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Lincoln Electric CV ADAPTER IM309-D manual

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Table of contents for the manual

  • Page 1

    C V AD APTER TM OPERA T OR’S MANUAL IM309-D January , 2005 Safety Depends on Y ou 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 INST ALL, OPERA TE OR REP AIR THIS EQUIPMENT WITHOUT READ- IN[...]

  • Page 2

    i SAFETY i CV ADAPTER FOR ENGINE powered equipment. 1.a. T urn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors. _________________________[...]

  • Page 3

    ii SAFETY ii CV ADAPTER ARC RA YS can burn. 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 protec[...]

  • Page 4

    iii SAFETY iii CV ADAPTER FOR ELECTRICALL Y powered equipment. 8.a. T urn 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. 8.c. Ground the equipment in accordance with th[...]

  • Page 5

    iv SAFETY iv CV ADAPTER 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. Le[...]

  • Page 6

    CV ADAPTER 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! Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick ref[...]

  • Page 7

    Page General DescriptIon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Secti on B K384 CV Adapter to SA-200 Engine Welder . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 8

    A-1 GENERAL DESCRIPTION A-1 CV ADAPTER 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-21 1, 5/64 NS-3M, Innershield electrodes within the current rating of the machine used. The unit can also b[...]

  • Page 9

    A-2 GENERAL DESCRIPTION CV ADAPTER A-2 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. T wo switches[...]

  • Page 10

    B-1 INST ALLA TION B-1 INST ALLA TION HA VE QUALIFIED PERSONNEL DO THE INST AL- LA TION WORK. TURN THE ENGINE OFF BEFORE WORKING INSIDE THE MACHINE. IN SOME CASES IT MA Y BE NECESSAR Y T O REMOVE SAFETY GUARDS T O PERFORM REQUIRED INST ALLA TION. REMOVE GUARDS ONL Y WHEN NECESSAR Y AND REPLACE THEM WHEN THE INST ALLA TION REQUIRING THEIR REMOV AL I[...]

  • Page 11

    B-2 INST ALLA TION CV ADAPTER 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 con- nection with tape. T ape 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 [...]

  • Page 12

    B-3 INST ALLA TION B-3 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 1 1 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 brushh[...]

  • Page 13

    B-4 INST ALLA TION B-4 K384 CV ADAPTER TO SA-250 ENGINE WELDER WITH AC AUXILIAR Y OUTPUT • TURN THE ENGINE OFF WHILE INST ALLING THIS ACCESSOR Y . • KEEP HANDS, HAIR, CLOTHING AND TOOLS A W A Y FROM MOVING P ARTS WHEN ST ARTING OR OPERA TING ENGINE. 1. Remove roof assembly , back panel, top exciter cover and bracket cover . See Figure 4. 2. Dri[...]

  • Page 14

    B-5 INST ALLA TION B-5 NOTE: FOR STEPS 9 THROUGH 12, REFER TO FIGURES 4 AND 7. 9. The negative generator brushholder , exposed when bracket cover (see Figure 4) is removed, is at the 1 1 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[...]

  • Page 15

    B-6 INST ALLA TION CV ADAPTER B-6 POLARITY OF THE ST ANDARD OUTPUT TERMI- NALS MUST BE AS ST A TED IN STEP 14 AND THE MAXIMUM OPEN CIRCUIT VOL T AGE WITH THE LOWER MODE SWITCH IN CV POSITION MUST BE AS ST A TED IN STEP 15 BEFORE PLACING THE UPPER MODE SWITCH IN CV POSITION. F AILURE TO HA VE THE CORRECT POLARITY AND VOL T AGE BEFORE PLACING THE UPP[...]

  • Page 16

    B-7 INST ALLA TION CV ADAPTER B-7 NOTE: FOR STEPS 4 THROUGH 1 1, REFER T O 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 [...]

  • Page 17

    B-8 INST ALLA TION CV ADAPTER B-8 8. Connect CV Adapter leads “Neg” and “Pos” to the back of the SA-250 negative and positive output terminals respectively . T ape these leads to gener- ator lead bundle for support. NOTE: FOR STEPS 9 THROUGH 1 1, REFER T O FIG- URES 10 AND 1 1. 9. The negative generator brushholder , exposed when bracket co[...]

  • Page 18

    B-9 INST ALLA TION CV ADAPTER B-9 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 co[...]

  • Page 19

    B-10 INST ALLA TION CV ADAPTER B-10 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. 6. Connect CV Adapter lead 602 to #602 on the ter- minal strip. Connect CV Adapter lead 600 to #600 on [...]

  • Page 20

    B-1 1 INST ALLA TION CV ADAPTER B-1 1 K384 CV ADAPTER TO CLASSIC II ENGINE WELDER • TURN THE ENGINE OFF WHILE INST ALLING THIS ACCESSOR Y . • KEEP HANDS, HAIR, CLOTHING AND TOOLS A W A Y FROM MOVING P ARTS WHEN ST ARTING OR OPERA TING ENGINE. 1. Remove roof assembly , back panel, top exciter cover and bracket cover . See Figure 1 1A. 2. Mount C[...]

  • Page 21

    B-12 INST ALLA TION CV ADAPTER B-12 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 c[...]

  • Page 22

    B-13 INST ALLA TION CV ADAPTER B-13 K385-1 CV ADAPTER TO SAE-300, SAE-400 OR SAE-400 WELD’N AIR ENGINE WELDER NOTE: BEFORE INST ALLING CV ADAPTER ON ENGINE WELDERS WITH DC AUXILIAR Y POWER, ST ART ENGINE WELDER AND USE A DC VOL TMETER TO CHECK THE POLAR- ITY OF THE RED AND BLACK LEADS CONNECTED TO THE AUXILIAR Y POWER RECEPT ACLE. THE RED LEAD SH[...]

  • Page 23

    B-14 INST ALLA TION CV ADAPTER B-14 9 . Connect CV Adapter lead 610 to same terminal on polarity switch that is connected to existing black lead. 10. • ( For SAE-300 and -400 welders with DC auxil- iary power) Use tape to separately insulate CV Adapter leads 61 1, 612 and 613. These leads are not used. • ( For SAE-300 and -400 welders with AC a[...]

  • Page 24

    B-15 INST ALLA TION CV ADAPTER B-15 • ( 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 [...]

  • Page 25

    B-16 INST ALLA TION CV ADAPTER B-16 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 1 1 o’clock posi- tion when the commutator is viewed from the con- trol panel end of welder . Remove the 5/16 bolt which connects t[...]

  • Page 26

    C-1 OPERA TION C-1 OPERA TION DO NOT OPERA TE SWITCHES ON CV ADAPTER WHILE WELDING. VV OR CV WELDING (All Power Sources) ANY LN-15, LN-22 AND LN-25 WIRE FEEDER OR CABLES A TT ACHED TO CV ADAPTER OUTPUT TER- MINAL AND ST ANDARD OUTPUT TERMINALS ARE AL W A YS ENERGIZED WHEN ENGINE IS RUNNING REGARDLESS OF MODE SWITCH POSITION. STORE LN-15, LN-22 AND [...]

  • Page 27

    D-1 TROUBLESHOOTING D-1 CV ADAPTER 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. CAUTION This T roubleshooting Guide is provided to help you locate and repair pos[...]

  • Page 28

    D-2 TROUBLESHOOTING D-2 CV ADAPTER Observe all Safety Guidelines detailed throughout this manual 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. CAUTION FUNCTION PR[...]

  • Page 29

    D-3 TROUBLESHOOTING D-3 CV ADAPTER Observe all Safety Guidelines detailed throughout this manual 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. CAUTION FUNCTION PR[...]

  • Page 30

    E-1 DIAGRAMS E-1 CV ADAPTER CONNECTION DIAGRAM — CV ADAPTER TO SA-200 (BELOW CODE 8678) CONNECTION DIAGRAM — CV ADAPTER TO SA-200 (ABOVE CODE 8678) S17514 A S17515 A[...]

  • Page 31

    E-2 DIAGRAMS E-2 CV ADAPTER CONNECTION DIAGRAM CV ADAPTER TO SA-250 WITH AC AUXILIAR Y POWER CONNECTION DIAGRAM CV ADAPTER TO SA-250 WITH DC AUXILIAR Y POWER S17517 A S17516 A[...]

  • Page 32

    E-3 DIAGRAMS E-3 CV ADAPTER CONNECTION DIAGRAM — CV ADAPTER TO SA-250 WITH AC AUXILIAR Y POWER AND REMOTE CONTROL CONNECTION DIAGRAM — CV ADAPTER TO SA-250 WITH DC AUXILIAR Y POWER AND REMOTE CONTROL S17766 A S17765 A[...]

  • Page 33

    E-4 DIAGRAMS E-4 CV ADAPTER CONNECTION DIAGRAM — CV ADAPTER TO SAE-300 OR SAE-400 ENGINE WELDER WITH AC AUXILIAR Y POWER FOR CODES 7160 TO 8812 CONNECTION DIAGRAM — CV ADAPTER TO SAE-300 OR SAE-400 ENGINE WELDER WITH AC AUXILIAR Y POWER FOR CODES 8812 THROUGH 10400 , 10549 and 10664 S17519 A S17561 A[...]

  • Page 34

    E-5 DIAGRAMS E-5 CV ADAPTER CONNECTION DIAGRAM — CV ADAPTER TO SAE-300 OR SAE-400 ENGINE WELDER WITH DC AUXILIARY POWER CONNECTION DIAGRAM — CV ADAPTER TO SAE-400 AND WELD‘N AIR WITH CODES 10601, 10602, 10856, 10884 and 10885 P8 + 4 R 2 3 1 G (+) AC D2 SWITCH FOR LOCAL OR REMOTE CONTROL SHOWN IN LOCAL POSITION. X Y W AL TERNA TOR ROTOR X + - [...]

  • Page 35

    E-6 DIAGRAMS E-6 CV ADAPTER - + CV ADAPTOR CONTROL LEADS U ELECTRICAL SYMBOLS U E A 2 F 1 N U AC W ARE NOT COLOR CODED LEAD 613 DOES NOT APPEAR ON CV ADAPTOR UNITS BELOW 8785 * R ON ALL UNITS Y FLASHING DIODE W PER E1537 AC U TO ALTERNA TOR N Y (-) B N TO ENGINE CIRCUIT COPPER TERMINAL TO WORK / POSITIVE CV & VV OUTPUT TERMINAL NEGATIVE CV OUTP[...]

  • Page 36

    E-7 DIAGRAMS E-7 CV ADAPTER CV ADAPTER WIRING DIAGRAM (FOR SA-200, SA-250, CLASSIC I AND CLASSIC II) M14822 A[...]

  • Page 37

    E-8 DIAGRAMS E-8 CV ADAPTER CV ADAPTER WIRING DIAGRAM (FOR SAE-300, SAE-350, SAE-400 AND 450-SAE) M15198 A[...]

  • Page 38

    E-9 DIAGRAMS E-9 CV ADAPTER POS BUTTON IDLER CONTROL P.C. BOARD START BATTERY AMMETER IGNITION SWITCH W MAG TO PLUGS +- U B H IDLER SOLENOID W MOTOR START G H B R Y ALTERNATOR EXC + OIL PRESSURE Y SWITCH AUX. POWER RECEPTACLE B R B - + E E E TO EXCITER OUTPUT N Y R WB B Y B 600A 41 OIL PRESSURE LIGHT ENGINE HOUR METER IDLER CONTROL SWITCH 42 RHEOST[...]

  • Page 39

    E-10 DIAGRAMS E-10 CV ADAPTER IGNITION SWITCH SWITCH FOR LOCAL OR REMOTE W B TERMINAL COPPER RESISTORS BELOW 600 AT THE TERMINAL STRIP. CONNECT THESE LEADS COPPER TERMINAL POTENTIOMETER REMOTE CONTROL PLUG FOR GROUND TERM. (WIDE SLOT) CONNECT TO CASE B W G REMOTE CONTROL POTENTIOMETER BOX GROUND TERM. (WIDE SLOT) 41 602 600 42 REMOTE CONTROL (OPTIO[...]

  • Page 40

    E-1 1 DIAGRAMS E-1 1 CV ADAPTER B R + - + - Y R W B B U U ALTERNATOR ROTOR SLIP RINGS SLIP RING NEAREST TO IRON R N A 54 3 2 1 ALTERNATOR AUXILIARY POWER WINDINGS CURRENT TRANSFORMER CB3 CB1 115 VOLT RECEPTACLE 230 VOLT RECEPTACLE Y N U Y W + - TO WELDING GENERATOR NEGATIVE N SELECTOR SWITCH WELDER LEAD BLOCK AC AC POTENTIOMETER CR2 REED RELAY 602 [...]

  • Page 41

    E-12 DIAGRAMS E-12 CV ADAPTER B R + - + - Y R W B B U U ALTERNATOR ROTOR SLIP RINGS SLIP RING NEAREST TO IRON R N A 54 3 2 1 ALTERNATOR AUXILIARY POWER WINDINGS CURRENT TRANSFORMER CB1 115 VOLT RECEPTACLE 230 VOLT RECEPTACLE Y N U Y W + - TO WELDING GENERATOR NEGATIVE N SELECTOR SWITCH WELDER LEAD BLOCK AC AC POTENTIOMETER CR2 REED RELAY 602 42 41 [...]

  • Page 42

    E-13 DIAGRAMS E-13 CV ADAPTER CV ADAPTER SCHEMA TIC L6922 A[...]

  • Page 43

    [...]

  • Page 44

    CV ADAPTER W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’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 F ABRICANT[...]

  • Page 45

    CV ADAPTER W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE PARA ESTE EQUIP AMENTO E AS P ARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust to remov[...]

  • Page 46

    • Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 441 17-1 199 U.S.A. TEL: 216.481.8100 F AX: 216.486.1751 WEB SITE: www .lincolnelectric.com • World's Leader in W elding and Cutting Products •[...]