Lincoln Electric Im278 D Users Manual

IM278-D to the manual 0bcb496e-e824-4c47-9a07-547d5c03f78d

2015-02-09

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NA-3 AND NA-4
AUTOMATIC WELDING SYSTEMS

IM278-D
June, 2008

RETURN TO MAIN MENU

Safety Depends on You
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.

MODELS

SHIPPING DAMAGE CLAIMS:

NA-3N
NA-3NF
NA-3S
NA3SF
NA-4

When this equipment is shipped, title passes to purchaser upon receipt by carrier. Consequently, claims
for material damage in shipment must be made by the
purchaser against the transportation company at the
time the shipment is received.

OPERATOR’S MANUAL

• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

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

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

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.

FOR ENGINE
powered equipment.

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

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
welding 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.

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.

___________________________________________________
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.

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

Mar ʻ95

SAFETY
ARC RAYS can burn.

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.

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. The operation of welding fume control equipment is affected
by various factors including proper use and positioning of
the equipment, maintenance of the equipment and the specific welding procedure and application involved. Worker
exposure level should be checked upon installation and
periodically thereafter to be certain it is within applicable
OSHA PEL and ACGIH TLV limits.
5.c. Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors to
form phosgene, a highly toxic gas, and other irritating products.
5.d. 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.e. Read and understand the manufacturerʼs instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employerʼs safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.f. Also see item 1.b.

AUG 06

iii

SAFETY
WELDING and CUTTING
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.
Remember that welding sparks and hot
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 though they have
been “cleaned”. For information, purchase “Recommended
Safe Practices for the Preparation for Welding and Cutting of
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.

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.

6.f. Sparks and spatter are thrown from the welding arc. Wear oil
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.
6.I. Read and follow NFPA 51B “ Standard for Fire Prevention
During Welding, Cutting and Other Hot Work”, available
from NFPA, 1 Batterymarch Park,PO box 9101, Quincy, Ma
022690-9101.
6.j. Do not use a welding power source for pipe thawing.

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

Jan, 07

SAFETY
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 LʼArc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à lʼélectrode 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 sʼisoler 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 lʼeau 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 sʼapplicuent aussi au pistolet de
soudage.
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 nʼimporte quelle partie
du corps.
3. Un coup dʼarc peut être plus sévère quʼun coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi quʼun verre blanc afin de se protéger les yeux du rayonnement de lʼarc et des projections quand on soude ou
quand on regarde lʼarc.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
lʻarc.
c. Protéger lʼautre personnel travaillant à proximité au
soudage à lʼaide dʼécrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de lʼarc de
soudage. Se protéger avec des vêtements de protection libres
de lʼhuile, 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
zones où lʼon pique le laitier.
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque dʼincendie 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 dʼincendie.
8. Sʼassurer que la masse est connectée le plus prés possible
de la zone de travail quʼil est pratique de le faire. Si on place
la masse sur la charpente de la construction ou dʼautres
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 dʼincendie ou dʼechauffement des chaines et des
câbles jusquʼà ce quʼils 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
dʼopérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de lʼarc 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.

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
lʼélectricité 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, Iʼinstallation et lʼentretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à lʼinterieur de poste, la debrancher à lʼinterrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.

Mar. ʻ93

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!

CUSTOMER ASSISTANCE POLICY
The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equipment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln
Electric for advice or information about their use of our products. We respond to our customers based on the best information in our possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customerʼs particular purpose,
with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or
correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any
warranty with respect to the sale of our products.
Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control
of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in
applying these types of fabrication methods and service requirements.
Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com
for any updated information.

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

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.

4HE ,INCOLN %LECTRIC #OMPANY
#LEVELAND /HIO

!SSEMBLY AND )NSTALLATION

30%%$
&%%$ ® $25-3
7!2.).'
FALLING
EQUIPMENT can
cause injury

s 5SE EQUIPMENT RATED TO LIFT WEIGHT OF THIS DRUM
s IF POSSIBLE LIFT FROM BOTTOM
s &OR TOP LIFTING
n ,IFT ONLY WHEN COVER LOCKED IN PLACE
n ,IFTING DEVICE CONTACT WITH UNDERSIDE OF CLOSING RING MUST BE
AT LEAST INCHES
s .EVER STAND UNDER A LIFTED LAOD

3EC ,
!

http://www.lincolnelectric.com/knowledge/articles/
content/steelhatconstruction.asp

Sec. L2.5.10-A (Continued)

Hat

Insulated
friction free
eyelet

Speed Feed Drum
Turntable

http://www.lincolnelectric.com/knowledge/articles/
content/drumhandling.asp

http://www.lincolnelectric.com/knowledge/articles/
content/speedfeeddrums.asp

Assembly and Installation

The Lincoln Electric Company
Cleveland, Ohio 44117-1199
Sec. L2.5.10-B

SPEED-FEED ® REELS

Assembly and Installation
Sec. L2.5.10-B (Continued)
INSTALLATION INSTRUCTIONS
SPEED-FEED REELS
®

The Lincoln Electric Company
Cleveland, Ohio 44117-1199

G1385

G1387

G1458

L6488

L6489

Connect
Lead #693 to P1
Lead # 690 to P2

Inch up & no contactor
delay

592

532
631
2
531A

539S

532

531

576

641

642

581
539S

STOP
START
SWITCH SWITCH

582

FLUX OR
WATER
SOLENOID

575

531A

2
4
31
32
21
75
76
77

N.D.

DOOR

539
541
627
626
GND.

528

539S

585

CR1
FLUX
RELAY

532

510

589
625

CR2
TRAVEL
RELAY

SWITCH #1

510

N.G.

N.C.
JUMPER CONNECTOR "C"
VARIABLE VOLTAGE P.C.BD. (NA-3S ONLY)

ELECTRODE TO POWER SOURCE
REED SWITCH ACTUATED
BY WELDING CURRENT

4CR

TERMINAL
STRIP

2
4
31
32
21
75
76
77
GND.
CONTROL CABLE TO
POWER SOURCE

A
B
C
D
E
F
G
H
I

MOTOR CONNECTOR

A
539
B
541
C
627
D
626
E
GND.

531A

A
532
25
B
C
531
D
GND.
TRAVEL
CONNECTOR

A
87
87
B
531
531
GND. C
GND.
FLUX CONNECTOR

N.E.

626

SUBPANEL

Connect
Lead #691 to P8
Lead #692 to P9

Start with start switch
Stop after crater fill
(Crater fill board installed)

541

Connect
Lead #691 to P5
Lead #692 to P7

Connect
Lead #691 to P6
Lead #692 to P7

N.F.

SWITCH #2

For Logic P.C. Boards with
dip switches

510

CR3
CONTACTOR
RELAY

682

610

250

N.H.
N.L.

626
627
541
539
532
631
610
510
510A

NA3 SHIPPED WITH LOGIC PC BOARD
SET FOR INDICATED MODE OF TRAVEL
AND BURNBACK.

F2
3/10A FUSE

510

2
11
12
9
8
10
5
6
4
3

N.K.

1
7

11
12
9
8
10
5
6
3
4

ELECTRICAL
SYMBOLS PER
E1537

GND
525
75
629
539
635
77
76
583(C)
515
588
584(C)
CRATER FILL P.C.BD.
(OPTIONAL)

N.K.

START P.C.BD. (OPTIONAL)

GND
525
75
629
539
635
77
76
515
583(S)
584(S)

3/10A FUSE

1/2A SLOW BLOW FUSE

SWITCH POSITION 1 IS UP
SWITCH POSITION 2 IS DOWN
SWITCH POSITIONS 3 AND 4 ARE NOT APPLICABLE

CONTROL P.C.BD.

2
1
10
7
12
9
6
8
11

SWITCH EXAMPLE

}

N.J.
693
586
587
637
562
589
585
581
582
689
528
510A
510A

For earlier logic P.C.
Boards with jumpers
Connect
Lead #694 to P10
Connect
Lead #694 to P8

No
(Install jumper connector "B"
from 584(c) to 583(c))

N.B.

Crater board installed?

681
576
575

510A
682
592
634

10
7
1
5
3
2
12
11
6
4
8
9

Yes
(Remove jumper connector "B"
from 584(c) to 583(c))

Use of crater fill board

6
4
1

8
9
2
3

JUMPER
CONNECTOR "B"

N.A.

JUMPER
CONNECTOR "A"

LOGIC
P.C.BD.

N.F. ON EARLIER UNITS, LEAD #689 WAS LOCATED BETWEEN
#31 AND #67 (FORMERLY #5), LEAD #510 WAS LOCATED
BETWEEN #87 AND #32 AND LEAD #31 WAS LOCATED
NEXT TO #681. CAREFULLY NOTE LEAD POSITIONS
BEFORE MAKING ANY CONNECTIONS TO TERMINAL
STRIP.

N.E. 87-531 115VAC - 1/2A SWITCHED.

N.A. WHEN START P.C. BOARD IS INSTALLED, JUMPER CONNECTOR "A" IS REMOVED.
N.B. THESE LEADS ARE NOT PRESENT ON LOGIC P.C. BOARDS
WITH DIP SWITCHES.
N.C. WHEN VARIABLE VOLTAGE P.C. BOARD IS INSTALLED,
JUMPER CONNECTOR "C" IS REMOVED.
N.D. 531-532 115VAC
250VA
531-25 115VAC (SWITCHED)

SWITCH #1

SWITCH #2

SWITCH #1

For Logic P.C. Boards with
dip switches
1

1 4 7 10
2 5 8 11
3 6 9 12

L6488-1

CAVITY NUMBERING SEQUENCE
(COMPONENT SIDE OF P.C. BOARD)

1 4 7
2 5 8
3 6 9

* INDICATES CONNECTOR CAVITY NUMBERS

N.G. WHEN CONTROLS ARE USED WITH R3S POWER SOURCES
OF THE TYPE WHICH USES TAPS CONNECTED WITH A
TRIANGLE PLATE FOR MAJOR VOLTAGE ADJUSTMENTS
JUMPER TO BE CONNECTED TO PIN "L". FOR ALL OTHER
POWER SOURCES, JUMPER TO BE CONNECTED TO PIN "H".
UNITS SHIPPED WITH CONNECTION MADE AT PIN "H".
N.H. THIS FUSE NOT PRESENT ON EARLIER CONTROL P.C.
BOARD MODELS.
N.J. THIS LEAD IS PRESENT ON CODES 10311 AND HIGHER.
N.K. THESE LEADS ARE NOT PRESENT ON EARLIER START AND
CRATER FILL P.C. BOARDS.
N.L. ALL FUSES WERE REPLACED WITH PTC RESETTABLE FUSES
ON LATER CONTROL P.C. BOARDS.

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside
the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.

517

5 AMP
CIRCUIT
BREAKER

531

517

WORK

ARM

For earlier logic P.C.
Boards with jumpers
Connect
Lead #691 to P6
Lead #692 to P5

Start with current
Stop with stop switch

Start/stop with current

Start/stop with switches

WIRE FEED MOTOR

CONTROL POWER
SWITCH
531

627

539

D.C. METER SHUNT

634

WIRE FEED
SPEED CONTROL

HAND
OFF
AUTO

SWITCH #2

POWER SOURCE 67
OUTPUT CONTROL
10K

SWITCH #1

SWITCH #2

SWITCH #1

WORK TO POWER SOURCE

592

INCH DOWN
SWITCH

593

SWITCH #2

SWITCH #1

532

TRAVEL
SWITCH

625
INCH UP
SWITCH

Connect
Lead #693 to P1
Lead #690 to P4

Inch up & contactor delay

For Logic P.C. Boards with
dip switches

For earlier logic P.C.
Boards with jumpers

539
525
539S
593
629
539
525
587
586
6
2
5
4
1
7
3
9
8

Connect
Lead #693 to P3
Lead #690 to P4

Wire feed stop & contactor
delay

Methods of Burnback

532
592
562
635
636
637
525
539
67
528
21
531A
1
5
6
12
8
11
4
10
9
7
3
2

510
4
2
87
32
541A
541
626
627
539
539S

1
2
3
4
635
584(S)
629
76

635
584(C)
629
76
588
515
75
GND
539
525
583(C)
77

31
67
681
21
77
76
75
689
528
582
581

*
*

GND
525
629
539
636
635
641
642
75
76
77
10
6
3
12
8
1
2
9
7
4
11
6
7
8
9
10
11
12
515
75
GND
539
525
583(S)
77
1
2
3
4
5
6
7
8
9
10
11
12

NA-3N AND NA-3S WIRING DIAGRAM

690
694
691
692

*
*

Methods of Travel

WIRING DIAGRAMS

592

539S

576

575

582

AM
-

518

SUBPANEL

DOOR

585
1

CR1
FLUX
RELAY

4
532

510
3
2
4

CR2
TRAVEL
RELAY

589
6251

VARIABLE VOLTAGE P.C.BD.

ELECTRODE TO POWER SOURCE

TERMINAL
STRIP

2
4
31
32
21
75
76
77
GND.
CONTROL CABLE TO
POWER SOURCE

A
B
C
D
E
F
G
H
I

CR4
67
528 539S 517

2
4
31
32
21
75
76
77

539
541
627
626
GND.

MOTOR CONNECTOR

A
539
B
541
C
627
D
626
E
GND.

531A

A
532
B
25
C
531
D
GND.
TRAVEL
CONNECTOR

A
87
87
B
531
531
GND. C
GND.
FLUX CONNECTOR

N.D.

626

541

NA-4 SHIPPED WITH LOGIC P.C. BOARD
SET FOR INDICATED MODE OF TRAVEL
AND BURNBACK.

510

N.F.

N.E.

N.G.

682

610

250

2
1
10
7
12
9
6
8
11

3/10A FUSE

510

3/10A FUSE

N.K.

Connect
Lead #691 to P8
Lead #692 to P9

Connect
Lead #691 to P5
Lead #692 to P7

Connect
Lead #691 to P6
Lead #692 to P7

Connect
Lead #691 to P6
Lead #692 to P5

626
627
541
539
532
631
610
510
510A

CONTROL P.C.BD.
F2

510

CR3
CONTACTOR
RELAY

Start with start switch
Stop after crater fill
(Crater fill board installed)

Start with current
Stop with stop switch

Start/stop with current

Start/stop with switches

N.J.

2
11
12
9
8
10
5
6
4
3

CRATER FILL P.C.BD.
(OPTIONAL)

GND
525
75
629
539
635
77
76
583(C)
515
588
584(C)

N.J.

1
7

2
11
12
9
8
10
5
6
3
4

START P.C.BD. (OPTIONAL)

GND
525
75
629
539
635
77
76
515
583(S)
584(S)

SWITCH #2

1/2A SLOW BLOW FUSE

SWITCH #1

SWITCH #2

SWITCH #1

SWITCH #2

SWITCH #1

For Logic P.C. Boards with
dip switches

N.H.

Inch up & no contactor
delay

Inch up & contactor delay

Wire feed stop & contactor
delay

Methods of Burnback

For earlier logic P.C.
Boards with jumpers
Connect
Lead #694 to P10
Connect
Lead #694 to P8

Crater board installed?

No
(Install jumper connector "B"
from 584(c) to 583(c))

510A
682
592
634
641
681
576
575

Yes
(Remove jumper connector "B"
from 584(c) to 583(c))

Use of crater fill board

8
9
2
3
5
6
4
1

JUMPER
CONNECTOR "B"

N.A.

JUMPER
CONNECTOR "A"

LOGIC
P.C.BD.

Connect
Lead #693 to P1
Lead #690 to P2

Connect
Lead #693 to P1
Lead #690 to P4

Connect
Lead #693 to P3
Lead #690 to P4

For earlier logic P.C.
Boards with jumpers

10
7
1
5
3
2
12
11
6
4
8
9

586
587
637
562
589
585
581
582
689
528
510A
510A

693

SWITCH #1

SWITCH #2

SWITCH #1

For Logic P.C. Boards with
dip switches

N.B.

SWITCH #2

SWITCH #1

SWITCH #2

SWITCH #1

For Logic P.C. Boards with
dip switches

L6489-1

SWITCH POSITION 1 IS UP
SWITCH POSITION 2 IS DOWN
SWITCH POSITIONS 3 AND 4 ARE NOT APPLICABLE

SWITCH EXAMPLE

CURRENT TRANSFORMER

WORK

531A

N.C.

ARM

WIRE FEED MOTOR

5 AMP
CIRCUIT
BREAKER

531

517
518

CURRENT SENSOR
P. C. BOARD

581
539S

STOP
START
SWITCH SWITCH

634

641
642
641

WIRE FEED
SPEED CONTROL

HAND
OFF
AUTO

627

539

CONTROL POWER
SWITCH
531

POWER SOURCE 67
OUTPUT CONTROL
10K

532

1 4 7 10
2 5 8 11
3 6 9 12

CAVITY NUMBERING SEQUENCE
(COMPONENT SIDE OF P.C. BOARD)

1 4 7
2 5 8
3 6 9

* INDICATES CONNECTOR CAVITY NUMBERS

FLUX OR
WATER
SOLENOID
531

WORK TO POWER SOURCE

592

INCH DOWN
SWITCH

593

625
INCH UP
SWITCH

532
631
2
531A

532

TRAVEL
SWITCH

N.F. JUMPER LEAD TO BE CONNECTED TO PIN "H" AT ALL TIMES.
UNIT SHIPPED WITH LEAD IN THIS POSITION.
N.G. THIS FUSE NOT PRESENT ON EARLIER CONTROL P.C.
BOARD MODELS.

N.E. ON EARLIER UNITS, LEAD #689 WAS LOCATED BETWEEN #31 and #67
(FORMERLY #5), LEAD #510 WAS LOCATED BETWEEN #87 & #32, AND
LEAD #31 WAS LOCATED NEXT TO #681. CAREFULLY NOTE LEAD POSITIONS
BEFORE MAKING ANY CONNECTIONS TO TERMINAL STRIP.

ELECTRICAL SYMBOLS PER E1537.

539
525
539S
593
629
539
525
587
586
6
2
5
4
1
7
3
9
8

N.D. 87-531 115VAC- 1/2A SWITCHED.

510
4
2
87
32
541A
541
626
627
539
539S

For earlier logic P.C.
Boards with jumpers

Methods of Travel

N.H. THIS LEAD PRESENT ON CODE 10318 AND HIGHER.
N.J. THESE LEADS ARE NOT PRESENT ON EARLIER START
AND CRATER FILL P.C. BOARDS.
N.K. ALL FUSES WERE REPLACED WITH PTC RESETTABLE
FUSES ON LATER CONTROL P.C. BOARDS.

532
592
562
635
636
637
525
539
67
528
21
531A
1
5
6
12
8
11
4
10
9
7
3
2

*
31
67
681
21
77
76
75
689
528
582
581

1
2
3
4
635
584(S)
629
76

635
584(C)
629
76
588
515
75
GND
539
525
583(C)
77

6
7
8
9
10
11
12
515
75
GND
539
525
583(S)
77
1
2
3
4
5
6
7
8
9
10
11
12

GND
525
629
539
636
635
641
642
75
76
77
10
6
3
12
8
1
2
9
7
4
11

*
*

N.A. WHEN START P.C. BOARD IS INSTALLED, JUMPER CONNECTOR "A" IS REMOVED.
N.B. THESE LEADS ARE NOT PRESENT ON LOGIC P.C. BOARDS
WITH DIP SWITCHES.
N.C. 531-532 115VAC; 531-25 115VAC (SWITCHED) - 250 VA

690
694
691
692

NA-4 WITH CURRENT CONTROL RHEOSTAT

WIRING DIAGRAMS

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Create Date                     : 2009:10:13 14:24:45-04:00
Modify Date                     : 2009:10:15 10:49:05-04:00
Subject                         : IM278C
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Format                          : application/pdf
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Title                           : im278.pdf
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Lincoln Electric Im278 D Users Manual

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