RETURN TO MAIN MENU CV ADAPTER IM309-D 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 READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT. And, most importantly, think before you act and be careful.
i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. The Above For Diesel Engines The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS.
ii ii SAFETY ELECTRIC SHOCK can kill. ARC RAYS can burn. 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. 3.b.
iii iii SAFETY 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. Avoid welding near hydraulic lines. Have a fire extinguisher readily available. 6.b.
iv iv SAFETY zones où l’on pique le laitier. 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 suivantes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. Les circuits à l’électrode et à la piéce sont sous tension quand la machine à souder est en marche.
v v Thank You 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! Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped, title passes to the purchaser upon receipt by the carrier.
vi vi 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. . . . . . . . . . . . . .
A-1 GENERAL DESCRIPTION PRODUCT PURPOSE The CV Adapter can be connected to certain variable voltage water-cooled engine welders to provide constant 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.
A-2 GENERAL DESCRIPTION The CV Adapter consists of a capacitor bank, an electronic control circuit and switches. The capacitors modify the dynamic output characteristics to make the welder suitable for Innershield welding, and the electronic 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 disconnected before the Adapter can be switched to the VV mode.
B-1 B-1 INSTALLATION 2. Set of socket wrenches. INSTALLATION 3. 11/32" wrench and 3/8" nut driver or pliers. WARNING HAVE QUALIFIED PERSONNEL DO THE INSTALLATION 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.
B-2 INSTALLATION B-2 4. FOR CODE NUMBERS BELOW 8678, connect CV Adapter lead 610 to black exciter lead bolted connection shown in Figure 2 and insulate the connection 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.
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. 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.
B-4 INSTALLATION K384 CV ADAPTER TO SA-250 ENGINE WELDER WITH AC AUXILIARY OUTPUT B-4 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. 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. See Figure 4. 2.
B-5 INSTALLATION B-5 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 generator 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.
B-6 B-6 INSTALLATION FIGURE 7 – View of Negative Generator Brushholder after Bracket Cover is Removed. CAUTION POLARITY OF THE STANDARD OUTPUT TERMINALS 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. 14.
B-7 INSTALLATION B-7 FIGURE 8 – Fuel Tank as Viewed from Top. NOTE: FOR STEPS 4 THROUGH 11, REFER TO S17516 CONNECTION DIAGRAM FOR UNITS WITHOUT REMOTE CONTROL AND S17765 FOR UNITS WITH REMOTE CONTROL. CV ADAPTER CONTROL 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). 5.
B-8 INSTALLATION B-8 FIGURE 10 – SA-250 with Roof Assembly Removed. 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 generator lead bundle for support. NOTE: FOR STEPS 9 THROUGH 11, REFER TO FIGURES 10 AND 11. 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.
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 31/2" 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.
B-10 B-10 INSTALLATION 5. Remove existing blue field lead from the center terminal 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. 6. Connect CV Adapter lead 602 to #602 on the terminal strip. Connect CV Adapter lead 600 to #600 on the terminal strip. If there are leads already present at 600 and 602 on the terminal strip, the leads remain there.
B-11 INSTALLATION K384 CV ADAPTER TO CLASSIC II ENGINE WELDER 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. See Figure 11A. 2. Mount CV Adapter (unit with “SA” above code number) to the support holes.
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 31/2" 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.
B-13 INSTALLATION B-13 FIGURE 12 – Engine Welder (Left Side). K385-1 CV ADAPTER TO SAE-300, SAE-400 OR SAE-400 WELD’N AIR ENGINE WELDER NOTE: BEFORE INSTALLING CV ADAPTER ON ENGINE WELDERS WITH DC AUXILIARY POWER, 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 NEGATIVE AND THE BLACK LEAD SHOULD BE POSITIVE.
B-14 INSTALLATION B-14 FIGURE 13 – Frame Rail Mounting. 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.
B-15 INSTALLATION B-15 FIGURE 15 –Decal Mounting. • (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 connected 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 disconnected and connect CV Adapter lead 612 to the other white lead.
B-16 INSTALLATION NOTE: FOR STEPS 13 AND 14 REFER TO FIGURES 12 AND 14. 13. The negative generator brushholder, exposed when upper bracket cover or wrap-around is removed (see Figure 12), 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 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.
C-1 OPERATION OPERATION CAUTION DO NOT OPERATE SWITCHES ON CV ADAPTER WHILE WELDING. 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 TERMINAL 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.
D-1 TROUBLESHOOTING D-1 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.
D-2 TROUBLESHOOTING D-2 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) RECOMMENDED COURSE OF ACTION FUNCTION PROBLEMS 1. With CV Adapter in CV position: 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 a. Open circuit voltage is 60 to ground. Then check 1/8(1) amp fuse on CV Adapter PC board and replace if blown.
D-3 TROUBLESHOOTING D-3 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) RECOMMENDED COURSE OF ACTION FUNCTION PROBLEMS 4. No output control when welding “STICK”. A. Lower CV Adapter mode switch in wrong position. 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.
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 E-1
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 E-2
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 E-3
E-4 DIAGRAMS E-4 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
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 REMOTE CONTROL RECEPTACLE AC B-BLACK + D2 (-) (+) B Y R W 3 R W Y B B 612 NEG POS - B W 2 611 W W U 1 R SEE BATTERY WIRING DIAGRAM W R 41 W Y-YELLOW RESISTORS W 600 FLASHING DIODE AND RESISTOR W-WHITE 4 W + G 42 602 5 CONNECT TO BASE 6 G
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 Y R B Y FLASHING DIODE LEAD COLOR CODE (+) + 120 B-BLACK R-RED G-GREEN U-BLUE N-BROWN W-WHITE POLARITY SWITCH - (REVERSING SWITCH) AC AC Y-YELLOW R (-) W Y W U W W TO ENGINE CIRCUIT 612 611 610 COPPER TERMINAL 600 W B 500 Y Y U B U W N RECEPTACLE FOR REMOTE CONTROL JOB SELECTOR RHEOSTAT G RHEOSTAT 602 W CURRE
E-7 DIAGRAMS E-7 CV ADAPTER WIRING DIAGRAM (FOR SA-200, SA-250, CLASSIC I AND CLASSIC II) M14822 A CV ADAPTER
E-8 DIAGRAMS E-8 CV ADAPTER WIRING DIAGRAM (FOR SAE-300, SAE-350, SAE-400 AND 450-SAE) M15198 A CV ADAPTER
CV ADAPTER GROUND + R - RED U - BLUE W - WHITE Y - YELLOW N - BROWN H - BROWN & WHITE ELECTRICAL SYMBOLS PER E1537 and insure all guards or covers are replaced after servicing. Keep hands, hair, clothing and tools away from moving parts, maintenance work requires it to be running. Turn the engine OFF before maintenance work unless the B - W H + - R OUTPUT TO EXCITER W G SWITCH RHEOSTAT + - ALL UNITS N E E B R 42 AUX. POWER P.C.
CV ADAPTER WARNING + R + TO BASE U R GROUND Y + OIL PRESSURE SWITCH R - RED W - WHITE Y - YELLOW G - GREEN N - BROWN H - BROWN & WHITE ELECTRICAL SYMBOLS PER E1537 Only qualified personnel should install, use, or service and insure all guards or covers are replaced after servicing. Keep hands, hair, clothing and tools away from moving parts, maintenance work requires it to be running.
CV ADAPTER * CB1 G B W R U B 15A. U N U N NEGATIVE VV OUTPUT TERMINAL R 602A A SWITCH FOR LOCAL OR REMOTE CONTROL SHOWN IN LOCAL POSITION. GROUND TERM. (WIDE SLOT) G W RESISTORS TO THE CORRESPONDING NUMBERS AT THE TERMINAL 600 AT THE TERMINAL STRIP. CONNECT THESE LEADS B COPPER TERMINAL 610 W G REMOTE CONTROL POTENTIOMETER BOX CONNECT TO CASE GROUND TERM.
CV ADAPTER * U B 42 600 602 41 U N NEGATIVE VV OUTPUT TERMINAL R CR2 REED RELAY N U 602A A SWITCH FOR LOCAL OR REMOTE CONTROL SHOWN IN LOCAL POSITION. GROUND TERM. (WIDE SLOT) G W RESISTORS TO THE CORRESPONDING NUMBERS AT THE TERMINAL 600 AT THE TERMINAL STRIP. CONNECT THESE LEADS B COPPER TERMINAL 610 W G REMOTE CONTROL POTENTIOMETER BOX CONNECT TO CASE GROUND TERM.
E-13 DIAGRAMS CV ADAPTER SCHEMATIC L6922 A CV ADAPTER E-13
● Do not touch electrically live parts or WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENÇÃO ● Keep flammable materials away. ● Wear eye, ear and body protection. ● Mantenga el material combustible ● Protéjase los ojos, los oídos y el electrode with skin or wet clothing. ● Insulate yourself from work and ground. ● No toque las partes o los electrodos bajo carga con la piel o ropa mojada. ● Aislese del trabajo y de la tierra.
● Keep your head out of fumes. ● Use ventilation or exhaust to ● Turn power off before servicing. ● Do not operate with panel open or guards off. remove fumes from breathing zone. ● Los humos fuera de la zona de res- piración. ● Mantenga la cabeza fuera de los humos. Utilice ventilación o aspiración para gases. ● Gardez la tête à l’écart des fumées. ● Utilisez un ventilateur ou un aspira- ● Desconectar el cable de ali- mentación de poder de la máquina antes de iniciar cualquier servicio.
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