254 alterna-
tor exciter, or 214 alternator exciter (above Code
7160) and all SAE-400 WELD’N AIR— NOTE: K-385
CV Adapter below Code 8785 will not operate prop-
erly on SAE engine welders above Code 8812.
The LN-15, LN-22 and LN-25 wire feeder is recom-
mended for Innershield welding with the CV Adapter
because no terminal strip is provided for wire feeder
control wires, and there is no output contactor. (The
K279 contactor voltage control option cannot be used
with the LN-15,LN-22, OR LN-25 in this application.)
An LN-7 can be used with an SA-250, SAE-350, SAE-
300, SAE-400 or SAE-400 WELD’N AIR that has AC
auxiliary power provided a K240 Contactor Kit is con-
nected between the LN-7 and the power source.
• SAE-350 — Factory installed only.
• International
350-SA —(Below Code 10066) All machines or fac-
tory installed.
450-SAE — Factory installed only.
Estimated time for field installation of the CV Adapter to
welder is 2 to 3 hours.
The voltage control range of the CV Adapter is 15 to
35 volts at the welder current rating. The table gives a
summary of CV outputs when the Adapter is connect-
ed.
Max. Output At
Rating At 60%
Duty Cycle
35% Duty
Cycle
Machine
Comments
SA-200
200 amp
at 35V
250 amp
at 30V
Many procedures
limited by
current rating
SA-250
250 amp
at 35V
310 amp
at 35V
AC auxiliary power
is reduced 25%
when in CV mode
SAE-300
300 amp
at 35V
375 amp
at 35V
Polarity switch
is disconnected
SAE-400 &
SAE-400
WELD’N AIR
400 amp
at 35V
500 amp
at 35V
Polarity switch
is disconnected
SAE-350
350 amp
at 35V
435 amp
at 35V
No polarity switch
installed
Inter-
national
AC auxiliary power
is reduced
350-SA
—
—
310 amp
at 35V
25% when in CV
mode
450-SAE
435 amp
at 35V
No polarity switch
installed
CV ADAPTER
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A-2
A-2
GENERAL DESCRIPTION
The CV Adapter consists of a capacitor bank, an elec-
tronic control circuit and switches. The capacitors mod-
ify the dynamic output characteristics to make the
welder suitable for Innershield welding, and the elec-
tronic circuit controls the field current to maintain a
constant voltage output. Two switches are used to
change from CV mode to VV mode. The switches are
interlocked to insure that the capacitors are discon-
nected before the Adapter can be switched to the VV
mode.
All the components are installed in a control box that
attaches to the welder gas tank rail with an adapter
plate. A control cable is used to connect the CV
Adapter to the welder control circuit and the output ter-
minals. A power cable is used to connect the CV out-
put terminal of the Adapter to the welder negative
brushholder. This connection by-passes the series field
for CV operation. A thermostat assembly is sent with
the Adapter model for the SA-200 and SA-250 to pro-
tect the welder if overloaded. Two thermostat assem-
blies are included, one to be used with the SA-200 and
one to be used with the SA-250. The assembly is field
installed in series with the welder negative brushhold-
er and the power cable. The chance of overloading the
SAE machines is much less so no protection is provid-
ed.
The operating schematic is L6922 and the wiring dia-
grams are M14822 and M14726. The assembly is
shown on G1643.
CV ADAPTER
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B-1
B-1
INSTALLATION
2. Set of socket wrenches.
INSTALLATION
3. 11/32" wrench and 3/8" nut driver or pliers.
4. 1/2" open end wrench and 9/16" wrench.
5. Screwdriver.
WARNING
HAVE QUALIFIED PERSONNEL DO THE INSTAL-
LATION WORK. TURN THE ENGINE OFF BEFORE
WORKING INSIDE THE MACHINE. IN SOME
CASES IT MAY BE NECESSARY TO REMOVE
SAFETY GUARDS TO PERFORM REQUIRED
INSTALLATION. REMOVE GUARDS ONLY WHEN
NECESSARY AND REPLACE THEM WHEN THE
INSTALLATION REQUIRING THEIR REMOVAL IS
COMPLETE. ALWAYS USE THE GREATEST CARE
WHEN WORKING NEAR MOVING PARTS.
6. Electrical insulating tape.
K384 CV ADAPTER TO SA-200 ENGINE
WELDER
NOTE: BEFORE INSTALLING CV ADAPTER, START
ENGINE WELDER AND USE A DC VOLTMETER TO
CHECK THE POLARITY OF THE RED AND BLACK
LEADS CONNECTED TO THE AUXILIARY POWER
RECEPTACLE. THE RED LEAD SHOULD BE NEGA-
TIVE AND THE BLACK LEAD SHOULD BE POSI-
TIVE. IF THE POLARITY IS NOT CORRECT, REFER
TO ENGINE WELDER OPERATING MANUAL FOR
INSTRUCTIONS TO FLASH THE EXCITER TO
OBTAIN THE CORRECT POLARITY.
LN-15, LN-22, LN-25 Connection — Instructions cov-
ered under “Operation”.
LN-7 Connection — An LN-7 can be connected to SA-
250, SAE-300, SAE-350, SAE-400 and SAE-400
WELD’N AIR engine welders that have AC auxiliary
power by using a K240 Contactor Kit. Connect the con-
tactor kit to the engine welder and LN-7 per S17525 or
S15416 connection diagram that is sent with the K240
Contactor Kit. The engine welder 115 volt receptacle
will supply the AC power that is needed. Place the
welder idler control in the high position before welding.
When the LN-7 is connected to an SA-250 or SAE-350,
it will not run at low idle when the idle control is in the
automatic position. The plug connecting the K240
Contactor Kit to the SA-250 or SAE-350 auxiliary
power receptacle must be disconnected to allow the
engine to run at low idle.
WARNING
• TURN THE ENGINE OFF WHILE INSTALLING
THIS ACCESSORY.
• KEEP HANDS, HAIR, CLOTHING AND TOOLS
AWAY FROM MOVING PARTS WHEN STARTING
OR OPERATING ENGINE.
1. Remove roof assembly and bracket cover (cover
on top and at rear of generator). (See Figure 2.)
Also, remove the two gas tank support mounting
bolts on the side opposite the output studs.
CAUTION
ANY SPEED UP OF THE ENGINE RPM BY
CHANGING THE GOVERNOR SETTING OR OVER-
RIDING THE THROTTLE LINKAGE WILL CAUSE
AN INCREASE IN THE AC AUXILIARY VOLTAGE.
IF THIS VOLTAGE GOES ABOVE 140 VOLTS, THE
LN-7 CONTROL CIRCUIT AND/OR THE CV
ADAPTER CIRCUIT WILL BE DAMAGED! THE
ENGINE GOVERNOR SETTING IS PRESET AT THE
FACTORY — DO NOT ADJUST ABOVE RPM
SPECIFICATIONS LISTED IN ENGINE WELDER
OPERATING MANUAL.
2. Mount CV Adapter (nameplate should have an
“SA” above the code number) to the gas tank sup-
port holes. Use one 3/8" bolt with hardware
removed in Step 1 and one stud on Adapter. One
3/8" bolt will not be used as a 3/8" stud from the
Adapter case replaces it. In mounting the unit, be
sure the fuel line and choke cable are not pinched.
(See Figure 1.)
NOTE: FOR STEPS 3 THROUGH 10, REFER TO
S17514 OR S17515 CONNECTION DIAGRAMS FOR
THE APPROPRIATE WELDER CODE NUMBER. CV
ADAPTER CONTROL LEADS ARE NOT COLOR
CODED ON ALL UNITS.
The following tools and materials are recommended for
attaching the CV Adapter to an engine welder:
1. Measuring tape, hammer, center punch and electric
drill with 13/32" drill bit. This is only needed for SA-
250 engine welders that do not have mounting
holes in fuel tank rail.
CV ADAPTER
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B-2
B-2
INSTALLATION
4. FOR CODE NUMBERS BELOW 8678, connect
CV Adapter lead 610 to black exciter lead bolted
connection shown in Figure 2 and insulate the con-
nection with tape. Tape unused lead terminal on
lead 610.
FOR CODE NUMBERS ABOVE 8678, tape up ring
terminal on CV Adapter lead 610 and connect
push-on terminal of CV Adapter lead 610 to black
exciter lead on idler control P.C. board that was
connected to brown field lead.
5. Remove existing blue field lead from the center ter-
minal of the Fine Current Adjustment rheostat and
connect it to CV Adapter lead 503 using #10 X 1/4
screw and nut provided. Insulate connection with
tape.
FIGURE 1 – CV Adapter Mounting.
6. Connect CV Adapter lead 602 to the center termi-
nal of the Fine Current Adjustment rheostat.
Connect CV Adapter lead 600 to the end terminal
of the Fine Current Adjustment rheostat that has
an existing lead connected to it.
3. FOR CODE NUMBERS BELOW 8678, unbolt
existing brown field lead from black exciter leads in
the lead bundle and bolt it to CV Adapter lead 509
using #10 x 1/4 bolt and nut provided. Tape up con-
nection and unused lead terminal on lead 509 (see
Figure 2 below).
7. Connect CV Adapter leads “Neg” and “Pos” to the
back of the SA-200 negative and positive output
terminals respectively. Tape these leads to gener-
ator lead bundle for support.
FOR CODE NUMBERS ABOVE 8678, remove
existing brown field lead from black exciter lead on
the idler control P.C. board and connect the brown
field lead to CV Adapter lead 509 using the exist-
ing push-on terminal. Tape up connection and
unused ring terminal.
FIGURE 2 – SA-200 with Roof Assembly Removed.
CV ADAPTER
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B-3
B-3
INSTALLATION
FIGURE 3 – View of Negative Generator Brushholder after Bracket Cover is Removed.
CAUTION
NOTE: FOR STEPS 8 THROUGH 10, REFER TO
FIGURE 3.
POLARITY OF THE STANDARD OUTPUT TERMI-
8. The negative generator brushholder, exposed
when bracket cover (see Figure 2) is removed, is
at the 11 o’clock position when the commutator is
viewed from the control panel end of welder.
Remove the 5/16 bolt which connects the two
existing cables to the negative brushholder. Locate
the thermostat assembly marked “200” and recon-
nect the two cables to the negative brushholder
with one end of the thermostat assembly bolted
between the cable lugs and the brushholder.
NALS MUST BE AS STATED IN STEP 12 AND THE
MAXIMUM OPEN CIRCUIT VOLTAGE WITH THE
LOWER MODE SWITCH IN CV POSITION MUST
BE AS STATED IN STEP 13 BEFORE PLACING
THE UPPER MODE SWITCH IN CV POSITION.
FAILURE TO HAVE THE CORRECT POLARITY
AND
VOLTAGE BEFORE PLACING THE UPPER
MODE SWITCH IN CV POSITION WILL RESULT IN
DAMAGE TO THE CV ADAPTER.
12. To check the VV output, place both CV/VV switch-
es on the CV Adapter in the “VV” position. Start the
SA-200 and place idler control in “high” position.
Use a DC voltmeter across the standard output ter-
minals to check the output polarity. If it is incorrect,
recheck Steps 3 through 10. Voltage should be
about 47-60 volts DC when the Fine Current
Adjustment is set at minimum and 87-100 volts DC
when set at maximum. These voltages may be
slightly higher if readings are taken when welder is
cold.
9. Route the CV Adapter leads, which exit from the
bottom of the Adapter case, through a 1-1/4 x
3-1/2" rectangular opening located at the 5 o’clock
position on the generator frame. Inside the frame,
the leads should be formed against the frame
shell. Use the 5/16-18 x 5/8 bolt with hardware
supplied to connect the #2 heavy cable from the
CV Adapter to the free end of the thermostat
assembly from Step 8. The flat side of the cable lug
should be against the bottom side of the thermo-
stat assembly with the nut washer and lockwasher
on the top.
13. To check the CV output, place only the lower
switch in the “CV” position. This may be done while
the engine is running as long as no welding is
being done. Voltage between the positive output
terminal and the CV output terminal should be 7-12
volts DC when the CV Adapter voltage control is at
minimum setting and 36-48 volts DC at maximum
setting.
10. Connect leads 608 and 609, routed into the gener-
ator in Step 9, to the two thermostat terminals. Use
tape to separately insulate the unused Y and W
leads. Insure that all leads are well clear of moving
parts and secured in place with tape.
11. Replace the roof assembly and bracket cover
removed in Step 1.
14. If output varies greatly from that specified in Steps
12 and 13, check wiring and refer to troubleshoot-
ing section of manual.
CV ADAPTER
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B-4
B-4
INSTALLATION
5. Tape up ring terminal on CV Adapter lead 610 and
connect push-on terminal of CV Adapter lead 610
to black lead on positive terminal of rectifier.
K384 CV ADAPTER TO SA-250 ENGINE
WELDER WITH AC AUXILIARY OUTPUT
WARNING
6. Remove existing field lead from the center terminal
of the Fine Current Adjustment rheostat and con-
nect it to the CV Adapter lead 503 using #10-24 x
1/4 screw and nut provided. Insulate the connec-
tion with tape. For units with remote control, leave
blue lead from remote switch in place on center
terminal of rheostat.
• TURN THE ENGINE OFF WHILE INSTALLING
THIS ACCESSORY.
• KEEP HANDS, HAIR, CLOTHING AND TOOLS
AWAY FROM MOVING PARTS WHEN STARTING
OR OPERATING ENGINE.
1. Remove roof assembly, back panel, top exciter
cover and bracket cover. See Figure 4.
7. Connect CV Adapter lead 602 to the center termi-
nal of the Fine Current Adjustment Rheostat.
2. Drill two holes in fuel tank rail opposite output ter-
minals as in Figure 2 if holes are not in unit.
For units without remote control — connect CV
Adapter lead 600 to the end terminal of the Fine
Current Adjustment Rheostat that has an existing
lead connected to it.
3. Mount CV Adapter (unit with “SA” above code
number) to the support holes. Use the one stud on
the Adapter case, a spacer, lockwasher, and nut on
one end and 3/8-16 x 1 hex head bolt and hard-
ware on the other end as shown in Figure 6. In
mounting the unit, be sure the fuel line and choke
cable are not pinched.
For units with remote control — remove remote
switch from panel to connect CV Adapter lead 600
to the remote switch terminal that has a yellow and
a black lead connected to it. Replace remote
switch on panel.
NOTE: FOR STEPS 4 THROUGH 12, REFER TO
S17517 CONNECTION DIAGRAM FOR UNITS
WITHOUT REMOTE CONTROL AND S17766 FOR
UNITS WITH REMOTE CONTROL. CV ADAPTER
CONTROL LEADS ARE NOT COLOR CODED ON
ALL UNITS.
8. Connect CV Adapter leads “Neg” and “Pos” to the
back of the negative and positive output terminals
respectively. Tape these leads to generator lead
bundle for support.
4. Remove existing brown field lead from the black
lead on the positive rectifier terminal and connect
the brown field lead to CV Adapter lead 509 using
the existing push-on terminal. Tape up connection
and unused ring terminal. Rectifier located on back
of control panel. See Figure 4.
FIGURE 4 – SA-250 with Roof Assembly Removed.
CV ADAPTER
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B-5
B-5
INSTALLATION
FIGURE 5 – Fuel Tank as Viewed from Top.
NOTE: FOR STEPS 9 THROUGH 12, REFER TO
FIGURES 4 AND 7.
11. Connect leads 608 and 609, routed into the gener-
ator in Step 10, to the two thermostat terminals.
9. The negative generator brushholder, exposed
when bracket cover (see Figure 4) is removed, is
at the 11 o’clock position when the commutator is
viewed from the control panel end of welder.
Remove the 5/16 bolt which connects the two
existing cables to the negative brushholder. Obtain
the thermostat assembly marked “250” and recon-
nect the two cables to the negative brushholder
with one end of the thermostat assembly bolts
between the cable lugs and the brushholder.
12. Disconnect the white and yellow leads connected
to the alternator brushes and reconnect the brush
leads as before. Re-route these white and yellow
leads over the top of the generator brushholder to
meet the W and Y leads of the CV Adapter from
Step 10. Connect W lead to white lead and Y lead
to yellow lead using #10 x 1/4 screw and nut pro-
vided. Insulate each connection with tape. Insure
that all leads are well clear of moving parts and
secured in place with tape.
10. Route the CV Adapter leads, which exit from the
bottom of the Adapter case, through a 1-1/4 X
3-1/2" rectangular opening located at the 5 o’clock
position on the generator frame. Inside the frame,
the leads should be formed against the frame
shell. Use the 5/16-18 x 5/8 bolt with hardware
supplied to connect the #2 heavy cable from the
CV Adapter to the free end of the thermostat
assembly from Step 9. The flat side of the cable lug
should be against the bottom side of the thermo-
stat assembly with the nut, washer and lockwash-
er on the top.
13. Replace roof assembly, back panel, top exciter
cover and bracket cover removed in Step 1.
FIGURE 6 – CV Adapter Mounting (Side View).
CV ADAPTER
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B-6
B-6
INSTALLATION
FIGURE 7 – View of Negative Generator Brushholder after Bracket Cover is Removed.
16. If output varies greatly from that specified in Steps 14
and 15, check wiring. If this does not solve problem,
refer to Troubleshooting Section of manual.
CAUTION
POLARITY OF THE STANDARD OUTPUT TERMI-
NALS MUST BE AS STATED IN STEP 14 AND THE
MAXIMUM OPEN CIRCUIT VOLTAGE WITH THE
LOWER MODE SWITCH IN CV POSITION MUST
BE AS STATED IN STEP 15 BEFORE PLACING
THE UPPER MODE SWITCH IN CV POSITION.
FAILURE TO HAVE THE CORRECT POLARITY
AND VOLTAGE BEFORE PLACING THE UPPER
MODE SWITCH IN CV POSITION WILL RESULT IN
DAMAGE TO THE CV ADAPTER.
K384 CV ADAPTER TO SA-250 ENGINE
WELDER WITH DC AUXILIARY OUTPUT
NOTE: Before installing CV Adapter, start engine welder
and use a DC voltmeter to check the polarity of the red
and black leads connected to the auxiliary power recep-
tacle. The red lead should be negative and the black lead
should be positive. If the polarity is not correct, refer to
engine welder operating manual for instructions to flash
the exciter to obtain the correct polarity.
14. To check the VV output, place both CV/VV switch-
es on the CV Adapter in the “VV” position. If welder
has remote control, set remote control switch to
local position. Start the SA-250 and place idler
control in “high” position. Use a DC voltmeter
across the standard output terminals to check the
output polarity. If it is incorrect, recheck Steps 4
through 12. Open circuit voltage should be about
43-53 volts DC when the Fine Current Adjustment
is set to minimum and 93-100 volts DC when set at
maximum. These voltages may be higher if read-
ings are taken when welder is cold.
WARNING
• TURN THE ENGINE OFF WHILE INSTALLING THIS
ACCESSORY.
• KEEP HANDS, HAIR, CLOTHING AND TOOLS
AWAY FROM MOVING PARTS WHEN STARTING
OR OPERATING ENGINE.
1. Remove roof assembly and bracket cover (cover on
top and at rear of generator).
2. Drill two holes in fuel tank rail opposite output termi-
nals as in Figure 8, if holes are not in unit.
15. To check the CV output, place only the lower
switch in the “CV” position. This may be done while
the engine is running as long as no welding is
being done. Voltage between the positive output
terminal and the CV output terminal should be 7-12
volts when the CV Adapter voltage control is at
minimum setting and 36-48 volts at maximum set-
ting.
3. Mount CV Adapter (unit with “SA” above code num-
ber) to the support holes. Use the one stud on the
Adapter case, a spacer, lockwasher, and nut on one
end and 3/8-16 x 1 hex head bolt and hardware on
the other end as shown in Figure 9. In mounting the
unit, be sure the fuel line and choke cable are not
pinched.
CV ADAPTER
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B-7
B-7
INSTALLATION
FIGURE 8 – Fuel Tank as Viewed from Top.
6. Remove existing blue field lead from the center ter-
minal of the Fine Current Adjustment rheostat and
connect it to CV Adapter lead 503 using #10 x 1/4
screw and nut provided. Insulate connection with
tape. For units with remote control, leave blue lead
from remote switch in place on center terminal of
rheostat.
NOTE: FOR STEPS 4 THROUGH 11, REFER TO
S17516 CONNECTION DIAGRAM FOR UNITS WITH-
OUT REMOTE CONTROL AND S17765 FOR UNITS
WITH REMOTE CONTROL. CV ADAPTER CON-
TROL LEADS ARE NOT COLOR CODED ON ALL
UNITS.
4. Unbolt existing brown field lead from black exciter
leads in the lead bundle and bolt it to CV Adapter
lead 509 using # 10 x 1/4 bolt and nut provided.
Tape up connection and unused lead terminal on
lead 509 (see Figure 10).
7. Connect CV Adapter lead 602 to the center termi-
nal of the Fine Current Adjustment rheostat.
For units without remote control — connect CV
Adapter lead 600 to the end terminal of the Fine
Current Adjustment rheostat that has an existing
lead connected to it.
5. Connect CV Adapter lead 610 to black exciter lead
bolted connection shown in Figure 10 and insulate
the connection with tape. Tape unused lead termi-
nal on lead 610.
For units with remote control — remove remote
switch from panel to connect CV Adapter lead 600
to the remote switch terminal that has a yellow and
a black lead connected to it. Replace remote
switch on panel.
FIGURE 9 – CV Adapter Mounting (Side View).
CV ADAPTER
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B-8
B-8
INSTALLATION
FIGURE 10 – SA-250 with Roof Assembly Removed.
9. The negative generator brushholder, exposed
when bracket cover (see Figure 10) is removed, is
at the 11 o’clock position when the commutator is
viewed from the control panel end of welder.
Remove the 5/16 bolt which connects the two
existing cables to the negative brushholder. Locate
the thermostat assembly marked “250” and recon-
nect the two cables to the negative brushholder
with one end of the thermostat assembly bolted
between the cable lugs and the brushholder.
8. Connect CV Adapter leads “Neg” and “Pos” to the
back of the SA-250 negative and positive output
terminals respectively. Tape these leads to gener-
ator lead bundle for support.
NOTE: FOR STEPS 9 THROUGH 11, REFER TO FIG-
URES 10 AND 11.
FIGURE 11 – View of Negative Generator Brushholder after Bracket Cover is Removed.
CV ADAPTER
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B-9
B-9
INSTALLATION
10. Route the CV Adapter leads, which exit from the
bottom of the Adapter case, through a 1-1/4 x 3-
1/2" rectangular opening located at the 5 o’clock
position on the generator frame. Inside the frame,
the leads should be formed against the frame
shell. Use the 5/16-18 x 5/8 bolt with hardware
supplied to connect the #2 heavy cable from the
CV Adapter to the free end of the thermostat
assembly from Step 9. The flat side of the cable lug
should be against the bottom side of the thermo-
stat assembly with the nut, washer and lockwash-
er on the top.
15. If output varies greatly from that specified in Steps
13 and 14, check wiring and refer to troubleshoot-
ing section of manual.
K384 CV ADAPTER TO CLASSIC I ENGINE
WELDER
NOTE: BEFORE INSTALLING CV ADAPTER, START
ENGINE WELDER AND USE A DC VOLTMETER TO
CHECK THE POLARITY OF THE RED AND BLACK
LEADS CONNECTED TO THE AUXILIARY POWER
RECEPTACLE. THE RED LEAD SHOULD BE NEGA-
TIVE AND THE BLACK LEAD SHOULD BE POSI-
TIVE. IF THE POLARITY IS NOT CORRECT, REFER
TO ENGINE WELDER OPERATING MANUAL FOR
INSTRUCTIONS TO FLASH THE EXCITER TO
OBTAIN THE CORRECT POLARITY.
11. Connect leads 608 and 609, routed into the gener-
ator in Step 10, to the two thermostat terminals.
Use tape to separately insulate the unused Y and
W leads. Insure that all leads are well clear of mov-
ing parts and secured in place with tape.
WARNING
12. Replace the roof assembly and bracket cover
removed in Step 1.
• TURN THE ENGINE OFF WHILE INSTALLING
THIS ACCESSORY.
• KEEP HANDS, HAIR, CLOTHING AND TOOLS
AWAY FROM MOVING PARTS WHEN STARTING
OR OPERATING ENGINE.
CAUTION
POLARITY OF THE STANDARD OUTPUT TERMI-
NALS MUST BE AS STATED IN STEP 13 AND THE
MAXIMUM OPEN CIRCUIT VOLTAGE WITH THE
LOWER MODE SWITCH IN CV POSITION MUST BE
AS STATED IN STEP 14 BEFORE PLACING THE
UPPER MODE SWITCH IN CV POSITION. FAILURE
TO HAVE THE CORRECT POLARITY AND VOLT-
AGE BEFORE PLACING THE UPPER MODE
SWITCH IN CV POSITION WILL RESULT IN DAM-
AGE TO THE CV ADAPTER.
1. Remove roof assembly and bracket cover (cover
on top and at rear of generator). (See Figure 2.)
Also, remove the two gas tank support mounting
bolts on the side opposite the output studs.
2. Mount CV Adapter (nameplate should have an
“SA” above the code number) to the gas tank sup-
port holes. Use one 3/8" bolt with hardware
removed in Step 1 and one stud on Adapter. One
3/8" bolt will not be used as a 3/8" stud from the
Adapter case replaces it. In mounting the unit, be
sure the fuel line and choke cable are not pinched.
(See Figure 1.)
13. To check the VV output, place both CV/VV switch-
es on the CV Adapter in the “VV” position. If welder
has remote control, set remote control switch to
local position. Start the SA-250 and place idler
control in “high” position. Use a DC voltmeter
across the standard output terminals to check the
output polarity. If it is incorrect, recheck Steps 3
through 10. Voltage should be about 47-60 volts
DC when the Fine Current Adjustment is set at
minimum and 87-100 volts DC when set at maxi-
mum. These voltages may be slightly high if read-
ings are taken when welder is cold.
NOTE: FOR STEPS 3 THROUGH 10, REFER TO
L8684 OR L8984 CONNECTION DIAGRAMS FOR
THE APPROPRIATE WELDER CODE NUMBER. CV
ADAPTER CONTROL LEADS ARE NOT COLOR
CODED ON ALL UNITS.
3. Remove existing brown field lead from black
exciter lead on the idler control P.C. board and
connect the brown field lead to CV Adapter lead
509 using the existing push-on terminal. Tape up
connection and unused ring terminal.
14. To check the CV output, place only the lower
switch in the “CV” position. This may be done while
the engine is running as long as no welding is
being done. Voltage between the positive output
terminal and the CV output terminal should be 7-12
volts DC when the CV Adapter voltage control is at
minimum setting and 36-48 volts DC at maximum
setting.
4. Tape up ring terminal on CV Adapter lead 610 and
connect push-on terminal of CV Adapter lead 610
to black exciter lead on idler control P.C. board that
was connected to brown field lead.
CV ADAPTER
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B-10
B-10
INSTALLATION
CAUTION
5. Remove existing blue field lead from the center ter-
minal of the Fine Current Adjustment rheostat and
connect it to CV Adapter lead 503 using #10 X 1/4
screw and nut provided. Insulate connection with
tape.
POLARITY OF THE STANDARD OUTPUT TERMI-
NALS MUST BE AS STATED IN STEP 12 AND THE
MAXIMUM OPEN CIRCUIT VOLTAGE WITH THE
LOWER MODE SWITCH IN CV POSITION MUST BE
AS STATED IN STEP 13 BEFORE PLACING THE
UPPER MODE SWITCH IN CV POSITION. FAILURE
TO HAVE THE CORRECT POLARITY AND VOLT-
AGE BEFORE PLACING THE UPPER MODE
SWITCH IN CV POSITION WILL RESULT IN DAM-
AGE TO THE CV ADAPTER.
6. Connect CV Adapter lead 602 to #602 on the ter-
minal strip. Connect CV Adapter lead 600 to #600
on the terminal strip. If there are leads already pre-
sent at 600 and 602 on the terminal strip, the leads
remain there.
NOTE: A TERMINAL STRIP, LOCATED NEAR THE
OUTPUT RECEPTACLE, IS PROVIDED TO SIMPLI-
FY THE INSTALLATION.
12. To check the VV output, place both CV/VV switch-
es on the CV Adapter in the “VV” position. Start the
Classic I and place idler control in “high” position.
Use a DC voltmeter across the standard output ter-
minals to check the output polarity. If it is incorrect,
recheck Steps 3 through 10. Voltage should be
about 47-60 volts DC when the Fine Current
Adjustment is set at minimum and 87-100 volts DC
when set at maximum. These voltages may be
slightly higher if readings are taken when welder is
cold.
7. Connect CV Adapter leads “Neg” and “Pos” to the
back of the Classic I negative and positive output
terminals respectively. Tape these leads to gener-
ator lead bundle for support.
NOTE: FOR STEPS 8 THROUGH 10, REFER TO
FIGURE 3.
8. The negative generator brushholder, exposed
when bracket cover (see Figure 2) is removed, is
at the 11 o’clock position when the commutator is
viewed from the control panel end of welder.
Remove the 5/16 bolt which connects the two
existing cables to the negative brushholder. Locate
the thermostat assembly marked “200” and recon-
nect the two cables to the negative brushholder
with one end of the thermostat assembly bolted
between the cable lugs and the brushholder.
13. To check the CV output, place only the lower
switch in the “CV” position. This may be done while
the engine is running as long as no welding is
being done. Voltage between the positive output
terminal and the CV output terminal should be 7-12
volts DC when the CV Adapter voltage control is at
minimum setting and 36-48 volts DC at maximum
setting.
14. If output varies greatly from that specified in Steps
12 and 13, check wiring and refer to troubleshoot-
ing section of manual.
9. Route the CV Adapter leads, which exit from the
bottom of the Adapter case, through a 1-1/4 x
3-1/2" rectangular opening located at the 5 o’clock
position on the generator frame. Inside the frame,
the leads should be formed against the frame
shell. Use the 5/16-18 x 5/8 bolt with hardware
supplied to connect the #2 heavy cable from the
CV Adapter to the free end of the thermostat
assembly from Step 8. The flat side of the cable lug
should be against the bottom side of the thermo-
stat assembly with the nut washer and lockwasher
on the top.
10. Connect leads 608 and 609, routed into the gener-
ator in Step 9, to the two thermostat terminals. Use
tape to separately insulate the unused Y and W
leads. Insure that all leads are well clear of moving
parts and secured in place with tape.
11. Replace the roof assembly and bracket cover
removed in Step 1.
CV ADAPTER
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B-11
B-11
INSTALLATION
5. Remove existing field lead from the center terminal
of the Fine Current Adjustment rheostat and con-
nect it to the CV Adapter lead 503 using #10-24 x
1/4 screw and nut provided. Insulate the connec-
tion with tape. For units with remote control, leave
blue lead from remote switch in place on center
terminal of rheostat.
K384 CV ADAPTER TO CLASSIC II
ENGINE WELDER
WARNING
• TURN THE ENGINE OFF WHILE INSTALLING
THIS ACCESSORY.
6. Connect CV Adapter lead 602 to #602 on the ter-
minal strip. Also connect the CV Adapter lead 600
to #600 on terminal strip. If there are leads already
present at 600 and 602 on the terminal strip, the
leads remain there. See Figure 11A for terminal
strip location.
• KEEP HANDS, HAIR, CLOTHING AND TOOLS
AWAY FROM MOVING PARTS WHEN STARTING
OR OPERATING ENGINE.
1. Remove roof assembly, back panel, top exciter
cover and bracket cover. See Figure 11A.
7. Connect CV Adapter leads “Neg” and “Pos” to the
back of the negative and positive output terminals
respectively. Tape these leads to generator lead
bundle for support.
2. Mount CV Adapter (unit with “SA” above code
number) to the support holes. Use the one stud on
the Adapter case, a spacer, lockwasher, and nut on
one end and 3/8-16 x 1 hex head bolt and hard-
ware on the other end as shown in Figure 6. In
mounting the unit, be sure the fuel line and choke
cable are not pinched.
NOTE: FOR STEPS 8 THROUGH 11, REFER TO FIG-
URES 7 AND 11A.
8. The negative generator brushholder, exposed
when bracket cover (see Figure 11A) is removed,
is at the 11 o’clock position when the commutator
is viewed from the control panel end of welder.
Remove the 5/16 bolt which connects the two
existing cables to the negative brushholder. Obtain
the thermostat assembly marked “250” and recon-
nect the two cables to the negative brushholder
with one end of the thermostat assembly bolts
between the cable lugs and the brushholder.
NOTE: FOR STEPS 3 THROUGH 11, REFER TO
L8594 OR L9071 CONNECTION DIAGRAMS.
3. Remove existing brown field lead from the black
lead on the positive rectifier terminal and connect
the brown field lead to CV Adapter lead 509 using
the existing push-on terminal. Tape up connection
and unused ring terminal. Rectifier located on back
of control panel. See Figure 11A.
4. Tape up ring terminal on CV Adapter lead 610 and
connect push-on terminal of CV Adapter lead 610
to black lead on positive terminal of rectifier.
FIGURE 11A
CV ADAPTER
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B-12
B-12
INSTALLATION
9. Route the CV Adapter leads, which exit from the
bottom of the Adapter case, through a 1-1/4 X 3-
1/2" rectangular opening located at the 5 o’clock
position on the generator frame. Inside the frame,
the leads should be formed against the frame
shell. Use the 5/16-18 x 5/8 bolt with hardware
supplied to connect the #2 heavy cable from the
CV Adapter to the free end of the thermostat
assembly from Step 8. The flat side of the cable lug
should be against the bottom side of the thermo-
stat assembly with the nut, washer and lockwash-
er on the top.
14. To check the CV output, place only the lower
switch in the “CV” position. This may be done while
the engine is running as long as no welding is
being done. Voltage between the positive output
terminal and the CV output terminal should be 7-12
volts DC when the CV Adapter voltage control is at
minimum setting and 36-48 volts DC at maximum
setting.
15. If output varies greatly from that specified in Steps
13 and 14, check wiring and refer to troubleshoot-
ing section of manual.
10. Connect leads 608 and 609, routed into the gener-
ator in Step 9, to the two thermostat terminals.
K385-1 MODEL CV ADAPTER
The K385 has been replaced with the K385-1. The only
difference between them is the mounting bracket. The
K385 was used on SAE-300 and SAE-400 Amp Engine
Welder with AC Auxiliary power between codes 8813
and 9782. The K385-1 has a universal mounting brack-
et which permits it to be mounted on codes between
8813 and 9782, as well as all codes above 9782
including the SAE-400 WELD’N AIR.
11. Disconnect the white and yellow leads connected
to the alternator brushes and reconnect the brush
leads as before. Re-route these white and yellow
leads over the top of the generator brushholder to
meet the W and Y leads of the CV Adapter from
Step 9. Connect W lead to white lead and Y lead to
yellow lead using #10 x 1/4 screw and nut provid-
ed. Insulate each connection with tape. Insure that
all leads are well clear of moving parts and
secured in place with tape.
The Figures A and B show the mounting bracket in dif-
ferent positions, depending on the type of fuel tank rail
being used.
12. Replace the roof assembly and bracket cover
removed in Step 1.
CAUTION
POLARITY OF THE STANDARD OUTPUT TERMI-
NALS MUST BE AS STATED IN STEP 13 AND THE
MAXIMUM OPEN CIRCUIT VOLTAGE WITH THE
LOWER MODE SWITCH IN CV POSITION MUST BE
AS STATED IN STEP 14 BEFORE PLACING THE
UPPER MODE SWITCH IN CV POSITION. FAILURE
TO HAVE THE CORRECT POLARITY AND VOLT-
AGE BEFORE PLACING THE UPPER MODE
SWITCH IN CV POSITION WILL RESULT IN DAM-
AGE TO THE CV ADAPTER.
FIGURE A
13. To check the VV output, place both CV/VV switch-
es on the CV Adapter in the “VV” position. If welder
has remote control, set remote control switch to
local position. Start the Classic II and place idler
control in “high” position. Use a DC voltmeter
across the standard output terminals to check the
output polarity. If it is incorrect, recheck Steps 3
through 11. Voltage should be about 47-60 volts
DC when the Fine Current Adjustment is set at
minimum and 87-100 volts DC when set at maxi-
mum. These voltages may be slightly high if read-
ings are taken when welder is cold.
FIGURE B
CV ADAPTER
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B-13
B-13
INSTALLATION
FIGURE 12 – Engine Welder (Left Side).
K385-1 CV ADAPTER TO SAE-300, SAE-400 OR
SAE-400 WELD’N AIR ENGINE WELDER
NOTE: FOR STEPS 3 THROUGH 13, REFER TO THE
PROPER CONNECTION DIAGRAM IN THIS MANU-
AL FOR THE WELDER WITH THE APPROPRIATE
TYPE OF AUXILIARY POWER AND CODE NUMBER.
CV ADAPTER CONTROL LEADS ARE NOT COLOR
CODED ON ALL UNITS.
NOTE: BEFORE INSTALLING CV ADAPTER ON ENGINE
WELDERS WITH DC AUXILIARY POWER, START ENGINE
WELDER AND USE A DC VOLTMETER TO CHECK THE POLAR-
ITY OF THE RED AND BLACK LEADS CONNECTED TO THE
AUXILIARY POWER RECEPTACLE. THE RED LEAD SHOULD
BE NEGATIVE AND THE BLACK LEAD SHOULD BE POSITIVE.
IF THE POLARITY IS NOT CORRECT, REFER TO ENGINE
WELDER OPERATING MANUAL FOR INSTRUCTIONS TO
FLASH THE EXCITER TO OBTAIN THE CORRECT POLARITY.
Only use K385-1 CV Adapter that has a code number
above 8785 on SAE-300, SAE-400 and SAE-400
WELD’N AIR engine welders with AC auxiliary power
and Code Number above 8812.
3. Remove existing yellow lead from the outside ter-
minal of the reversing switch and connect it to the
same terminal on the reversing switch that is con-
nected to the red lead (a green lead may also be
on this terminal).
4. Remove existing blue resistor lead from reversing
switch and connect both ends of this blue lead to
the same resistor terminal to store lead.
WARNING
• TURN THE ENGINE OFF WHILE INSTALLING
THIS ACCESSORY.
• KEEP HANDS, HAIR, CLOTHING AND TOOLS
AWAY FROM MOVING PARTS WHEN STARTING
OR OPERATING ENGINE.
-----------------------------------------------------------------------
1. Remove the upper bracket cover or the wrap-
around bracket cover on older welders with AC
auxiliary power. Also, remove the two fuel tank
support mounting bolts on the side opposite the
output terminals. See Figure 12. On the SAE-400
(with codes 10601, 10856 and 10884) and all
WELD’N AIR, remove the guards mounted on the
inside of the front control panel.
5. Remove existing blue field lead from its connection
point and connect it to CV Adapter lead 503 using
#10 x 1/4 screw and nut provided. Insulate con-
nection with tape.
6.
•
(For codes 8812 through 10400, 10549 and 10664,
10665) Disconnect existing brown field lead (that
runs from the generator field) from the center ter-
minal of the Job Selector rheostat, and connect it
to the CV Adapter lead 509 using #10x1/4 screw
and nut provided. Insulate the connection with tape
(requires 115V insulation). On SAE-400 WELD’N
AIR models a second brown lead exists on the Job
Selector rheostat center terminal. This lead runs to
the remote control switch and is to be left in place.
2. Mount the K385-1 loosely in position as shown in
Figure B and Figure 13 for SAE-400 (Codes 9783
and above) or loosely in position as shown in
Figure A and Figure 13 for SAE-400 WELD’N AIR.
It is important that the CV Adapter be positioned
flush against the fuel tank rail. Take care not to
pinch any leads or lines.
• (For SAE 400 and WELD N’ AIR with codes
10601, 10602, 10856, 10884 and 10885) Remove
the existing brown field lead from the 500Ω resister
and connect it to the CV Adapter lead 509 using the
#10-1/4 screw and nut that is provided. Insulate the
connection with tape.
CV ADAPTER
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B-14
B-14
INSTALLATION
FIGURE 13 – Frame Rail Mounting.
9. Connect CV Adapter lead 610 to same terminal on
polarity switch that is connected to existing black
lead.
7.
• (For code 8812 through 10400, 10549 and
10664, 10665) Route CV Adapter leads 600, 602,
610, 612 and 613 through plastic lead clamp on
Current Control reactor housing. Connect CV
Adapter lead 602 to the center terminal of the Job
Selector rheostat.
10.
• (For SAE-300 and -400 welders with DC auxil-
iary power) Use tape to separately insulate CV
Adapter leads 611, 612 and 613. These leads are
not used.
• (For SAE 400 and WELD N’ AIR with codes
10601, 10602, 10856, 10884 AND 10885) Route
the CV Adapter leads 600, 602, 610, 612 and 613
through the plastic lead clamp on the side of the
“Current Control” reactor box. Connect the CV
Adapter leads 600 and 602 to the 500Ω resistor
with the exiting yellow lead.
• (For SAE-300 and -400 welders with AC auxil-
iary power between Codes 7160 and 8812)
Disconnect the flashing diode lead from the flash-
ing contactor solenoid. The flashing diode and the
flashing contactor solenoid are mounted on the
side of the reactor box located behind the control
panel. Connect CV Adapter lead 611 to diode lead
removed from flashing contactor solenoid using
#10 x 1/4 screw and nut provided. Insulate connec-
tion with tape. Connect CV Adapter lead 612 to
flashing contactor solenoid terminal that was con-
nected to flashing diode lead. Insulate lead 613
with tape.
8.
• (For Code 8812 through 10400, 10549 and
10664) Connect the CV Adapter lead 600 to the
end terminal of the Job Selector rheostat that has
an existing lead connected to it.
• (For SAE 400 and WELD N’ AIR with codes
10362 and 10665) Connect the CV Adapter lead
600 to the resistor terminal with two existing yellow
leads connected to it.
FIGURE 14 – View of Negative Generator Brushholder after Bracket cover is Removed.
CV ADAPTER
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B-15
B-15
INSTALLATION
FIGURE 15 –Decal Mounting.
• (For SAE 400 and WELD N’ AIR with codes
10884 and 10885 Only) Disconnect the white
flashing diode lead from the white hour meter
lead at the taped junction (the flashing diode is
mounted on the inside of the reactor box located
behind the control panel). Connect the CV
Adapter leads 611 to the white flashing diode
lead, 612 to the white hour meter lead, and tape
off lead 613. Insulate all screw connections with
tape.
• (For SAE-300, SAE-400 and SAE-400 WELD’N
AIR welders with AC auxiliary power Code
8812 through 10400, 10549 and 10664, 10665)
Disconnect the junction in the white lead connect-
ed to the flashing diode. The flashing diode is
mounted on the side of the reactor box located
behind the control panel. Connect CV Adapter
lead 611 to one of the white leads that was dis-
connected and connect CV Adapter lead 612 to
the other white lead. Insulate both connections
with tape. Disconnect reversing switch (switch
used to reverse output stud electrode polarity)
end of green lead connected between reversing
switch and welder frame. Connect this green lead
to CV Adapter lead 613 and tape up connection.
11. Connect CV Adapter lead marked “Neg” to the
back of “Electrode” output terminal. Connect CV
Adapter lead marked “Pos” to the back of “To
Work” output terminal. Tape leads to generator
lead bundle for support.
NOTE: ON UNITS BELOW CODE 9936, THE LEAD CONNECT-
ED BETWEEN THE REVERSING SWITCH (switch used to
reverse output stud electrode polarity) AND
WELDER FRAME WAS RED.
12. Tape CV Adapter control cable leads to lead bun-
dle to secure control cable.
• (For SAE 400 and WELD N’ AIR with codes
10601, 10602 and 10856 Only) Replace lead
#200 that connects the "Diode Bridge" (D1) neg-
ative and the control panel ground screw with the
diode lead assembly provided with the K385-1 CV
Adapter. Disconnect the white flashing diode lead
from the white hour meter lead at the taped junc-
tion (the flashing diode is mounted on the inside
of the reactor box located behind the control
panel). Connect the CV Adapter leads 611 to the
white flashing diode lead, 612 to the white hour
meter lead, and tape off lead 613. Insulate all
screw connections with tape.
CV ADAPTER
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B-16
B-16
INSTALLATION
NOTE: FOR STEPS 13 AND 14 REFER TO FIGURES 12 AND 14.
16. To check the VV output, place both CV/VV switch-
es on the CV Adapter in the “VV” position. Set the
Remote Control Switch to the “REMOTE” or
“LOCAL” position as applicable, if so equipped.
Start the engine welder and set for full speed oper-
ation. Use a DC voltmeter to check the output
polarity. The “Electrode” output terminal that is
relabeled “Negative” must be negative and the “To
Work” output terminal that is relabeled “Positive”
must be positive. If polarity is not correct, recheck
Steps 3 to 12. Voltage should be about 40-60 volts
DC when the “Job Selector” control is set at mini-
mum and 90-100 volts DC when set at maximum.
These voltages may be higher if readings are
taken when welder is cold.
13. The negative generator brushholder, exposed
when upper bracket cover or wrap-around is
removed (see Figure 12), is at the 11 o’clock posi-
tion when the commutator is viewed from the con-
trol panel end of welder. Remove the 5/16 bolt
which connects the existing cable to the negative
brushholder. Route the #2/0 heavy lead which
exists from the bottom of the CV adapter case as
shown in Figure 14. Obtain a 5/16 X 3/4 bolt from
the hardware sent with the CV Adapter and con-
nect the #2/0 heavy lead which exits from the bot-
tom of the CV Adapter case, along with the cable
removed above, to the negative brushholder. The
#2/0 heavy lead lug should be between the exist-
ing cable lug and the brushholder. Tape the #2/0
heavy lead to the battery lead on welders with DC
auxiliary power to support lead. On welders with
AC auxiliary power, tape the #2/0 heavy lead to the
alternator exciter lead bundle coming from the
alternator to support lead where possible.
17. To check the CV output, place only the lower CV
Adapter switch in the CV position. This may be
done while the engine is running as long as no
welding is being done. On codes 10600 and
above the “Job Selector” must be at Maximum.
Check voltage between the output stud on the CV
adapter and frame ground. The voltage should be
less than 10 VDC. Voltage between the “To Work”
output terminal that is relabeled “Positive” and the
CV Adapter output terminal should be 7-12 volts
DC when the CV Adapter voltage control is at min-
imum setting and 36-48 volts DC at maximum set-
ting.
14. Replace bracket cover removed in Step 1. Also,
tighten the K385-1 CV Adapter which was loosely
mounted in Step 2. For the SAE-400 WELD’N AIR
the CV Adapter must be positioned flush against
the fuel tank rail after tightening.
15. Peel backing from decals sent in mounting kit
package and install as shown in Figure 15. On the
(SAE-400 codes 10601, 10856 and 10884) and all
WELD’N AIR reinstall the two guards that were
removed at step 1. Be sure that the guards have a
clearance of at least one half inch from any electri-
cally live part. All new and existing leads must be
routed so they are clear of any sharp edges on the
guards.
18. If output varies greatly from that specified in Steps
16 and 17, check wiring and refer to the trou
bleshooting section of the manual.
CAUTION
POLARITY OF THE STANDARD OUTPUT TERMINALS MUST BE AS
STATED IN STEP 16 AND THE MAXIMUM OPEN CIRCUIT VOLTAGE
WITH THE LOWER MODE SWITCH IN CV POSITION MUST BE AS STAT-
ED IN STEP 17 BEFORE PLACING THE UPPER MODE SWITCH IN CV
POSITION. FAILURE TO HAVE THE CORRECT POLARITY AND VOLT-
AGE BEFORE PLACING THE UPPER MODE SWITCH IN CV POSITION
WILL RESULT IN DAMAGE TO THE CV ADAPTER.
--------------------------------------------------------------------------------------------------
CV ADAPTER
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C-1
C-1
OPERATION
The negative standard output terminal is not used for CV
welding of either polarity. Set the Wire Feeder polarity
switch to same polarity that is required by electrode.
Connect control lead from the Wire Feeder control box to
work using the spring clip on the end of the lead.
OPERATION
CAUTION
DO NOT OPERATE SWITCHES ON CV ADAPTER
WHILE WELDING.
The output voltage is set with the voltage control dial on
the CV Adapter. Set the welder “Current Range Selector”
to the 190-120 position for optimum welding characteris-
tics with Innershield electrodes. Changing the “Current
Range Selector” affects arc characteristics. The setting of
the “Fine Current Adjustment” does not affect the opera-
tion in “CV” mode.
VV OR CV WELDING (All Power Sources)
ANY LN-15, LN-22 AND LN-25 WIRE FEEDER OR
WARNING
CABLES ATTACHED TO CV ADAPTER OUTPUT TER-
MINAL AND STANDARD OUTPUT TERMINALS ARE
ALWAYS ENERGIZED WHEN ENGINE IS RUNNING
REGARDLESS OF MODE SWITCH POSITION. STORE
LN-15, LN-22 AND LN-25 GUN OR ELECTRODE
HOLDER SO THEY DO NOT CONTACT WORK WHEN
NOT WELDING.
When the CV Adapter is in the “CV” mode, the maximum
auxiliary power on SA-250’s and Classic II’s with AC aux-
iliary power will be reduced by 25%. To obtain maximum
output, place both switches in “VV” position.
If the current rating of the welder is exceeded, a thermo-
stat will reduce the output voltage to about 5 volts. The
thermostat will reset automatically as the machine cools.
If the thermostat trips, lower wire feed speed or duty
cycle.
VV STICK WELDING (All Power Sources)
Place both mode switches on the CV Adapter to VV Stick
position. For units with remote control, place the Remote
Control Switch in the desired position.
CV INNERSHIELD WELDING
(SAE Engine Welders)
NOTE: THE UPPER SWITCH MUST IN VV POSITION
BEFORE THE LOWER SWITCH CAN BE PLACED IN
VV POSITION. An interlocking handle prevents operation
of the switches in the wrong sequence.
Place both switches in CV Innershield position.
NOTE: THE LOWER SWITCH MUST BE IN THE “CV”
POSITION BEFORE THE UPPER SWITCH CAN BE
PLACED IN “CV” POSITION. An interlocking handle pre-
vents operation of the switches in the wrong sequence.
For codes 10600 and above, the “Job Selector” Must
be at maximum.
Connect the welding cables to the standard output termi-
nals of the engine welder and use the standard controls to
set the welding current. On the SAE-300, SAE -400 and
SAE-400 WELD’N AIR engine welders, the polarity switch
is disconnected so the standard “To Work” terminal that
has been relabeled “Positive” is always positive, and the
standard “Electrode” terminal that has been relabeled
“Negative” is always negative.
For electrode negative Innershield welding, connect the
electrode lead of a Wire Feeder to the output terminal on
the CV Adapter and connect the work to the “To Work”
standard SAE output terminal that is relabeled “Positive”.
For electrode positive, reverse the output leads. (The
Wire Feeder electrode lead is then connected to the out-
put terminal that is labeled “Positive”.) The standard SAE
“Electrode” output terminal that is relabeled “Negative” is
not used for CV welding of either polarity. Set Wire Feeder
polarity switch to same polarity that is required by elec-
trode. Connect control lead from the Wire Feeder control
box to work using the spring clip on the end of the lead.
CV INNERSHIELD WELDING
(SA-200, SA-250, Classic I AND Classic II)
Place both mode switches in CV Innershield position.
NOTE: THE LOWER SWITCH MUST BE IN THE CV
POSITION BEFORE THE UPPER SWITCH CAN BE
PLACED IN THE CV POSITION. An interlocking handle
prevents operation of the switches in the wrong
sequence.
The output voltage is set with the voltage control dial on
the CV Adapter. Set the SAE “Current Control” to the 9
o’clock position for optimum welding characteristics with
Innershield electrodes. Changing the “Current Control”
affects arc characteristics.
For electrode negative Innershield welding, connect the
Wire Feeder to the output terminal on the CV Adapter and
connect the work to the positive standard output terminal.
For electrode positive, reverse the output leads.
(The Wire Feeder electrode lead is then connected to the
positive standard output terminal.)
The setting of the “Job Selector” does not affect operation
in “CV” mode on codes 8812 through 10400 only.
CV ADAPTER
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D-1
D-1
TROUBLESHOOTING
HOW TO USE TROUBLESHOOTING GUIDE
WARNING
Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
and machine operator and will invalidate your factory warranty. For your safety and to avoid
Electrical Shock, please observe all safety notes and precautions detailed throughout this
manual.
__________________________________________________________________________
This Troubleshooting Guide is provided to
help you locate and repair possible machine
malfunctions. Simply follow the three-step
procedure listed below.
Step 2. RECOMMENDED COURSE OF
ACTION
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled “PROBLEM
(SYMPTOMS)”. This column describes pos-
sible symptoms that the machine may exhib-
it. Find the listing that best describes the
symptom that the machine is exhibiting.
This column provides a course of action for
the Possible Cause.
If you do not understand or are unable to
perform the Recommended Course of Action
safely, contact you local Lincoln Authorized
Field Service Facility.
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.
CV ADAPTER
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D-2
D-2
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
RECOMMENDED
COURSE OF ACTION
FUNCTION PROBLEMS
A. For Codes below 10400 and 10664 and 10665.
1. With CV Adapter in CV position:
a. Open circuit voltage is 60 to
70 volts and cannot be adjust-
ed.
Check to see if DC field circuit is grounded to frame of welder. If grounded, remove
(1)
ground. Then check 1/8 amp fuse on CV Adapter PC board and replace if blown.
(Grounded DC field circuit may or may not cause fuse to blow.) NOTE: On SAE-300,
SAE-400 and SAE-400 WELD’N AIR Engine Welders with AC auxiliary output, discon-
nect one side of flashing diode. On SAE-300, SAE-400 and SAE-400 WELD’N AIR
machines above Code 8812 or SAE-350 machines also disconnect SAE green lead from
CV Adapter lead 613.
b. Open circuit voltage cannot be
adjusted above 38 volts.
c. Open circuit voltage can be
adjusted to 60-70 volts instead
of the normal maximum 36 to
48 volts.
NOTE: ON SAE UNITS BELOW CODE 9936, THE SAE GREEN
LEAD WAS RED.
Reconnect the above items after trouble is determined and resolved.
B. For Codes 10601,10602,10856,10884 and 10885.
Verify that the diodes in the lead between D1 negative and the ground
screw are not shorted and are oriented properly. Check 1/8 amp fuse
on CV adapter PC board and replace if blown.
A. Check to see if DC field circuit is grounded to frame of welder. If
2. On SA-250, open circuit voltage
remains at 5 to 10 volts and can-
not be adjusted.
(1)
grounded remove ground. Then check if either 5 amp fuse mounted
in CV Adapter box is blown and replace if blown. (Grounded DC field
circuit may or may not cause fuse to blow.) Also check if 2 amp fuse
on CV Adapter PC board is blown and replace if blown.
A. Lower CV Adapter mode switch in wrong position.
3. No CV control of output voltage.
B. On SA-200, SA-250, Classic I and Classic II, thermostat tripped. Wait
for machine to cool down.
C.2 amp fuse blown on CV Adapter PC board — replace fuse.
D.Output not connected to the proper output terminals. See manual for
proper connections.
E. Defective lower mode switch — replace 3PDT toggle switch (Sl).
F. Defective relay — replace relay.
G.Defective CV Adapter PC board — replace PC board.
(1)
These fuses are not on earlier units.
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.
CV ADAPTER
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D-3
D-3
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
RECOMMENDED
COURSE OF ACTION
FUNCTION PROBLEMS
4. No output control when welding A. Lower CV Adapter mode switch in wrong position.
“STICK”.
B. Defective lower CV Adapter mode switch — replace 3PDT toggle switch (Sl).
C. For units with remote control, Remote Control Switch set in the wrong
position.
5. Poor arc characteristics
A. Mode switch in wrong position.
B. Output connected to wrong output terminal.
C.In CV mode — standard current control or range selector in wrong
position. See operating manual.
D.Check bank of capacitors in CV Adapter control box. A failure is indi-
cated if the small vent plug on top of a capacitor is raised or blown out.
Replace entire bank of capacitors. Do not replace individual capacitors.
WARNING
THE LIQUID ELECTROLYTE IN THESE CAPACITORS IS TOXIC.
AVOID CONTACT WITH ANY PORTION OF YOUR BODY. CLEAN UP
VENTED ELECTROLYTE USING RUBBER GLOVES AND A WATER
DAMPENED CLOTH. ANY ELECTROLYTE WHICH GETS ON SKIN,
CLEAN WITH SOAP AND WATER.
--------------------------------------------------------------------------------------------------
6. Welder does not stay a high
speed while welding.
A. Under certain conditions with smooth, spray-type arc transfer, the
idler control may not stay energized. Place idler control in “high” posi-
tion.
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.
CV ADAPTER
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E-1
E-1
DIAGRAMS
CONNECTION DIAGRAM — CV ADAPTER TO SA-200
(BELOW CODE 8678)
S17514
A
CONNECTION DIAGRAM — CV ADAPTER TO SA-200
(ABOVE CODE 8678)
S17515
A
CV ADAPTER
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E-2
E-2
DIAGRAMS
CONNECTION DIAGRAM
CV ADAPTER TO SA-250 WITH AC AUXILIARY POWER
S17517
A
CONNECTION DIAGRAM
CV ADAPTER TO SA-250 WITH DC AUXILIARY POWER
S17516
A
CV ADAPTER
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E-3
E-3
DIAGRAMS
CONNECTION DIAGRAM — CV ADAPTER TO SA-250 WITH
AC AUXILIARY POWER AND REMOTE CONTROL
S17766
A
CONNECTION DIAGRAM — CV ADAPTER TO SA-250 WITH
DC AUXILIARY POWER AND REMOTE CONTROL
S17765
A
CV ADAPTER
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E-4
E-4
DIAGRAMS
CONNECTION DIAGRAM — CV ADAPTER TO SAE-300 OR SAE-400 ENGINE WELDER
WITH AC AUXILIARY POWER FOR CODES 7160 TO 8812
S17519
A
CONNECTION DIAGRAM — CV ADAPTER TO SAE-300 OR SAE-400 ENGINE WELDER
WITH AC AUXILIARY POWER FOR CODES 8812 THROUGH 10400, 10549 and 10664
S17561
A
CV ADAPTER
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E-5
E-5
DIAGRAMS
CONNECTION DIAGRAM — CV ADAPTER TO SAE-300 OR SAE-400 ENGINE WELDER
WITH DC AUXILIARY POWER
S17518
A
CONNECTION DIAGRAM — CV ADAPTER TO SAE-400 AND WELD‘N AIR
WITH CODES 10601, 10602, 10856, 10884 and 10885
PLUG FOR REMOTE CONTROL
POTENTIOMETER
REMOTE CONTROL RECEPTACLE
AND SWITCH
AC
G
G
ALTERNATOR
ROTOR
COLOR CODE
B-BLACK
X
G
Y
X
+
RESISTORS
-
D2
B
Y
(-)
(+)
SLIP
G-GREEN
N-BROWN
R-RED
RINGS
R
W
W
AC
R
U
600
FLASHING DIODE
AND RESISTOR
U-BLUE
R
41
W
W-WHITE
Y-YELLOW
W
1
2
R
W
611
612
W
G
3
42
602
Y
NEG
-
B
R
4
5
POS
+
B
1
W
SEE BATTERY
WIRING DIAGRAM
W
W
CONNECT
TO BASE
B
6
G
B
4
610
GROUND
SCREW
REMOTE CONTROL
POTENTIOMETER BOX
2
3
P8
(+)
TO LOWER PANEL
GROUND SCREW
G
SWITCH FOR LOCAL OR
REMOTE CONTROL SHOWN
IN LOCAL POSITION.
AC
AC
U
D1
U
G
G
G
500
Y
TO RECEPTACLES
TO ALTERNATOR
POLARITY
SWITCH
1
(-)
2
3
4
Y
600
602
Y
W
REACTOR
613
503
509
U
N
U
N
BACK VIEW
OF POLARITY
SWITCH
TAPE UP LEAD
POS.
CV ADAPTOR CONTROL LEADS
ARE NOT COLOR CODED
ON ALL UNITS
TO WORK TERMINAL
NEG.
F
E
A
2
1
S24465
CV
ADAPTER
A
ELECTRODE
2CR
NEG.
POS.
R
B
WELD CURRENT
SENSING SWITCH
TO NEGATIVE
BRUSH HOLDER
CV ADAPTER
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E-6
E-6
DIAGRAMS
CONNECTION DIAGRAM — CV ADAPTER TO SAE-400 AND WELD’N AIR ENGINE WELDER Code 10362 AND 10665
TO ALTERNATOR
ELECTRICAL SYMBOLS
B
PER E1537
R
Y
B
Y
FLASHING DIODE
120
LEAD COLOR CODE
(+)
+
-
POLARITY SWITCH
R-RED
B-BLACK
G-GREEN
N-BROWN
(REVERSING SWITCH)
U-BLUE
AC
AC
W-WHITE
Y-YELLOW
R
(-)
W
W
Y
U
TO ENGINE CIRCUIT
W
W
612
611
B
610
600
500
COPPER TERMINAL
Y
Y
W
U
B
U
W
N
RECEPTACLE FOR
REMOTE CONTROL
RHEOSTAT
JOB SELECTOR
RHEOSTAT
G
602
W
CURRENT CONTROL
REACTOR
RESISTORS
25
G
GROUND TERMINAL
WIDE SLOT
25
25
N
U
N
U
509
503
REMOTE CONTROL
(SWITCH SHOWN IN
LOCAL POSITION)
G
E
F
1
*
A
2
G
R
613
TO WORK
CV
/
POSITIVE
&
VV OUTPUT TERMINAL
TO ALTERNATOR
POS.
NEG.
S24466
B.01
ELECTRODE
/
NEGATIVE
VV OUTPUT TERMINAL
*
LEAD 613 DOES NOT APPEAR
ON CV ADAPTOR UNITS BELOW 8785
CV ADAPTER
CB2
CB1
NEGATIVE CV OUTPUT TERMINAL
CV ADAPTOR CONTROL LEADS
ARE NOT COLOR CODED
ON ALL UNITS
TO NEGATIVE BRUSH HOLDER
CONNECTION DIAGRAM — LN-7 WIRE FEEDER TO ENGINE WELDERS WITH
115 VOLT AC AUXILIARY POWER, CV ADAPTER AND K240 CONTACTOR KIT
S17525
7-15-83
N.A. Connection shown for negative polarity. For positive polarity, reverse cables connected to output terminals.
N.B. 3 conductor #16 power cord physically suitable for the installation and plug rated at 115 volts 15 amperes AC.
N.C. Plug into 115 volt AC receptacle on welder control panel or other 115 volt AC supply rated a minimum of 500 volt amperes.
N.D. Leads #21 and GND. do not appear on LN-7’s with codes below 7026.
N.E. Welding cables must be of proper capacity for the current and duty cycle on immediate and future applications.
N.F.
If LN-7 is equipped with a meter kit, extend lead 21 using #14 or larger insulated wire physically suitable for the installation. An
S16586-[ ] remote voltage sensing work lead is available for this purpose. Connect it directly to the work piece keeping it electrically
separate from the welding work lead circuit and connection. For convenience, this extended #21 lead should be taped to the welding
work lead.
N.G. Tape up bolted connection.
CAUTION: Any speed up of the engine RPM by changing the governor setting or over-riding the throttle linkage will cause an increase in
the AC auxiliary voltage. If this voltage goes above 140 volts, the LN-7 control circuit will be damaged. The engine governor set-
ting is pre-set at the factory — do not adjust above RPM specifications listed in engine welder operating manual.
CV ADAPTER
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E-7
E-7
DIAGRAMS
CV ADAPTER WIRING DIAGRAM (FOR SA-200, SA-250, CLASSIC I AND CLASSIC II)
M14822
A
CV ADAPTER
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E-8
E-8
DIAGRAMS
CV ADAPTER WIRING DIAGRAM (FOR SAE-300, SAE-350, SAE-400 AND 450-SAE)
M15198
A
CV ADAPTER
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E-9
E-9
DIAGRAMS
CLASSIC I — CONTINENTAL F163 ENGINE
CV ADAPTER
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E-10
E-10
DIAGRAMS
CLASSIC I — CONTINENTAL TM27 ENGINE
T O P L U G S
CV ADAPTER
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E-11
E-11
DIAGRAMS
CLASSIC II — DEUTZ ENGINE WITH CIRCUIT BREAKERS (CSA)
CV ADAPTER
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E-12
E-12
DIAGRAMS
CLASSIC II — DEUTZ ENGINE
CV ADAPTER
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E-13
E-13
DIAGRAMS
CV ADAPTER SCHEMATIC
L6922
A
CV ADAPTER
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● Do not touch electrically live parts or ● Keep flammable materials away.
● Wear eye, ear and body protection.
electrode with skin or wet clothing.
● Insulate yourself from work and
ground.
WARNING
Spanish
● No toque las partes o los electrodos ● Mantenga el material combustible
● Protéjase los ojos, los oídos y el
bajo carga con la piel o ropa moja-
da.
● Aislese del trabajo y de la tierra.
fuera del área de trabajo.
cuerpo.
AVISO DE
PRECAUCION
French
● Ne laissez ni la peau ni des vête-
ments mouillés entrer en contact
avec des pièces sous tension.
● Gardez à l’écart de tout matériel
inflammable.
● Protégez vos yeux, vos oreilles et
votre corps.
ATTENTION
● Isolez-vous du travail et de la terre.
German
● Berühren Sie keine stromführenden
Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!
● Isolieren Sie sich von den
● Entfernen Sie brennbarres Material! ● Tragen Sie Augen-, Ohren- und Kör-
perschutz!
WARNUNG
Elektroden und dem Erdboden!
Portuguese
● Não toque partes elétricas e elec-
trodos com a pele ou roupa molha-
da.
● Mantenha inflamáveis bem guarda- ● Use proteção para a vista, ouvido e
dos.
corpo.
ATENÇÃO
● Isole-se da peça e terra.
Japanese
Chinese
Korean
Arabic
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO
BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-
STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
CV ADAPTER
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● Keep your head out of fumes.
● Use ventilation or exhaust to
remove fumes from breathing zone.
● Turn power off before servicing.
● Do not operate with panel open or
guards off.
WARNING
Spanish
● Los humos fuera de la zona de res-
piración.
● Mantenga la cabeza fuera de los
humos. Utilice ventilación o
aspiración para gases.
● Desconectar el cable de ali-
mentación de poder de la máquina
antes de iniciar cualquier servicio.
● No operar con panel abierto o
guardas quitadas.
AVISO DE
PRECAUCION
French
● N’opérez pas avec les panneaux
ouverts ou avec les dispositifs de
protection enlevés.
● Gardez la tête à l’écart des fumées. ● Débranchez le courant avant l’entre-
● Utilisez un ventilateur ou un aspira-
teur pour ôter les fumées des zones
de travail.
tien.
ATTENTION
German
● Anlage nie ohne Schutzgehäuse
oder Innenschutzverkleidung in
Betrieb setzen!
● Vermeiden Sie das Einatmen von
Schweibrauch!
● Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
● Strom vor Wartungsarbeiten
abschalten! (Netzstrom völlig öff-
nen; Maschine anhalten!)
WARNUNG
Portuguese
● Não opere com as tampas removidas.
● Desligue a corrente antes de fazer
serviço.
● Mantenha-se afastado das partes
moventes.
● Não opere com os paineis abertos
ou guardas removidas.
● Mantenha seu rosto da fumaça.
● Use ventilação e exhaustão para
remover fumo da zona respiratória.
ATENÇÃO
● Não toque as partes elétricas nuas.
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
CV ADAPTER
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• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
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