Lincoln Electric IM309-D User Manual

Safety Depends on You

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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.

CV ADAPTER

TM

IM309-D

January, 2005

Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com

OPERATOR’S MANUAL

Copyright © 2005 Lincoln Global Inc.

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

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

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040,
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.

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

i

FOR ENGINE
powered equipment.

1.a. Turn 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.

____________________________________________________

1.c. Do not add the fuel near an open flame weld-

ing arc or when the engine is running. Stop
the engine and allow it to cool before refuel­ing to prevent spilled fuel from vaporizing on
contact with hot engine parts and igniting. Do
not spill fuel when filling tank. If fuel is spilled,
wipe it up and do not start engine until fumes
have been eliminated.

____________________________________________________

1.d. Keep all equipment safety guards, covers

and devices in position and in good
repair.Keep hands, hair, clothing and tools
away from V-belts, gears, fans and all other
moving parts when starting, operating or
repairing equipment.

____________________________________________________

1.e. In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.

___________________________________________________

1.f. Do not put your hands near the engine fan. Do not attempt to
override the governor or idler by pushing on the throttle con­trol rods while the engine is running.

___________________________________________________

1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.

1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.

ELECTRIC AND
MAGNETIC FIELDS
may be dangerous

2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines

2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.

2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.

2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:

2.d.1.

Route the electrode and work cables together - Secure
them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode and

work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close as

possible to the area being welded.

2.d.5. Do not work next to welding power source.

Mar ‘95

CV ADAPTER

ii

SAFETY

ii

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.

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.

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:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.

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.

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.

3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

ARC RAYS 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 protect your skin and that of your helpers from
the arc rays.

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.

FUMES AND GASES
can be dangerous.

5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases.When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep

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.

5.b.

Do not weld in locations near chlorinated hydrocarbon
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
form phosgene, a highly toxic gas, and other irritating
products.

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.

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.

vapors

to

5.e. Also see item 1.b.

CV ADAPTER

Mar ‘95

iii

SAFETY

iii

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.

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. 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.

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.

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
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society

(see address above).

6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.

Sparks and spatter are thrown from the welding arc. Wear oil

6.f.
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.

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.

6.h. Also see item 1.c.

Remember that welding sparks and hot

though

they have

Preparation

for Welding and Cutting of

CYLINDER may explode
if damaged.

7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
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.

7.c. Cylinders should be located:

• Away from areas where they may be struck or subjected to

physical damage.

• 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.

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.

FOR ELECTRICALLY
powered equipment.

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.

8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.

Mar ‘95

CV ADAPTER

iv

SAFETY

iv

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. 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 met­allique 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 defonc­tionnement.

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 soud­er parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.

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.

zones où l’on pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.

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.

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.

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.

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.

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.

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 ray­onnement 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.

c. Protéger l’autre personnel travaillant à proximité au

soudage à l’aide d’écrans appropriés et non-inflammables.

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, pan­talons sans revers, et chaussures montantes.

5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les

PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR

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.

3. Avant de faires des travaux à l’interieur de poste, la debranch­er à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leur
place.

Mar. ‘93

CV ADAPTER

for selecting a QUALITY product by Lincoln Electric. We want you

Thank 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. 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___________________________________________________________________________

vv

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

“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:

WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then

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

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. . . . . . . . . . . . . . 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

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

CV Adapter to SAE-300, SAE-400 or SAE-400 WELD’N AIR Engine Welders

. . . . . . B-13

vi

Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Appendix

CV ADAPTER

A-1

GENERAL DESCRIPTION

A-1

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. 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 SA­250 welders, one for SAE-300, SAE-400 and SAE-400
WELD’N AIR engine welders and one for SAE-350 engine
welders.

The LN-15, LN-22 and LN-25 wire feeder is recom­mended 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, SAE­300, SAE-400 or SAE-400 WELD’N AIR that has AC
auxiliary power provided a K240 Contactor Kit is con­nected between the LN-7 and the power source.

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 connect­ed.

NOTE: WHEN ENGINE WELDER IS SUPPLIED
WITH A METER, THE AMMETER DOES NOT WORK
WHEN WELDING IN THE CV 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.

• SAE-300 and SAE-400 without Remote Control
option and with 115V FDW DC exciter, 254 alterna­tor 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 prop­erly on SAE engine welders above Code 8812.

• SAE-350 — Factory installed only.

• International
350-SA —(Below Code 10066) All machines or fac­tory installed.
450-SAE — Factory installed only.

Estimated time for field installation of the CV Adapter to
welder is 2 to 3 hours.

Rating At 60% 35% Duty

Max. Output At

Machine Duty Cycle Cycle Comments

SA-200 200 amp 250 amp Many procedures

at 35V at 30V limited by

current rating

SA-250 250 amp 310 amp AC auxiliary power

at 35V at 35V is reduced 25%

when in CV mode

SAE-300 300 amp 375 amp Polarity switch

at 35V at 35V is disconnected

SAE-400 & 400 amp 500 amp Polarity switch

SAE-400 at 35V at 35V is disconnected

WELD’N AIR

SAE-350 350 amp 435 amp No polarity switch

at 35V at 35V installed

Inter- AC auxiliary power

national is reduced

350-SA — 310 amp 25% when in CV

at 35V mode

450-SAE — 435 amp No polarity switch

at 35V installed

CV ADAPTER

A-2

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.

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 ter­minals. A power cable is used to connect the CV out­put 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 pro­tect the welder if overloaded. Two thermostat assem­blies 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 brushhold­er and the power cable. The chance of overloading the
SAE machines is much less so no protection is provid­ed.

GENERAL DESCRIPTION

A-2

The operating schematic is L6922 and the wiring dia­grams are M14822 and M14726. The assembly is
shown on G1643.

CV ADAPTER

B-1

INSTALLATION

B-1

INSTALLATION

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.

LN-15, LN-22, LN-25 Connection — Instructions cov-

ered under “Operation”.

LN-7 Connection — An LN-7 can be connected to SA­250, 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 con­tactor 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.

2. Set of socket wrenches.

3. 11/32" wrench and 3/8" nut driver or pliers.

4. 1/2" open end wrench and 9/16" wrench.

5. Screwdriver.

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 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.

WARNING

• TURN THE ENGINE OFF WHILE INSTALLING
THIS ACCESSORY.

• KEEP HANDS, HAIR, CLOTHING AND TOOLS
AWAY FROM MOVING PARTS WHEN STARTING
OR OPERATING ENGINE.

CAUTION

ANY SPEED UP OF THE ENGINE RPM BY
CHANGING THE GOVERNOR SETTING OR OVER­RIDING 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.

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 SA­250 engine welders that do not have mounting
holes in fuel tank rail.

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 sup­port 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.

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 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. 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.

B-2

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 con­nection and unused lead terminal on lead 509 (see
Figure 2 below).

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 exist­ing push-on terminal. Tape up connection and
unused ring terminal.

6. Connect CV Adapter lead 602 to the center termi­nal 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.

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 gener­ator lead bundle for support.

FIGURE 2 – SA-200 with Roof Assembly Removed.

CV ADAPTER

B-3

INSTALLATION

FIGURE 3 – View of Negative Generator Brushholder after Bracket Cover is Removed.

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 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 recon­nect the two cables to the negative brushholder
with one end of the thermostat assembly bolted
between the cable lugs and the brushholder.

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 thermo­stat assembly with the nut washer and lockwasher
on the top.

10. Connect leads 608 and 609, routed into the gener­ator 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.

CAUTION

POLARITY OF THE STANDARD OUTPUT TERMI­NALS 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 switch­es 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 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 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” 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 troubleshoot­ing section of manual.

CV ADAPTER

B-4

INSTALLATION

B-4

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. See Figure 4.

2. Drill two holes in fuel tank rail opposite output ter­minals as in Figure 2 if holes are not in unit.

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 hard­ware 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 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.

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.

6. Remove existing field lead from the center terminal
of the Fine Current Adjustment rheostat and con­nect it to the CV Adapter lead 503 using #10-24 x
1/4 screw and nut provided. Insulate the connec­tion with tape. For units with remote control, leave
blue lead from remote switch in place on center
terminal of rheostat.

7. Connect CV Adapter lead 602 to the center termi­nal 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.

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.

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

B-5

INSTALLATION

FIGURE 5 – Fuel Tank as Viewed from Top.

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 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 recon­nect the two cables to the negative brushholder
with one end of the thermostat assembly bolts
between the cable lugs and the brushholder.

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 thermo­stat assembly with the nut, washer and lockwash­er on the top.

11. Connect leads 608 and 609, routed into the gener­ator in Step 10, to the two thermostat terminals.

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 pro­vided. Insulate each connection with tape. Insure
that all leads are well clear of moving parts and
secured in place with tape.

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