Lincoln Electric IM309-D manual K384 CV Adapter to Classic I Engine Welder

B-9 INSTALLATION 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 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.

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.

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.

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.

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.

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.

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.

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 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.

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