250-300 AC Box Assemble (PL1109)

Your Price: $536.93

Part Number: PL1109

Availability: Drop shipped within 1 - 2 business days

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Feature 7

Cable Control Kits are made to last! One of the best products on the market today! These boxes are made in the USA and should last 10 years or more. Others on the market do good to make it a year before they fall apart. Cable Control Kits has been in business for over 50 years. Making remote kits for welders that can stand the test of time!

250-300 A/C Box Assemble

Complete remote box with 14/4 (SOOW Carol) wire coming out of the box with 4 prong male plug (HBL2421) on one side and a double receptacle on the other side
Your extension cord must have a female HBL2423 on it to plug the box into
For SA250, 300 AC, 300D, 300E models
Made in the USA

Supplied by PL Welder, Capitan, NM - drop shipped by the manufacturer (generally ships UPS the same day or the following work day)

These come directly from Cable Control Kits. P/L Welder holds no responsibility for these suggestions, instructions, directions. If you have any questions, please call Cable Control Kits 318-292-4417

Problem: You have to turn your knob to 100 or more for grinder to work.

Solution: Plug the box directly into the switch pigtail. Check grinder, if it works, it's your cord. If it doesn't work, check the wiring in your Control Kit plugs. (See #6 in the instructions). If the connections are OK then take the back off of the box. Reverse the black and white wire on the Rheostat. Also recheck your blue scotch lock on green wire to make sure it's clipped into the wire.

Problem: Rheostat works but the grinder doesn’t.

Solution: Breaker is either burned up or the blue scotch lock connector under the hood that you connected the green wire to the factory ground has come apart or burned up.

Problem: The Rheostat burned up when I changed the plugs.

Solution: When replacing a plug on our 200 units, make sure you put the white wire on green screw, the green wire on silver screw and black wire on brass screw. On all 200 D's T.L. plug, the black wire goes to the Y screw - green wire to X screw and white wire to silver screw. On 300 D male T.L. plug, that goes into welding machine, put the red wire on Y screw and green wire on silver screw.

Problem: Grinder works but Rheostat will not register but Rheostat in welding machine does work.

Solution: The white wire is broken between the welding machine and box somewhere. On your extension cord it could be the green wire, but on the box pigtail it will be the white wire. SUGGESTION: plug your box directly into short pigtail hanging from your machine and try your grinder. If it works a wire is broken in your extension cord.

Problem: Switch complaints, (single pole, double throw)

Solution: Your switch should not be moved with machine running. It is not moisture proof. It's a slide bar and has a 55 DC amperage rating and it has a center OFF position.

Problem: Remote gets awful hot

Solution: Check female plug on extension cord. May have arc inside when unplugging box from extension cord with welding machine running. Also, it could be a loose connection in plugs or inside of box. Don't lay box on its back because it will stop flow of air. Also check the RPMs on your welding machine. If they're too high, it will cause box to run hot. RPMs should be 1550 high idle, no load.

Problem: Burned up switch

Solution: Until you can get another switch, transfer the white wire on switch to center screw on switch. Control on Remote only.

New SA 300 D

All you need to do is plug in the male TL plug into the female TL plug on the welding machine and plug in the 110 plug into the 110 plug on your machine. Use the Lincoln switch on machine for your Local-Off-Remote.

Lincoln SA 250 AC, Gas, Diesel & Classic II & III

The Control Kit Box allows you to run your grinder under fuse protection, plus the heat will be at your fingertips. The box will be dead when the switch is directed for the welding machine Rheostat. You can still use your tools at any time. Both Rheostats will be dead when the switch is in the center position and you can't weld.

Drill a hole where desired (1/2 in.) but allow for length of wire on switch to reach Rheostat on welding machine. ON YOUR CLASSICS ONLY you have a factory cross shaped hole in the center of the back panel. Punch it out and use the extra switch plate (in invoice) on the back and one on the instruction sheet on the front to hold the switch on. No hole to drill.
Remove wire from center terminal that aligns with shaft in center of Rheostat on machine. Replace with short wire from switch. The wire taken from center of Rheostat goes on the center lug of the switch. On your classic II or III you may take both wires off and put on middle of switch.

NOTE: DO NOT REMOVE ANY OTHER WIRE FROM RHEOSTAT.
Loosen nut of OFF-SET lug of Rheostat, then place on light red wire with spaded lug. Re-tighten nut.
Plug goes into 110 receptacle on back or front of your machine.

ATTENTION: Our units are ONLY designed to go hard wire to the factory Rheostat on your machine, not to be wired into plug that is designed just for Lincoln Accessories such as portable wire boxes and the flux core wire welders.

CAUTION: For your information the 110 volt line on your unit is not safety grounded. Use DOUBLE insulated hand tools only.

NOTE: Please do not remove any wires from switch when you receive your kit. The green wire goes on one side of switch and short black wire on the other side of switch.

New SA 200 G or D

All you need to do is plug in the Male Twist Lock Plug into your welding machine. Put your own cord, no smaller than a 16/3 wire, between my yellow female plug on cheater plug and the male plug from the box pigtail.

If your Cable Control Kit box is getting hotter than usual, first check your open circuit voltage, it should be running 93 volts and it is more probably the RPMs are too high, plus, the new 200 Ds have approximately 400 more windings than the regular 200 Machines.

ATTENTION: If you want to put the twist lock plug on your existing extension cord please wire it to your cord the same as we have it wired to the short adapter. You will also need to take the regular female three prong plug on our adapter and wire it the same as we have it wired to the other end of your extension cord. This will save you from burning your rheostat up.

Lincolns SA 200 Amp & SA 25 Amp Auxiliary 110 DC ONLY

CAUTION: Our new concept of the Control Kits allows you to buy the extension cord length and size. (I recommend nothing smaller than gauge 16/3 wire.) The caution warnings are to impress upon you that you need to be sure the cord you put in between my plugs on my unit has the plugs wired to code. My plugs are not wired to code but wire to my own design. When you have to replace any of the plugs on the unit I sell you, they should be wired the same as when you take them off.

Drill hole (15.32) where desired but allowing for length of wire on switch to reach Rheostat on welding machine. On your Classic ONLY you have a factory cross shaped hole in the center of the back panel. Punch it out and use the extra switch label (in invoice) in the back and the one on the instruction sheet on the front to hold the switch on. NO hole to drill.
Remove wire from center terminal that aligns with shaft in center of Rheostat on machine. Replace with short wire from switch. The wire taken from center of Rheostat goes on the vacant center lug of switch. ON your newer Classic 1 you may use both wires from center of Rheostat and put on the center lug of switch.
NOTE: DO NOT REMOVE ANY OTHER WIRES FROM RHEOSTAT.
Loosen nut of OFF-SET lug of Rheostat, then place on black wire with spaded lug, Re-tighten nut.
On newer machines with PC boards find short wire going from board to receptacle and crimp green wire with the blue clip into it making sure the green wire is in blue clip far enough for the spade to cut into wire.
On older machines, one wire on the receptacle goes to Rheostat. Find the opposite wire on receptacle and crimp green wire with blue clip into it, making sure the green wire is in blue clip far enough for spade to cut into wire.
On your Classic 1 ONLY: Clip your green wire onto the black in between the fuse and the factory receptacle.
Use the plastic wire tie to tie the wire to the choke cable, etc.

New SA 200 Kit

Take off one side at a time on your old receipt. on your welding machine.

First locate wire on old recept that goes from recept to offset post on Rheostat. Take both wires on this side of old recept and put on the Brass Screw of new recept. The offset post will be a 2:00 o'clock or 8:00 o'clock on machine, depending on how its mounted on your machine.
The other wire or wires on other side of old recept goes to Silver Screw on new recept.
To Install Switch: Take wire off of center post of Rheostat, (It will be at 3:00 o'clock or 9:00 o'clock on your machine Rheostat) and put on center post of switch. Then take jumper wire from switch and put on center post of machine Rheostat.
When Mounting Switch: Rotate switch with jumper wire on top. This will align it to switch label.

Do not flip switch while machine is running.
This new adapter kit allows you to run your tools and control kit from same recept at all times.

From SA 250 to 300 D TL Plug Adapter

To install TL Plug & Switch: Take wire or wires off of center post of rheostat. Put these wires on center post of switch. Take jumper wire from switch and put on center post of rheostat.
Take red wire from TL Plug and add it to the offset post of rheostat.
When mounting switch, take extra switch label and use it for a spacer on switch. Rotate switch with jumper wire on top. This will align it to switch label.

Do not flip switch while machine is running.
This kit allows you to convert your SA 250 machine to a 300 D hook-up and allows a Lincoln remote to work off of it also.

250-300 AC Box Assemble (PL1109)

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