Classic IIID/300D/SAE300/3+3 Flyback Diode Install and Points

In this tutorial, we will describe how we are to install a flyback diode prior to the use of a wireless rheostat receiver. More than one way to skin a cat so try to understand and ask on messenger and or info@dkwremotes.ca

The purpose of the flyback diode and its install is the following: It protects the receiver and your remote switch from inductive voltage spikes released from the shunts when the circuit interrupts. some newer machines have this prebuilt. But, can’t take this for granted so we are installing a redundant one. PLEASE READ CAREFULLY SO TO NOT INSTALL IT BACKWARDS

The uttermost important note is to never disconnect both wires at the same time. That way you wont mix them up.

Step #1 ( Identify the two wires coming out of your generator) Coming out of your generator are "two" 14 gauge wires which go into the back side of the J5 connector. As seen in a pic below, the J5 connector is the 4x3 connector consisting of twelve spots.

Step #2 (Figure out which is blue wire and which is the brown wire) The best way to identify the black(old brown) wire is no matter which way on the J5 it will go into the end spot of the middle row on the back of the connector. If you take note, in no situation can the "green( old blue) wire" occupy that position. Once you are holding the black( old brown) wire which you identified by the method above, disconnect it at the factory spade and insert inline the adapter The green(old blue) wire will be on the same length of six wires but occupy the other position. also the brown wire traces back to the two 610 wires from the square bridge rectifier

Step #3 At this point, very recommended to try welding a bead with your original remote or machine rheostat. Why? Because if you installed it correctly, you will be able to still adjust your heat. If you installed it backwards, it may be stuck at max heat <- never tried it though

So why are we doing this anyway. Well let me tell you. All inductive loads, ie, relays, magnets, and such carry a built up source of energy. Your main shunt coil has such an energy reserve. Once flow is stopped, this flowing amount of energy has no where to go. Imagine it as water. You are welding at full load on remote, and your helper toggles the remote receptacle switch. Suddenly, this flowing water (energy) rushes down to the switch only to see it has no where to go. Two things happen. the energy hits a wall and the energy behind it as well creative a voltage spike and then a backwards wave of energy since it has no where to go. Our flyback diode will just redirect all this pent up pressure until it dissipates halting the process of an inductive reverse voltage spikes. Reverse voltage spikes will damage your receiver transistor.14