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IM309-D
CV ADAPTER
TM
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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Table of Contents
Troubleshooting
Related Manuals for Lincoln Electric CV ADAPTER IM309-D
Summary of Contents for Lincoln Electric CV ADAPTER IM309-D
- Page 1 RETURN TO MAIN MENU IM309-D 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.
- Page 2 Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
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Page 3: Electric Shock Can Kill
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. - Page 4 WELDING SPARKS can cause fire or explosion. 6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent 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.
- Page 5 PRÉCAUTIONS DE SÛRETÉ 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: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a.
- Page 6 The code number is especially important when identifying the correct replacement parts. - 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.
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Page 7: Table Of Contents
K384 CV Adapter to SA-200 Engine Welder....... . . B-1... -
Page 8: General Description
With the CV Adapter installed, the welder can be easily set to operate in either the CV mode or the standard VV mode. 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... - Page 9 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.
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Page 10: Installation
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. - Page 11 FIGURE 1 – CV Adapter Mounting. 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).
- Page 12 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. 13. To check the CV output, place only the lower switch in the “CV”...
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Page 13: K384 Cv Adapter To Sa-250 Engine Welder With Ac Auxiliary Output
K384 CV ADAPTER TO SA-250 ENGINE WELDER WITH AC AUXILIARY OUTPUT 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, back panel, top exciter cover and bracket cover. - Page 14 (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”...
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Page 15: K384 Cv Adapter To Sa-250 Engine Welder With Dc Auxiliary Output
DAMAGE TO THE CV ADAPTER. 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”... - Page 16 FIGURE 8 – Fuel Tank as Viewed from Top. 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.
- Page 17 (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”...
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Page 18: K384 Cv Adapter To Classic I Engine Welder
AGE TO THE CV ADAPTER. 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”... - Page 19 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. 13. To check the CV output, place only the lower switch in the “CV”...
- Page 20 (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”...
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Page 21: K385-1 Model
AGE TO THE CV ADAPTER. 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”... -
Page 22: K385-1 Cv Adapter To Sae-300, Sae-400 Or Sae-400 Weld'n Air Engine Welders
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. - Page 23 B-14 • (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.
- Page 24 Connect this green lead to CV Adapter lead 613 and tape up connection. NOTE: ON UNITS BELOW CODE 9936, THE LEAD CONNECT-...
- Page 25 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”...
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Page 26: Operation
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”... -
Page 27: How To Use Troubleshooting Guide
HOW TO USE TROUBLESHOOTING GUIDE 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. -
Page 28: Troubleshooting
FUNCTION PROBLEMS A. For Codes below 10400 and 10664 and 10665. Check to see if DC field circuit is grounded to frame of welder. If grounded, remove ground. Then check 1/8 amp fuse on CV Adapter PC board and replace if blown. - Page 29 4. No output control when welding “STICK”. 5. Poor arc characteristics 6. Welder does not stay a high speed while welding. 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.
- Page 30 CONNECTION DIAGRAM — CV ADAPTER TO SA-200 S17514 CONNECTION DIAGRAM — CV ADAPTER TO SA-200 S17515 DIAGRAMS (BELOW CODE 8678) (ABOVE CODE 8678) CV ADAPTER...
- Page 31 CV ADAPTER TO SA-250 WITH AC AUXILIARY POWER S17517 CV ADAPTER TO SA-250 WITH DC AUXILIARY POWER S17516 DIAGRAMS CONNECTION DIAGRAM CONNECTION DIAGRAM CV ADAPTER...
- Page 32 CONNECTION DIAGRAM — CV ADAPTER TO SA-250 WITH AC AUXILIARY POWER AND REMOTE CONTROL S17766 CONNECTION DIAGRAM — CV ADAPTER TO SA-250 WITH DC AUXILIARY POWER AND REMOTE CONTROL S17765 DIAGRAMS CV ADAPTER...
- Page 33 CONNECTION DIAGRAM — CV ADAPTER TO SAE-300 OR SAE-400 ENGINE WELDER WITH AC AUXILIARY POWER FOR CODES 7160 TO 8812 S17519 CONNECTION DIAGRAM — CV ADAPTER TO SAE-300 OR SAE-400 ENGINE WELDER WITH AC AUXILIARY POWER FOR CODES 8812 THROUGH 10400...
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Page 34: Diagrams
CONNECTION DIAGRAM — CV ADAPTER TO SAE-300 OR SAE-400 ENGINE WELDER S17518 CONNECTION DIAGRAM — CV ADAPTER TO SAE-400 AND WELD‘N AIR WITH CODES 10601, 10602, 10856, 10884 and 10885 COLOR CODE B-BLACK SLIP G-GREEN RINGS N-BROWN R-RED FLASHING DIODE... - Page 35 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.
- Page 36 DIAGRAMS CV ADAPTER WIRING DIAGRAM (FOR SA-200, SA-250, CLASSIC I AND CLASSIC II) M14822 CV ADAPTER...
- Page 37 DIAGRAMS CV ADAPTER WIRING DIAGRAM (FOR SAE-300, SAE-350, SAE-400 AND 450-SAE) M15198 CV ADAPTER...
- Page 38 DIAGRAMS CLASSIC I — CONTINENTAL F163 ENGINE CV ADAPTER...
- Page 39 E-10 E-10 DIAGRAMS CLASSIC I — CONTINENTAL TM27 ENGINE PLUGS CV ADAPTER...
- Page 40 E-11 E-11 DIAGRAMS CLASSIC II — DEUTZ ENGINE WITH CIRCUIT BREAKERS (CSA) CV ADAPTER...
- Page 41 E-12 E-12 DIAGRAMS CLASSIC II — DEUTZ ENGINE CV ADAPTER...
- Page 42 E-13 E-13 DIAGRAMS CV ADAPTER SCHEMATIC L6922 CV ADAPTER...
- Page 44 ● WARNING ● Spanish ● AVISO DE PRECAUCION ● French ● ATTENTION ● ● German WARNUNG ● Portuguese ● ATENÇÃO ● Japanese Chinese Korean Arabic ● ● ● ● ● CV ADAPTER ● ● ● ● ●...
- Page 45 ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● CV ADAPTER WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENÇÃO Japanese Chinese Korean Arabic...
- Page 46 • 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...