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Lincoln Electric IM305-C Welding System User Manual

1. GEHOLIMS HEHOLIMS Ld OL 6698 av31 NI GATIVLSNI 8d OL 769 v Zd OL 0694 Qv31 HOLOVLNOO ON HUM HON 2E HOLIMS HEHOLIMS 84 912698 QAYIT TVNOLLAO LOANNOO ON r FEZI LOANNOO 94 01 1698 0411 H3 dV 4015 SR HOLIMS
2. NO 1N3S3Hd LON TWNOLLdO TIVLSNI OL WOH H3dWnr 319v Ld303H HALVHO SAOWSH JNVEA OL 2 NO GALNNOW ANY SH3LLEINOLLN3LOd i oma SI FINAOW 4 IOHLNOO 1 18 JINGOW NOLLV IN3IHO IN3839310 V NI L8 SHIAWNN IWYS GVH TIVLSNI OL WOH DIA 1 18 1 Wes JUNLV34 18 109 OL AVL AHL OL GALOANNOO 38 OL NOLLO3NNOO NO 03110345 SSIINN AVL HOIH 12 STONIS V 3S3HL 3AVH LON lt 1 4019 OL OL SI 2 NO LON e ae de ee 2S 39V LIOA NO LON WN 0202 001 250 560 TIONIS 822015 vie 9 lt 025 E nim 8 906916 lt Ond SI AI
3. u m man ZILA 22222 KEIN LALA AY 2 2 21326 9 15 78A 4 79 132 1 132 1 Use only the parts marked X in the column under the heading number called for in the model index page Indicates a Change This Printing ITEM DESCRIPTION PART NO QTY 1112131415 789 Carriage Assembly 325 5 5 75 in min Includes Below Code 8400 Carriage Assembly K325 S 5 75 in min Includes Code 8400 to 9000 Carriage Assembly K325 S 5 75 in min Includes Above Code 9000 Carriage Assembly K325 F 15 270 in min Includes Below Code 8400 Carriage Assembly K325 F 15 270 in min Includes Code 8400 to 9000 Carriage Assembly K325 F 15 270 in min Includes Above Code 9000 Carriage Assembly K325 HC S 5 75 in min Includes Below Code 8400 Carriage Assembly K325 HC S 5 75 in min Includes Code 8400 to 9000 Carriage Assembly K325 HC S 5 75 in min Includes Above Code 9000 Carriage Assembly K325 HC F 15 270 in min Includes Below Code 8400 Carriage Assembly K325 HC F 15 270 in min Includes Code 8400 to 9000 Carriage Assembly K325 HC F 15 270 in min Includes Above Code 9000 G1326 1 G1565 1 G1565 3 x G1434 1 x G1564 1 G1564 3 PROSTAR 2085 O A AAA ___ 22 2 pu E E
4. DR 00 BP DR 4 lo 09 27 2007 P 100 G NA 3 4 and 5 P 100 G NA 3 4 and 5 WIRE REEL AND REEL MOUNTING NA 3N NA 3S NA 4 NA 5N and NA 5S gt R N S WS X a v Bracket Indicates a Change This Printing ITEM DESCRIPTION PARTNO am 123456789 Ill lh cl Wire Reel Shaft Asbly Includes M12908 1 2 13 x 1 00 HHCS CF000276 Lock Washer E106A 5 Plain Washer 59262 14 Plain Washer S9262 119 Brake Assembly Includes 514882 Brake Shoe 113519 Wire Reel Shaft 515492 Roll Pin T9967 9 Pull Knob S11038 Following Parts Not Illustrated Wire Reel 4604 U Shaped Shaft Mounting Bracket M12907 Following Parts Mount M12907 No High Frequency Flat Insulation 18477 20 Insulation Tube 112478 6 Insulation Washer S10773 9 1 2 13 x 1 75 HHCS CF000277 1 2 13 HN CF000027 Following Parts Mount M12907 w High Freq Insulation Insulation Asbly S11771 2 1 2 13 x 1 00 HHCS Insulation to M12907 CF000276 1 2 13 HN CF000027 09 27 2007 100 100 CABLE ASSEMBLIES POWER SOURCE CONTROLS amp CONTROLS TO HEAD Indicates a Change This Printing ITEM DESCRIPTION PART NO QTY 1lalalalslelz ao NA 2 NA 2F amp NA 2FV Cable Assembly Power Source to Controls Incl
5. ee 7 13193 1 Screw S8025 70 8 Grommet Strip T12823 18 9 Lead Grommet 1192743 1 10 Lead Grommet 7244 1 11 Motor End Cover Not Shown S16718 3 13 2001 EN __ LE LL II LL Connection Box Assembly M1391 1 Cable Assembly Includes 6209 Polarized Connector Tach Cable S12020 17 Cable Clamp Tach Cable S12024 4 Polarized Connector Motor Cable S12020 27 Cable Clamp Motor Cable S12024 1 Tr P 135 D P 135 D CONTROL BOX ASSEMBLY G1555 24 81 10 7 96 135 0 1 135 0 1 Indicates Change This Printing ITEM DESCRIPTION PART NO am 12 34 5 Door Assembly See P 135 E Lead Clamp 112563 8 Volts Meter Printed Circuit Board 6685 Speed Meter Printed Circuit Board Standard 6233 Speed Meter Printed Circuit Board High Speed L8575 1 Burnback Timer Printed Circuit Board K337 10 Procedure Printed Circuit Board Code 8205 Only G1507 1 Procedure Printed Circuit Board G1566 3 Printed Circuit Board Insulation 516695 Switch Panel Asbly Includes Below Code 11000 16713 Switch Panel Asbly Includes Above Code 11000 16713 1 Circuit Breaker T12287 10 Travel Switch Below Code 11000 113543 Travel Switch Above Code 11000 110800 23 Control Power Switch Below Code 11000 T10800 9 Control Power Switc
6. 124024 eq 3snu 921005 19404 ay 4 13 92 005 9 4 241 L paysew awesy 01 2 4 2 0234052 941 i29uucj 3 N 0 1402 G YN 9u3 30 5 1 9 241 Jeq due 5 y 4epun pabSnus aq 5 52 4 2 1 ayy uo Je ado 294044 104 uO 12auuO2 dn ede 243 O 1u ujsn pe Ou ued 22241 22015 SeyN 2943 YIYM 24 1 e qe xJ0 1 S 4 aq pinoys pe z4 5141 59014200 95041 564 Ar ea uo 3495929 100 sem 11 LH 5619 diiis peujusoz 904 304 03914 X10 943 03 UO1120Uu02 91995 alesedas 1 Buideex 22319 243 04 11 322440 asod nd 5141 20 9123 eujuJ83 243 uo OS e 24 pue 98 saujuoeu EY 39114698 pea bujsuss obe3 o 10 7 9849 6 uy 15 ayqeqzins 4 2154 4 us 10 Bu sn 21 52 V N 224 ppe pue 41135 00 1 YO 9 5 LH pea 2 2 1235 jeujuuoa1 EEE vh 9 9 peo 41115 93 G 4 01 SLE 129uuO
7. P 100 D 2 Head 4 8 P 100 F Wire Reel and Reel Mounting NA 3 NA 4 and 5 P 100 G NA 3 NA 4 and NA 5 Cable Assembly Power Source to Controls P 100 H Flux Cored Wire Straightener 1 16 5 32 P 100 K Cross Seam 4 P 100 L Solid Wire Straightener 5 64 7 92 P 100 M Flux Cored Wired Straightener P 100 N K218 Horizontal Fillet Lap Attachment P 101 C K233 and K103 Contact Nozzle K104 Linc Fill Extension P 101 D K96 Horizontal Adjuster P 101 E K233 Solenoid Assembly NA 3 4 and 5 P 101 F K129 Submerged Arc Twinarc Kit P 101 G K281 Wire Straightener for Tiny Twinarc P 101 G 2 FIX TODOS A re ren eee Ged Be ahah P 101 H K148 Contact K149 Linc Fill Extension P 101 K K225 Submerged Arc TWwinare Kit
8. 090 lt L 7 lt gt 095 2 18 24 gt 9 gt 289 gt 6 gt 659 gt p gt 005 gt 2 005 gt 6 25 96 WES 14 LIM 3IVIALNI 90 IVNV 960c NOTES e Do not touch electrically live parts or electrode with skin or wet clothing e insulate yourself from work and ground e Keep flammable materials away Wear eye ear and body protection Spanish AVISO DE PHECAUCION e Prot jase los ojos los o dos el cuerpo e No toque las partes o los electrodos bajo carga con la piel o ropa moja da e Aislese del trabajo y de la tierra e Mantenga el material combustible fuera del rea de trabajo French e Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension e Isolez vous du travail et de la terre e Gardez l cart de tout mat riel inflammable e Prot gez vos yeux vos oreilles et votre corps ATTENTION German WARNUNG Portuguese Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung e Isolieren Sie sich von den Elektroden und dem Erdboden e Entfernen Sie brennbarres Material Tragen Sie Augen Ohren und K r perschutz e
9. gt Ptejysseuu 03 595 e Utd 91 D2329uu02 e 5 7374 102340 uo pee 7 Te 9 145390 1 93 YIJIMS 4 M pee 2014 pue 59p0113313 072 90 304 s PIROY 7374 1013007 UO peaj 72 i 24 408 A O1 4231458 195 2 Uld s 7274 1023009 DIIM z qns 104 IT 91452 01 A 01 211 5 196074 5 08 0008 53402 009 24 3 Ji g ir 2 9 a 595595014 229 ued 101 pesn eq 03 5502014 ir YN lt 243 10 90131509 21159 243 O3 4213145 195 a js bs 4 83 26 Uld 2 gt 1 93048Y 231 815501 195 S VN OL 222 HH s P1e98 7274 04100 uo pea 7 u0j329uuO2 gt LO 244 ang 01 311 5 yas 942 58 owes 0 216603 395 2 p S 4 PARES 04 jo bind m qns 1991 23 01 9 1 159 9 2 3 1041802 399005 0048 9108 53003 009 20 YIMOd ANANI 330 Ni a 53 53009 11v 3189 0431 S VN NY LIINNOISIA 334005 33M0d 30 W3HLO ANY 803 Ld mu MO13d NMOHS SY ATLOV
10. 100 100 FLUX CORED WIRE STRAIGHTENER TWINARC Indicates a Change This Printing ITEM DESCRIPTION PARTNO am 123456789 09 27 2007 Wire Straightener Includes M12470 Body Assembly M10311 1 Bearing M9300 55 Roll Pin T9967 3 Lock Washer E106A 3 5 16 18 HN 00029 Socket Head Screw 9447 20 9967 30 Connecting Link T12141 Wire Guide M12469 18 32 x 50 RHS CF000033 Retainer Plate 112145 Ingoing Wire Guide S14888 Wing Screw T9078 Adjusting Knob 512547 Adjusting Screw T12102 h mb h N wur A hd dd dd dd yy dl S Y Aa 101 101 218 HORIZONTAL FILLET LAP NOTE CONTACTS MUST ALIGNED SO THAT WITH A 7 32 WIRE IN PLACE THE WIRE IS 35 o CENTERED IN THE CHANNEL DXT T 22222001 4 S N 15313 47 6 12 81U 10 3 84 P 101 C b P 101 C b Indicates a Change This Printing ITEM DESCRIPTION PART NO QTY 11213141 51617 89 Socket Head Screw T9447 10 Flat Washer S9262 23 1 4 2 4 3 Insulating Washer 10773 12 8 4 Insulating Bushing T8390 4 5 Adapter M12478 1 6 Adapter Insulation 18391 1 8 Head Screw 5 16 18 1 00 1 9 Spring 18528 1 10 Pivot Assembly M8592 1 11 Lead Block 7273 1 12 18573 0 1 13 Head
11. 1198340 S YN 33S 5 01120816 1 011911915 1 TONO 111009 804 043009 G UN OPIS 319 90 due o et APUN pab6nus eq 5 4 epo noe je eui 501394990 499049 404 HN 9300 19 04 0919 50013090090 2104 O nUOO DISA G UN 40 Jenumy 61394990 G YN 03 493904 5131 8104 aedoad pasn 94 paddinmba y 924005 49809 uo 1 5 eux 40131509 pue 8291005 6411915 01131 499 G UN AY 30 940369 eui 18 speo pue eu 95 40 94 440 Jemod uam do S 010nu 6u 3 4615 02 eu 4851 Jedun 8a13 S0d epo noe o SMOYS SIU POQ 37 4 96 3 G UN y LO AMWAJOISUE N y 0109 PILOTE 482 94 U99 1eq s Jadun e sse un 93604940 100 1 003304 uou G UN 941 3401390 009 1 0 00 3 40 00 94 2901390 eur IMOYITA 0058 5003 51021005 5 9 DUIS USUM 019 aedun UA 10290002 YMOM 5 919 359440 SMOLO SMW p eoq aber G YN 94 uo saedun 941 3 N HN FON es mos Jemod eui aed 22 492919 E peioeuuoo
12. JLON 351 NOILISNNOI N3dOHd 303 SNOILINIMLSNI 941443390 33S 340939049 13M 30 1103135 3L0W34 804 SIVNIAY31 NOIIO3NNOO 0430 iqv3tsNI 035 Sy3anne sauvog IINITIOAI ILTINN 430310 NO JNILi13S 3 20 35 403 SNOLLINYLSNI 941194336 335 IlN3 dIHS 340338 HILIMS 410 3800320844 11 MA VN Assembly and Installation The Lincoln Electric Company Cleveland Ohio 44117 1199 Sec T2 5 20 Continued 906215 196 61 1 SS3NHVH 40 LNINO4WOO 3415 OL SAVIT NO 6 F ad 2 SNId 40 38 H3dOHd 4 SNOILONYLSNI 33S 54 SLIOA S134431 TVNDIS TOB LNOO DOTVNV YO3 STVNINYAL NOLLO3NNOO QV31l IVNBH3IX3 3ON3nO3sS ALIAVO HOLOANNOO X SJLON OO lt 86 S VN OL 41815 TWNINYSL NOLLISOd TWNODIS NI NMOHS TON 209 SS3NHVH 1 i e LLI gt m gt 40193138 MOTISA 3718 em quo os pee eee N p 08 96 lt 408 4019 lt 3199193934 026 lt 9 NET Bez 569 lt 6 S VN OL 2 E y lt i JIIHM lt lt gt 6 gt 4019 d 0
13. eq snw 500 39900009 Jamod ndu eoanos 11854 LOVINOD IYIN S YN A omod ey pue F Dur puno eoanos noya 31883 01 1108 lt 4amod sul di gt peel uses 99 ANOS J9 od oUt 9 O N AE 145 mum 1 Gm jo AVLI 9Y pee e qeo 01109 y 1999003 Q N yO 2 dn 9461 193 943 OA G YN 94 03 40449 SPPE 1 39900003 1 49 949 300 81 SIUL VEUL 3 11150 JALLVO3N 910N INS PUJW I91 99 UO 12 9414493 32941 LEI pue eq peeu 100 SBOP 124 91490 0 2109 voyr 9214 119 eq 0 eq LEI 609013290002 pue 4045 1 2102412 9 xao un 6ue y j 6Gurp o y gt eq PINOYS peo 2 eouelu9SAUOO 404 UO O UUOD pue 1102 12 peo 440m ay 93909 184958 AI 891 129919 2 99 5919 x10 y 03 3199 p 339002 2504404 1 40 S ge ere 6 pea yom sues 9087 93 09 1 19 311 984915 99 0 36 6350 ay 40 91463105 2 1 55444 960 40 989 bly DUISN 124 Pee 78 501399 dde pue 34e paw pue eui 40 A1oedeo 494044 jo 94
14. P 101 L K239 Innershield Twinarc Kit P 101 L 2 K231 and K31 Contact Nozzle Assembly P 101 M K226 and K32 Contact Jaw Assembly P 101 N Head Mounting and Lift Mechanism For K23 K236 K247 K325 and HG P 101 Q K29 Vertical Head Lift Assembly 1 2 3 4 and 5 and LAF 3 4 5 P 101 S K238 MOM Frequency UNIT ou tinea aa cra 2 4 2 101 K386 Narrow Gap Deep Grove Nozzle P 101 U K224 Solid State Remote Field Control P 114 H K285 Concentric Flux CONG v cas eani re Enden Esp een P 114 J K278 Spreadarc Complete Assembly P 114 K Spreadarc Carriage Track and Drive Motor Assembly P 114 L Spreadarc Carriage Assembly P 114 M K237 Linc Fill Starting Relay Assembly P 114 N K325 TC 3 Travel Carriage General P 132 C Motor and Gear Box Assembly P 132 D Gear Box Assembly puro eos pe een ete X ERES E e EU P 132 E Travel Control Box A
15. 133 AL ym e RE os d rav 2208 nim LETI bey 3 ih E un 8553 Bol il assn LON E Wr Mania SHE c 14 2 32 35015 oo T 30 was 55022 CNILNO I 3 De ar QL 00 TAE Sin o eu m 1138 Ww EM c 8 10812 ELM ine 2317 1009 OL 202 40 5015 192 er uaa 39 all 34 er Ee a 4 2996 Silky 9NLLNDOW SU incuv 7177 im c 53194108 DIMENSION M IDDI PODA LEA 01 18721 04 7538 rar 8 15 MOLLY TSN LEN Par iE ES 9NIINnCGW Oven sci 22 SHON OL PPS 29 welen an Uy SIH Lodi say Los IYL oo oL ovi 333 WSN ryan AT Sixy s
16. 1538 NIVISO OL SI9ONYAY QUVONYLS NON YO OVINA HLIM 008 NY IMUM A 501120215 LNGWLSACAY 2 992992 13860485 SV 38157 589 Galle 13316 DONIS ONISINO 33 14938 30 11 130 VIVERO 1 202 00721 7779982 9 0001 14 51 008 Mis Ye 644416 73315 DNIYIS DNIAINOFY 30 WvL3g 144002 Q02 VH 14 EST 9000 SWASFINI 00 21 LY SNOT P 9 e a SY_H19N31 IWYS SHH 0909 5211 NOLL23S 008 18 1344 2 9091 203 BEF 0021 493 6 9 532 131174 4 139 OL ONIGTIM 3i liv Ps s OV3H ONIOTIM tt 1 t t i SY 419 31 IWYS 0521 66 1 4 OQ b LY 9N07 00 6 x 077 SE INI AIHSINIINN 7 73 31 1 NON HIIM 250 203 SONAS 9548068 WN3d lOVINOS ya Vina AVI SONISVAS TW AHL WIHS HONS GIIWASSY 51 Q3ddlHS Sv 2 Nasa 39 ISO 181330 i t8GNvONVAS O3HsnBOd BRADY Ol 1 32 693101 Wiz 3323
17. 4 SSINYVH 30 3015 4 31 QuvOS 40 3015 1N3NOdMO2D a2 er iP 32431035 ALIAVO YOLIINNOI OST Qa 916 0 24 V SIGNALS SWITCHES Gus dmm COMMON YN L _ 9 gt GIG 3 64 515 Es l y lt 9 p 8658 b 965 gt 55 5 6 lt lt lt 65 gt 2 gt 596 lt 26 65 I I 165 KA lt 65 i enm NO 1 33135 JONAA 0 8 3514 8 1 gt 9 454 gt E F gt 9019 e E gt 6559 I 4 065 08908 38 030034 TAN un 2 GN lt 9 lt 906 9 lt p 095 H 5 095 lt 2 lt ce ee 41 Vp 9S M GT lt 6 0015 8 269 xL 025 9 Gt 9 X 6 SIS lt y 009 lt p9S 2 095 lt 1 3194143334 5S JNHYH 3419320 11 INN S YN 01 isayvog NO IN3S34d 10 51 211415 0813313 403 SAVES 01 931934409 34 94909 38 033084 11 TNA NO 9 HILIMS JHL QNY 5104 TIV 3H1 01 11133419 3930105 3438 50 31 3S3H1 204 8 117 43010 0351 jd LON S IVNINJ3i
18. djjis 42 UO 608291 1 seujqoem 20114099 40 J N 4142136 94183091 910 92 SES 1209009 41136 5 918 1284402 9 4062 0 2105 412 3 5 j 3 5 Ajsedaid eq 10909 By 4123 90183091 2090 ey 1890 4 O3 pee 4 2 023 0 gt 41 329440 3 dn ede apq Bulpjam 24 pjnous 24 pepueixe 5143 leue gt 204 2521494 440 8 492 bu 243 2120425 1 4994 92914 21 129440 9604014 5143 10 2190 peo x10 5 95 0581 21092 7 99591 5 35 943 20 9 qe1jns 11921 peze nsu sable JO Gujsn 7 peo puSixi 3 n 60 1382199 pue O 2 gt pue 1901102 941 10 294029 eq 15 91922 9192 022402 S YN 3294402 pue 0 1402 p 9 j 91973204 WYS 145364 SUN 335 SNOILINBLSNI NOIIMOYYAVAiISNI 804 2 0 102300 S vN Pes nbes 10 jenumw
19. 01 J0 9y A3pjsejod 209029 01 22404 YO 3 6 943 0131509 jjo semod usn Aly od Ol 310N oL 5 5 8033 37895 OL 2709 0138 NMOHS SY A112VY3 38 ISNW SNOLIO3NNO2 S9NI113S VN 9NI 1139 33 0 431804 WYS WN ONS O 5 29044 4 941 01 21922 dyl 942 12894402 7 6 J9qwnN 93 0 1460 9 5 1 0A 19 16440 943 195 35915403 01 1 2941 395 77 94 5592019 ey 10 o 3 2 Od 941 1 94 128 3 395 1 Mid 8955820279 Day 940 203 24 422 102 274 9693 2 2 914 pnis 334v 221229 02 2 pgo pay 1990915 4 00 943 01 49 3 943 3294409 104 S YN OL o 8 0 1060 JUEJSU 395 12 lt 525592024 Day 49990 404 L 194 3 4194 39835062 56 OHANOD v aber 10219007 07 2115 216603 41 385 77 M ck 5522014 10 oe O 2 322040 gt 5 peo 72 3112109 241 01 4131 08 29 3 941 1
20. 035160 SED 6179 Wi QNO 2SUVWOl V __ 2 42 7 TULAAN e SI II 69919
21. 5 uid 5955 2014 104 7 006 1943409 14921302 ay 0 40 1 pue i9 qunN 0 1007 10 135027 ay 395 318 Cj MR 0 50 N 01 P3123UU02 1 3 g pay LOdNI S WN OL ER dai Ri 19635007 5 916603 241 195 77 0 9 585592014 IJY 9990 je 404 5 pesn 55920 4 uva Utd ay 20 11 09 ey 0111509 9663 a a ne en 21 pei22uu22 PIROG 274 UO peal ar ym 7 Sau Jon sia Gi Us me aui 1s 5 Utd qns 20 Oi psi22uuO2 s uo ANY 50431 S YN TW 123 0254 324005 4 30 360 310 ANY 304 203 310 328005 u3 Od NYAL MOVIA NMOHS SY A115VY3 MYW 39 1504 SNOLLIINNOI M 13986 SONILL9IS 334005 4 WYS Connection of NA 5 All to a SAM 400 Motor Generator or Engine Welder M13986 9 17 82B 88My The Lincoln Electric Company Cleveland Ohio 44117 1199 Assembly and Installation Sec T2 3 4 E S YN 9 359 244 494 247 pabbnus aq 7909 5214992 245 uotqoaAsdo G YN 494943 303 HN
22. Newer Versions of the Multi procedure Board Newer Versions of the Multi procedure Board Configuring the Multi Procedure Board for weld procedure selection from the panel non remote On older models when the blue jumper is connected to pin P the kit s panel selector switch is fully functional This corresponds to setting the DIP switch to the UP position on newer versions of the Multi procedure board Blue Jumper to PIN P Older Versions of the Multi procedure Board This configuration must be used if remote procedure selection is not used or if it is desired to permit panel selector switch override of remotely selected procedures while welding However remote proce dure selection will be disabled if the panel selector switch is not set to the REMOTE position Configuring the Multi Procedure Board for Remote weld procedure selection On older models when the blue jumper is connected to pin R the kit s panel selector switch is disabled allowing for weld procedure selection from a remote source This corresponds to setting the DIP switch to the DOWN position on newer versions of the Multi procedure board Blue Jumper to PIN R Older Versions of the Multi procedure Board This configuration provides exclusive remote selec tion of weld procedures while welding regardless of the position of the kit s panel selector switch This prevents selector switch override of the remotely selected weld procedure
23. jqe 023 0 gt Z X J8p o ue buisn y J N 5401322 4 pue Jeipaum 30 92545 inp pue 322475 241 10 2 gt 1230 44 jo aq 5nw 2 98 gt GM ON ado Saar AN 3111 Sou 9NILV l3dO0 6 336 SNOILINAISNI NOILVTIVLSNI TWNOILIGGY 903 suo 329uuOo 053402 20 enuew 240 G yN 13 399 Ay aejod 2124049 UO YIJIMS 293 11501 pue 221005 19 Od 941 52 4 2 pue 9 4410 Jamod A3j1e 0d abuey gt 2AJ1 SOd epoj129 9 e OQg 310 Ol MENISSY 20418900 FAM T q G 1N 31895 ol LOA e 1 1 3A1LV93N vn 5 uld 03 3 4 UO pea 2314 P31 59P 241 01 24415509 se 9 N 2 274 pay 95012 se uoj1isod e uj aj6ue sy e6e3 0 474 595592014 22 304 O3 1 5 21560 195 i mnm v Tp ki 1 Mic Uld gt 9poj129je eui se A E A O3 pe129uuO2 5 pJeog 4 uo pes 2
24. 6 3000 193915 ONILNNON Y EVN ONIMOHS AVMV LND 31V9 TINA E RE Ey N N NJ LNAWdIHS 1593 SZ OL WALI AdVL ONILNNOW 89 lt 1 ONIMOHS AVMV LND TIVOS TINA 21221 SS SERS LLL ML Ml LL lt 222 1777 12747474 CARA G1326 5 15 81B 3 8 82 101 1 Supersedes 52 1 101 1 Supersedes P 52 C 1 For 23 amp K236 Models below code 7500 use the parts marked X in Column 1 For K247 Models above code 7500 use the parts marked X in Column 2 For K247 HC Models above code 7500 use the parts marked X in Column Indicates a Change This Printing ITEM DESCRIPTION PART NO QTY 6 789 N NIO OJO gt O OJo 19 19 20 20 21 21 22 23 24 25 Q This part is obsolete and no longer available Motor and Gear Box Assembly See P 101 R Control Panel Assembly See P 101 O _ Upper Guide Wheel Assembly Includes E Upper Guide Wheel Assembly Includes Upper Guide Wheel Assembly Includes Shaft Shaft Bearing Bearing Retaining Ring Roll Pin 19967 43 Lockwasher Guide Wheel Mounting E106A 5 Washer Guide Wheel Mounting S9262 1 Lo
25. G1653 5 18 84 9 11 84 P 101 U b P 101 U b Indicates a Change This Printing ITEM DESCRIPTION PART NO 1112131415 789 N OJO A OJIN Hollow Set Screw T12932 2 1 Ceramic Insert T12576 1 1 Ceramic Insert T12576 2 4 Spring Liner T12931 35 1 Nozzle Tube Assembly 17543 1 Insulation Jacket S17545 1 Cooling Bar Assembly S17546 1 Nozzle Pivot Hub Assembly 114891 Set Screw S11604 42 Key M8776 89 Rotational Lock Screw Assembly T14885 Snap Ring S9776 46 Pivot Assembly 114883 Nozzle Insulator Assembly Socket Head Screw Nozzle Insert Assembly Pressure Belt 889 Pressure Arm Assembly T14890 Socket Head Cap Screw T9447 56 4 4 0 4 4 mb Flux Tube Clamp S17542 Button Head Socket Screw 111551 6 Hex Head Screw 1 4 20 x 1 25 Plain Washer S9262 23 Wing Nut T9968 1 Pivot Housing Arm M14717 Lock Washer E106 A14 Hex Head Screw 5 16 18 x 1 50 Mounting Clamp Assembly S17550 Roll Pin T9967 43 Plain Washer S9262 104 Roll Pin T9967 29 Pivot Handle 114939 1 Hex Head Screw 1 2 13 x 1 25 9 11 84 Flange Nut T3960 Nozzle Tube Strap T14974 Items Not Illustrated Flux Hopper Extension Bracket 17558 Flux Hopper Extension Pin S17559 Extension Pin Nut 1 4 20 Flex Tube T10642 106 101 101 405 AUTOMATIC INNERSHIELD NOZZLE ARAN el TARO SANS AA 7102 5 17 85 Indicates a Change This Printin
26. SuO 132a2uuO2 09 rm IIR E 043402 Sey pesinbes 10 jenuew 3 1990 G yN O 1949y 10 19 JO 550 pue 043u0 914 2IPIS P1 OS WANYW DNILV33d0 vN 33S SNOILOMBLSNI NOLLVTTVISNI TVNOILIGAV 303 11 6 04 swes 241 325 jsnu 921 05 293 4231 3146 04 ay pue 0 1402 9 4 2 5 05 943 5 Ay sejod ay Ar sejod burbueya 20 99 4015 939 duo e 9407 01 31 pue 440 Alluv10a SNISNVH ANV LUC dk AYOM OL LOBANOD WW Men2assy LOWINO S NN WO 13 SAY MOS 7 A WHIWY3L WHOM SN ON X Y z AVRINYaAl 3003813313 9341539 OL LO3WNNOD 1 41093 Said ERKA 9 12 Z 16 N S vN OL 774 5 943 93 304923002 91422 ay 32824407 TONINO EIE mn HERES 03 5 241 395 LA 9 uM Uld 03 ASA 03 259 gt 5 274 1595592024 10M1N02 Uld n 20 9 7774 2 pea p4eog 7974 uo pay oo 998 5 Vid 03 Tt 999 35 E
27. e SHO AHS Aia Aj y e Do not operate with panel open guards off e No operar con panel abierto o guardas quitadas e N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enleves e Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen e Mantenha se afastado das partes moventes e opere com os paineis abertos ou guardas removidas e XJ 27 amp IRGUAL EEE 5 e EX eo gel 2133 AREY cai Jas y e ale 441 gll Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENCAO jx 2 Chinese LEIA E COMPREENDA AS INSTRUCOES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE 080 E SIGA AS PRATICAS DE SEGURANCA DO EMPREGADOR ESMERO HOBETEE LIRA 3880 TLTMHOREME LN KIT PEt EE Ef MA E ER DE A EE BS SR ET 75 SEE HAY HYAA ira EPA Jail gll 03 al gll geil lala 1 LINCOLN 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 lincol
28. straight The tips should be in line with the O D of the drive roll for initial straightening adjustment If the wires are bowing to the right it is being over straightened If the wire is bowing to the left then the wire is not being straightened enough Adjust the knob until the wire comes out parallel and uni form Depending on how the electrode enters the straightener there may be some side bend to the electrode After the wire is coming out of the nozzle with satisfactory straightness the tip orientation can be changed to whatever angle between in line or cross seam is required This is accomplished by loosening the hexagon clamping nut and then rotating the tip or tip holder to whatever wire orientation is required February 1982 The Lincoln Electric Company Cleveland Ohio 44117 1199 Sec T2 5 6 File as Sec L2 5 6 for IM 278 A GENERAL INFORMATION The K278 Spreadarc oscillator has been designed for use with the NA 3N NA 3S NA 4 NA 5N or NA 5S head and control The primary application for this ac cessory piece of equipment is for hardfacing buildup using a Twinarc nozzle The Spreadarc Twinarc cov ers large areas quickly with smooth beads of minimum admixture with the base metal Flux cored electrode open arc and submerged arc procedures can be used The K278 Spreadarc produces a linear oscillation of the automatic head and nozzle The advantages of the K278 Spreadarc are as foll
29. 2 NA 3N 3 NA 4 NA 5N and 5 with high frequen Cy use parts marked X in column 2 For NA 2FV NA 3SF NA Indicates a Change This Printing 5NF and NA 5SF use parts marked X in column 3 DESCRIPTION PART NO QTY 123456789 Head Support M8232 Mounting Bracket Not Used on Tractor Models M6769 Includes Items 68 thru 77 Welding Head Support Bracket Includes M4016 1 Draw Bolt Head Support to Bracket T4893 3 4 10 HN Head Support to Mtg Bracket CF000025 Insulation 54322 Insulation Bushing T7305 18 Insulation Washer S10773 9 1 2 13 x 1 75 HHCS CF000277 Washer S9262 1 Lock Washer E106A 5 1 2 13 00027 Insulation Asbly High Frequency S11771 1 1 2 13 1 25 5 CF000030 Lock Washer E106A 5 e Clamping Bracket M10213 Clamping Band 512472 3 8 16 x 75 HHCS Clamp to Gear Case CF000034 x Socket Head Screw Clamp to Gear Case 19447 18 Pivot Block M10215 3 8 16 x 1 50 SHCS Block to Clamping Brkt Except NA 5N amp 5 T9447 18 3 8 16 x 2 75 Block to Clamping Brkt NA 5N amp Only 79447 31 Roll Pin Pivot Block to Head Support T9967 29 Draw Bolt Pivot Block to Head Support T4893 3 3 4 10 HN Pivot Block to Head Support CF000025 Spacer NA 5N amp NA 5S Only S10262 6
30. 289 1 appropriate for the NA 5 NA 5R speedmeter and wire drive being used 2 Remote Analog Signal Connections a Turn off the input power to the NA 5 and remove the Analog Interface Kit side cover panel by removing the two lower panel screws b Use twisted pair shielded cable to connect each analog signal to the Analog Interface Kit The cable shield should be connected to the signal source as close to lead connection as possible see connection diagram These leads should be routed through the cable clamp provided on the Analog Interface Box or through an appropriate user provided replacement box connector NOTE A plug buttoned hole cluster is also provided on later units to accept mounting of an MS3102A 18 type box receptacle such as L E Part No S12021 11 4 socket receptacle for 12020 3 4 pin plug with 512024 1 cable clamp c Using 250 x 032 quick connect female lead terminals connect the remote leads to the proper Analog Interface Board terminals per the connection diagram The Lincoln Electric Company Cleveland Ohio 44117 1199 3 Selection of NA 5 Front Panel Controls While Welding The two J quick connect terminals located at the left center of the Analog Interface Board can be connected together using a jumper lead This will permit selection of the NA 5 WELD controls by the Idle Mode Switch while welding as opposed to Idle Mode only selection
31. 600 Ib amp 1000 Ib Drum Inside Diameter in 34 3 8 178 3 8 87 3 cm 0 32 cm 0 95 Inside height of core in Central Not to exceed Assembly and Installation Sec T2 5 7 A Continued File as Sec L2 5 10 A for IM278 The Lincoln Electric Company Cleveland Ohio 44117 1199 INSTALLATION INSTRUCTIONS SPEED FEED DRUMS Axis diameter pulleys electrode M Check pull limits 4 4 and wire angle entry instructions Item 5 Drum Setup ALWAYS use caution proper equipment and appropriate procedures when moving the drums Improper handling may cause personal injury and or damage to the product For more information on safe drum handling please visit http www lincolnelectric com knowledge articles content drumhandling asp Drum Hat Installation 1 Before removing the lid set the drum on an appropriate dereeler Remove the drum lid used for shipping but DO NOT remove the center cardboard core Figure 2 Figure 2 2 Place the drum hat on the drum core Figure 3 03 2008 30 Minimum 10 inch 2 to 3 feet Insulated friction free eyelets a Hat N ON Speed Feed Drum gt gt Insulated friction free eyelet Load the wire from the drum past the hat Figure 4 and into the low friction insulated eyelet s Figure 5 The eyelet s must be between a 20 and 40 degree angle with respect to the vertical axis of the
32. A Just SUN i On Rona TAAVYL lt 129 QuvogH3WIL 171 O AA 1 7 a 24 DES asn Be ere YY YY 91901 282208 4888 LEVLS 8 25585535 AJUNOS HIMOA OL NON TVNOLLAO S85 4 4 4 2 anayo 300419373 e 268 ava dd viss 397104 Lyros The Lincoln Electric Company L 5721 Cleveland Ohio 44117 1199 Dimension Print 10 10 86F K278 SPREADARC DIMENSIONS MAXIMUM RRIA TRAVEL 2 131 90 Ga 4 n THIS AREA MUST BE KEPT UERR FOR MENTA 1 87Se DIMENSION PRINT 26691 INSWisnrdy NE Sam e s OL av Ti sarvios 352 0 6081 Was 55535 E SLUT v Ad 4939 guna OLLY 17 NL NO SY TE SI 3A N 7 Hm ANA EMT 18 wn mu 3393 3 rae Las 8771 on 8721 SOLOW 4533
33. RETURN MENU IM305 C 5 AUTOMATIC WELDING SYSTEM 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 READ ING THIS MANUAL AND THE SAFETY PRECAUTIONS CON TAINED THROUGHOUT And most importantly think before you act and be careful Damage Claims When this equipment is shipped title passes to the purchaser upon receipt by the carrier Consequently claims for materi al damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received 150 9001 E 4 it Under a a CERTIFICATE NUMBER 30273 For use with Models NA 5N NA 5NF NA 5S NA 5SF OPERATOR S MANUAL Copyright O Lincoln Global Inc LINCOLN go 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 A WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to t
34. toque partes el tricas e elec trodos com pele ou roupa molha da e Isole se da e terra e Mantenha inflam veis bem guarda dos e Use protec o para a vista ouvido e corpo Japanese BIR EGA ZIEHE J amp 5n dcofMn5toct grek Chinese ERARIO DEMAS e 9 55 HP 13 HESMEEGHWRR s HA e ti E RUNE T A Korean eta SHE sj g ees SUB AZIZ ug er HAY 20 5552 e YA YAR SHALL T TAY AE a AL e JUI el N E gl gS Sd dana Ally As Je day e 9 READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER S SAFETY PRACTICES SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSAT
35. 0 01 IPM x 1000 2682 262 2 249 2 265 2 250 2 260 2 Present on Hi Speed NA 5 Speedmeter board only ID PRELIMINARY POWER SUPPLY CHECKS Be sure that the power source is ON and CONTROL Due to the unpredictable behavior that may result from POWER Sven ON NA faulty power supply outputs the 5 Power Supply Lights Check each light listed in the table below on the P C should be checked before further troubleshooting is at Boards tempted Power Board 15 V Analog 1B Power Board 10 V Analog Power Board 115 V Relay Logic Board 15 V Logic Reed Front Panel 5 V Speedmeter Dey r Front Panel 5 V Voltmeter 1 If the lights in the table are all ON then the power 3 Locate the ADDITIONAL SYMPTOM best describing supplies are probably OK If any lights are OFF or are the problem being experienced and proceed step by very dim refer to COMPREHENSIVE TROUBLE step through the troubleshooting instructions given for SHOOTING GUIDE the specific symptom 2 If power supplies check OK locate the problem being experienced in the COMPREHENSIVE TROUBLE LESHOOTING GUIDE INDEX and refer to the sec tion specified by the Index July 1992 135 135 RETURN MAIN INDEX NA 5 SEC T7 1 PARTS LIST INDEX Wire Feed Gear Box Wire Feed Drive Roll Box For Codes Below 8800 Only P 100 D Wire Feed Drive Roll Box For Codes Above 8800
36. 2 Unplug the wire feed motor and flux hopper cords from the control box 3 Remove the flux hopper Be sure the draw bolt nut H is tight and remove the roll pin G from the head mount ing block F 4 Support the head so it cannot fall loosen the draw bolt nut H and lower the head from the mounting E or optional horizontal adjuster D or vertical lift adjuster Optional Vertical Lift Adjuster Standard Mounting 88My 6 7 Horizontal Adjuster Optional 8 2 Remove the four Allen screws which hold the mount ing block to the gear box mounting plate Save items G H J Q and F for reassembly if the K218 is to be removed Attach the pivot assembly S included in the kit to the gear box mounting plate using the two 2 13 hex head screws T and lockwashers included in the kit Put the draw bolt U shipped with the kit into the pivot assembly S with the cut in the bolt in proper position to allow the assembly to slide onto the head mounting With the wire feed motor vertical slide the entire assem bly onto the post of the head mounting E or optional horizontal D or vertical lift adjuster E and tighten the nut V Drive the safety roll pin W shipped with the kit into the pivot assembly This pin holds the head on the mounting but allows it to pivot about the axis of the mounting post when the nut V is loose Loosen the lock nut
37. If the selector switch is not set to the REMOTE position the weld procedure will automatically alter to that selected by a remote signal when the weld is started and return to the selector switch procedure when the weld cycle has ended D OPERATION 1 Panel Controls a 96Fe Panel Lights The Multi Procedure Kit panel lights always indicate the weld procedure number which is presently selected However the selected weld procedure is not functional nor displayed on the NA 5 meters unless the NA 5 WELD mode light is on Panel Selector Swtich The Multi Procedure Kit panel selector switch allows the selection of any of the four weld procedures by rotating the knob to the positions for Weld Procedure 1 2 3 or 4 Assembly and Installation By rotating the selector switch knob to the RE MOTE position the weld procedure is selected by a remote signal connected to the kit as described in Section C The kit s panel lights will indicate the selected weld procedure Procedure Controls The standard NA 5 Weld Controls are used to set the Wire Speed and Volts for Weld Procedure 1 Weld Procedures 2 3 and 4 are set using the appropriate Wire Speed and Volts controls located under the lockable security panel of the Multi Procedure Kit The weld procedure control settings are functional and displayed on the 5 meters only when the NA 5 WELD mode light is on and the specific Weld Procedure number has been sele
38. T13586 23 Drive Wheel Helical Tooth Std Above Code 9000 T13586 1 24 Key 00000000000 O i Nut T10552 26 1879 2 27 Bearing Assembly Includes 4 27 Bearing Assembly Includes 4 Bearing 1 a rm 28 Roll Pin 19967 43 43 WEY 5 Mounting Angle S16138 2 X 1 30 Nameplate 5 75 in min 30 Nameplate 15 270 in min M13469 4 1 39 Hex Head Screw 3 8 16x 875 3 34 Lockwasher E106A 4 3 35 Hex Jam Nut 3 8 16 1 36 Wire Reel Support L3154 1 37 Roll Pin 19967 30 1 38 Lift Handle M12968 1 39 Mounting Plate 515082 1 40 Hex Head Screw 1 4 20x 75 4 41 Plain Washer S9262 98 6 42 Lockwasher E106A 2 6 43 Hex Nut 1 4 20 4 44 Insulation Washer S10773 12 4 45 Insulation Tube T7305 19 4 46 Insulation Plate S10300 1 47 Lead Clamp T12563 7 2 48 Lead Clamp T12563 7 1 49 Lead Clamp T12563 6 1 50 Round Head Screw 10 24x 750 1 05 20 2005 P 132 D a P 132 D a MOTOR AND GEAR BOX ASSEMBLY 15197 9 11 86 9 11 86 P 132 D b P 132 D b Use only the parts marked X in the column under the heading number called for in the model index page Indicates a Change This Printing ITEM DESCRIPTION PART NO QTY 11231456 789 1 Motor amp Adapter Assembly 255 amp K325HC S Includes L5195 4 1 1 Motor amp Adapter Assembly K325F K325HC F Includes L5195 1 Motor Assembly Includes L5198 3 Motor Assembly Includes L5198 2 1 Motor In
39. at a standstill until the arc starts Standstill travel starting is used when the electrode must be started at a precise location For consistent arc striking with Standstill travel starting always clip the end of the electrode to a sharp point before starting Stopping Sequences As shipped the travel stops when the Stop button is pressed producing a smaller crater area When the end overlaps the beginning of the weld re connecting to stop the travel later in the sequence spreads the crater over a longer area Reconnecting the Travel Starting and or Stopping Sequence To change the travel sequence turn off all input power to the NA 5 control box Open the control box The logic board is mounted on the back of the box in the upper right hand corner To change the travel circuit for the various modes of starting and stopping follow the information on the table of the wiring diagram for the NA 5 being used Table T 3 5 at the end of this seciton also shows information on reconfiguring the travel sequences Wire Feed Motor Acceleration The NA 5 has two different speeds of controlled wire feed motor acceleration As shipped the unit is con nected for fast acceleration which is best for most ap Operating Instructions Sec T3 5 2 Continued CN 3 plications To change to the slower acceleration turn off all input power to the NA 5 control box Open the control box Locate the Contr
40. control 3 When it makes electrical contact with the work the arc strikes and the circuit automatically switches from Strike settings to Weld or Start if used settings B NA 5 models above Code 8300 offer both hot start arc striking as described above cold start arc striking which operates as follows 1 Press the Inch Down button until the tip of the elec trode touches the work automatically stops and the flux if used is automatically dispensed NOTE If Inch Speed is set too high the electrode may stop with too much force on its tip resulting in possibly poor starting 2 The arc establishes when the Start button is pressed and the circuit automatically switches to Weld or start if used settings Should the arc not start immediately the wire will retract slightly until the arc is established and then feed down in the normal manner Use either the standard on the fly travel starting or rewire the controls for standstill travel starting per Sec T3 5 2 below C Optional Start Controls Recommended for applications where penetration bead size and other weld characteristics must be care fully controlled at the start The starting sequence is as described above except when the arc strikes the machine welds at the wire speed and voltage set by the Start Controls panel until the time set on the thumbwheel switch elapses The circuit then automatica
41. periodically thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV limits 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 prod ucts 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 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 Also see item 1 b 6 j 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 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 249 1 and the operati
42. 118 Washer S9262 23 119 Lock Washer E106A 2 120 1 4 20 x 1 00 HHCS CF000015 121 Contact Jaw T10266 122 1 2 13 x 1 50 HHS CF000052 123 1 2 13 HN CF000027 124 Socket Head Screw T9447 10 N A AJA A gt 125 Washer 126 Nameplate 127 Drive Screw 128 Flux Tube Support Assembly 129 5 16 18 x 3 4 HHCS CF000049 Outer Drive Rolls KP1889 1 Center Drive Roll S14905 Drive Roll Spacer T12146 1 Idle Roll Assembly 513165 Drive Roll Key M8776 6 Wire Guide Tubes Upper amp Lower KP1982 1 Wire Straightener See P 100 M ply BA ALAR A Al Ala A Second Wire Reel amp Reel Mounting See P 100 G 08 28 2007 P 101 L 2 P 101 L 2 K239 INNERSHIELD TWINARC KIT j Water cooled Socket HD a SS SY S ge E Eto 21233002 Screw Part of item ket asbly Wire guide 4 block asbly jac d BEER KSSS E EE SN 77 EN lt lt Y EXE LAM ATS TD 101 L5421 3 22 85M P 101 L 3 P 101 L 3 Indicates a Change This Printing ITEM DESCRIPTION PART NO 1123456 7 Twinarc Complete Includes All Below K239 Nozzle Assembly L5421 1 0 AI 2 Hex Head Screw 5 16 18 x 75 2 3 Socket Head Screw 79447 10 4 Flat Washer S9262 23 4 3 Insulating Washer S10773 12 8 3 Insulating Bushing T83
43. 24 x 50 2 14 Lock Washer E106A 1 2 15 Oil Cup T10643 1 16 Needle Bearing S10116 1 1 17 Thrust Washer S9262 37 1 x 18 Cover Plate T14606 1 19 Lock Washer E106A 1 2 20 Round Head Screw 10 24 x 50 2 21 Expansion Plug 110542 1 1 22 Shim As Req d 23 Locking Plate 1 24 Socket Head Cap Screw 2 25 Lock Washer 2 02 04 2002 101 101 HIGH FREQUENCY UNIT 238 TRANSFORMER RESISTOR HI FREQU CAPACITOR TERMINAL STRIP CAPACITOR RELAY SPARK ASSBLY AIR CORED TRANSFORMER SPARK GAPE MOUNTING PANELO AND BRACKET L6329 10 21 83 6 15 84 P 101 T b P 101 T b Indicates a Change This Printing ITEM DESCRIPTION PART NO 1123456 7 High Frequency Unit Includes K238 Capacitor 17571 Transformer M15359 9 Hesistor S10404 53 Case L3815 1 Case Cover L3816 Nameplate M9591 Terminal Strip 13323 1 Number Plate T10726 92 Relay 512807 Spark Gap Assembly S16501 3 Electrode T11236 1 R F Choke T12218 1 Air Core Transformer 14283 11111 07 11 2002 N ja lo 0 This part is obsolete and no longer available P 101 U a P 101 U a K386 NARROW GAP DEEP GROOVE SUBMERGED ARC NOZZLE N E SECTION THRU NOZZLE sey 9 10 11 12 13 14 15 16 17 WITH JACKET REMOVED O DOUBLE SIZE 7 ee ee nen 5 5 SS 228 um PM RE T 18 19 20 21 22 23 24
44. Change This Printing ITEM DESCRIPTION PART NO 5 789 Flux Hopper Assembly Includes Flux Hopper Assembly Includes Standard Flux Hopper Assembly Includes 225 226 227 228 229 234 235 236 237 241 241 250 250 250 251 252 Flux Hopper Base Flux Gate Spring Flux Gate Wear Plate Flux Gate Spring Flux Gate Assembly Includes Flux Gate Sub Assembly Solenoid Plunger Spring Retaining Washer Retaining Ring Washer Flux Tube Assembly Sems Screw Solenoid Switch Flux Hopper Assembly Flux Hopper Assembly Standard Flux Hopper Assembly Sems Screw Gasket 256 Flux Tube Shown 257 Flux Tube Not Shown Pointer and Mounting Bracket Assembly Includes T12590 Pointer and Mounting Bracket Assembly Includes T12590 1 NIO CO lO E Insulating Washer Washer Wing Nut Hex Head Bolt Insulating Bushing Pointer Bracket Door Hinge Assembly Hex Head Bolt Hopper Mounting P 101 H 1 For the NA2 use the parts marked X in Column 1 For the NA4 and NA5 use the parts marked X in Column 2 For the NA454 use the parts marked X in Column 3 gt lt 21 NENNEN X XX X X X X XIX XXX o T10082 4 X T10545 T10642 11 57748 35 O o OO ONN 1 4 20 x 6 0 This part is obsolete and no longer available 04 12 2004 101 K148 CON
45. Company Cleveland Ohio 44117 1199 Operating Instructions SEC T3 2 ROUTINE EQUIPMENT OPERATION pecs 13 2 1 File as Sec L3 2 for IM 278 Operator s Instructions Have an electrician install and service this equipment Turn the input power off at the fuse box before working on equipment not touch electrically hot parts can kill Once properly set up per Sec T3 4 the operator can make production welds without readjusting controls using the following simple instructions l Be sure there is enough electrode in the machine to complete the weld 2 If submerged arc welding fill the flux hopper with new or freshly screened flux All reused flux must be screened 100 through an 8 mesh screen a 065 075 opening Turn the switch on the hopper to On 3 Start the power source 4 Turn the Power Control switch on the wire feeder control to On 5 Position the welding head at the start of the weld Be sure the travel carriage or other tra vel mechanism is set to move in the proper direction 6 Set the travel switch to Automatic Travel 12 When set to Travel the travel system operates without welding For best starts cut the electrode to a sharp point Press the Inch Down button to feed the elec trode out of the nozzle a For most applications when using hot
46. Cross Seam Adjuster May 1988 82Fe Assembly and Installation The Lincoln Electric Company Cleveland Ohio 44117 1199 Sec T2 2 1 S Available Models MODEL NA 5S SET UP FOR TWINARC Required Power Source DC Variable Voltage or DC Constant Voltage REEL MOUNTING SHAFT with brake assembly optional CONTROL BOX order separately WIRE REEL for 50 amp 604 Coils optional Pr VERIS Te ADJUSTER optional TRAVEL CARRIAGE optional CROSS SEAM ADJUSTER TRAVEL BEAM customer furnished STD 4 CONTROL TO HEAD CABLE ASSEMBLY includes two 4 0 electrode cables HEAD HEAD MOUNTING PARTS 8 with insulation FLUX HOPPER and hardware with electric flux valve ASSEMBLY includes extra wire reel reel brake and mounting optional TWINARC CONTACT 5 4 CORD flux hopper to control box MODEL NA 5SF HEAD For Machinery and Fixture Builders NA 5 Control order separately Required Power Source DC Constant Voltage Identical to the NA 5S except the following parts are not included Head Mounting Parts 4 Electrode Cable Cross Seam Adjuster Flux Hopper and Pointer Assembly July 1992 The Lincoln Electric Company Cleveland Ohio 44117 1199 Installation MECHANICAL INSTALLATION CONT D dec 12 2 2 File as Sec L2 2 2 for IM 278 Head Installation A GENERAL REQUIREMENTS All Models Mountings and Fixtures Desi
47. DILWWOLT OL LO 91315 IL TUS AM WAS Avan Y 129902 16 00819 DILVWOLTTY OL 4815 0993 18 AV Y 1938805 77 32594005 VIMOS 39 NA ALMA BOs AUDVIVI STRRV ONIGIIN 325 s WATE now NOWWO Bt ONILNHOW Q HOW 24 Q ani an 2234708 AL MINI ANY 238 5 NA 5 Head AND Controls Must Above Code 8300 9 Y Wi 2 OW SONILNQOW QN3H 304 NOILWINGN SIA AH 4 AOA NOV Wen X013 Bod NOHNINSN 038343 22015084 2 _ 30104 GYAN 3314 4 AWOL 1 2 LNA 3HI 9NILS3NNOO 3303389 0110655 4 February 1982 The Lincoln Electric Company Assembly and Installation Cleveland Ohio 44117 1199 1119 S 918 02 2 NOISNAWIG IOBINOO YS YN 3370H 7 00 21 1 02 7 1 6071 vet 1 LIT d 26 01 ig 100008 S310H 299 Q na 87 022 19 9 eer 9 38149335084 IVNOILdO K349 MULTI PROCEDURE 971115 21 1 5
48. February 1982 Sec T6 4 2 Wire Reel Mounting for 50 or 60 Coils Periodically coat the reel shaft with a thin layer of grease No maintenance of the two position adjustable brake is needed except to replace the shoe assembly if it wears through February 1982 Sec T6 4 3 Travel Carriage See maintenance information in Sec T2 2 4 C February 1982 Sec T6 4 4 Vertical Lift Adjuster Every month add a few drops of SAE 140 oil or equivalent to the oil cup on the back of the vertical lift housing Every year replace the grease in the top section gear cavity with a medium grease If the unit is disassembled for cleaning apply a layer of medium grease to the screw threads of the head lift tube Item 2 of P 101 S and head lift screw 8 Apply a thin layer of grease to the OD of the head lift tube and the ID of the long hole in the head lift body 1 Slide the head lift tube into the head lift body and screw in the head lift screw Fill the upper section gear cavity one half full of grease Be sure the needle bearings are packed with grease February 1982 Sec T6 4 5 Horizontal Adjuster Twice a year apply a thin coat of grease to all sliding sur faces Every year replace the grease in the gear cavity with a medium grease February 1982 92Jy Sec T6 4 6 High Frequency Generator K238 See maintenance information in Sec T2 5 8 February 1982 Sec T6 4 7 Spreadarc K278 See maintenance information in
49. HO y LA 9 005 289 019 TVNOILdO Zug 222 1018 009 lt 9 29 1 289 lt 079 019 18 16 lt 589 v y 685 129 NOILdO pa c one ae 1 828 les UN 795 2 S 585 5 vies 5 ser 0L mn i 018 m 5 225 NOLLOANNOO P mo a 1594 8 gt 9013 d Me 009 zes v 3004109313 yee aoe 28 Sla a 2 2 951 28 Les 006 5 eni tanod 143038 THAVHL SP S 824 2 S 9 ezr 7 1 00070 6 918 5991 26 089 NON MOTS CURAS iio 6829 noron 199 9 829 HOLOV INOO L al 095 8 gt 009 1 6 H gt SEM 0 29 56 829 am ATIVOLLINO VIN 22 e 885 L ips 189 689 009 9 3snd ami VN Danna WN UM Jda Bi SEE Ses 2 los 889 019 8 MOS VEL OO 91 282333 err 2 999 A 4 ar 626 lt 1 C otaga 888 00 88 VOR 598 2 188 2 9 GALWNLOV HOLIMS 98 roo z EA H313ALLTOA 9586 L lt A AV 13H S ASN INIL 1991
50. Helical Gear 95 1 Ratio Helical Gear 55 1 or 57 1 Ratio Helical Gear 142 1 Ratio 512503 512881 512882 Socket Head Screw T9447 28 Snap Ring 59776 23 Gear Case Collar M10256 Hollow Set Screw 511604 13 Output Shaft Assembly 512509 Drive Roll Spacer T12146 gy P n mm o mo2crm2 r r r c Oil Seal 57611 15 Gasket 0125 Thick Gasket 004 Thick T12119 1 T12119 2 As Req d As 0 This part is obsolete and no longer available Spacer Washer 003 Thick Spacer Washer 010 Thick 59262 110 59262 111 Req d Req d 09 27 2007 WIRE FEED DRIVE ROLL BOX P 100 D 1 P 100 D 1 For Twinarc two electrodes fed through one head For 3 32 thru 7 32 wire use the parts marked X in column 1 parts see the appropriate Twinarc Assembly parts list in the P 101 series For 1 16 thru 3 32 wire use the parts marked X in column 2 Indicates a Change This Printing For 035 thru 052 wire use the parts marked X in column 3 ITEM DESCRIPTION PART NO 123456789 1 Faceplate 4052 1 2 Idle Roll Assembly 512475 1 3 Incoming Guide Tube 3 32 thru 7 32 Includes S10168 4 1 X 3 Incoming Guide Tube 1 16 thru 3 32 Includes S10168 2 1 3 Incoming Guide Tube 035 thru 0
51. Lincoln Spec E2322 For access to the gears in one chamber remove the adapter plate and motor assembly To lubricate the gears in the other chamber remove one of the pipe plugs and feed grease in contact with the bevel gear teeth while rotating the output shaft until all teeth are lubricated February 1982 Sec T6 2 2 Changing Wire Size and Wire Feed Gear Ratios Four wire size conversion kits are available to convert wire feeder for different size or type electrodes The kits include drive rolls and guide tubes for the wire specified 3 32 7 32 Solid or Cored T13724 A 1 16 3 32 Solid or Cored T13724 B 035 052 Solid T13724 C 045 052 Cored T13724 D To have proper wire speed calibration the proper combi nations must be used See section F 5 or NA 5 wiring dia gram for proper pin settings on the wire speed meter PC board Four gear ratios are available 21 1 57 1 95 1 and 142 1 To change the gear ratio replace the motor pinion and the first reduction gear per the following instructions Refer to P 100 C and P 135 C l Remove the four round head screws which mount the motor adapter plate to the gearbox Remove the motor and adapter plate from the gearbox 2 Take the two longer screws removed in Step a and screw one into each of the tapped holes located in the face of the fiber input gear Item 13 Insert the screws through the full thickness of the gear and using a 92Jy screwdriver wedged bet
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53. Present on Hi Speed NA 5 Speedmeter board L8575 1 only b Check for proper inches of wire fed per revolution of drive roll IPR 1 Set the STRIKE Speed Control to any setting bet 12778 Single 035 052 Solid ween 50 and 125 in min Measure the precise length 19113 Single 045 052 Cored of wire fed by exactly 10 revolutions of the drive 512515 Single 1 16 3 32 roll while pressing the INCH DOWN button dm nis as 2 The measured length should be within the range 513161 052 Twin 045 052 specified by the table below for the drive roll and 512161 5 64 Twin 1 16 5 64 wire size employed 514905 inner Twin 3 32 12514 Single 3 32 7 32 14904 outer 514905 inner Twin 5 64 1 8 92 Troubleshooting Guide The Lincoln Electric Company Cleveland Ohio 44117 1199 Sec T6 6 Continued table below 3 If the measured length is not within the specified 2 While pressing the INCH DOWN button the Drive lengths refer to Section IA 1 and IA 6 Roll RPM revolutions counted in 60 seconds and the ACTUAL Speedmeter reading ACTUAL button c Check for proper drive roll revolutions per minute pressed should be as per table and correspond to the USENI SET Speedmeter reading If accuracy checks do not 1 Set the STRIKE Speed Control to obtain the SET match per table refer to COMPREHENSIVE Speedmeter reading specified for the Speedmeter TROUBLESHOOTING GUIDE Calibration Pin and head ratio employed per the 0 27
54. TERMINAL STRIP Lincoln lt Part No 5 13605 Leads from normally open relay contacts to switch exter nally powered load rated 3 amp 125 VAC max February 1982 Sec T2 5 15 K224 Solid State Remote Field Control Discontinued Required when using a SAF 600 or SA 800 motor generator type power source Mounting instructions are shipped with each kit Electrical connections are included in the appro priate connection diagram Sec T2 3 4 A July 1983 Sec T2 5 16 K223 Solenoid Kit The solenoid includes a valve for control of the water flow when using the cooling attachment on the K148 or K239 The Lincoln Electric Company Cleveland Ohio 44117 1199 contact nozzle assembly It opens when the Start button is pressed and closes when the Burnback timer times out Installation instructions are shipped with each kit February 1982 Sec T2 5 17 K58 Magnetic Separator The K58 is a permanent magnet type separator designed to fit the top of the standard fill funnel of the continuous flux feed system or the top of the K219 flux hopper of a full automatic head The purpose of the separator is to remove magnetic mate rials such as mill scale and any other extraneous magnetic materials which may have been recovered along with the flux to be processed It s important to remove these magnetic particles from the flux which is to be reused in the continuous flux feeding system If the magnetic material is no
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56. Time control The control starts timing when the Weld Controls become operative and energizes the stop circuit when it reaches its set time Install the optional Weld Timer module per the instructions included with the kit Setting the weld time for zero seconds will bypass the weld mode control settings during the welding cycle Crater Controls 13 Optional On some appli cations and procedures it 1 desirable to weld at a different wire speed and voltage at the finish of a weld for a short period of time for crater filling purposes The optional Crater Controls has been designed for this purpose and allows higher or lower values than when welding Setting the Crater time to 0 00 seconds will give zero crater fill time however the crater settings will be active during Burnback time until the arc goes out Install the optional Crater Controls per the instruc tions included with the kit Note that the same The Lincoln Electric Company Cleveland Ohio 44117 1199 Sec T3 3 1 Continued 88My kit can be used for either Start Controls or Crater Controls and proper function depends on correct installation Although the timer can be set for 9 99 seconds the majority of applications will require only 0 25 to 2 00 seconds A good rule to follow for the initial settings of the Crater Controls is to set them at the same settings as the Weld Controls wire speed and voltage The time delay can be set for about one second After
57. V and position the pivot shaft of the pivot assembly S parallel to the weld travel direc tion Tighten the lock nut V INSTALL THE CONTACT ASSEMBLY AND FLUX TUBE Rotate the drive roll box to position the wire straightener ontop Put the outgoing wire guide from the drive roll mechanism into the hole in the top of the fillet lap at tachment contact assembly Place the contact assembly in position on the bottom ofthe drive roll box and tighten the two screws which hold it to the head Assembly and Installation Sec T2 5 4 and L2 5 4 Continued 3 Connect the electrode cable from the control box to the contact assembly Place one cable on each side of the connection tab with the lugs flat against the tab and tighten the bolt and nut nstall the flux hopper If adding a flux hopper kit to an NA 3N or NA 5N install per instructions shipped with the kit Attach the flux tube included in the kit to the flux hopper and tighten the wing screw Plug the wire feed motor and flux hopper cords into the appropriate receptacles on the side of the control box INSTALL THE FLUX CONTROL KIT T 14861 This kit includes a mechanical flux flow control arm which is installed as follows l Remove the 5 hex head screw from the sloping surface of the flux hopper Replace this screw with the longer screw and lockwasher included in the kit and tighten the screw Put the flat washer from the k
58. brushes are checked also inspect the grease in the gear box If it appears hardened or dirty it should be changed as follows Disassemble the unit as described in Step B Do not loosen the motor mounting screws for the reason stated in Step B Remove the four screws holding the gear case to the motor frame at the large flange Assembly and Installation Remove the gear case from the motor Remove as much as possible of the old grease from the gear case Do not wash in solvent Repack with Plas tilube 2 Warren Refining Company Cleveland Ohio or an equivalent grease and reassemble Control box Every six months inspect the control box If needed blow dirt out using low pressure air Replace screw holding cover in place E TROUBLESHOOTING 1 Circuit Protection The 0 8 circuit breaker mounted on the control box door protects the con trol circuit and motor from short circuit conditions It also protects from severe overload conditions such as an obstacle restricting carriage movement If it opens determine and correct the cause of the overload To reset the circuit breaker push the red button The motor may or may not have an automatic thermostat mounted within the motor case If the motor has a thermostat and operated under server conditions the thermostat may or may not open before the circuit breaker opens The ther mostat will close when the motor has cooled down If the motor does not have a
59. can usually be positioned to meet the requirements B INSTALLATION PROCEDURE 1 Remove ingoing spring wire guide 2 Remove ingoing wire guide tube 3 Insert the new ingoing wire guide tube ceramic in serts 4 Place the wire straightener over the guide positioned as outlined in above and tighten the two hex head screws C REELS AND SPEED FEED DRUMS See Sec T2 5 7 for detailed instructions on wire feed ing from Speed Feed Drums and Reels D WIRE LOADING AND STRAIGHTENER AD JUSTMENT 1 Turn the straightener knob to the maximum open position 2 Remove the top ingoing guide block by loosening the thumb screw 3 Straighten each coil end for a distance of approxi mately 10 the straighter the wire the easier to load 4 Insert one wire in each of the guide block holes 5 Enter both wires down through and between the rollers then through the upper wire guide tube until the wires touch the drive roll Push the inch button and start the wires through the wire feeder 92Jy Assembly and Installation K281 SOLID WIRE STRAIGHTENER FOR TINY TWINARC 6 Replace the upper ingoing guide block which is 4 with two roll pins Make sure that each wire is in its respective groove in each of the rolls Tighten the thumb screw 7 Turn the adjusting Knob until the moving arm is ap proximately in the mid position of its total move ment Electrode Adjusting knob straight a
60. drum or reel per Section T2 5 7 A or B Straighten the first six inches of electrode and push it through the wire straightener to the drive rolls To use the cored wire straightener remove the knurled nut at the top feed the wire through the nut down into the straightener and into the drive rolls Screw the nut back onto the straightener Feed wire through the nozzle tip and adjust the straightener for optimum straightness With wire contact assemblies except the K231 adjust until the electrode is straight as it comes out of the nozzle Do not completely straighten the wire when us ing a K231 contact nozzle because the nozzle relies on a small curvature of the electrode for proper electrical contact within the contact tip Set the travel speed as specified by the procedures With the wire feeder travel switch set to Hand Tra vel the travel runs without welding permitting accu rate measurement of travel speed When using a Lin coln travel carriage adjust the speed with the rheostat and the direction with the toggle switch on the carriage control panel Connect the work lead to the work or a suitable piece of scrap Clip the end of the electrode to a sharp point Preset the Start if used Weld and Crater if used Controls to the wire speed and voltage specified in the procedure Make several test welds readjusting the controls in the following order a Set the Arc Striking Inch Wire Speed and Volt
61. either on the standard travel carriage or a separate fixture It is electrically grounded by alead in the input cable assembly When mounting to the travel carriage use mounting kit T14469 Bolt the adapter plate to the top of the carriage using the hardware supplied The NA 5 control box is then mounted to the adapter plate using four bolts and lock washers two from the bottom and two on the back M 13945 Adapter Plate 1 4 20x 3 4 Screw 1 gt gt gt Did TC 3 Carriage Lockwashers 106 2 4 174 20 x 62 H H Screws 4 4 LP O d c d S d u A n bl dl Dn qu 1 4 20x 3 4 Screw 2 1 4 20 Hex Nut 2 E106A 2 Lockwashers 2 For complete details on carriage operation see Sec T2 2 4 If mounting the controls on a fixture use the mounting holes provided in the bottom and or back of the box See dimen sion print 16717 The control box should be mounted so the controls and meters are convenient for the operator February 1982 The Lincoln Electric Company Cleveland Ohio 44117 1199 Installation MECHANICAL INSTALLATION CONT D Sec T2 2 4 C File as Sec L2 2 4 C for IM 278 K325 Travel Carriage Installation Codes Above 8000 The carriage is available in two versions a Standard Carriage for normal loads and a High Capacity HC Carriage for heavy loads The units are convertible f
62. exposed and 12 inch unexposed electrical clearance between the head mounting bracket and mounting surface including electrically common mounting hardware A GENERAL The K238 High Frequency Unit supplies high frequency power to the welding leads for more positive starting on some jobs It operates on 115 volts 50 or 60 hertz power supplied from the NA 5 The welding circuit of the K238 is rated at 750 amps 10096 duty cycle welding current It cannot be used with the Linc Fill Starting Relay or the Spreadarc options It is to be used only with the hot start ing start sequence B HIGH FREQUENCY INTERFERENCE PRO TECTION It is important that the energy from the High frequency unit be utilized at the arc and the amount radiated kept at a mini mum The following instructions must be followed to minimize the amount of RF radiation as required by the to prevent malfunctioning of the NA 5 control and for safety 92Jy l The work terminal at power source must be connected to a driven ground at the welder or to a water pipe that enters the ground within 10 feet of the power source The ground connection should be securely made and as short as possible using cable of the same size as the work cable or larger Grounding to the building frame or a long pipe system can result in re radiation effectively making these members radiating antennas 2 Keep the work and electrode leads between the high fre quency unit and the
63. filter lens should conform to ANSI Z87 standards Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays 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 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 within applicable OSHA PEL and ACGIH TLV limits using local exhaust or mechanical ventilation In confined spaces or in some circum stances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel 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 spe cific welding procedure and application involved Worker exposure level should be checked upon installation and
64. for three wire size ranges are available 035 thru 052 thru 332 and 382 thru 7527 If chang ing to wire sizes outside the range change the drive rolls and the incoming and outgoing guide tubes Also change the gear ratio Sec T6 2 2 if necessary The electrode is driven by gripping between the grooved drive rolls and a spring loaded idle roll Replace the drive rolls when they become worn The drive rolls for 045 052 cored electrode 6 and larger diameter electrodes have two sets of teeth so they can be reversed once before they must be replaced February 1982 Sec T6 2 4 Wire Straighteners 1 For Solid Electrode Periodically inspect the slide bushing at the top of the straightener and the ingoing wire guide at the bottom of the straightener for signs of wire milling If neces sary rotate the guide to present an unworn surface To reverse the slide bushing for a fresh wear surface remove the cross adjustment screw and turn the bush ing over Maintenance The Lincoln Electric Company Cleveland Ohio 44117 1199 Sec T6 2 4 Continued 2 For Flux Cored Electrode Severe wear to groove in the curved arm of the straightener can result in wire wander at the arc Periodically check the groove and replace the arm when badly worn Also replace the ingoing guide at the top of the straightener if it shows signs of milling the wire February 1982 The Lincoln Electric Company Cleveland Ohio 4
65. graphite and put the rubber boot back in place 2 V tracks and bearings Clean inspect and re lu bricate twice a year more often under severe duty applications as follows see Figure 3 Remove the four screws 1 holding the limit switch bracket 2 to the top cover 3 Remove the four screws 4 holding the top and bottom track covers 5 in place and remove track covers Clean the The Lincoln Electric Company Cleveland Ohio 44117 1199 Sec T2 5 6and L2 5 6 Continued 970c four groove bearings 6 and the top and bot tom V tracks 7 and inspect for wear Providing the tracks are not severely worn re lubri cate the contact surface of the bearings and tracks with a graphite or moly filled grease such as auto motive chassis grease and reassemble If the wear on the inside edge of the top track has reached 040 either interchange the top and bottom tracks if the bottom track is not severly worn or re place both tracks To remove the tracks loosen the 5 13 hex head screws 8 which hold the bottom bearings in place by rotating the screws 8 and holding the eccentric nuts 9 from turning Ro tate the eccentric nuts 9 to give maximum clear ance of the bearings to the track Remove the four screws 10 and 14 holding the control box 15 in place Maintain support on the control box to pre vent straining the leads from the motor While supporting the moving carriage remove
66. grease per Lincoln specifications E 2067 and Anti Sieze and Lub Compound made by Never Seez Compound Corporation 2910A 18th Ave Broad view Illinois Replace the locking ring and tighten securely 6 Check the contact tip to be certain it is tight in the nozzle body If the tip is not tight arcing will take place between the tip contact surface and the nozzle contact surface which will damage the nozzle body 92 April 1988 Assembly and Installation The Lincoln Electric Company Cleveland Ohio 44117 1199 Sec T2 2 8 File as Sec L2 2 8 for IM 278 For Submerged Arc Welding K285 Concentric Flux Cone The concentric flux cone was designed to fit on the K148 alone K148 with a K149 the K129 and K391 nozzles The maximum electrical stickout when using the K149 will be four inches Use of this attachment results in the flux being fed concentrically around the electrodes The unit consists of two members that are electrically in sulated from each other One of the members is fastened to the nozzle body with two worm type hose clamps The sec ond member is adjusted up and down on the stationary member to the desired height and then locked in position with a wing screw The moving member supports the flux hose and the concentric copper flux cone NOTE The concentric flux cone does not have suitable insulation for use with high frequency starting INSTALLATION A K148 Nozzle Remove spring pressure on
67. hits the shoulder on the screw 4 Insert one wire guide into the top of the faceplate Item 1 and slip the wire straightener down over the top of it The holes in the wire guide should be lined up squarely with the grooves in the drive roll as shown Point the bent arm of the wire straightener either to the right or the left depending upon the lo cation of the wire reels When properly set clamp straightener in position using the two L shaped clamps Item 5 EIN 5 Fit the other electrode guide into the top of the nozzle Install the nozzle to the head by first sliding the guide tube into the faceplate until the mounting screws supplied with the nozzle can be started into their respective tapped holes Tighten these two screws The lineup of the outgo ing guide is automatic 6 Fasten the electrode cables to the nozzle Use two 4 0 cables for currents up to 1 000 amperes at 8096 duty cycle Place one on the top and one on the bot tom of the electrode terminal and tighten the Y 13 bolt and the nut provided 7 Water cooling is required for Innershield Twinarc welding Connect the tubes included on the nozzle to the water supply and drain using rubber tubing obtained locally Water flow should be about gal lon of tap water per minute Installation of a solenoid valve assembly K223 for the NA 3 and 5 M10502 for the NA 2 is recommended to control cooling water flow Installation ins
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69. of the spring on the contact assembly holds the guide rolls in contact with the joint This system automatically compensates for misalign ment between the work and the head up to either ver tically or horizontally MAINTENANCE 1 Periodically grease the contact assembly pivot point through the grease fitting on the assembly Rusty or dirty wire and excessively high currents in crease jaw wear When arcing occurs in the jaws or the wire becomes loose in the jaws remove the jaws and dress them down by filing When an excessive amount of material 15 worn off replace the jaws Contact jaws manufactured after April 1979 have replaceable contact inserts refer to 101 April 1983 The Lincoln Electric Company Cleveland Ohio 44117 1199 Sec T2 5 5 File as Sec L2 5 5 for IM 278 The K281 Tiny Twinarc wire straightener will straighten 045 through 2 32 wire diameters It is recommended for welding procedures requiring long stickout and where wire position accuracy is essential The maximum recommended electrical stickouts are as follows A GENERAL INSTALLATION 1 For best wire straightening the plane of the straightener rolls should be as close as possible to the same plane as the wire reels 2 The straightener moving arm should be pointing to ward the reels and the adjusting knob should be away from the reels 3 The wire straightener can be mounted in two posi tions and the NA 3 NA 4 or NA 5 head
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71. plane as the drive rolls The distance between the wire reels and the head should be far enough 3 to 4 ft to allow the Innershield electrode to orient itself before entering the wire straightener INITIAL PREPARATION 1 Remove the following items from the head Save the parts so the head can be reconverted to single wire operation if required The wire straightener assembly Single wire nozzle assembly Upper and lower wire guide tubes The idle roll assembly See Sec T2 5 3 K129 e All the parts on the output shaft including the drive roll locating collar which is held on by a small set screw Cog me C INSTALLATION Refer to Parts List P 100 D l Install the new idle roll assembly and hold it in place with the pivot bolt Item 18 and nut Item 17 Do not install the idle roll spring screw Item 6 yet Install the drive rolls as shown Apply a little grease or oil to the O D of sleeve Key and carefully slide it D into the dust seal Drive roll Nut 92Jy Drive roll Drive roll locating collar 3 NA 3 or NA 5 Install the idle roll spring Item 8 spring screw Item 6 washer Item 7 and yoke in dicator assembly Item 10 Tighten the idle roll spring screw to the 035 32 setting on the yoke in dicator assembly NA 2 Install the idle roll spring Item 8 and spring screw Item 6 with its washers and the square nut Item 10 Tighten the spring screw until the nut
72. required to guide the electrode This is to help guide the wire out of the drum and prevent tangles or accidental grounding which can cause personal harm and or damage to the equipment See Figure 1 below for labeled illustration 6 Friction less insulated eyelet 4 Post 2 Turntable 3 Ball bearing 1 Fixed floor Plate Use equipment rated to lift weight of this drum If possible lift from bottom Lift only when cover locked in place Lifting device contact with underside of closing ring must be at least 38 Never stand under a lifted load Hats which fit inside the drum core are necessary to prevent the electrode from flipping over the top of the drum core and becoming tangled Please visit the Steel Hat Construction document at http www lincolnelectric com knowledge articles content steelhatconstruction asp for specifications on how to construct permanent steel hats Reusable fiber hats are available from the Lincoln Electric Company The Lincoln Electric product number for the reusable fiber hats is ED020219 Drum Dimensions 1 Dimensions of SPEED FEED DRUMS 30015 Drum _ Outside Diameter in 23 3 8 1 16 56 8 0 16 17 3 4 1 8 1 4 45 1 0 32 0 64 Height in without 2338 116 56 8 0 16 16 0 12 _ 40 6 1 3 Inside Diameter in 17 1 16 1 8 1 4 43 3 0 32 cm 0 64 Inside height of core in
73. steel plate on the nozzle to which the flux hose retainer ring is attached Remove the two screws holding this plate and rotate the plate 180 so the ring is closer to the bottom of the nozzle Replace the screws tdle roll arm d Insert the three prong line cord plug into a 115 volt 60 or 50 hertz outlet The Spreadarc unit is grounded through the line cord but the head mounting is insulated from the Spreadarc carriage Do not allow any con ducting element to bridge from the Spreadarc to the head since the head including the motor and gear box case is at welding potential 4 The Spreadarc can also be powered by an NA 3 4 NA 5 unit providing the welding power source supplying 31 and 32 has sufficient au The Lincoln Electric Company Cleveland Ohio 44117 1199 xiliary power capacity Instructions are as follows a Turn off the input power to the NA 3 NA 4 or NA 5 control box b Remove the three prong plug from the Spreadarc power cord and remove the rubber jacket 10 in ches from the end of the cord c Install a terminal for a 10 screw on the green lead and terminals for 6 screws on the white andblack leads d Install the power cord through the access hole n the left side of the control box using a strain re lief cable clamp e Remove the nut from the grounding stud located on the same side as the access hole Install the terminal of the green lead on the grounding stud keeping the other terminals
74. sw 591490 DUID OM 6 7 J 2322 muero se ES Y 318 2 1 S VN 01 IN A 90 94 92 05 BAO 19QUUOISH e pe oue SABADO INA 630 3000 30u 00 e ONINYYM w S 7575 N pt EE 2 m m Me r gt m 0 51 04 Hart 51 021 42919 YNN 304 00 517375 1 20 89 88 The Lincoln Electric Company Cleveland Ohio 44117 1199 Assembly and Installation SEC T2 5 OPTIONAL FEATURE INSTALLATION Sec T2 5 3 K129 File as Sec L2 5 3 K129 for IM 278 File as Sec E2 7 5 K129 for IM 245 K129 Submerged Arc Small Wire Twinarc In Twinarc welding two small diameter 045 5 64 3 32 solid wires are fed through a single wire feeder Both wires must be the same size Any standard NA 2 NA 2F 3 4 or 5 can be used Gear ratio of the head must be 95 1 The jumper on the 5 wire speed meter board must be in the proper position per Item E Adjust ments The Twinarc assembly includes a wire reel reel brake shaft and mounting bracket drive roll idle roll assembly and the needed dual wire guides nozzle and contact tip or contact tip holder Spacing between the wires is fixed by the holes in the contact tip or contact tip holder A Twinarc assembly is available for each wire size 045 1 16 5 64 and 3 32 Convertin
75. the controls should be set to O and the remote analog signals readjusted for the correct procedures These controls are functional and their settings are displayed on the NA 5 meters whenever the front panel light of the Analog Interface 15 on The Lincoln Electric Company Cleveland Ohio 44117 1199 Sec T2 5 20 Continued 2 Welding With Remote Analog Signal Control a Set proper strike procedure using NA 5 strike mode controls then set the NA 5 selector switch to WELD mode NOTE Step a 1 not required when using an NA 5R unit b Set the Analog Interface Idle Mode selector switch to ANALOG SIGNAL position and the Procedure Override Controls to c Adjust the Remote Analog S gnal levels so the NA 5 meters display the desired procedure d Start the weld and the welding procedure can be adjusted or changed as desired at any time during the weld by changing the Remote Analog Signal levels NOTE The Kit s Procedure Override Controls may be used for fine tuning of the weld procedure but the controls must be returned to 0 for proper IO volt for 10096 rated range calibration 3 Welding with NA 5 Weld Controls a Connect a jumper to the J terminals inside the kit s box refer to Section C 3 b With the Analog Interface Idle Mode selector switch set to NA 5 position the NA 5 operation is the same as if the Analog Interface Control was not installed c With the Analog In
76. the first test weld the controls can then be readjusted as desired February 1982 Operating Instructions The Lincoln Electric Company Cleveland Ohio 44117 1199 Operating Instructions SEC T3 4 SET UP INSTRUCTIONS AAWARNING Have an electrician install and service this equipment Turn the input power off at the fuse box before working on equipment Do not touch electrically hot parts can kill If using a multiprocess power source SAM SAF SA DC 400 DC 600 DC 1000 or DC 1500 type make connections and settings per the power source connec tion diagram for the process being used See Sec T2 3 4 AUTO TAB When using the NA 5 with a DC 400 power source the Auto Tab jumper on the NA5 voltage P C board must be connected in order for the inch down circuit to function When the Auto Tab jumper is connected the Cold Starting feature of the NAS is disabled and only the Hot Starting technique can be used Ifthe Cold Starting technique is to be used the optional K826 Diode Kit must be installed on the DC 400 Set the power source and NA 5 circuit polarity per in formation on Electrode Polarity in Sec T2 3 Depending upon the procedures and applications de cide a The means of arc striking and whether to start the travel with the Start button or the arc b Whether the initial bead size or penetration requires use of the optional Start Controls
77. weld 1 If the NA 5 still shuts down go to Step B below 2 If the NA 5 keeps welding change the R3S triangle setting to the next higher voltage and reset the NA 5 set point to the desired procedure The R3S is now set properly unless there is a signifi cant change in input voltage Skip the following step 88My B Move the 5 voltage set point 2 volts higher than the desired procedure and make a test weld 1 If the NA 5 now keeps welding change the R3S triangle setting to the next ower voltage and reset the NA 5 set point to the desired procedure The R3S is now set properly unless there is a signifi cant change in input voltage 2 If the NA 5 still shuts down refer to the following paragraph and the other possible causes previously listed In some cases it is also possible to hold the ACTUAL button pressed while starting the arc Before the 5 shuts down the actual arc voltage can be read on the digital meter Comparing this reading to the SET reading will tell what change in the range controls of the power source are required so it can supply the desired voltage Should the meter read zero check the NA 5 sensing leads 21 and 67 connections Should the meter read a minus voltage the polarity connections or settings at the NA 5 power source are Wrong This same general procedure can be used on other power sources For example if the NA 5 keeps shutting down and the other possi
78. would result in the wrong wire feed direction when the weld is started See Sec T3 8 In the case of full range control power sources such as the DC 600 this protective shutdown circuit could prevent welding under the conditions of 3 4 and 5 above by holding the power source output at minimum possibly pro viding too low of a power source output to even establish an arc or causing the field fuse to blow because of rapid field reversals with NA 5 controls above Code 8300 See Sec T3 8 Although out of range shutdown can occur with all power sources when working with very low or very high arc vol tages it is most likely to occur when using the R3S models with the somewhat limited voltage range of the various taps For instance if the R3S 400 triangle tap setting is for 31 volts the range of control from the remote circuit is approxi mately 7 volts i e 2712 to 341 volts at nominal input vol tage If the NA 5 controls are set for 29 volts and the input voltage to the R3S goes up it may not be possible for the 5 control circuit to hold the 29 volts so the welding will shut down By changing to the 27 volt triangle setting the range will be approximately 2312 to 301 volts and at high input voltage there will be sufficient control to hold the SET arc voltage On these machines if the NA 5 stops welding follow this procedure A Move the NA 5 voltage set point 2 volts lower than the desired procedure and make a test
79. 04 LINC FILL EXTENSION NOTE A The K103 nozzle for the NA2 is identical to the K233 except for Item A noz zle insert For the NA2 use both the appropriate Item A and the appropriate outgoing guide tube Item 15 of P 100 D PART OF HEAD ASSEMBLY for item A nozzle insert For the NA2 use both the appropriate Item A NOTE A The K103 nozzle for the NA2 is identical to the K233 except and the appropriate outgoing guide tube Item 15 of P 100 D re lt lt NOZZLE ASSEMBLY 2 17 V En A ehr gt AN 22 UU S AJ gt SS FT ARERR RU ERRE ke LLI LLI 02 LLI N N O K104 M12736 1 11 74B 512776 5 27 66 5 80 P 101 D b P 101 D b Indicates a Change This Printing ITEM DESCRIPTION PART NO 1123456 7 Nozzle Assembly Includes Nozzle Insert 035 052 Electrode Nozzle Insulator Socket Head Screw Hex Head Screw Hex Nut Nozzle Body Socket Head Cap Screw Pressure Spring Assembly Contact Pressure Shoe Socket Head Cap Screw Qo o JO AIO gt D gt 12 Nozzle 12 Nozzle 12 Nozzle 12F Nozzle 12 Nozzle Tip 12 Nozzle Tip Extension Assembly Includes All Below Insulating Plate Insulating Bushing Insulating Washer Flat Washer Lock
80. 1 3294403 esodund 5143 10 9146 16 pee Jom Bui Sues 3091 90591 5 0130 35 93 10 4631 5 an poje nsu Jable 40 50 7 pea g N 40 1321 pue ej3e peuu pue 3491415 293 40 42490 44 94 150 59 46 V N 5403294405 04 041402 20 enuey 3 4940 9 O J9jey uoij32euuo gt 4 2 94 y 03 5 94402 92105 9 04 IN 943 UO YDIIMS 2 1 3 1509 ey 500 921005 Jamod 991 3167 3081 2 73525006 spee pue gt ey 95 9 94 110 Jemod 4 09 31191 ebueu A13 SOd 29 SMOYS 941 4 OL S 16889 S16889 7 6 84G 88My The Lincoln Electric Company Cleveland Ohio 44117 1199 Connection of NA5 to DC400 or CV400 Assembly and Installation Sec T2 3 4 G 22195 3140104 0026 9poo 94 00 20 03 496 ou 5000 x Si 41146104 8P0 N9919 941 eq ISAW LOL 198UUOD 141 3340104 310m 5 Fey 16016403 2g 07 3594005 di 133 9 0 03 SI 124 y x N
81. 1 16 thru 3 32 S12515 2 14 Drive Roll 035 thru 052 512778 1 14 Drive Roll 045 thru 052 Cored Wire NA5 NA4 NA3 519113 2 16 Snap Ring S11910 2 1 XIX XIX 17 Drive Roll Key M8776 5 1 XIXIXX 18 Wire Straightener Single Wire oee P 100 K or M 1 XIX 19 Outgoing Tube 3 32 thru 7 32 10170 1 1 X 19 Outgoing Tube 1 16 thru 3 32 113635 3 32 1 19 Outgoing Tube 035 thru 052 045 thru 052 T13635 052 1 e 20 Socket Head Screw T9447 12 2 XIX XIX 21 Socket Head Cap Screw T9447 32 1 XIX XIX 24 24 Thru 27 See P 100 F 28 Cross Seam Adjuster Assembly See P 100 L 1 XIX XIX 29 29 thru 34 See P 100 F XIXIXX 35 Plain Washer S9262 131 1 36 Locking Key T14896 1 37 Hollow Head Set Screw S11604 8 1 Optional Drive Roller Conversion Kits Includes Drive Roll Incoming amp Outgoing Guide Tubes 3 32 thru 7 32 Wire T13724 A 1 16 thru 3 32 Wire 113724 B 035 thru 052 Solid Wire 113724 C 045 thru 052 Cored Wire T13724 D 035 thru 045 Spring Guide T9367 4 Note When using K231 or K233 Contact Nozzle a long guide sleeve is required inside the nozzle See P 202 M or P 101 D 09 27 2007 100 100 HEAD MOUNTING S For standard NA 2 NA 3N 3 NA 4 NA 5N and NA 5S use parts marked X in column 1 For
82. 1 Ratio W H F M14132 3 Drive Motor W O H F S16979 1 Drive Motor W H F 516985 Brush amp Spring Assembly M12254 1F Brush amp Spring Assembly Stature Motor M13312 12 Brush Cap Early Design 7 8 27 THD 9655 7 Brush Cap Present Design 3 4 27 THD M9655 7B Brush Cap Stature Motor M13312 13 Pinion 57 1 Ratio S15013 1 Pinion 95 1 Ratio S15013 2 Pinion 142 1 Ratio S15013 3 Pinion 21 1 Ratio S15013 6 DY NIN N AA Roll Pinion For Pinion T9967 33 Shaft Extension W H F Motor S12869 Coupling W H F Motor S12876 1 Roll Pin Coupling To Motor W H F T9967 28 Roll Pin Coupling To Ext Shaft W H F T9967 1 Bearing W H F Motor 9300 46 Snap Ring Holds Bearings S9776 27 Insulation W H F Motor S11756 A Tachometer Pickup Printed Circuit Board M14701 2 Tachometer Disc S16180 Tachometer Shield Mounting Plate 13629 Pickup Housing mss 0 This part is obsolete and no longer available 02 18 2002 QQ DD mb P 135 C 1 b P 135 C 1 b W O Without High Frequency Insulation W H F With High Frequency Insulation Indicates a Change This Printing ITEM DESCRIPTION PART QTY 1234567 1 CoverAssembly mes 1 2 Motor Adapter Plate 102551 3 4 HoseClamp 3 S108820 1 5 6
83. 101 1 Use only the parts marked X in the column under the heading number called for in the model index page Indicates a Change This Printing ITEM DESCRIPTION PART NO QTY 11231456 789 Nozzle Assembly Includes Items 110 thru 125 as appropriate for wire size specified Nozzle Assembly for LT34 ONLY Includes Items 110 111 118 121 and 122 Order Items 119 120 123 124 and 125 separately for the desired wire size 111 111A Nozzle Extension 5 38 long For 3 82 amp Larger Wire Specify Wire Size Note 1 When tip life is limited by tip being fused over the use of T14726 5 64 Tips may result in a lower overall cost Note 2 This adapter is no longer available order Adapter 516844 and the appropriate T14050 Tips or 113A Cone Body Assembly Includes M8249 1 X 113B Flux Cone Plug 510138 1 113C Roll Pin T9967 30 1 114 Retaining Nut 510147 1 115 Flux 2085 1 1 116 Locking Ferrule 110574 1 X Socket Head a 118 Special Socket Head Screw T10570 1 119 Rubber Flux Tube Not Shown 811111 119 Rubber Flux Tube LT34 Only Not Shown T10642 11 1 IX 120 Steel Flux Tube Not Shown T6996 9 120 Steel Flux Tube LT34 Only Not Shown S10487 1 IX 121 1 2 13 x 1 50 HHCS Lead to Nozzle e 122 1 2 13 Lead to Nozzle CF000027 1 X X 123 Contact Tip 7 32 Wire Size KP1962 5 1 X X 123 Contact Tip 3 16
84. 2 37 Needle Bearing S10116 1 Crank Housing M10223 Cross Slide Assembl 512491 Socket Head Screw Roll Pin Draw Bolt Hex Nut 02 04 2002 101 NA4 and NA5 P 101 F NA4 and 5 K223 SOLENOID ASSEMBLY 4 and NA5 TO NOZZLE C ASSEMBLY M12665 7 22 831 Indicates Change This Printing ITEM DESCRIPTION PARTNO am 123456789 3 13 2000 Solenoid Assembly Includes K223 oolenoid Mounting Bracket L5276 Solenoid and Valve Assembl M11675 A Strain Relief Grommet T9274 3 Cable Assembly M12664 Name Plate S13246 ll 101 P 101 G K129 SUBMERGED ARC TINY TWINARC NOTES Nozzles with spring loaded contact shoes illustrated below right should be converted to the newer design by discarding items named below and using the appropriate contact tip holder and tips or correct one piece contact tip depending on wire size Intermediate design one piece contact tips for 4 wire should be converted to the new lower replacement cost contact tip holder and contact tips design by ordering the appropriate contact tips and tip holder from the parts list below Spring Mounting Bracket Roll Pin Contact Pressure Shoe M11609 4 16 76J 101 1 P 101 G 1 Specify Wire Size Indicates a Change This Printing ITEM DESCRIPTION PART NO QTY 5 7 8 9 Twinarc Complete Includes All Below
85. 2 seconds INSTALLATION Assembly and Installation K278 SPREADARC 1 used with the wire reels mounted on the carriage the K325HC heavy duty carriage is recommended In many applications it may be desirable to use the K29 vertical lift adjuster The Spreadarc cannot be used with a K96 horizontal head adjuster or with high frequency starting 2 Remove the hex nut A and the support pin B from the Spreadarc mounting block C With the draw bolt D properly in place mount the Spreadarc to the head support or vertical lift E Maintain support until the support pin B is in serted into the mounting block C and install hex nut on draw bolt D Rotate the Spreadarc until it is perpendicular to the travel carriage beam and tighten hex nut A Make certain that travel car rage beam or stationary mounting is properly squared up The Spreadarc must be level in the hori zontal plane within 2 see Figure 1 Figure 1 1 my Tt Control Box Spreadarc must be level in this plane 3 Remove the head mounting block from the NA 3 NA 4 or 5 head by removing the four allen head cap screws This part is not used Mount the head to the Spreadarc using the two 9 13 X hex head 92Jy 1 The Spreadarc can be mounted on a K325 travel carriage or on a stationary head mount in which case the work must be moved When the Twinarc process screws washers and lockwashers supplied with the Spreadarc throug
86. 21 12 Travel Receptacle Code 8205 Only S12101 2 Travel Amphenol Connector S12021 11 Rotary Switch Knob Procedure Board 113639 Optional Printed Circuit Board Not Illustrated Start of Crater Module Option Includes K334 Timer Printed Circuit Board K337 10 Option Printed Circuit Board L6246 3 Remote Interface Printed Circuit Board K336 Weld Timer Printed Circuit Board 10 Second K337 10 Weld Timer Printed Circuit Board K337 100 LL 11 07 2005 co NIO OIA N lt bh 00 001 dd dd om ol dl oL oL mh oh oA oL e eL eA e e 135 135 CONTROL BOX DOOR ASSEMBLY Indicates a Change This Printing DESCRIPTION Control Box Door Below Code 11000 S16706 Control Box Door Above Code 11000 S16706 1 Nameplate Below Code 11000 6243 Nameplate Above Code 11000 L6243 1 Nameplate Cover 516696 Nameplate Cover S10509 108 Lock Tab 110045 40 Meter amp Locating Pin Asbly Below Code 8990 Not Shown Order 17748 Gasket Below Code 8990 E1852 125 500 2 50 Bezel Assembly Above Code 8990 17720 Meter Shield Standard Clear Welding Lens Below Code 8990 T14771 Filter Lens Above Code 8990 T14807 2 Meter Shield Frame M13934 Actuator amp Switch Assembly 14751 1 Start Switch 113541 2 Security Panel A
87. 21007 60 6 9 8 6 8 6 Pd p JO SCOHLAW 6000 8 8 2 008 8 2 8 6 OJO Ome 2 v 9 OO 65 0 0 0 96000 ODO GALVOIGNI Y MO139 SLUVHO OL 138 38 OL S3HOLIMS did 91907 udu NIVLNOO LON OG 7224 VS HO 475 WYS ANY SNOLLOSNNOO FLVNHALTV 2 4 JO NOILOANNOO OL 43434 1 90 ATIVOIdAL ASN NEHM Eu OL GALOANNOO HAdWNF Su Nid OL GALOANNOO 39N3NO3S NOLLO3NNOO Su JO ISN TVNNVW 336 8 udu OL GALOANNOO TOHLNOO 3snd 53 Old SVM ISNA IHL S N diyos OIDOH QNT BANN IR IESU THRON SED 0148 Nid OL 9698 21901 LOANNOO JOHLNOI ualvuo sv
88. 3 4 and 5 29 VERTICAL ASSEMBLY 101 22 cub Oe IH e N N LA All FALL MANN 11 13 81P 15882 101 1 101 1 In mid 1978 the K29 was redesigned Old design assemblies may be identified by three socket head screws in the head lift lock area New design assemblies have only one socket head screw Use parts marked X in Column 1 for old design Use parts marked X in Column 2 for new design Indicates a Change This Printing ITEM DESCRIPTION PART NO QTY Head Lift Housing K29 Head Lift Housing 5881 1 1 1 1 z Ex e 2 Head Lift Tube M8228 1 1 3 Lift Lock Pin S16067 3 112121 1 i cap Sew 1 4 Socket Head Cap Screw 79447 32 1 5 Spring T10247 11 1 6 Spring Retainer S11295 5 1 7 Snap Ring S9776 14 1 8 Lift Screw Assembly Includes 1 Head Lift Screw 1 XX Ball Bearing 1 XX Snap Ring 1 XIX Gear 1 X X Woodruff Key 1 X 2 9 Boot S10442 1 X 10 Clamp S10888 11 1 X 11 Clamp S10888 8 1 12 Adjusting Shaft Assembly Includes 1 X Crank Arm Assembly 1 X X Snap Ring 1 X X Thrust Washer 1 X X Drive Pin 1 X X Shaft 1 Bearing Retainer 1 Needle Bearing 1 Oil Seal 1 5 5 13 Round Head Screw 10
89. 3 1 43 36 04 aues 24 03 231 5 11 46 04 943 195 AVS 8 YN LAJN S YN OL Y Uld tae od 9006 A s j d 9be3 0A uo pes 9 21159 CujuJ831 O 2 4 2 9poJj3123 9 129uuo Pseog 974 peo peu 5 Cul 19 3 Sav ONiNOS B Jay qns 103 595592014 104 gt 5 330 329005 33904 323005 SINILLIS S VN 59811135 328005 W3A Od SEY S3WN2 sawal amp VN VIV L123NNODSIQ 323005 30 360 33110 804 0139 MOHS SV A1L20VX3 30VW 38 ISAW SNOILO3NNOO M 5 88My Assembly and Installation The Lincoln Electric Company Cleveland Ohio 44117 1199 Sec T2 3 4 D 033403 43 jO 3040 943 uo due 5 243 sepun aq Isnw 52 4 2 1129 943 0 164940 9 384034 193 HN 81135 943 UO SEM 14 fsoujycew 10911489 UY D N 4116 0 uo 9 4 pue 5 Spee 329402 441236 1 6 02 9 1290u0 91 402 0943405 0 2 3 19 9 5 4129019 aq 1504 924005 semod ey 41135 92106 jJ8MOd 941 Jeou Pieu 19914203 9492 943 peo ejqe gt 0203002 43 329uu0oj uOj32euuoo dn ede Buip 0m ay pede pinoys pes 7
90. 31005 JHL 1 53787 AYOM 3004812313 358 340 YIMOA ALIYV Wd JINVHI 01 JALLISOS 9315239490 390312313 MOHS 31 ON AYOM 01 LO3NNOJ A18M3SSY LIVLNOI 3818 S VN MOu3 537197 OL 1108 OL LI3NNO SN 18813559 12 1 02 5 5318 9 OL 1108 225 SN 37 ONILL3S HILIMS 390 HILVN 01 5318 2 104100 LIINNO 04350 38 01 5533084 3 303 0111504 0351530 01 HILIMS 135 3190933 01 HILIMS 319901 135 NOILIINNOI 378 300812313 SV 3 YS OL HILIMS 319901 135 9014 318 2 1 104 0381539 30 SIYNIMA3L 01 5318 2 3904193713 123 02 INdNi S VN 01 YN H3MOd INdNI 330 TONSHNY SONILL3S 394N0S 43MOd 319 WYLNOD 328005 318 2 7103140 328105 Odd 05930 41415 IVNINY3L INISN NOILO3NNOO INISA NOIL23NNOO2 5 9 S VN OL 052 30 04 099 90 NOILO3NNOO Connection of 5 All to a DC 650 With No Line voltage Compensator Obsolete The Lincoln Electric Company Cleveland Ohio 44117 1199 Sec T2 3 4 B 1 The Lincoln Electric Company Cleveland Ohio 44117 1199 f 5 to R3S 400 600 or 800 ine voltage Compensator Obsolete Assembly and Installation Sec T2 3 4 C Connection With NoL M13985 9 17 82B
91. 4 20 HN CF000017 2 X X XIXXX Flux Hose Clamp 112929 1 XXIX XIX 5 8 11 HJN 1 X X XIXIX X Extension Tube 2 Long 1 Extension Tube 1 Long 1 Extension Tube 2 3 4 Electrical Stickout 1 Extension Tube End 2 1 4 Electrical Stickout 1 Extension Tube End 1 X Extension Tube End 1 Extension Tube End 1 XIX Flux Hose T10642 34 1 Flux Hose S7748 35 1 Nozzle Assembly 4261 6 See Above List 1 X 08 28 2007 225 SUBMERGED ARC TWINARC BEEN T 599 SUSE 0 22 au a 541550509 P 101 L P 101 L 1 P 101 L 1 Indicates a Change This Printing ITEM DESCRIPTION PART NO QTY Twinarc Complete Includes All Below K225 Nozzle Assembly Includes Items 101 through 129 L5314 1 101 Adapter Plate M12478 1 102 Adapter Insulation 18391 103 Socket Head Screw T9447 10 104 Washer S9262 23 105 Insulating Washer 2 12 106 Insulating Bushing 107 Electrode Guide Tube 1 108 Socket Plate 59842 109 Nozzle BE M7913 m ox Eos a 111 1 4 20 x 1 00 7 CF000015 112 Center Contact Block 375 Electrode Spacing T10252 1 112 Center Contact Block 500 Electrode Spacing T10252 2 112 Center Contact Block 625 Electrode Spacing T10252 3 113 Line Up Plate T10245 114 Socket Head Screw T9447 11 115 Spring S7664 116 Spring Insulation 18724 117 Insulating Bushing 18725
92. 4117 1199 Maintenance SEC T6 3 ELECTRICAL MAINTENANCE Sec T6 3 1 Control Box Every three months inspect the control box If needed blow dirt out using low pressure air No other maintenance should be required February 1982 Sec 10 3 2 Circuit Protection The circuit breaker mounted at the bottom left hand corner of the control box protects the control circuit from short circuit conditions and from severe wire feed overloads If it opens determine and correct the cause of the overload To reset the circuit breaker push the button If a complete or partial short occurs in the field circuit or if there is a defect on the Power P C board a 1 2 amp slow blow type fuse will blow on early model machines or a PTC Resettable Fuse will open on later model machines This field circuit protection 1 mounted on the Power P C board inside the control box Before replacing the fuse or allowing the PTC Resettable Fuse to reset and restoring power to the machine check the motor field for a shorted condition Normal field resistance is approximately 700 ohms With NA 5 controls above Code 8300 the field circuit protection may also open due to frequent motor field reversals from application problems affecting the cold starting circuit such as the power source output being too low to establish an arc or the welding procedure causing frequent electrode to puddle shorting Refer to Sec T3 7 The power supply for the ele
93. 5 Volt 110728 14 Tach Connector S13100 71 y Sd 05 22 2008 NOTE 1 These Parts are only used in NA 5 systems that include 500 welder For all other Power Sources order S16705 135 135 K349 MULTI PROCEDURE KIT 1 29 2002 135 1 135 1 Indicates Change This Printing ITEM 01 5 03 O 12 13 14 15 16 17 18 19 DESCRIPTION PART NO M14288 517147 517139 G1567 2 M14220 1 T13470 T9639 2 T10397 14 S14165 287 M14264 114767 114034 110491 113639 S17149 T10045 40 S8025 70 S8025 70 T9274 3 Control Box Control Box Cover Printed Circuit Board Insulation Multi Procedure P C Board Remote Selection P C Board Warning Decal Box Connector Plug Button Harness Nameplate Square Insulating Tube Shaft Seal Rheostat Knob Rotary Switch Knob Security Panel Lock Tab Self Tapping Screw Self Tapping Screw Not Illustrated Mounts Box Grommet 3 30 2000 NOTES E E E 3NNNH3 SX a3aNa V ANYODS de 2 eee LIO ONINU3S 412945 Sa32vdc Nos SAvH MIHM SWIG NO 340 NOA JAAA ONY
94. 52 Includes 512857 1 e X 035 045 Spring Guide 9367 4 1 4 5 16 18 x 75 HHCS CF000040 2 X X X 5 Guide Tube Mounting Clip T8400 4 6 Idle Roll Spring Screw NA 2 Models Only T10317 6 1 6 3 8 16 x 3 HHCS NA 3 NA 4 amp 5 Models CF000039 1 7 Flat Washer S9262 120 1 X X X 8 Idle Roll Spring 110247 7 1 10 5 16 18 SQN 2 Models CF000212 1 10 Yoke Indicator Asbly NA 3 4 amp 5 Models 113610 1 XXIX 11 Drive Roll 3 82 thru 7 32 512514 2 11 Drive Roll 1 16 thru 3 32 S12515 2 11 Drive Roll 035 thru 052 S12778 1 e e X 12 Socket Head Cap Screw T9447 32 1 14 Socket Head Screw T9447 12 2 15 Outgoing Guide Tube 3 32 thru 7 32 S10170 1 1 15 Outgoing Guide Tube 1 16 thru 3 32 113635 3 32 1 15 Outgoing Guide Tube 035 thru 052 113635 052 1 e e X 16 Draw Bolt T12090 1 0 1 17 1 4 20 CF000017 1 X X X 18 Stripper Bolt T10317 7 9 1 19 Drive Roll Nut T10552 1 20 Drive Roll Washer S9262 44 1 X X X 21 Snap Ring 11910 2 1 22 Drive Roll Key M8776 5 1 23 Wire Straightener Single Wire See P 100 K or P 100 M 1 XIX Note When using K231 or K233 Contact Nozzle a long guide sleeve is required inside the Nozzle See P 101 M or P 101 D 0 This part is obsolete and no longer available 09 27 2007 100 0 2 100 0 2
95. 7 89 10 24 CF000010 Flat Spring T8701 1 Shoulder Screw 112535 Adjusting Screw 913202 Roll Pin T9967 8 Retaining Ring 59776 3 M8776 6 N A O N Adjusting Block 913203 Handle T8312 Socket Head Screw 19447 18 Mounting Arm 913204 Socket Head Screw T9447 9 Socket Head Screw T9447 10 Spatter Guard 913233 Sleeve 112537 Drive Pin T8433 4 4 4 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 09 27 2007 100 100 SOLID WIRE STRAIGHTENER SINGLE amp TWINARC 5 64 thru 7 32 Electrodes Be E Use only the parts marked X in the column under the heading number called for in the model index page Indicates a Change This Printing ITEM DESCRIPTION PARTNO am 123456789 09 27 2007 Wire Straightener Single Arc Includes M8269 1 Wire Straightener Twinarc Includes M8269 2 Body M8268 Cross Slide Screw 510159 Bushing Locates Slide Screw Body T10585 Roll Pin Bushing to Slide Screw T9967 5 Slide Bushing 110584 Slide Bushing 110587 Wire Guide Wheel Bearing M9300 55 Wire Guide Wheel T10592 1 Plainwasher Bearing to Body S9262 140 5 16 18 x 1 25 HHCS Bearing to Body CF000028 Lock Washer Bearing to Body E106A 3 5 16 18 HN Bearing to Body CF000029 4 4 4 4 4 4 4 4 2 4 2 4 4 4
96. 8 beam for 10 and 12 beams see G1458 NA 3 NA 4 and 5 for instructions for proper shimming NOTE These carriages above Code 8427 are equipped with a T13586 1 drive wheel with a helical tooth suitable for driving on a smooth drive rail If the carriage is to be used with a beam drive rail having a straight cut knurl it will be necessary to replace the drive roll with a T13586 drive roll straight tooth which must be ordered separately The carriage release handle wire reel support bracket and the head supporting bracket are not factory mounted These three items should be mounted to the carriage before it 1s placed upon the beam see instruction sheet M13297 After installing the wire reel shaft support and the head support be sure both of these supports are electrically isolated from the carriage frame With the carriage release handle all the way down set the carriage upon the beam It should run freely along the entire beam length With the release handle in the up position the drive gear should engage the track and hold the carriage securely in position Mount the control box on top of the carriage see instruction sheet M13297 Insert the 3 prong plug codes above 8300 use a 4 prong plug of the carriage drive motor cable into the matching receptacle on the side of the control box The carriage re quires 250 volt amperes of 115 volt AC 50 or 60 hertz power Keep the load on the carriage as uniform as practi
97. 8 18 49 129 d3ddlHS N3HM V 12 HO 96 OL 1HVHO GSAO1dNA 050 5 008 Gn ag A 90894 gt FUNS HINOJ S VN G3LO3NNOO OL SI HAdWNF zes 008 289 019 SSVAAG JH OL u 260469 vies vies 008 265 5 jl 16414 Yad SIOEWAS 1991319573 o o ee P 5 pum 269 YN 3TZZON 35 265 aliis NEM S g S 988 WNIAH3 L 319V 1d3938 INdNI LP aa gt e CEU 9 ME h 169 gt 124 7 Bee 8 g TES N p 1 es 2555 2 a ak 3 g a a a ues 555 N L 8 99 8 5 858 066 28 895888 Ss 4 wis 969 aL ci V9 m m 2 1 v4 9 7 2 143038 23 3 48 5 NAON 4019 t AN o OO is OL zr oven 522225 SLOWSY diis aN 8888 8 2 318vo sla E 919 er 2 _ 118 so 23 9 e S IVNINH3L 2 ce a TOULNOS m 8 gt 999 TVNLOV 13S 4 SOVLION 225 2 S P RE
98. 9 341815 1VNIMH3L NO 11 Ol 116 0Y31 123 02 41415 IVNINY3L JHL NO 914 916 QY31 123NOO 41815 NO Ste 01 Gte QV31 1534405 131893 1031905 512 3 83010 INISN 31 MN 01 3LIHM 123NNOD 5 Nid 01 034 123 02 SMOT104 SY 431934905 38 15091 089808 39YL10A S YN 583940 HN 9 11135 HILIMS 3009 05920 HILYN OL 50015 01 53787 10400 JALLVO3N 193NNOJ IN 1041109 5 JHL 30 3015 1331 JHL NO 12 03990145 38 150 53787 300412313 380 5 834084 901 NOILIZNNOD dN IN 319 2 9SNIQ134 FHL 9 19 03481 38 GINOHS 0 31 Q30N31X3 SIHL 39N3IN3ANOO 404 39314 3 1 01 01123 02 379 AYOM 1 31 435 11 39314 AYOM OL 41133419 4 31 Q3QN31X3 103 NOILYIIVLSNI 303 31891105 ATIVIISAHd 0319 3398971 HO V INISN 12 QV31 QN31X3 NOILYIIVLSNI HL 304 31971105 AYIWIISAHA OJLVINSNI 839 1 NO ble Y OL LI 9 1123 02 ONY 31815 MOY4 2 09371 ONIAOMIY AG ViZs QY3 QN31X3 ON 011 21144 30 3142 ALN ANY IN3UUN 8403 03215 38 15101 531993 9 107138 Assembly and Installation SNOILIINNOI 118 104 1031405 5 03811038 803 941193330 S VN OL 43434 11 104 834084 01 3924105 H3MOd 3HL HOLIMS JHL NOILISOd ONY 359
99. 9 231 5 ejppnd queuind 4614 uy 1983 404 230u89y 04310 3indin 5 1023402 ey 395 20 pebaeuqns 239493 YN 5 401 193 S o41402 0041 20 40 0001 20 eya 395 0046 5730041 0001 20 NO NOLLI3NNOD WNIWSSL BAILISOd 005 AN uid 4edun JLIHM 32990 4 6 814 0 edwn 9034 32924499 5 0 58 943 uo s edwnf y 329uuo 4N AYOM OL 123NNOD 41435 A18W355V 13410 uo pee 3221005 441435 80 91 H 03 9 33iM 4 pee hee O3 SL peo 158010 10 SNN ol 11089 gf SL spee 9 92 044 02 2139UOjne J9PjO ue Duisn J 3 aN NP ON 199014 eq 3snu 921 05 AALLISOd 3AILN 93N 7911345 91 921008 29 04 941 jeeu cy pexJeu guiuJe3 293 O3 pes e qe 041402 G YN 943 13394403 Q N 12 BER uoj32euuc2 dn 3 e 2 462 i yom Buip em y oq 5 28 papuezxa 51 3 2 2 104 380914 03 33 4 gt 9192 1 941 vyesedes buideex 92914 24 03 4 323941 t
100. 90 4 4 Adapter Insulation 1 5 Socket Plate 1 6 Socket Head Screw 2 7 Electrode Guide Tube 2 o 2 8 Drive Screw S8025 8 2 9 Round Head Screw 1 4 20 x 50 2 10 Lock Washer E106A 2 2 11 Clamp 8970 14 2 12 Contact Block 515482 1 1 13 Socket Head Screw T9447 7 2 14 Jacket amp Guide Block Assembly S15487 1 1 15 Hex Head Screw 3 8 16 x 2 25 2 15 Flat Washer S9262 120 4 15 Lock Washer E106A 16 2 15 Hex Nut 3 8 16 2 han 16 Contact Tip 114050 3 32 17 Current Bar S15483 18 Hex Head Screw 1 4 20 x 1 00 mas o 19 Hex Nut 1 2 13 20 Nozzle Body M7913 21 Conductor Bar Insulation 13831 2 22 Insulating Sleeve 113829 23 Tip Insulation 24 Insulating Sleeve 25 Water Jacket Insulation 26 Flat Washer 27 Flat Washer S9262 103 514904 514905 T12146 1 513165 8776 6 514901 100 100 Outer Drive Rolls Center Drive Roll Drive Roll Spacer Idle Roll Assembly Drive Roll Key Wire Guide Tubes Upper amp Lower ZEE Wire Straightener Second Wire Reel amp Reel Mounting This part is obsolete and no longer available 02 04 2002 101 101 K231 and K31 CONTACT NOZZLE ASSEMBLY For K31 order K231 assembly All parts are interchangeable 22 T TOT e A d 0006 i Da DE 00000006 0 EC a ES lt 7 122 10 18 2006 101 1
101. 930 40 S 51 S379vv 710 Zoo s 51 STwwis3a 2 NO 9502 3 334 53215 Non NO 031312395 SSIINN 77570 aNY13A310 7402 218120313 wawvis 350 00 41325 138205 DNIAVIO 25 134205 OS El 2 051 El 00000000 00 2 1 MADS 12205 TWLIN ZIAOH 3425 133205 niana 221 Pd Ps NE 0001 NEIN NO 5232545 m NNOLJO 4118979 OS 2 amp l 2 u 303 ANO os 00 8 NI NMOS EL LEE IIVAA All2Udu2 HIH SoNuNOOW ONIAY 3A 18034 QuYONVIS WV38 0 031935 1303 51 1724 anaq 30 3943 JHL VINO SAINA LINN SWIHS MON 30 83H10 3WOS 539 13 SWHIG NO IMBA 140328 ASIJ JHL 44 489 OL 5NilNOQW HIVA ANIMAS W033 WIHS 90 FHL 53914914 ON 88 01 49 705 SWIHS 2079 9NLUNQOW LIN MOIOW 95515552 MOFA 7702 3A 2d 7799 2 59589 3910 29 QV3H SINNEY NOLLJ3JIG 06
102. 95 5 Utd 416 203 gt 34 5 pIe 7274 peo SIY ANY 0431 6 VW 123 023514 324105 YAIMGA 30 350 MIHLO Y0 7249 476 294 7130 329005 u3AOd 9 9 z 9 Engine Welder M13987 9 17 82B 88My Assembly and Installation Connection of 5 All toa DC 1000 or DC 1500 The Lincoln Electric Company Cleveland Ohio 44117 1199 Sec T2 3 4 F G WN 943 YIM 951 20 d d Tm 4 3 5 104 SOU YEW 49 429 95941 1628 9po 94 SOMPPIOI SWOS 10 pesn eq 06 8 UO 129UU02 Au 414 seuiydew 0051 34 3495944 JOU pue C 518016591 eer oca ndn wen m 04 2 G YN 343 40 149 943 UO y Jepun IP pue 1 9991 9 pirog pebbnus 24 3514 2 9 ey uoijejedo 194029 104 suid Burpuodss1109 4029 pue sujd sJedun eniq pue 4 9 549 44 Sujpessedns pue 2 0651 9 041402 0061 20 i YIrIMms y 195 595525044 404 7 344 pue 0061 24 4309 500 3 90 02 2995 bu xeu O3 u231 S 941 195 595597202 DAY 040
103. ARC CARRIAGE ASSEMBLY K278 1 114 2 114 2 Indicates a Change This Printing ITEM DESCRIPTION PARTNO am 12134 516 7 ala Carriage Assembly L12007 Includes NSS 1 Carriage M20174 1 2A Head Mounting Plate 15872 1 2 1 2 13 x 2 50 HHCS 000110 2 2C Lock Washer E106A 15 2 2D Plain Washer S9262 1 4 2 Insulating Washer S10773 9 2 2F Insulating Tube T7305 38 2 2G Bearing Bushing T14038 2 2 2H Roller 515884 2 2J 1 2 13 HN CF000027 2 3A 1 2 13 x 1 50 HHCS CF000052 2 3B Plain Washer S9262 1 2 3C Lock Washer E106A 15 2 4A Eccentric Adjuster 114039 2 4 Roller 515884 2 4 Bearing Bushing 114038 1 2 4D Plain Washer S9262 1 2 4E Lock Washer E106A 15 2 AF 1 2 13 x 2 25 HHCS CF000064 2 5 Head Insulation 515869 1 6 Head Support S15870 1 7A Stud T12581 7 1 7B Insulating Tube 17028 258 1 7C Cam 15871 2 70 3 8 16 CF000067 6 TE Lock Washer E106A 16 2 Drive Shaft Rack 514747 1 8B Spacer 114036 1 8C Socket Head Cap Screw 79447 22 80 Lock Washer T4291 A 3 08 29 2006 NSS Not Sold Separately P 114 N P 114 N K237 LINC FILL STARTING RELAY ASSEMBLY NOTE This parts list covers two versions of the K237 Assembly One built before Sept 1988 identified by one box connector and two grommets located in the box tops and one built after Sept 1988 with two box connectors in the box top Use column one for assem blies built before Sept 1988 Use column two
104. CABLE ASSEMBLY Figure 1 C CONNECTION OF CONTROL TO POWER SOURCE CABLE ASSEMBLY At the NA 5 control in order to activate the NA 5 weld current sensing switch the electrode cables of the K215 cable assembly must be placed under the clamp bar on the left hand side of the control box See Figure 1 This is necessary for proper operation of the reed switch The nuts holding the clamp bar in place need only be pulled up snug Do not over tighten If a carriage is used the electrode cables should also be clamped to it with the cable clamp supplied on the carriage Do not clamp the control cable under the travel carriage clamp but route it over its top Insert the polarized connector of the control cable in the K215 assembly into the matching receptacle on the side of the control box With the power source off connect the K215 Power Source to Control cable assembly to the power source as follows 1 If using a multiprocess power source SAM SA 800 SAF 600 DC 400 DC 600 DC 1000 or DC 1500 types be sure it is properly set for the welding process being used per the connection diagram 2 Connect the K215 control cable leads to the power source terminal strip exactly as specified on the appro priate connection diagram Include all jumpers on the terminal strips as shown on the diagram Do not put on any other jumpers If currents or duty cycle higher than 1000 amperes at 8096 duty cycle will be used add additional electrode cab
105. CRIPTION PART NO QTY ee Carriage amp Track Assembly See P 114 L 2 111111 Bottom Shield Thread Forming Screw M13277 1 59225 70 Top Shield 10 24 x 50 5 Lock Washer M20176 CF000371 T9695 1 Proximity Sensor Bracket Grommet 10 24 X 50 HHCS Lock Washer M20331 T12380 4 CF000371 T9695 1 Proximity Sensor Assembly 21347 Control Box Assembly See P 114 P Carriage Guard Thread Forming Screw M13284 59225 70 Draw 3 4 10 Support Pin Assembly 14893 3 CF000025 T14042 Grommet T9274 1 Decal T13470 Decal 519338 Guard 10 24 x 50 HHCS Lock Washer M21264 CF000371 T9695 1 Decal T13086 62 AA RA DR A 01 19 2007 P 114 L 2 P 114 L 2 SPREADARC CARRIAGE TRACK amp DRIVE MOTOR ASBLY K278 1 Use only the parts marked X in the column under the ITEM DESCRIPTION PARTNO am 12 00 00 005 Carriage amp Track Asbly 112002 Includes NSS Carriage Assembly See P 114 M 2 Track Assembly M20165 Includes NSS Track Support Welded Assembly M20166 Track 515882 3 8 16 x 625 HHCS CF000018 Lock Washer E106A 16 Plain Washer S9262 76 Drive Motor Assembly 112135 Plain Washer Not Shown S9262 98 Hex Lock Nut Not Shown 19187 6 Plug Button T10397 2 08 29 2006 NOTES SPREAD
106. Cap Gasket 110649 1 Dust Gasket T10649 2 Flat Head Screw Dust Cap to Case 10 24 x 1 2 Dust Cap For Cross Shaft 110672 9 0 This part is obsolete and no longer available 08 13 2001 P 101 R 1 P 101 R 1 Use only the parts marked X in the column under the heading number called for in the model index page Indicates a Change This Printing ITEM DESCRIPTION PART NO QTY 56 7 8 9 181 Caution Plate S10346 1 182 Round Head Screw Dust to Gear Case 10 24 x 1 2 4 183 Lock Washer E106A 1 4 184 Small Bearing Cage 10077 1 X X 185 Small Bearing Cage Gasket 510084 1 186 Flat Head Screw Small Cage to Gear Case 10 24 x 1 2 4 187 Large Bearing Cage S10079 1 X X 188 Large Bearing Cage Gasket 510085 1 189 Flat Head Screw Large Cage to Gear Case 10 24 x 1 2 6 190 Oil Seal Output Shaft S7611 5 1 Motor Assembly 144 1 Ratio Only Includes M10301 2 Motor Assembly 324 1 and 648 1 Ratio Includes 10301 1 1 191 Motor 1 Brush and Spring Assembly 2 Brush 2 Phillips Flat Head Screw Motor to Base 4 Input 144 1 Ratio Only 1 X e Input Worm 324 1 and 648 1 Ratio 1 XIX Roll Pin Input Worm to Motor Shaft 1 Four Contact Plug 1 Oil Throw Ring 1 Cross Shaft Assembly 144 1 Ratio Only Includes Items 199 through 202 S10080 3 o 1 X Cr
107. Connection Box Assembly Includes Drive Motor amp Connection Box Assembly Includes 142 1 Ratio W H F M13902 6 Drive Motor amp Connection Box Assembly Includes 21 1 Ratio W O M13902 7 0 0 This part is obsolete and no longer available 07 20 2001 135 1 135 1 W O Without High Frequency Insulation W H F With High Frequency Insulation Indicates a Change This Printing ITEM DESCRIPTION PART NO QTY 12 34 5 1 Drive Motor Assembly Includes 57 1 Ratio W O L6440 1 1 Drive Motor Assembly Includes 95 1 Ratio W O L6440 2 1 Drive Motor Assembly Includes 142 1 Ratio W O L6440 3 1 Drive Motor Assembly Includes 57 1 Ratio W H F L6440 4 1 Drive Motor Assembly Includes 95 1 Ratio W H F L6440 5 1 Drive Motor Assembly Includes 142 1 Ratio W H F L6440 6 1 Drive Motor Assembly Includes 21 1 Ratio W O H F 16440 9 1 Drive Motor amp Pinion Includes 57 1 Ratio W O S16660 1 1 Drive Motor amp Pinion Includes 95 1 Ratio W O S16660 2 1 Drive Motor amp Pinion Includes 142 1 Ratio W O S16660 3 1 Drive Motor amp Pinion Includes 21 1 Ratio W O High Speed S16660 5 1 Drive Motor amp Pinion Includes 57 1 W H F M14132 1 1 Drive Motor amp Pinion Includes 95 1 Ratio W H F M14132 2 1 Drive Motor amp Pinion Includes 142
108. Cross Adjuster and Head Loosen Nut OS With Vertical Lift Adjuster 22 Also Loosen Screw Rotate Head Only ENTIRE HEAD ROTATES ABOUT MOUNTING BAR USUALLY KEPT WITHIN 220 OF VERTICAL HEAD SLIDES IN AND QUT WITH STANDARD HEAD MOUNTING WITH STANDARD HEAD MOUNTING WITH STANDARD HEAD MOUNTING OR VERTICAL LIFT ADJUSTER OR VERTICAL LIFT ADJUSTER OR HORIZONTAL HEAD ADJUSTER Fig T3 2 3 3 Fig T3 2 3 4 Fig T3 2 3 5 88My Operating Instructions The Lincoln Electric Company Cleveland Ohio 44117 1199 Sec T3 2 3 and L3 2 3 Continued CROSS SEAM ADJUSTER Fig T3 2 3 9 Operation of the hand screw of the cross adjustment assem bly permits a 212 inch cross seam adjustment This adjust ment can be done while welding This adjustment can be locked in position by tightening two socket head screws By Rotating The Horizontal The Horizontal Plane 2 Head Moves In and Out HORIZONTAL HEAD ADJUSTER ONLY Fig T3 2 6 7 VERTICAL HEAD LIFT ADJUSTER ONLY Adjuster As Shown In Fig T3 2 3 5 The 2 Movement Is In Any Direction Fig T3 2 3 6 This adjustment can be used during setup or while welding To control the rotational movement of N as it moves up and down the key is made in two parts U and W These parts are spaced by the shims Y to allow vertical movement of N with the minimum amount of rotational movement when screws Z are tight and socket head screw X is
109. DJUSTMENT AND LOCKING ARRANGE MENT The rotational movement of the lift mechanism is kept to a near zero level at all times because the spring loaded wedge shaped pin 1 always in intimate contact with the vertical slide The socket head screw on the right side of the lift housing is used as a locking screw Its function is to pull the wedge tight against the vertical slide and thus lock the unit at a desired height This screw should always be a half turn loose unless a locked condition is wanted Extreme tightening of the locking screw may lock the wedge so that the lift cannot be moved in either direction If this should occur loosen the locking screw a turn or two and tap the screw into the head lift body This will loosen the locking wedge July 1992 Assembly and Installation Sec T2 2 12 File as Sec L2 2 12 for IM 278 File as Sec E2 7 8 for IM 245 K96 Horizontal Head Adjuster This accessory provides an easy means of moving the head in a horizontal direction by simply turning a crank handle Install per the following 1 2 Be sure nut H is tight Drive out roll pin G While holding the head loosen nut H and lower the head from the head support E or E If a vertical lift adjuster is to be used install it now per instructions in Sec T2 2 11 With draw bolt A and nut B in place fit the horizon tal adjuster D to the stub shaft of E or the vertical lift adjuster E if iti
110. E Sec 3 4 Starting and Stopping Sequences o 124528 debct OME ee Nw doe du e eed Sec T3 5 Means of Are StriKing iilud Las ars nannten Sec T3 5 1 Setting Travel Starting and Stopping Sec T3 5 2 Voltage Control Response rss para nie te Sec T3 6 Automatic ShutdoWD 4 0 0 Sec T3 7 Cold Start C eng Sec T3 8 Security Weld Procedure Settings RE A ge SURE Dru eds Sec T3 9 99Ju Index Sec T6 Maintenance Wire Drive Gearbox Changing Wire Feed Gear Ratios Wire Drive Mechanism Wire Straighteners Electrical Maintenance Optional Feature Maintenance Wire Contact Assemblies Wire Reel Mounting 50 60 Lb Coils Tr veliCatase RT HERS Vertical Lift Adjuster csc 5 Dd ana ee Horizontal Adjuster e eR I High Frequency Generator Spresdare un sun nes OEC I ____ d General Troubleshooting Guide Sec 7 Parts Lists Wiring Diagrams and Dimension Prints At back of Manual Wo o RO COD 82 27 79 9 gt 4 The Lincoln Electr
111. E 88My 1 Replacethe contact tips when the output current and voltage become unstable For access to the tips re move the two screws holding the guide block as sembly Holes worn in the guide block assembly allow the wire to wander When replacing the assembly it is absolutely essential to follow these replacement in structions a Shutthe welding power source off b C Shut water flow off Disconnect water lines from the water cooled jacket Remove the two hex head screws which mount the water cooled jacket to the tip contact block and current bar Slide the jacket down off of the tips With the use of a small propane torch apply just enough heat to melt the soft joint between the guide block and the water jacket Do not over heat 600 F max Remove the socket head screw while the joint is still hot then remove the guide block Guide block ASS a I N 5 7 2 x3 Assembly and Installation gt SUITED Al NA Insulation ES aX Y Ama QUID vo NS 2 1222 l m Insulating tubes Water jackets Locating shoulder Soft soldered joint Remove the two tip insulating tubes from the two holes in the water cooled jacket Re tin the mating surfaces of the water cooled jacket using an acid core 50 50 solder Avoid getting solder into the holes The new gui
112. EN Head Lift Mounting Plate 15553 Lift Link S15552 Roller Shaft Roller Link Shaft Link Shaft Roll Pin Locates Lift Link on Crank Link Shaft T9967 1 1 Crank Bracket Crank Bracket DD S10266 1 T10654 Roll Pin Roller to Roller Shaft T9967 6 E 0266 3 0 State 0266 4 TS Ree 14 Link Shaft 510266 2 0 Link Shaft S10266 4 510285 9 113874 0 This part is obsolete and no longer available 6 16 2000 101 P 101 R Supersedes P 52 F Supersedes P 52 F CARRIAGE DRIVE MOTOR AND GEAR CASE Ma NSS lt 555 NR QOO Use only the parts marked X in the column under the heading number called for in the model index page 2 B IAMO 5 E y bs TAN TER S 9 2 ENS ANO K N 21810 N 5 180 16 BAY 2 STILL 5 Indicates Change This Printing ITEM DESCRIPTION PARTNO am 123456789 Drive Motor and Gear Case Assembly 144 1 Ratio Includes All items in Column 1 Marked X L3094 1 o JE Drive Motor and Gear Case Assembly 324 1 Ratio Includes All items in Column 2 Marked X L3094 2 Drive Motor and Gear Case Assembly 648 1 Ratio Includes All items in Column 3 Marked X L3094 4 es Gear Case G1027 0 Dust Cap For Output Shaft 110559 Dust
113. Gear 142 1 Ratio 12 Helical Gear 57 1 Ratio NIO BIW 12 Helical Gear 21 1 Ratio High Speed 13 Socket Head Screw 13 Socket Head Screw High Speed 14 Snap Ring 15 Gear Case Collar 16 Hollow Set Screw 17 Output Shaft Assembly 18 Spacer 19 Oil Seal 20 Gasket 0125 Thick 20 Gasket 004 Thick 21 Spacer Washer 003 Thick 21 Spacer Washer 010 Thick NENNEN NENNEN 304 1 59776 16 1 511604 26 2 512511 1 304 1 39262 121 1 16 18 1 312882 1 312881 1 Tm 8 1 Leal 6 59776 23 1 10256 1 511604 13 1 mb S12509 112146 Anm S7611 15 LT T12119 2 As ESSEN NENNEN 59262 111 As X Q This part is obsolete and no longer available 02 05 2002 P 132 F a P 132 F a TRAVEL CONTROL BOX ASSEMBLY M14172 6 25 82M 11 2 84 P 132 F b P 132 F b For Carriage Codes 8018 8019 8020 amp 8021 use parts marked X in Column 1 For Carriage Codes 8424 8425 8426 amp 8427 use parts marked X in Column 2 Indicates a Change This Printing ITEM DESCRIPTION PART NO QTY 1112131415 6 789 Travel Control Box S16128 XIX Travel P C Board Insulation T14189 2 2 1 2 3 Travel P C Board L6944 1 4 A C Relay 13929 2 1 5 Circuit Breaker T12287 8 1 EHE 7 Insulation T12792 1 AA Knob T10491 9 Res
114. I 13968 9 9 17 82 88 The Lincoln Electric Company Cleveland Ohio 44117 1199 Assembly and Installation Sec T2 3 4 B pepuno46 129046 94 5 231005 samod ay 74415 jeutwial 922 05 2 941 Jesu eujwia owesy 243 03 pea Buipunojb gt 011403 G yN 243 322440 40132244052 231049 dn 0 392 eq Pinoys peut 2 143 404 99918 0 4013221602 e qgo 440m 441 3 Buydeay 22214 243 03 23911p 21 129440 asodind 61413 20 9 ye ene s pes 6ujsuss ebej O 210121 7 9856 6 Uy WOLLE 2354 243 10 9 4 5 15 44 pa3e nsui 20 2 ou tl 4 I p 19 Pee pu21x3 3 N 3391 243 uo seq dwej gt 241 pebbaus isnu sajqe gt spoJj29 3212490 5 4 428024 204 5101322 1 99 pue 30 1 gt 2AD pue 34922415 ey 10 1289862 120014 40 84 150 5242 bulp am 1023009 914 pue G y Spee 1 1923409 1913 JO 9 4 01 9 pee 2 94465 913592 6 2 4 buisn 3 043 6 9 pea dn ade A ajeJedas 1013224 0 gt edei pue 3106 AXE
115. II COMPREHENSIVE TROUBLESHOOTING GUIDE The following is a list of digital meters which would meet or exceed the required 0 5 accuracy To per form the meter accuracy check you must have a meter as accurate as these 0 5 or better The Lincoln Electric Company Troubleshooting Guide Cleveland Ohio 44117 1199 Sec T6 6 Continued 3 Data Precision 935 1 Fluke 8022A Data Precision Corp Electronics Avenue John Fluke Mfg Co Box 43210 Danvers MA 01923 Mountlake Terrace W A 98043 4 Keithley Model 169 2 Triplett 3400 Keithley Instruments Inc Triplett Corp 28775 Aurora Road 286 Harmon Road Cleveland OH 44139 1891 Bluffton OH 45817 2 Wire Speed Accuracy a Check that the Speedmeter Calibration Jumper is connected to the proper calibration pin for the head and drive roll system employed per the table below 219 512778 Single 035 052 Solid 100 2070 57 512778 Single 035 052 Solid 40 778 519113 Single 045 052 Cored 97 12515 95 12514 Single Single 1 16 3 32 3 32 5 32 38 762 22 428 956 512515 Single 1 16 3 32 23 456 519113 Single 045 052 Cored 513161 052 Twin 045 052 13161 5 64 Twin 1 16 5 64 14904 514905 inner Twin 3 32 142 12514 Single 3 32 7 32 1421 14904 outer 514905 inner Win 9 64 1 8 Early Speedmeter pins were labeled 55F and 55 respectively 2 Early Speedmeter P C Boards did not include these calibration pins
116. IRE STRAIGHTENER FOR TINY TWINARC 05 10 2005 P 101 G 2 b P 101 G 2 b USE COLUMN ONE FOR TINY TWINARC NIS USE COLUMN TWO TWIN TORCH Indicates a Change This Printing HH ITEM DESCRIPTION PART NO QTY 115 314516 789 515943 XX 515946 2 Tension Arm 3 Roller Assembly Includes Roller Shaft 2 1 4 Shaft Retaining Ring 3 Roller Assembly Includes 3A Roller Shaft 3B Bushing 3C Retaining Ring 4 Roller Assembly Includes x X X X x XXX CX X OO 2 1 2 Shaft Bearing Shaft Retaining Ring Bearing 4A Hex Head Cap Screw 5 16 18 x 2 00 4B Lock Washer E106 A3 4C Hex Nut 5 Incoming Guide Assembly Includes 5A Thumb Screw 5B Nozzle Insert Not Shown 6 Roll Pin 7 Screw Assembly 8 Large Pivot 114086 9 Retaining Ring S9776 12 X X 10 Small Pivot Shaft 114087 X X 12 Roll Pin T9967 8 XX 13 Wire Guide Assembly 114093 14 Set Screw S11604 21 05 02 2001 A XX X X 0X KK X X X X KK X x 101 101 FLUX HOPPER SECTION AA YN Y 112590 l 3 1 22 eru ee 2222 Je DI II U N 22222 ML in 2222222 1 16 76 13552 8 21 81P 101 1 Indicates
117. N IE qns 103 22 gt S pswog 3 d LO PRA 231 IE 0759 2 56001322 jidde 36e3 0 03 914 pue 53 97 suo 3e gt 1 dde 9451 C peij29uuo2 51 374 uo pay 20 031003 9 3 325 Arj ejod INZ VN i gt 71 249 975 p94 sop 993 204 23 5 1146 04 9pOJ329 3 9943 125 1 oL pasn 198 103 293 104 dey 405 dde 243 01 4012 1 03 GY 2 422 941 329uu0 595593014 Diy 203 93 u21j s abuey 943 395 330 324005 NYNL XU 9L SL 3 TEEN 2195 Bison 59811135 6 59411195 328005 VIMOS 008 95 20 009 445 01314 5 quos 14 2 4431 S VN 11 LIINNOISIO 323005 83 04 40 350 SAULO ANY 304 0138 NMOHS Sy 38 SnolL gt D3annoD 13984 6 Solid State Field Control Obsolete Connection of NA 5 All to a SAF 600 or SA 800 Types O or and M G M13984 9 17 82B 26 91 41315 IVNINYIL 324105 YIMOS JHL HVJN T JHL OL Qv31 10 089 378 1081 02 S VN JHL 12344
118. Nozzle Assembly Stripped Includes Items 1 3 5 8 6 045 Wire Kit Includes Items 2 4 A amp B 1 16 Wire Kit Includes Items 2 4 7 A amp B 5 64 Wire Kit Includes Items 2 4 7 A amp B 3 32 Wire Kit Includes Items 2 4 7 A amp B 1 518164 2 Guide Tube 045 amp 052 Wire meee TT 2 Guide Tube 1 16 5 64 amp 3 32 Wire KP2092 2 2 3 513157 __ 1 4 Contact Tip 045 Wire 1 4 Contact Tip 052 Wire 1 4 Contact Tip 1 16 Wire 2 4 Contact Tip 5 64 Wire See Note AA 2 4 Contact Tip 3 32 Wire 1 E 6 1 2 13 x 1 50 HHCS CF000052 1 7 Tip Holder 1 16 5 64 amp 3 32 Wire Std Includes 1988 1 Nozzle Insert KP2094 4 7 Tip Holder Special Side by Side Wire KP2171 1 Note When Tip Life is limited by tip being fused over the use of T14726 5 64 Tips may result in a lower overall cost Drive Roll 045 amp 052 Wire 1 Drive Roll 1 16 amp 5 64 Wire 1 Drive Roll Assembly 3 32 Wire Includes Outer Drive Rolls 2 Center Drive Rolls 1 Drive Roll Spacer 1 Drive Roll Key 1 B Wire Guides 045 amp 052 Wire KP1970 1 2 B Wire Guides 1 16 Wire KP1970 2 2 B Wire Guides 5 64 amp 3 32 Wire KP1970 3 2 Idie Roll Assembly Includes gx bbs Idle 518583 P sesona Wre Reel amp Mountings __ __ 1 Second Wire Reel amp Mountings See P 100 G 08 28 2007 gt gt gt 101 2 101 2 281 W
119. One Tapered Jaw For 1 8 thru 7 32 Wire Includes K226 R Contact Jaw Assembly Two Tapered Jaws For 3 32 and 1 8 Wire Includes K226 T Socket Head Screw T9447 10 Washer S9262 23 Insulating Washer S10773 12 Insulating Bushing T8390 Cover Plate T8404 Lead Block 57273 Hex Jam Nut 3 8 16 Adapter Plate Rectangular M12478 Insulation Plate 18391 10 Bottom Wire Guide M6656 11 Spring Insulation 18724 12 Hex Head Screw 1 4 20 x 1 00 2 14 Hex Head Cap Screw 3 8 16 x 1 00 ome eee T 15N Hex Jam Nut 1 2 13 16 Lock Washer E106A 2 17 Plain Washer S9262 23 18 Spring 57664 r 311111111 20 Plain Washer 59262 4 2 um rU 21 Contact Block E 516640 2 22 3 6916 75 23 Hex Head Cap Screw 2233 23 Hex Head Screw 3 8 16 x 1 25 24 Braided Lead K226 R Only 57266 25 Contact Jaw S16640 2 26 Flux Tube Clip 110683 3 8 16 x 1 50 5 16 18 x 75 29 Flux Hose 30 Flux Hose Tip S7748 35 5 Item 8 for 2 Jaws Sold with LAF and 113 Tractors was round Part 57258 02 04 2002 NIO AO NIN NIN NIN N Bj HO A 2 nj uu 27 Hex Head Cap Screw 28 Hex Head Screw T10642 2 mb 101 Supersedes 52 101 Supersedes 52 TRAVEL CARRIAGE GENERAL ASSEMBLY i zm ONILNNOW 8 STASHM H3ddf 9NIMOHS TIVOS TINA gt M RS EL SYJINAN
120. S10NVH DNIAOW 390 2 dials 13315 ONIadS O3334W31 3018 0001 1 5290 13A31 v NO 3104340 TUM 49114 115150 NO 30 1VUJON Q3SV33ONI AVIVIYILUW 1 IHL ONMIAYI LN3WIdIDO3 30 1H9 3M IHL NIHM 03033N AINO S 39 9 E a a ee 43925 47 002 91 97 AA v 3d 001 NAANA 1 919416 1504 Sowisau 31940440999 OL 900 1311 29 ONY QIM 01 53199 1890 LY 38 1504 39411 20 MIHLIM 04391 1991021 1504 40 HIDNZA qV1X31UM 203 2345 2 ILU id i S310H 2 0 034 7 SIUE TWAT 962 MISIS GH YIH 7 BI 278 41515 13315 5 Q3434Wil H9IH S 29 x 270 MAIS 40151131 41415 DNlads 1 517 ONG QUIE LNIYD NOISNFWIG 050090 3389 9 0 88 gt 790 aor LVIWLENCOS TELNOZSON pon A ERIT 87 2277 2820334 598 674 SUN 22 XOTA 27272 09 LYOdA OS 72779 62 OE CUN ENN 0 702402 3722004 QU3H PO NOS OLN QUIM HUM 39892 17597 LHOIZM
121. STRIKE light will be on After the various controls are set the knob must be positioned at STRIKE before the start but ton will function The important thing to re member is that regardless of the setting of the knob the light which is on shows the set of con trols which are functioning When welding the NA 5 control will disable the selector switch and automatically switch the various sets of controls into the circuit and the lights will show which set of controls are operative This control can be useful for loading new coils of wire Usually the Arc Striking inch wire speed 1 set rather slow By turning the Mode Selector to one of the other modes such as Weld the wire speed is set to the higher speed as set by the Weld wire speed After wire is loaded the Mode Switch is set back to Strike Electrode HOT Light 10 This light comes on when the start button is pressed and the elec trode circuit is electrically hot It will stay on until the control signals the power source output to be off Circuit Breaker 15 Protects the circuit from severe wire feed overloads or short circuit condi tions B Controls Under the Lockable Security Cover l Arc Striking Controls 11 There are two con trols in this mode The Inch Wire Speed rheostat sets the wire speed during idle and after the NA 5 is energized by the Start circuit until welding cur rent begins to flow The Volts potentiometer con trols the powe
122. Screw 3 8 16 1 00 2 14 Head Screw 1 2 13 x 1 75 2 16 Jam Nut 5 16 18 1 1 mb 17 Head Lap Ataciment 1 17 Hex Head Screw Lap Attachment T9694 8 18 Roller Bracket Assembly Fillet Attachment nr Lir 18 Roller Bracket Assembly Lap Attachment 57398 0 19 Hex Jam Nut 3 8 16 20 Wire Guide Spring S7664 21 Head Cap Screw 3 8 16 x 1 25 22 Flat Washer S9262 4 I yy 23 Hex Jam Nut 3 8 16 4 24 Hex Jam Nut 1 2 13 1 25 Hex Head Cap Screw 1 2 13 x 1 00 1 26 Thread Cutting Screw S9225 17 2 27 Insulation Bushing 18725 2 28 Lockwasher E106A 2 2 29 Flat Washer 59262 23 2 30 Spring Insulation 18724 2 31 Hex Jam Nut 1 2 13 2 32 Cover Plate T8404 1 33 Insulating Bushing 17028 23 2 34 Insulating Washer 10773 41 2 35 Socket Head Screw T9447 11 2 36 Flat Washer S9262 30 2 37 Spacer 18752 1 38 Hex Head Cap Screw 3 8 16 x 1 50 2 39 Lead 57266 1 40 Insulation 57387 1 41 Roll Support 57386 0 1 42 Head Cap Screw 1 2 13 x 1 25 1 43 Wire Contact Block S16640 2 1 44 Leaf Spring T8435 1 45 Wire Contact Block 516640 1 1 DD 46 Grease Fitting T11683 1 47 Hex Head Screw 5 16 18 x 75 Items Not Illustrated 1 1 1 Flux Tube 0 This part is obsolete and no longer available 10 07 2002 Flux Control Head Pivot P 101 D a P 101 D a K233 and K103 CONTACT NOZZLE K1
123. Sec T2 5 6 February 1982 The Lincoln Electric Company Troubleshooting Guide Cleveland Ohio 44117 1199 SEC T6 6 NA 5 GENERAL TROUBLESHOOTING GUIDE INTRODUCTION How To Use This Guide Sec T6 6 1 Problems incurred with the NA 5 do not necessarily involve failures in the circuitry More often problems are caused by misapplication misconnection or shutdown of the NA 5 protective features Therefore when a problem is experienced first refer t0 the GENERAL APPLICATION TROUB LESHOOTING GUIDE below The instructions in this guide should solve most problems 2 Ifthe problem being experienced cannot be solved by using the GENERAL APPLICATION TROUB LESHOOTING GUIDE the problem may be due to a fault in the control circuitry To detect and correct this fault refer to the COMPREHENSIVE TROUBLESHOOTING GUIDE IM 305TS TABLE OF CONTENTS SUBJECT GENERAL APPLICATION TROUBLESHOOTING GUIDE For general maintenance connection and mechanical problems Application Problems Out of Range Shutdown Accuracy Checks Preliminary Power Supply Checks gt 92 y Troubleshooting Guide Sec T6 6 Continued IA APPLICATION PROBLEMS The Lincoln Electric Company Cleveland Ohio 44117 1199 1 Drive rolls turn but wire will not feed or wire feeding 1 rough or uneven CAUSE WHAT TO DO a Wire jammed or kinked on route through head a Remove wire from head then feed in new wire Note any obstruction b Inc
124. Sec T3 8 B under Electrode Backup NA 5 Controls above Code 8300 with Starting may feed in the wrong direction when the start button is pressed When the electrode contacts the work the arc will be established and the circuit will automatically switch from the Arc Striking Controls to the Weld Controls If the optional Start Control is installed however the circuit will switch from the Arc Striking Controls to the Arc Start Controls and then after the Start Controls time out will switch to the Weld Controls If the circuit is connected see table on wiring dia gram for starting the travel circuit will be energized when the start button is pushed If the circuit is connected for starting from a standstill the travel will be energized when the arc is established See Sec T3 5 1 Stop Button 3 Pressing this begins the stop ping cycle As shipped from the factory the wire feed motor will stop immediately and there will be a burnback as set by the Burnback and Elec trode Backup Time control However if the Crater Control option is installed the unit will first switch from the Weld Control to Crater Control and after the Crater Control Time ends will then go into the stop sequence Travel Switch 9 When in the Hand Travel position the travel circuit will be energized When in the Off position the travel will not operate and when the switch is in Automati
125. See Sec T3 5 for descriptions of these various starting sequences and the rewiring needed to accomplish them Depending upon the procedures and applications a Select the arc and travel stopping sequence See Sec T3 5 2 for a description of these various stop ping sequences and the rewiring needed to accom plish them b Decide if control of the ending bead size or crater filling requires use of optional Crater Controls See Sec T3 5 2 Set the head position relative to the work as required for the fixture application and procedures See Sec 13 23 Rotate wire straightener if used until the top of the straightener faces the wire reel This is required for smooth feeding of the electrode into the straightener 88My 7 10 Refer to the instructions for the wire contact assembly being used See Sec T2 2 6 T2 2 7 T2 5 3 or T2 5 4 The mount for standard 50 and 60 pound electrode coils includes a two position brake assembly Gener ally the brake should be at the inner position nearest to the wire reel shaft for wire feed speeds below 400 min It should be at the outer position for faster wire speeds To adjust the brake position remove the wire reel Pull the cotter pin that holds the brake shoe to the arm move the shoe and replace the cotter pin Do not bend the cotter pin it is held in place by a friction fit Load the wire reel per Section T3 2 2 or install the Speed Feed
126. TACT NOZZLE ASSEMBLY K149 LINC FILL EXTENSION ASSEMBLY P 101 K al ide 7 B ASE L 9 QD D EC Bash 11 4 98 P 101 K 1 Indicates a Change This Printing P 101 K 1 Use Columns 1 2 amp 3 for Standard K148 Nozzles Use Columns 4 4 5 for Modified Series Arc Equipment Nozzles Use appropriate column for K149 Extensions based on wire size for standard extensions or Part No for Modified Series Arc Equipment DESCRIPTION PARTNO Nozzle Asbly Wire Size 3 32 120 1 8 Includes K148A Nozzle Asbly Wire Size 5 32 3 16 Includes K148B Nozzle Asbly Wire Size 068 5 64 Includes K148C 1 Nozzle Asbly Wire Size 5 32 3 16 Includes L4621 4 amp 6 1 e Nozzle Wire Size 3 32 120 1 8 Includes L4621 5 1 EX 1 1 2 13 x 1 5 HHCS CF000052 1 X X X X X 2 1 2 23 HN CF000027 1 Cable Connector S12576 1 X X X X X 4 Roll Pin 19967 35 1 X X X X 1X 5 Pivot Body M10340 1 1 X X X XX 6 Guide Tube Asbly 3 32 120 1 8 Wire KP1974 1 1 Xp o 6 Guide Tube Asbly 5 32 3 16 Wire KP1974 2 1 6 Guide Tube Asbly 068 5 64 Wire KP1974 3 1 7 Set Screw S11604 19 1 XX X X X 8 Insulating Spacer 112157 1 X X X X X 9 Flat Washer S9262 23 2 10 Lock Washer E106A 2 2 XXI
127. The travel speed ranges are listed below Al though carriages operate at speeds down to zero speed varia tions increase rapidly with uneven loading when travel speeds below the listed minimums are used 88My Installation MAINTENANCE Periodically 1 Disengage the release handle and see that the carriage moves freely along the beam 2 Add a few drops of machine oil to each of the head lift bearings This can be done through the front opening in the carriage 3 Addafew drops of oil to clutch handle bearings 4 Add a few drops of oil into each of the oil cups at the travel mounting pivot point No change of lubrication is required for cold tempera ture operation Once a year 1 Check the motor brushes If 25 or shorter replace with new 2 Check the carriage drive gear teeth If the teeth are badly worn replace the drive gear 3 After 5 000 hours of operation the motor and the first reduction should be removed from the gear box and all of the gear teeth should be re coated with a good grade of graphite grease February 1982 The Lincoln Electric Company Cleveland Ohio 44117 1199 SEC L2 2 6 SUBMERGED ARC CONTACT ASSEMBLIES Also See Sec L2 2 7 the K 148 nozzle when using high currents or Linc Fill long stickout procedures Sec T2 2 6 File as Sec L2 2 6 for IM 278 File as Sec 2 7 1 for IM 198 A K231 Contact Nozzie Assembly For NA models For submerged arc welding usi
128. UNTING SCREWS ABOVE THE DECAL ON THE ANALOG INTERFACE KIT SIDE COVER Remove the top most screw from the right side of the NA 5 control box and save for use in Step 4 below Route the Analog Interface Kit plug harness into the NA 5 control box through the square access hole Then align the Analog Interface Kit s top and two bottom mounting holes with the holes in the 5 box side and secure with the removed top screw and the two screws provided with the kit Open the NA 5 control box door and locate the 2 cavity harness receptacle lying near the lower right rear corner of the box Remove the receptacle s jumper plug T13498 1 and save for future re use Remove the jumper leads from the Analog Interface Kit harness plug and connect the plug to the 5 harness receptacle Connect the red 531B and 532 leads to the 531B and 532 terminals on the right side of the upper NA 5 terminal strip NOTE a If the Analog Interface Kit is removed from the NA 5 both the Warning label and the jumper plug removed in Steps 2 and 5 above must be replaced on the NA 5 b Access to the circuit board mounting screws located between the NA 5 and kit control boxes 15 obtained by removing the kit s top mounting screw and hinging the box down If the Analog Interface Kit contains a parts bag that includes two metal set screws and two plastic set screws please follow the rest of instruction 8 Remove the set screws
129. WIRE FEED DRIVE ROLL BOX For Codes Above 8800 6991 09 27 2007 P 100 D 3 P 100 D 3 Twinarc two electrodes fed through one head For 3 32 thru 7 32 wire use the parts marked X in column 1 parts see the appropriate Twinarc Assembly parts For 1 16 thru 3 32 wire use the parts marked X in column 2 list in the P 101 series For 035 thru 052 wire use the parts marked X in column 3 Indicates a Change This Printing For 045 thru 052 Cored Wire use the parts marked in column 4 DESCRIPTION PARTNO QTY 123456789 1 Gear Box Assembly See P 100 C 1 2 Face Plate 16987 1 XIX XIX 3 Idle Roll Assembly 512475 1 XIX XIX 4 Incoming Guide Tube 3 32 thru 7 32 KP2116 2 1 4 Incoming Guide Tube 1 16 thru 3 32 KP2116 1 1 4 Incoming Guide Tube 035 thru 052 045 thru 052 Cored 1967 1 1 5 5 16 18 x 75 5 CF000040 2 6 Mounting Clip T8400 4 XIXIXX 7 3 16 16 x 3 00 HHCS CF000039 1 8 Plain Washer S9262 120 1 9 Pivot Pin T12206 1 1 X X X X 10 Idle Roll Spring T10247 7 1 XIX XIX 11 Yoke Indicator Assembly 113610 1 X X X X 12 Drive Roll Nut 110552 1 XIX XIX 13 Drive Roll Washer 59262 44 1 X X X X 14 Drive Roll 3 32 thru 7 32 S12514 2 14 Drive Roll
130. Wire size KP1962 2 1 123 Contact Tip 5 32 Wire Size KP1962 4 1 123 Contact 1 8 Wire Size KP1962 1 1 123 Contact Tip 3 32 Wire Size KP1962 3 1 X X 123 Contact Tip 3 32 Wire Size 3 8 24 Thread Old Style KP2082 1 1 X X 123 Contact Tip 3 32 Wire Size 5 16 18 Thread KP2100 3 1 X X 123 Contact Tip 5 64 Wire Size 3 8 24 Thread Old Style KP2082 2 1 X X 123 Contact Tip 5 64 Wire Size 5 16 18 Thread See Note 1 114050 5 64 1 124 Adapter for 3 32 and 5 64 58087 Tips With 3 8 24 Female Thread See Note 2 1 X X 124 Adapter for 3 32 and 5 64 T14050 Tips With 5 16 18 Female Thread 1 X 125 Nozzle Insert for 3 32 and 5 64 Wire For NA S15106 3 32 1 125 Nozzle Insert for 5 64 Wire For LAF amp LT KP2121 2 1 X Mounting Clip For Mounting Nozzle on LAF2 110714 2 T14726 5 64 Tip As 231 1 M8241 1 X 110 Nozzle Insulator S10493 1 XIX Nozzle Body S10157 Roll Pin T9967 10 X X 10 18 2006 P 101 N P 101 N K226 and K32 CONTACT JAW ASSEMBLY For K32 order a K226 assembly All parts are the same except Item 8 e 222 e O 287 2 10 9 2 Ur M13879 6 12 81 P 101 N 1 P 101 N 1 Indicates a Change This Printing ITEM DESCRIPTION PART NO 1123456 7 Contact Jaw Assembly One Rectangular and
131. X XIX 11 1 4 20 x 1 00 HHCS CF000015 2 XX X X X 12 Nozzle Body M11327 1 X X X X X 13 Insulating Tube 17028 51 1 X X X X X 14 Insulation 512579 2 XXIX XIX 15 Snap Ring S9776 25 2 X X X X X 16 Pivot Pin 112158 1 X X X X X 17 Spring 110247 8 1 XIXIXIXIX 18 Nozzle Holder 513762 1 X X X X X 19 Window Cover 57748 64 1 20 Thread Protecting Collar 513805 1 X X X X X Nozzle Collar S13804 1 X X X X X Nozzle Tip KP1973 1 1 XIXI Nozzle Tip KP1991 1 1 e X Inner Guide KP1980 1 1 Extension Support Arm Mounting Bracket S13758 1 Set Screw S11604 19 1 e e XX Water Cooling Tube Assembly Not Illustrated T12928 1 X ej K149 Linc Fill Extension Asbly Includes K149 3 32 Wire 1 K149 Linc Fill Extension Asbly Includes K149 120 Wire 1 K149 Linc Fill Extension Asbly Includes K149 1 8 Wire 1 e K149 Linc Fill Extension Asbly Includes K149 5 32 Wire 1 K149 Linc Fill Extension Asbly Includes 1 Linc Fill Extension Asbly 4 L4621 6 Nozzle Includes 1 X Extension Arm Asbly 1 XIXIXIXIXIX Mounting Block 1 XIXIXIXIX I Set Screw S11604 19 1 1 4 20 x 1 3 8 HHCS CF000118 2 X X XIXXX Insulation T8477 16 2 X X XIXIX X Insulating Tube 111851 3 2 X X X X Lock Washer E106A 2 2 Plain Washer S9262 23 2 X X XIXXX 1
132. Z DES HER STELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN e Keep your head out of fumes e Use ventilation or exhaust to remove fumes from breathing zone e Los humos fuera de la zona de res piraci n e Mantenga la cabeza fuera de los humos Utilice ventilaci n o aspiraci n para gases e Gardez la t te l cart des fum es e Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail e Vermeiden Sie das Einatmen von Schweibrauch e Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes e Mantenha seu rosto da fumaga Use ventila o e exhaust o para remover fumo da zona respirat ria 2215 CRATHELTPBERLTTE L AR 24748 Wess 2478 HHPI Ask TAAA ARHAR gaal dalj aay e Qul bids Y qii Jaial uu A pe gl e Turn power off before servicing e Desconectar el cable de ali mentaci n de poder de la m quina antes de iniciar cualquier servicio e D branchez le courant avant l entre tien e Strom vor Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine anhalten e N o opere com as tampas removidas e Desligue a corrente antes de fazer servico e N o toque as partes el tricas nuas 7 7 3 57 1294 Lro
133. achines if the NA 5 stops welding follow this procedure A Move the 5 voltage set point 2 volts lower than the desired procedure and make a test weld 1 If the NA 5 still shuts down go to Step B below 2 If the NA 5 keeps welding change the R3S triangle setting to the next higher voltage and reset the 5 set point to the desired procedure R3S is now set properly unless there is a significant change in input voltage Skip the following step The Lincoln Electric Company Cleveland Ohio 44117 1199 B Move the 5 voltage set point 2 volts higher than the desired procedure and make a test weld 1 If the NA 5 now keeps welding change the R3S triangle setting to the next lower voltage and reset the NA 5 set point to the desired procedure R3S is now set properly unless there is a significant change in input voltage 2 If the 5 still shuts down refer to paragraph below and the other possible causes previously listed This same general procedure can be used on other power sources For example if the NA 5 keeps shutting down and the other possible causes have been checked adjust the SET voltage higher and or lower than the desired vol tage If the NA 5 continues to weld at one of these voltages it can then be determined what change in the range controls of the power source are required so it can supply the desired voltage In some cases it is also possible to hold the ACTUAL button pressed while start
134. age in this part of the circuit is danger ously high when the unit is energized Turn off the 5 control turn off the power source and disconnect the input power to the power source before removing the screw that holds the access door in place Replace the screw holding the access door closed after the adjustment is made Only a qualified electrician is to do the maintenance work February 1982 The Lincoln Electric Company Cleveland Ohio 44117 1199 The Lincoln Electric Company Cleveland Ohio 44117 1199 Assembly and Installation SEC T2 5 OPTIONAL FEATURES INSTALLATION CONT D Sec T2 5 9 K219 Flux Hopper Kit Standard on the NA 5S The flux hopper can be mounted on the NA 5N or NA 5NF heads for submerged arc welding Installation instructions are shipped with each kit Operation is as follows 1 Flux valve switch on off The flux valve is then on manual operation and must be held open It will close when released 2 Flux valve switch on on When starting cold the valve automatically opens when the electrode makes electrical contact with the work while the inch down pushbutton is pressed When starting or cold the flux valve automat ically opens when the Start button is pushed It re mains open until the Burnback timer times out or the flux valve switch is turned February 1982 Sec T2 5 10 K337 10 or 100 Weld Timer M
135. alvloy 15 ie St 016 4935 5508 SEITE 4594 mei Th a os EEES 4 raat al SSL 3415 i a 1503 va FRANO HUSNE TERT tW mer pp 2 RSLS X98 BSD 203 Lids OR OL 181 mia 23871 LON 5 ASNO 61 MHL 0001 5108 1 7 jus L 6229 Dimension Print 2 20 81B NA 5 MOTOR GEAR BOX AND FACE PLATE ASSEMBLY The Lincoln Electric Company Cleveland Ohio 44117 1199 See Lb B 3 1231 32 oy DIVA IH LES 149111594 ANY 01 ONYO 2 3915 996 63919104 38 NVI MSV BOLOW ONY KOE 49399 310N NOLISOd al LaWHS 10041000 OF 43194102 31912 3293 310N 2 vid 298 February 1982 88My The Lincoln Electric Company Cleveland Ohio 44117 1199 Connection Diagram M 14156 AVI OM 300815313 INV 1108 d 3655313373 A AA F d AE AYOM OL d REN GL
136. arc as close together as possible Lengths should be as short as possible but never exceed 25 feet Tape the leads together where practical 3 Be sure the rubber covering the electrode and work ca bles is free of cuts and cracks that allow high frequency leaking Use cables with high natural rubber content such as Lincoln Stable Arc which more effectively re sists high frequency leakage than neoprene and other synthetic rubber insulated cables 4 The control leads from the high frequency unit to the NA 5 must be shielded as specified in the Electrical Connections section 5 covers on the High Frequency Unit 6 Mount the wire reel as close to the head as possible The electrode and reel become an antenna radiating energy into space Make certain the electrode cannot touch the NA S control box 7 Make sure all parts carrying high frequency are insu lated from all other parts Even though the parts are not grounded they might become radiating antennas 8 Route the wire feed motor leads flux hopper leads and any other remote control leads so they are no closer than 6 to the High Frequency unit head mounting parts wire reel wire reel mounting welding cables etc Use lead clamps as necessary C ELECTRICAL CONNECTION While observing all the points made in above Section B make the electrical connections as follows 1 Turn off all input power to the power source and NA 5 Mount the High Freque
137. as shipped This allows full range manual procedure control independent of the Analog signal leads if 5 override is not sufficient for some applications ANALOG INTERFACE TWISTED PAIR SHIELDED CABLE 2 REQUIRED ANALOG INTERFACE C BOARD D OPERATION 1 Panel Controls a Panel Light Whenever the Analog Interface light is on the procedure is being controlled by the levels of the 0 10 volt remote analog signals When the kit is connected to an NA 5R the Analog signal levels will be functional and displayed on NA 5R meters However when the kit is connected to an NA 5 they will not be functional nor displayed on NA 5 meters unless the NA 5 WELD mode light is on When the panel light is off procedure setting 1 returned to the NA 5 or 5 controls b Panel Idle Mode Switch The panel idle mode switch allows the selection of NA 5 WELD controls or analog signal levels for procedure settings in the idle mode This switch will also function while welding if the J terminals are connected as described in Section C The kit s panel light will always indicate the selected weld procedure setting method c Analog Procedure Override Controls These controls are located under the lockable security panel of the Analog Interface Kit They are used to provide minor changes n remote analog signals approximately 5 in order to find the best welding procedure Once the proper procedure is determined
138. b with the lugs flat against the tab and tight en the bolt and nut Operation Do NOT completely straighten the elec trode A slight curvature is required in the electrode to insure good electrical contact inside the contact tip Extensions When required the nozzle can be lengthened by making extensions per the following drawing Screw the extensions into the nozzle body and screw the contact tip or small wire adapter into the extension A flux tube of the appropriate length must be made for the installation A 5 extension is available from The Lincoln Electric Company e Order Part 512003 ji53X 452 CHAMFER 32 4 te DR 2 18 CLASS 5 64 or 3 32 1 8 or 5 32 3 16 or 7 32 1 4 a3 M 24 DRILL DEEP 2 18 DEEP CLASS FIT 4 MATERIAL HARD DRAWN COPPER or HEAT TREATABLE COPPER ALLOY oU Maintenance Replace the contact tip when no longer provides accurate wire location or good electrical contact Rusty and dirty wire or high currents increase tip wear Always keep replacement tips in stock To replace the contact tip first loosen the retaining wing screw and remove the flux cone Then unscrew the tip and replace it The special socket head screw ltem 118 of P 101 M holds the nozzle body to the insulator If the nozzle body becomes loose remove the nozzle from the head tighten the screw and reass
139. ble causes have been checked adjust the SET voltage higher and or lower than the desired vol tage If the NA 5 continues to weld at one of these voltages it can then be determined what change in the range controls of the power source are required so it can supply the desired voltage July 1983 The Lincoln Electric Company Cleveland Ohio 44117 1199 Operating Instructions SEC T3 8 COLD START CIRCUITRY NA 5 controls above Code 8300 contain circuitry added to the Voltage P C board to facilitate the cold starting features of these units This circuitry senses the voltage present between the electrode and work via leads 67 and 21 and permits normal wire feed if this voltage ex ceeds typically about 6 5 volts DC However if this voltage level is not exceeded or drops below typically about 3 5 volts DC the Auto Stop activates while inching down or electrode backup occurs if the arc start circuit has been initiated Units below Code 8300 can be provided with the cold start circuitry by replacing the old code L 6257 Voltage board with the new G 1556 Voltage board This new board will mount and connect in the same manner as the old board except the third harness connector previ ously connected to a jumper plug must be connected to the lower receptacle of the new Voltage board NOTE HI FREQ starting cannot be used with converted units below Code 8300 Auto Stop When the inch down button is pres
140. c 2 5 7 K238 High Frequency Generator Sec T2 5 8 K219 Flux Hopper Kit _ _ Sec T2 5 9 1337 Weld Timer Module Sec 2 5 10 K336 Remote Interface Module Sec T2 5 11 K237 Linc Fillstar ng Relay un ws na sn ce EET ee RE ds e Sec T2 5 12 K334 Start and and Crater Controls a Br Ea are Sec T2 5 13 Current Sec T2 5 14 K224 Solid State Remote Field Control oo Sec T2 5 15 IE sou dr ea Sec T2 5 16 58 Magneto Separator X oe DEAS Sa OARS ee ooo Sec T2 5 17 Screen ee Sec T2 5 18 K349 Multi Proced re Kit osc redox x are Ub dod nahe Sec T2 5 19 K373 Analog Interface Procedure Control Sec T2 5 20 Sec T3 Operating Instructions Routine Equipment Operation Sec T3 2 Operators Instructions 22225 a a gt Ud Sec T3 2 1 Loading the 50 60 Pound Reel Sec T3 2 2 Head Position Adjustmetts s as tusa 2a Sec T3 2 3 Controls and Their Functions 2 2 Sec T3 3 1 Setup eae amp MO
141. c T2 2 Head Installation cos X ede A A toe ose Sec T2 2 2 Control Box installation 2 2 2 ars A Des Sec 12 2 3 Travel Camapge Installation ip EOS rA tenta d Sec T2 2 4 Submerged Arc Contact Assemblies Sec T2 2 6 148 Nozzle and K149 Linc Fill Extension aaa a aaa Sec T2 2 7 285 Coneentrie Flux Cone ceeds ware Eae nde Ow een na due dx Sec T2 2 8 K29 Vertical Head Adjuster Sec T2 2 11 K96 Horizontal Head Adjuster Sec 12 2 12 Electrical Installation Tre IUS Sd eed doeet d Sec T2 3 Wiring the Eguipment 2 32 Vete a Rod LEER Sec T2 3 1 Connection Diagrams xc oo AUR OW Sec T2 3 4 Installation Other Optional Features Sec T2 5 Contact INOZZIeS 1 3 deo xut arte ds Vb Sec T2 5 3 K218 Horizontal Sec T2 5 4 Wire Straightener 2 acu 554 he eost aate Rd Ee htc AO boxe Sec T2 5 5 K2 8 Spreadare we fete d Sed ende Bee Ale i teur atas M oro dh ar Sec T2 5 6 Speed Feed AA Sec 2 5 7 yu Se
142. c Travel position the travel will be automatically controlled by the NA 5 control circuit during the welding operation Control Power Switch 1 This switch opens both sides of the AC input power to the control circuit In the event of circuit malfunction this switch can be thrown to the OFF position which will turn the entire circuit off However if it is necessary to service the inside of the control box the power to the box should be disconnected at the power source Although this switch turns off both sides of the AC line power to the control unit the power lines and power source control leads are still brought into the control box and therefore this power switch should not be relied upon to protect maintenance personnel SET ACTUAL Pushbutton 6 After the weld has been started the ACTUAL wire speed and volts can be read by pressing the pushbutton to the left of the START button When the pushbut ton is not being pressed the meters read the SET value Mode Selector Switch and Lights 7 When the NA 5 is at idle the knob can be set to point to the STRIKE START WELD or CRATER controls for presetting purposes For example by turning the knob to WELD the WIRE SPEED and VOLTS rheostats for the Weld Controls will Operating Instructions Sec T3 3 1 Continued 11 12 be operative With this setting the WELD light will be on If the knob is set for optional controls which are not installed the
143. cal Install cables so they move smoothly with the carriage Clamp the 4 0 electrode cables from the power source to the left rear corner of the carriage using the holes provided for the cable clamp Suspend all cables off the floor to prevent excessive drag and damage to the cables For Twinarc installations install the second wire reel as specified in the instructions shipped with the Twinarc kit After all of the equipment wire reel shafts wire reel and wire and control box have been installed on the carriage the tracking of the carriage bearings and the drive gear should be checked The carriage drive unit is properly shimmed at the factory so that the face of the driving gear is flat against a 88 thick beam flange when the release handle is in the up position If the flange is other than 88 thick the shims under the gear box mounting brackets will have to be changed per Figure 2 CARRIAGE BEARING TRACKING The bearing tracking can be checked by placing a strip of white paper along the area over which each set of bearings ride Disengage the release handle and move the carriage over these paper strips If the carriage has been properly in stalled the trace on each paper should show a uniform trace leftby the bearing face The Lincoln Electric Company Installation Cleveland Ohio 44117 1199 Sec T2 2 4 C Continued Cable Clamp Full Face Contact Beam Flange Incorrect Incorrect ADD Shims REMOVE Shims Beam Bea
144. center guide tube by applying a clamp as shown in Figure Apply only enough clamping force to relieve the tang pressure from the I D of the tip Figure 1 2 Remove the nut holding the contact tip in place Remove the contact tip 3 Remove the secondary threaded collar which will allow the dirt shield to come off the barrel of the nozzle 4 Make sure that all threads and contact surfaces are clean and bright then replace the threaded collar contact tip and the tip locking nut Tighten both the collar and the tip locking nut securely 5 Remove the C clamp releasing the internal guide 92Jy Installation Unscrew the hose clamps entirely so that the open ends may be placed around the body of the nozzle Put the hose clamps back together and tighten the clamps with the stationary part of the cone mounting covering up the opening in the nozzle body Position the moving member to the desired height of flux coverage and tighten the wing screw into the top tapped hole See Figure 2 Travel Direction Figure 2 8 Connect flux hose from hopper to the flux entry port on the concentric flux cone arm cut the hose length to suit B K149 Linc Fill Nozzle 1 Unscrew the hose clamps entirely so that the open ends may be placed around the body of the nozzle Place the stationary member of the unit directly opposite the arm coming out of the window of the nozzle put the hose c
145. cludes NSS 1 Brush amp Spring Assembly Universal Motor M12254 1F Brush amp Spring Assembly Stature Motor M13312 12 Brush Cap Universal Motor Early Design 7 8 27 THD M9655 7A Brush Cap Universal Motor Present Design 3 4 27 THD M9655 7B 0 2 Brush Cap Stature Motor 2 1 1 1 Pinion Gear S15013 3 Pinion Gear S15013 2 Motor Lead Plug 110662 Adapter Assembly Includes Gear Box Adapter Helical Gear S15008 1 o Helical Gear 2 Gear Box Assembly See P 132 E pr es ee Lock Washer E1 06A 2 2 2 xx Lock Washer 2 E106A 2 31 2001 Q This part is obsolete and no longer available 8 31 200 P 132 E a P 132 E a GEAR BOX ASSEMBLY Gear Ratio is stenciled on the side of the gear case and on top of Item 12 Na 5199 7 24 815 7 31 91 P 132 E b Indicates a Change This Printing P 132 E b Use only the parts marked X in the column under the heading number called for in the model index page ITEM DESCRIPTION PART NO QTY 56 789 Gear Box Assembly 3255 amp K325HC S 142 1 Ratio Gear Box Assembly K325F amp K325HC F 57 1 Ratio Gear Box Assembly K579 1 K580 amp K581 21 1 Ratio Gear Box Gear Snap Ring Woodruff Key Snap Ring Set Screw Bevel Shaft Assembly Woodruff Key Flat Washer 10 Spur Shaft Assembly 11 Hex Nut 12 Helical
146. cted as indicated by the kit s panel lights 2 Presetting the Weld Procedures a b set the 5 mode selector switch to WELD posi tion Select Weld Procedure 1 using the Multi Procedure Kit panel selector switch Adjust Weld Procedure 1 controls on NA 5 panel so the NA 5 meters display the desired values of wire feed speed and arc voltage Repeat Steps b and c above for Weld Procedures 2 3 and 4 as required for the application 3 Welding Without Remote Selection of Weld Proce dures a The Multi Procedure board must be configured to weld procedure selection from the panel as origi nally shipped See Section C 4 Select the desired Weld Procedure number using the Multi Procedure Kit panel selector switch Start the weld and the selected weld procedure will become operative when the NA 5 WELD mode light turns on indicating that the weld mode of the welding cycle is in progress The selected weld procedure will remain operative as long as the NA 5 weld mode is operative or until another weld procedure is selected during the weld mode 4 Welding With Remote Selection of Weld Procedures a b Set the Multi Procedure Kit panel selector switch to the REMOTE position Select the desired Weld Procedure number using the appropriate remote selection signal Refer to Section C Start the weld and the remotely selected weld pro cedure will become operative when th
147. ctronic circuitry is protected by a 1 2 ampere slow blow type fuse It is located on the Power P C board inside the control box The 1 8 amp fast blow fuse on the Voltage P C boards built since 1983 protects the NA 5 circuitry from damage which may result from a ground or case faulted control lead If this fuse blows the NA 5 arc voltage sensing lead circuit will be opened see Section T3 7 and the NA 5 Troubleshooting Guide should be consulted to detect and clear the fault September 1998 98Sept Sec T6 3 3 Ground Fault Fuse Protection A 1 8 amp fast blow fuse is located on the NA 5 Voltage board This fuse will protect the 5 circuitry from dam age resulting from a ground or case faulted control lead when arc voltage potential exists between ground and the NA 5 circuit common 510 Such a condition typically exists when the NA 5 polarity connections are set for elec trode negative Apr l 1988 The Lincoln Electric Company Cleveland Ohio 44117 1199 Maintenance SEC T6 4 OPTIONAL FEATURE MAINTENANCE Sec T6 4 1 Wire Contact Assemblies Dirty or rusty electrode and excessively high currents cause rapid wear of the contact tips The nozzle contact tip must be replaced when it no longer provides accurate wire loca tion or good electrical contact See Sec T2 2 6 T2 2 7 T2 5 3 and T2 5 4 for specific instructions for replacing contact tips and other maintenance of the various contact assemblies
148. d for trouble free wire feeding c Put the cover plate on the reel so the four arms of the cover straddle the spring loaded arms of the reel proper Tighten the cover as much as possible by hand Do NOT hammer on the spinner nut arms Cut and remove the tie wire holding the free end of the coil Insert the free end into one of the holes in The Lincoln Electric Company Cleveland Ohio 44117 1199 the cover and secure it by bending it back Cut and remove the remaining tie wires NOTE Always be sure the free end of the coil is securely held while the tie wires are being cut and until the wire is feeding through the drive rolls Fail ure to do this will result in back lashing of the coil which may tangle the wire A tangled coil will not feed so it must either be untangled or discarded Replace the reel on the wire feeder Grasp the shaft knob pull it out and swing it across the reel hub Turn the reel until the free end of the electrode 1s acces sible While tightly holding the electrode cut off the bent end Straighten the first six inches and insert it through the wire straigthener or small wire spring guides to the drive rolls Press the Inch Down button until the rolls pick up the wire and feed it through the nozzle NOTE When using the flux cored electrode wire straightener remove the bushing from the top of the straightener Then insert end of the electrode through the bushing and down throug
149. de block is tinned at the factory and only a light amount of sanding of the mating sur faces will be necessary Assemble the guide block to the water jacket using the socket head screw removed previ ously Make sure the guide block is back against the locating shoulder Stand the unit up vertically with the guide block at the bottom then heat the assembly again until the solder melts between the joints tighten the screw during the time the solder is in a liquid state Add a little solder to the mating edges to insure a good soldered joint Do not overheat Improper soldering will cause the joint to overheat and fail while welding Allow piece to cool and insert new tip insulating tubes into the water cooled jacket Reassemble the unit February 1982 The Lincoln Electric Company Cleveland Ohio 44117 1199 Assembly and Installation K218 HORIZONTAL FILLET LAP ATTACHMENT Sec T2 5 4 File as Sec L2 5 4 for IM 278 K218 Horizontal Fillet Lap Attachment This special contact assembly is recommended for sub merged arc welding horizontal fillet and lap joints on 6 and thicker plate With the special head pivot assembly loose the guide wheels ride in the joint for accurate bead placement often eliminating the need for expensive fixtures and clamps INSTALLATION OF HEAD PIVOT ASSEMBLY 1 If already installed remove the straight contact assem bly from the head Remove the electrode cables from the contact assembly
150. drum From this point load the wire according to the process which you are using Appropriate wire conduit or insulated guides should be used to prevent wire from making contact with objects at welding ground potential Installation of automatic Drum Brakes High electrode feed speeds generally 2300 inches per minute may require the use of a turntable with an automatic brake to stop the drum rotation from overrun at the end of the weld For more information on drum brakes and for instructions on how to install the brake into the turntable visit http www lincolnelectric com knowledge articles content speedfeeddrums asp Turntable The Lincoln Electric Company Assembly and Installation Cleveland Ohio 44117 1199 EW2357 B Sec T2 5 7 B FOR IM305 SPEED FEED REELS File as Sec L2 5 10 B for IM278 General Installation Reel Setup The Reels require dereeling equipment that ALWAYS use caution proper equipment and permits them to rotate freely as the electrode is used appropriate procedures when moving the reels Dereelers can hold the reels in vertical or horizontal Improper handling can cause personal injury and or position depending on the application The dereeler damage to the product needs to include at least one low friction insulated Reel Dimensions Friction less insulated eyelet Fixed floor Plate Friction less insulate A spacer may be needed on the dereeler shaft fo
151. e NA 5 WELD mode light turns on indicating that the weld mode of the welding cycle is in progress The remotely selected weld procedure will remain operative as long as the NA 5 weld mode is opera tive or until another weld procedure is selected dur ing the weld mode Assembly and Installation Sec T2 5 19 Continued E SECURITY OF WELD PROCEDURE SETTINGS There are two means provided to prevent or limit unau thorized readjustments of the Multi Procedure Kit voltage and wire feed speed controls once set to the desired proce dure l Once the procedure is set the security panel of the Kit can be locked to prevent access to the control knobs 2 The control range of the procedure control knobs can be limited to either about 3 or about 15 of the full range control by installing a knob rotation stop screw to any or all of the control knobs This stop screw 15 installed in the same manner as described for the NA 5 Control see Sec T3 9 F MAINTENANCE Every three months inspect the control box If needed blow dirt out using low pressure dry air No other mainte nance should be required Except when used with NA 5R Controls see in Section February 1996 The Lincoln Electric Company Cleveland Ohio 44117 1199 The Lincoln Electric Company Cleveland Ohio 44117 1199 Assembly and Installation K 373 ANALOG INTERFACE PROCEDURE CONTROL Sec T2 5 20 NOTE Reference to NA 5 also
152. e connection to the NA 5 head or work 3 ncorrect electrode polarity connections at the NA 5 or power source 4 Little or no output voltage from the power source 92Jy 5 An open 67 or 21 voltage sensing lead to the NA 5 control box or a blown Ys amp fuse on voltage P C boards built since 1983 July 1983 The Lincoln Electric Company Operating Instructions Cleveland Ohio 44117 1199 SEC T3 9 SECURITY OF WELD PROCEDURE SETTINGS There are two means provided to prevent or limit unau thorized readjustment of the NA 5 voltage and wire feed speed controls once set to the desired procedure 1 The security panel of the NA 5 can be locked to pre vent access to the control knobs 2 The control range of the procedure control knobs can be limited to either about 3 or about 15 of the full range control by installing a knob rotation stop screw to any or all of the control knobs This stop screw is installed in the following manner a Turn off the input power to the NA 5 b Loosen each knob set screw and remove all knobs including the rotary selector switch knob c Remove the felt seal and square spacer tube mounted behind each control knob d Open the control box and disconnect then remove the procedure control P C board assembly and its panel insulation e Install a long pan or round head 4 sheet metal screw into the 10 dia hole located beneath each square hole so the head is on the back s
153. e is running Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporiz ing 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 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 EMF fields may interfere with some pacemakers and welders having pacemaker should consult their physician 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 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 qe 1 g To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work disconnect the spark pl
154. eads at rect polarity at the terminal strip inside the control the and terminals per 5 wiring diagram ornorcommecicd to work and electrode b Check the appropriate power source connection dia b Control leads may be improperly connected at the gram power SONS c Reset the output range controls of the power source so c Welding power source is unable to supply the SET that it can supply the desired voltage See Out of voltage Range Shutdown Section IB d Power source voltage control switch not set to RE d Voltage control switch of R3S DC 600 orDC 1500 type power sources must set to REMOTE e A fuse on voltage P C board is blown e Refer to Section II Problem T6 to determine cause of fuse blowing Voltage P C boards built prior to 1983 did not have fuse protection The Lincoln Electric Company Troubleshooting Guide Cleveland Ohio 44117 1199 Sec T6 6 Continued 5 Poor arc striking with sticking or blast offs weld porosity narrow and looking bead or electrode stubbing into plate while welding CAUSE WHAT TO DO a Improper procedures or techniques a See to Make Submerged Arc Welds S604 or Innershield Production Welding Guide N675 b Improper wire feed acceleration setting for the b See IM 305 manual process in use Voltage Control response not set properly for c See IM 305 and the appropria
155. ection diagram for the proper connection of the jum pers located on the NA 5 Voltage Board To change the voltage control response Turn off all input power to the NA 5 control 2 Open the control box 3 Locate the Voltage P C board mounted on the right side of the box Position the jumper plugs on the Vol tage Board per the appropriate power source connec diagram RED JUMPER WHITE JUMPER VOLTAGE BOARD February 1982 88My The Lincoln Electric Company Cleveland Ohio 44117 1199 Operating Instructions SEC T3 7 AUTOMATIC SHUTDOWN If the NA 5 voltage control is unable to supply the SET value of arc voltage while welding the automatic shutdown circuit will activate This protection circuit immediately re turns the N 5 control to idle state within a few seconds after the arc voltage discrepancy occurs Typical causes for the activation of this protective shutdown circuit are as follows 1 SET value of arc voltage is outside the power source range 2 Power source voltage control not set for REMOTE 3 Misconnection of NA 5 control cable leads to power source 4 Incorrect weld polarity connections or settings at NA 5 or power source 5 Lost connection of 5 voltage sensing leads 67 and 21 between arc and voltage control or a blown 18 amp fuse on voltage P C boards built since 1983 With 5 units above Code 8300 the conditions of 4 and 5 above
156. emble the nozzle October 1997 Assembly and Installation B K226 Contact Jaw Assembly For Models 3 NA 4 and 5 For submerged are welding generally at currents from 600 to 1000 amps Model K266T with two tapered jaws feeds 3 32 and electrodes K226R with one tapered and rectangular jaw feeds s thru 7 2 electrodes The braided shunt is not included with the K226T Installation Insert the outgoing wire guide from the wire feed mechanism into the top of the contact assembly body Install the assembly in position on the bottom of the wire feed mechanism with the pressure spring as shown in the K226 following sketch and lock it in position with the two screws pro vided with the assembly Note By removing the four screws which hold the body to the mount ing block the jaws can be rotated WORK to the appropriate one of four FRAVEL positions 90 apart Contact Spring NOZZLE TRAVEL Connect two electrode cables coming from the control box to the contact jaws by placing one under each of the 13 nuts on the assembly see arrows in photograph with the cable lugs flat against the copper and tighten the nuts Slip the rubber tube shipped with the contact assembly onto the valve below the flux hopper If installing other rubber tubing be sure it is non conductive Fit the cop per tube in the other end through the clip on the jaw as sembly Maintenance Rusty or dirty wi
157. end of the electrode and inch it up until it is free of the contact tip Loosen the locking nut about one half turn and pull the nozzle body to relieve the pressure of the tang against the inside of the contact tip hole At this moment rotate the tip proper amount and then retighten the locking nut To install a new contact tip proceed as follows 1 Clip the end of the electrode and inch it up until it is free of the tip 2 Remove the contact tip locking nut 3 Relieve the spring pressure of the contact tip against the steel tang in the hole of the contact tip To do this push the nozzle body so the steel tang is approximately cen tered in the 3 8 9 5 mm hole in the contact tip Under these conditions the contact tip can be easily removed from the nozzle body The Lincoln Electric Company Cleveland Ohio 44117 1199 Sec T2 2 7 Continued File as Sec L2 2 7 for IM 278 File as Sec M2 2 7 for IM 279 4 b Before installing the new tip make sure the threads and the bottom surface of the nozzle are clean and bright These surfaces are current carrying areas and must be clean Push the nozzle body to one s de and insert the new contact tip Check the locking ring threads making sure they are free of any foreign material A small application of high temperature anti sieze compound on these threads insures a longer thread life of the two mating parts Suggested anti sieze compounds are Graphite
158. epate 12688 1 Polarity Swith S13479 1 o mes 1 Fuse T10728 8 1 913490 1 Diode o 1270515 1 SCRandHeatSink 133420 1 Control Board Code 7359 Only EL L3 mI Control P C Board Code 7683 amp Above 5759 1 Caution Decal 1134 0 1 Choke 1681464 1 Resistor Code 7742 amp Above 2731 42F K224 Mounting Angles 14 1 513709 h I I 8 lI D 0 This part is obsolete and no longer available 01 28 2003 P 114 J P 114 J K285 CONCENTRIC FLUX CONE 5 9 Indicates a Change This Printing ITEM DESCRIPTION PART NO Concentric Flux cone Includes K285 Side Plate 114177 1 1 Items Not Illustrated Flux Hose T10642 10 Flux Hose Tube T6996 9 lt n 21111111 ___ 2934 ___ 143 21111111 e 10 28 98 114 2 114 2 278 1 SPREADARC COMPLETE ASSEMBLY 08 29 2006 P 114 K 3 P 114 K 3 Use only the parts marked X in the column under the heading number called for in the model index page Indicates a Change This Printing ITEM DES
159. for assemblies built after Sept 1988 M15663 7 15 88F Use only the parts marked X in the column under the heading number called for in the model index page Indicates a Change This Printing ITEM DESCRIPTION PART NO al SFU RROD Box Welded Assembly S15316 1 0 1 ADN Self Screw S8025 12 2 19639 2 1072 510255 14 514301 T12339 am tnn Hex Nut 10 24 2 XIX Solid State 551771 1 X X Rue i Es LLLI AC Contactor 17 1 WamingDecal Tan 1 xi 1 13 14 Terminal Strip Assembly Includes 713885 1 Capacitor 111577 30 1 Resistor 112731 9 1 XX 9 10 2001 132 132 TC 3 SELF PROPELLED TRAVEL CARRIAGE Parts Lists Index This parts list covers machines thru Code 9021 For Codes above 9021 contact Service Dept For K325 S K325 F Use Column One on P 132 C D amp F For K325 HC K325 HC F Use Column Two on P 132 C D amp F TC S General 132 Motor and Gear Box P 132 D Gear BOcASSembI a 132 132 Travel Control ASSOIbly 2 2432 dea Od _ _ __ 03 23 05 132 132 TC 3 GENERAL ASSEMBLY T T 222 2222 22 777 222 777777 Cum
160. from both Analog Procedure Overide Contro Knobs and discard these set screws b Install one metal set screw from the included parts bag into each control knob c Rotate the control shafts fully CCW as viewed from the shaft end and position a knob on each shaft so that the marker line of the knob is in line with the bottom left marker line on the nameplate and tighten the knob set screw Assembly and Installation d Install one plastic set screw on top of the metal set screw already in each knob using a moderate installation torque so as not to strip the plastic screw e Rotate the control knobs to the 0 position C REMOTE ANALOG SIGNALS Speedmeter Pin 45 Requirements The Analog Interface Board of the Analog Interface Kit permits setting of NA 5 volts and wire feed speed procedures by user supplied external analog signal levels and provides isolation of the kit s control circuitry from these signals Full range 0 to 100 linear control over the 5 rated volts or wire feed speed setting ranges can be obtained using analog signal levels per the following Analog Signal Levels 0 to 10 VDC with ripple content lt 50 mV gt 50 Hz The following ranges should be observed for best operation Volts 12 0 to 60 0 VDC Wire Feed Speed 80 978 I P M 40 778 I P M 38 762 I P M 50 611 I P M 50 600 I P M 23 456 22 428 1 15 300 I P M 15
161. g Nozzle Tip 062 Wire Size S17614 062 Nozzle Tip 068 Wire Size S17614 068 Nozzle Tip 5 64 Wire Size S17614 5 64 ITEM DESCRIPTION PART NO am 1 Nozzle Tip 3 32 Wire Size S17614 3 32 Nozzle Tip 120 Wire Size S17614 120 Straight Nozzle Assembly 062 3 32 Wire Size M14808 1 Straight Nozzle Assembly 122 Wire Size M14808 4 0 Collar 517745 Nozzle Body Assembly S10157 3 Socket Head Screw T10570 Nozzle Insulator Assembly S10493 Nozzle Insert Assembly 062 3 32 Wire Size Only 15106 1 Hex Head Screw 1 2 13 x 1 50 Hex Nut 1 2 13 4 4 4 4 4 2 2 3 4 5 6 7 8 9 A a a gt Lm MEN GENE NES 2221 T _ pp e a 1 le 0 This part is obsolete and no longer available 07 19 2001 NOTES 114 114 K224 SOLID STATE REMOTE FIELD CONTROL DISCONTINUED L5297 10 2 81Q Indicates a Change This Printing ITEM DESCRIPTION PARTNO am 11231415 67 Solid State Remote Field Control Includes K224 106394 1 az oa Number Plate 110726 90 810593 1 Auto Transformer 127020 1 BoxAssembly M1270600 1 Transormr 515257 0 1 __ Toz 1 Nam
162. g chains or cables until they fail Also see item 1 c 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 Do not use welding power source for pipe thawing 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 Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Cylinders should be located e Away from areas where they may be struck or subjected to physical damage eA safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication Precautions for Safe Handling of Compressed Gases in Cylinders a
163. g to a different wire size is accomplished by changing a few parts See Parts List P 101 G An 17728 side by side tip holder is available for Lincore overlay welding procedures employing the same tips A REEL INSTALLATION 1 See drawing on next page for mounting suggestions for the second electrode reel The reel support bracket must be made by the fixture builder to fit the particular installation B INITIAL PREPARATION For 045 or 5 64 wire 1 Remove the following parts from the wire feed unit a The wire straightener b The complete nozzle c Both the upper and lower guide tubes d The drive rolls e The idle roll assembly 2 Place the double grooved drive roll on the shaft and insert the key Place the clamping washer back on the shaft and tighten the hex locking nut C INITIAL PREPARATION For wire Remove the following parts from the wire feed unit a The wire straightener b The complete nozzle c Both the upper and lower guide tubes d The drive rolls e The idle roll assembly f The drive roll key g The output shaft drive roll spacer 2 Oil or grease the new shorter drive roll spacer place it on the output shaft and push it back as far as it will go 3 Place the key in the keyway of the shaft On later models the shoulder bolt pivot replaced by a pin secured by a set screw located on the mounting surface of the face plate 92Jy 4 Place an ou
164. gic board as follows WHEN THE STOP BUTTON IS PRESSED Feed motor stops and electrode burns back with con tactor delay standard For older models For newer models lead 693 to pin 3 lead 690 to pin 4 Switch 2 2 Feed motor inches up and electrode burns back with contactor delay For newer models Switch 2 3 Feed motor inches up and contactor opens no burn back Eor older models lead 693 to pin 1 lead 690 to pin 4 For older models lead 693 to pin 1 lead 690 to pin 2 For newer models mm Switch 2 Optional Crater Controls Recommended for applications where the ending bead size must be controlled the crater must be filled in cluding roundabouts and other welds where the end overlaps the start When the Stop button is pressed the machine welds at the wire speed and voltage set by the Crater Con trols until the time set on the thumbwheel switch elapses The circuit then automatically switches to the arc stopping sequence described above NOTE Setting crater time to 0 00 seconds will give zero crater fill time however the crater settings will be active during burnback time until the arc goes out Wire will retract at Weld Mode Speed or Crater Mode Speed if installed until the arc goes out then retract at Strike Mode Speed for remainder of bumback time February 1996 The Lincoln Electric Company Cleveland Ohio 44117 1199 Sec T3 5 2 Con
165. ging from 20 psi thru 100 psi For ease of handling the user should connect the incoming air line to the pipe elbow with the aid of a fast discon nect type air coupling July 1983 The Lincoln Electric Company Assembly and Installation Cleveland 44117 1199 K349 MULTI PROCEDURE KIT NOTE References to NA 5 also include 5 units ex cept where specifically noted Sec T2 5 19 6 Remove the jumper leads from the Multi Procedure Kit harness plug and connect the plug to the NA 5 A GENERAL harness receptacle The Multi Procedure Kit is an optional control box de signed to mount and connect to NA 5 automatic controls above Code 8300 and the NA 5R The kit provides three removed clarity additional Weld mode procedure settings of wire feed speed and voltage allowing the choice of four NA 5 Weld mode procedures Weld Procedure 1 is set with the standard NA 5 Weld Controls and Weld Procedures 2 3 and 4 are set with the weld controls provided under the kit s lockable X security panel Any one of the four weld procedures may SSS Ses be selected by the operator before or during welding using OU the kit s panel selector switch or by connection of custom amp er furnished remote signals Lights on the front panel of the indicate the selected weld procedure and the NA 5 meters show that procedure when the NA 5 Weld mode light is on NOTE NA SR control
166. gn the installation with the adjustability required by the welding application Include sufficient clearance for the head adjustments described in Sec T3 2 3 For best arc striking use a rigid mounting which prevents the head from moving when the electrode strikes the work Insulation The head and electrode are electrically when welding They must be insulated from ground B SPECIFIC REQUIREMENTS FOR NA 3N NA 3S NA 4 5 Head mounting hardware and insulation is shipped with these heads If installing an optional vertical lift adjuster or horizontal adjuster see Sec T2 2 11 or Sec T2 2 12 re spectively To mount heads on the standard travel carriage see Sec T2 2 4 To mount heads on a separate fixture pro vide the mounting holes specified in the dimension print C SPECIFIC REQUIREMENTS FOR THE NA 3NF AND NA 3SF AND NA 5SF These models do not include the head mounting parts and cannot be installed on the standard travel carriage Design the head mounting and insulation parts to fit the fixture Refer to appropriate dimension print WIRE FEED MECHANISM heads are shipped with the wire feed speed gear box ratio specified for the model ordered To change the gear box ratio see Sec T6 2 2 heads are shipped ready to feed the wire sizes specified on the order Feeding other sizes may require changing drive rolls and guide tubes see Parts List P 100 D Adjust t
167. h E Stop Above Code 11000 M20853 Pilot Light 113486 Inch Push Buttons 113541 2 Stop Push Button 113541 1 Nameplate Below Code 11000 M13935 Nameplate Above Code 11000 M13935 1 Control Box See P 135 F Control Printed Circuit Board Code 8205 Only 16019 Control Printed Circuit Board 6445 Expansion Nut Board Mounting S14020 3 Voltage Printed Circuit Board Code 8205 Only 6257 Voltage Printed Circuit Board Below Code 9100 except 8205 G1556 3 Voltage Printed Circuit Board Above Code 9100 G1556 5 Logic Printed Circuit Board L6242 2 Expansion Nut Board Mounting S14020 3 Power Printed Circuit Board Code 8205 Only 6252 Power Printed Circuit Board L6252 2 Expansion Nut Board Mounting S14020 3 Rheostat Knob Procedure Start and Crater Boards 110491 Shaft Seal T14034 Square Insulating Tube T14767 Jumper Plug Remove when using Start or Crater Board Options T13498 10 Jumper Plug Remove when using Multi Procedure Kit Code 8300 T13498 1 Caution Decal Below Code 11000 113470 Patent Decal Below Code 11000 513232 Warning Label Code 8205 Only S16722 2A Warning Label Below Code 11000 S16722 2B Warning Label Above Code 11000 S16722 33 R F Bypass Printed Circuit Board Not used on Code 8205 M14133 1 Items Not Illustrated Motor Amphenol Connector S12021 32 Flux Amphenol Connector S12021 17 Tech Amphenol Connector S12021 18 Input Amphenol Connector S120
168. h the straightener When the drive rolls start feeding wire stop and reinstall the bushing February 1982 The Lincoln Electric Company Operating Instructions Cleveland Ohio 44117 1199 ROUTINE EQUIPMENT OPERATION Sec T3 2 3 File as Sec L3 2 3 for IM 278 Head Position Adjustments The NA 3N NA 3S NA 4 NA 5N and NA 5S heads can be easily adjusted to any welding position These adjustments are illustrated below The most frequently used adjustments Fig T3 2 3 1 and Fig T3 2 3 2 are also available on the NF and SF units The other NF or SF adjustments depend upon the fixture design Loosen Set Screw With a 5 16 Allen Wrench L oosen Set Screw With a 5 16 Allen Wrench ROTATES AROUND DRIVE ROLL SHAFT ROTATES AROUND Cross Seam MOTOR AXIS Adjuster Can Be Mounted To Top Or Bottom Of Box ALL HEADS ALL HEADS Fig T3 2 3 1 Fig T3 2 3 2 NOTE If the head is positioned so the wire feed roll box is placed upside down the wire straightener and nozzle positions must be interchanged Then to feed the electrode down through the nozzle the wire feed motor direction of rotation must be reversed To do this interchange leads 626 and 627 from the feed motor plug at the terminal strip inside the control box With Vertical Lift Adjuster Clamps D Can Be Set To Restrict In and Out HEAD ROTATES AROUND Movement to Any Distance up to 3 3 4 VERTICAL MOUNTING AXIS 2221 12 22 Rotate
169. h the two large holes in the head mounting pad Assembly and Installation Sec T2 5 6 and L2 5 6 Continued NOTE Before mounting an NA 5 head to the Spreadarc to assure adequate clearance between the motor connection box and the Spreadarc head mounting surface the motor mounting to the gearbox should be rotated per the instructions below 1 Remove the four screws mounting the gearbox assembly to the motor adapter plate and remove the gearbox 2 Remove the three screws mounting the adapter plate to the motor rotate the adapter plate 90 clockwise and replace the three mounting screws 3 Remount the gearbox assembly with the four mounting screws The drive motor is to be in the vertical position and the drive rolls are to face the front Loosen the head face plate clamp screw and rotate the face plate so that the idle roll arm is down Install the nozzle wire straightener and flux hopper if used per the NA 3 NA 4 or NA 5 operating manual see Figure 2 1 2 13 head mounting screws 5 motor connection box Motor Vertical Drive rolls to be in front as shown Figure 2 When using a K225 Twinarc nozzle 219 hopper and a standard head mounting on a travel carriage and when welding from left to right a special 12 flux tube is required The tube which is included with the Sprea darc may be trimmed in length to fit the installation In addition it is necessary to reposition the
170. he dle roll pressure adjustment screw for the wire 85 Drive diameter to be used in produc eH tion As shown on the indi cator there are two settings 035 3 32 120 7 32 Make this adjustment only i with the appropriate wire size D ME between the drive and idle rolls On some cored or soft electrodes it may be necessary to set for a lower pressure to prevent crushing When shipped the drive roll rotates clockwise to feed elec trode down see photo If de As Shipped sired the faceplate can be ro tated 180 and the wire straightener and contact assembly lo cations switched The drive roll rotation direction must be re versed by interchanging leads 626 and 627 from the wire feed motor plug at the terminal strip inside the control box 92Jy For 5 64 amp Larger E CONTACT ASSEMBLIES Several different contact assemblies are available See Sec 2 2 6 T2 2 7 T2 5 3 T2 5 4 for installation instruc tions F WIRE REEL If 300 to 1000 pound Speed Feed reels or Speed Feed drums are to be used see Sec T2 5 7 When ordered the reel for 50 or 60 pound coils 1 shipped with the needed mounting shaft hardware and insulation Shaft mounting hole requirements are on the head dimen sion drawings Install the reel mounting shaft on the fixture or travel car riage so the wire goes as directly as possible to the wire straightener without going arou
171. he NA 5 control box by turning off the welding power source Open the control box door and locate the terminal strips mounted on the back of the box in the lower left hand corner On the right end of the lower ter minal strip interchange the black and white leads going to the terminals marked and The black lead No 67 must be connected to the same polarity as the electrode weld ing lead i e if the electrode is positive connect the black lead to the terminal on the terminal strip The white lead No 21 is connected to the opposite polarity terminal E TRAVEL MECHANISM 115 volt AC power to drive the standard Lincoln travel carriage or for starting and stopping other travel mecha nisms is obtained from a receptacle on the control box This 2109 21 1 512778 K579 1 K580 1 K581 1 The Lincoln Electric Company Cleveland Ohio 44117 1199 TERMINAI Gomas STRIPS Te ae s a 4 prong receptacle connected to leads 531 532 25 and a grounding lead Leads 531 and 532 are 115 volts AC Leads 25 and 531 are 115 volts AC with 25 connected through the wire feeder travel switching circut for manual or automatic starting and stopping See Sec T2 2 4 C for completed details on the K325 Travel Carriage F ARC AND TRAVEL STARTING AND STOP PING Various sequences for starting and stopping the arc and travel are possible with standard machines or optional features The choice of sequences depends upon t
172. he State of California to cause can chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer birth defects or other reproductive harm The Above For Diesel Engines 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 amp 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 0 d 1h To avoid scalding do not remove the Ol 09 57 radiator pressure cap when the engine is powered equipment ce 1 Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires to be running 1 6 Operate engines in open well ventilated areas or vent the engine exhaust fumes 2 outdoors 1 c Do not add the fuel near an open flame welding arc or when the engin
173. he guide tube so that they are parallel with outside diameter of the drive roll and tighten the two locking screws Fit the other electrode guide into the top of the Twinarc nozzle Install the nozzle to the head by first sliding the guide tube into the faceplate until the mounting screws supplied with the nozzle can be started into their respective tapped holes Tighten these two screws The lineup of the outgo ing guide is automatic Fasten the electrode cables of the proper size to the copper bar on the nozzle Use two 4 0 cables for currents up to 1 000 amps at 80 duty cycle Split the cables so they will be on both sides of the copper bar Install the rubber flux tube provided onto the metal discharge tube at the bottom of the flux hopper Slip the end of the rubber tube with the copper tip through the clip to the T winarc nozzle assembly Assembly and Installation Sec T2 5 3 K225 and L2 5 3 Continued D ADJUSTMENTS Electrode Spacing The wires are held against a center contact block by the two pressure springs on the jaws The center block controls the distance between the wires Center blocks for and inch spacing are available To change the blocks loosen the two pressure springs Then remove the two 4 20 socket head screws that hold the contact block Before installing the new block use graphite grease on the 4 20 screw threads and be sure the mating surfaces between the center contact b
174. he specific requirements of the procedures and application See Sec T3 5 2 for a de scription of these sequences and the needed reconnection in structions G SPEEDMETER CALIBRATION The jumper on the 5 Speedmeter board located on the backside of the NA 5 door behind the digital speedmeter is factory shipped connected to Pin 95 which is correct for a 95 1 NA 5 head ratio using the S12514 drive roll For 5 heads with other ratios or drive rolls the jumper must be reconnected per chart below an inmin Single 035 052 100 2070 57F0 57 1 12778 19113 K331C Single 035 052 Solid 40 778 K332C or 045 052 Cored 570 57 1 12515 K331B Single 1 16 3 32 38 762 K332B 95 95 1 512514 K331A Single 3 32 5 32 22 428 K332A 9550 95 1 512515 519113 K346B Single 1 16 3 32 23 456 K347B or 045 9550 95 1 513161 052 K346B 13161 5 64 K347B 514904 outer with K129 14905 inner or K239 Twin 045 052 23 456 Twin 1 16 5 64 Twin 3 32 142 142 1 12514 K346A Single 3 32 7 32 15 289 K347A 142T0 142 1 S14904 outer K346A S14905 inner K347A with K225 1 Earlier speedmeter pins were labeled 55F and 55 respectively 0 Earlier speedmeter P C boards did not include these calibration pins 9 Present on Hi Speed 5 Speedmeter board L8575 1 only Twin 5 64 1 8 15 300 Standard on K579 1 NA 5 Hi Speed Control ordered separately for K356 Standard NA 5 Contro
175. i fied when the nozzle was ordered either a liner for 035 thru 052 electrode or for thru electrode is shipped with the assembly Insert the appropriate liner into the nozzle body with the adapter ring on top Insert the outgoing wire guide from the wire feed mecha nism into the top of the nozzle body and place the nozzle in position on the bottom of the wire drive mechanism Operation pressure shoe and contact tips for the electrode diameter specified on the order are shipped with each assembly different contact tip is required for each electrode size used The electrode is automatically held against the nozzle contact tip with a preset pressure to assure good electrical contact Because the electrode is held against the tip it tends to wear a groove in the tip When the groove be comes too deep to maintain good electrical contact the tip must be replaced A groove is also worn in the contact pressure shoe This shoe has two chamfered edges 90 apart When a groove is worn in one direction remove the shoe turn it 90 and replace it so the second chamfered edge fits into the con tact tip This provides a new wearing surface When both wearing surfaces are grooved replace the shoe October 1997 The Lincoln Electric Company Cleveland Ohio 44117 1199 Assembly and Installation FOR SUBMERGED ARC AND WELDING WITH INNERSHIELD ELECTRODES K148 Contact Nozzle and K149 Linc Fill Long Stickout Exten
176. ic Company Cleveland Ohio 44117 1199 hae ee Er Sec T6 2 1 ig Soe gh be 2 Sec T6 2 2 sods te eat dee Sec T6 2 3 Sec T6 2 4 a Sec T6 3 Sec T6 3 1 A Sec T6 3 2 Sec T6 4 both he ar Sec T6 4 1 Sec T6 4 2 ee ane Gong Be aca re Sec T6 4 3 Soot fe Sec T6 4 4 Sec T6 4 5 a ds da Sec T6 4 6 aud Eee a Sec T6 4 7 pna o Sec T6 6 February 1982 The Lincoln Electric Company Assembly and Installation Cleveland Ohio 44117 1199 SEC T2 2 MECHANICAL INSTALLATION Sec T2 2 1 N Available Models REEL MOUNTING SHAFT ee MODEL NA 5N With brake assembl optional 2 Required Power Source DC Constant Voltage TET TT h 1 ARC WELDER _ VERTICAL ADJUSTER optional WIRE REEL for 50 amp 60 Coils optional iTRAVEL CARRIAGE optional STD 4 CONTROL TO c WIRE STRAIGHTENER electrode cables for cored wire HEAD MOUNTING PARTS 427 with insulation Ei CROSS SEAM and hardware Y ADJUSTER Y CONTACT ASSEMBLY optional MODEL NA 5NF HEAD For Machinery and Fixture Builders 5 Control order separately Required Power Source DC Constant Voltage Identical to the NA 5N except the following parts are not included Head Mounting Parts 4 Electrode Cable
177. ide of the panel inside the control box f Remount the P C board assembly and its panel in sulation then reconnect the P C board and close and secure the control box g Remount the rotary selector switch knob and re place each square spacer tube and felt seal so the 4 screw protrudes between the tube and the felt seal h Turn on the NA 5 input power and set the desired procedure by rotating the shafts of the controls i Carefully replace each control knob so the 4 screw inserts into the center of the shorter length channel on the back of the knob for about 3 of the total range of control or into the center of the longer length channel for about 1596 of the total range of control j With finger pressure on the knob against the felt seal carefully retighten the set screw of each knob NOTE Steps h thru j will have to be repeated if it is desired to change the procedure settings to values outside the selected 3 or 15 control range limit February 1982 88My The Lincoln Electric Company Cleveland Ohio 44117 1199 Maintenance SEC T6 MAINTENANCE Sec T6 2 Mechanical Maintenance Have an electrician install and service this equipment Turn the input power off at the fuse box before working on equipment Do not touch electrically hot parts can kill Sec T6 2 1 Wire Drive Gearbox Once a year recoat all gears with a non fluid type lubricant
178. in place Replace and securely tighten the nut on the grounding stud f Install the white lead on terminal 32 on the termi nal strip g Install the black lead on terminal 31 on the termi nal strip C OPERATION 1 Set the oscillation speed control and the rear and front dwell controls as called for in the welding pro cedure The front dwell control controls the dwell when the nozzle is farthest from the Spreadarc mounting bracket Turn the power switch on After the dwell period and oscillation starts adjust the oscillation travel distance by rotat ing either or both of the limit switch stops as re quired to give proper front and rear electrode posi tion After the desired oscillation track is obtained lock the stops in place by tightening the hex nuts against the stops 2 If there is a major change in the speed control set ting the oscillation track will change requiring readjustment of the limit switch stops D MAINTENANCE Before doing any of the following maintenance work remove the line cord plug from its receptacle or turn the input power off at the power source if powered by an NA 3 4 or 5 Remove the head from the Spreadarc for Steps 2 3 and 4 1 Limit switches Twice a year check the limit switch plungers by rotating them They should turn freely If they stiff pull back the rubber boot and clean the plunger with a cleaning solvent Apply a dry lubricant such as moly or
179. include NA 5R units unless specifically noted A DESCRIPTION The Analog Interface Procedure Control is an optional control box designed to mount and connect to NA 5 automatic controls above Code 8300 and the NA 5R The control provides circuit isolated interface for remote user provided 0 to 10 volt DC analog signal levels to linearly set the 5 weld procedures between 0 and 100 of the rated range of wire feed speed and arc voltage The kit also provides 5 procedure override controls under lockable security panel and a selector switch to permit the choice of procedure setting control using remote analog signals or the standard NA 5 weld controls Maximum versatility is obtained when the 5 15 connected to a DC 600 DC 1000 or DC 1500 type power source or SAF 600 and SA 800 with the Solid State Remote Field Control When used with a SAM R3S power source the voltage range of the required procedures may exceed the range covered by the power source remote control and it would therefore be impossible to obtain the range of set procedures without readjustments at the power Source B INSTALLATION TO THE NA 5 1 Turn off all input power to the 5 at the power source 96My 2 Remove the four screws securing the of the 516722 Warning label on the right side of the NA 5 control box and remove the Warning label to expose the l inch square access hole REMOUNT THE WARNING LABEL WITH ITS MO
180. incoln Electric Company Cleveland Ohio 44117 1199 When using 062 1 6 mm or 5 64 2 0 mm Innershield electrode with a K148 C nozzle make sure that the wire is in the vee groove of the pressure tang Idle roll pressure settings should be made per marks on the idle roll arm except for the smaller diameter electrodes For the 062 1 6 mm and 5 64 2 0 mm wire sizes back off on the idle roll pressure so that there is little or no flattening of the wire Because the electrode is held against one point of the con tact tip it wears a groove at that point When the groove is about one half the diameter of the electrode rotate the con tact tip to a new position per the instructions below Careful positioning of the contact tip will provide four to six wear spots depending upon the electrode size When welding with the small diameter electrodes it will be necessary to change contact position more frequently since the amount of tip wear that can be tolerated is much less The tang should never be allowed to touch the I D of the contact tip To do so will allow welding current to go through the tang causing electrical wear and overheating of the tang and contact tip If the groove is allowed to wear until the tang touches the I D of the contact tip welding current passes through the tang This causes electrical wear and overheating of the tang and contact tip New Time to rotate Too late To rotate the tip clip the
181. ing the arc Before the NA 5 shuts down the actual arc voltage can be read on the digital meter Comparing this reading to SET reading will tell what change in the range controls of the power source are re quired so it can supply the desired voltage Should the meter read zero check 5 sensing leads 67 and 21 connections Should the meter read a negative voltage the polarity connections or settings at the NA 5 or power source are wrong IC NA 5 ACCURACY CHECKS 1 Voltmeter Accuracy Perform the following checks with the automatic equip ment connected to the welding power source per the proper connection diagram The power source 15 to be ON and both the power source and automatic equip ment properly set up for welding a Connect a test voltmeter with at least 3 digits and 0 5 accuracy see box below between work and the electrode cable connection at the welding head b While welding the test voltmeter reading should match the ACTUAL VOLTS meter reading within 0 5 V typically 0 2 V If it does not refer to COMPREHENSIVE TROUBLESHOOTING GUIDE c Remove the test voltmeter and while welding com pare the SET VOLTS and ACTUAL VOLTS meter readings Depending upon the arc voltage charac teristics of the process being welded the ACTUAL reading may vary somewhat about an average value The average ACTUAL reading should match the SET reading within 0 5 V typically 0 2 V If it does not refer to Section
182. ire through small diameter tubes 3 Minimize sharp bends in the electrode When a change in direction is required use free wheeling idler rolls of at least 10 inches 25 4 centimeters in diameter 4 Position the eyelets and idler rolls so there is as little loading on the feed motor as possible Ideally the total force at the head to move the electrode or electrodes in Twinarc welding should not exceed 20 pounds 89 newtons 5 Be certain the electrode enters the straightener or ingoing guide at an angle no greater than 30 from its central axis 6 Load Speed Feed reels on the turntables so they are centered and balanced 7 Do not over tighten the electrode in the drive rolls The Lincoln Electric Company Cleveland Ohio 44117 1199 Assembly and Installat on SEC T2 5 OPTIONAL FEATURES INSTALLATION CONT D Sec T2 5 8 K238 High Frequency Generator NOTE When using the K238 HF unit the NA 5 control must have a code above 8300 and the equipment being used must have the following special high frequency insulation 1 Factory installed between head motor and gearbox Factory provided for head mounted flux hopper Factory provided for wire reel mounting bracket BW Factory provided for head mounting Fixture builder models which do not have head mounting insulation must be mounted with a minimum of I inch thick polyester laminate providing the head with no less than inch
183. istor S10404 73 Round Head Screw 10 24 x 2 75 Insulating Washer S10773 7 Plain Washer S9262 27 Lockwasher E106A 1 XIX Hex Nut 10 24 XIX 10 Resistor S10404 78 Round Head Screw 8 32 x 2 50 Insulating Washer S10773 7 X X Plain Washer S9262 3 Lockwasher Hex Nut X 2 11 12 13 Cable Assembly Includes Plug 13 Cable Assembly Includes Polarized Plug Cable Clamp 14 Travel Control Box Cover 515238 1 15 Insulation 1400 6 016 2 00 2 75 16 Warning Decal 113470 17 Socket and Lead Includes ES 1 HIN ES 1 18 Thread Cutting Screw S9225 36 1 Lockwasher T9695 1 1 Hex Nut 10 24 2 20 Instruction Tag He 0 This part is obsolete and no longer available 07 20 2001 NOTES 135 135 WIRE FEED DRIVE MOTOR 2 SONQUCTOE SHIELDED CAME CONDUCTOR CABLE M13902 6 3 83E W O Without High Frequency Insulation W H F With High Frequency Insulation Indicates a Change This Printing ITEM DESCRIPTION PARTNO ary 1213 4 5 6 789 Drive Motor amp Connection Box Assembly Includes UHE 57 1 Ratio W O H F M13902 1 Drive Motor amp Connection Box Assembly Includes 95 1 Ratio W O H F Dr 2 Drive Motor amp Connection Box Assembly Includes 142 1 Ratio W O H F 3 Drive Motor amp Connection Box Assembly Includes 57 1 Ratio W H F M13902 4 1 Drive Motor amp
184. it following the instructions supplied with the kit The Linc Fill Starting Circuit was designed for especially difficult long stickout procedures for which the NA 5 adjust ments of acceleration strike or start controls do not give satisfactory starting It bypasses the normal path for the welding current and puts the current into the wire at the long stickout extension guide This permits starting with a short electrical stickout and then switching to a long electrical stickout once the arc is established Only a portion of the cur rent is actually bypassed to the extension guide The remain der of the current follows the normal path in through the con tact tip This heats up the wire while the arc is being estab lished Then about one second after the arc is struck the Linc Fill Starting Relay drops out and all of the current pas ses through the normal path through the nozzle contact tip Linc Fill Starting Relay Circuit Operating Instructions 1 Set the start control timer for about one second delay The start wire speed is set for about 50 to 75 of the Weld speed and the Start voltage control is set about the same as the Weld voltage 2 Cut the end of the electrode to a sharp point and make atest weld Make certain that the starting relay drops out after the start time has expired If stubbing occurs when the arc first strikes the Inch Wire Speed may be set too high or the strike or start voltage may be settoo low If
185. it is set 3 There may be occasions where the two wires will be used other than in line with the seam to be welded To adjust the nozzle for staggered or cross seam wire position loosen the contact tip clamping nut Rotate the nozzle tip until the desired wire posi tion is set then retighten the nut Readjust the head position to get proper angle of wire to work User to supply 1 2 13x1 00 Hex Hd screw amp lockwasher Bracket Support User to make the nozzle are clean and bright These surfaces are current carrying areas and must be clean Check the locking ring threads making sure they are free of any foreign material A small applica tion of high temperature anti sieze compound on the threads insures a longer life of the two mating parts Suggested anti sieze compounds are Graph ite grease per Lincoln specification E 2067 Inch electrode out of end of nozzle If the long steel guide tubes came out with the old contact tip slide the guide tubes over the wire Then insert the wire through the holes in the new contact tip or contact tip holder This procedure simplifies the assembly and line up of the component parts 4 Replace the locking ring and tighten securely Tip Holder Ceramic Replacement 1 16 thru 2 32 wire Should the ceramic inserts in the tip holder break they may be replaced as follows Standard U Bracket e Remove nozzle tips e Remove hollow lok screws with a 5 32 Alle
186. it over the screw Place the control arm inside the hopper with the bent section straddling the top edge of the hopper and the hole over the screw installed in paragraph 1 Screw the special pivot nut from the kit onto the screw so the shoulder of the pivot area enters into the hole in the control arm Tighten the nut against the flat washer The arm must be free to rotate about the pivot nut Flat Washer Lock Washer Hex Head Screw Flux Valve Assembly The Lincoln Electric Company Cleveland Ohio 44117 1199 OPERATION 1 If making lap welds thru plate install the grooved guide roll shipped with the kit This guide roll is designed to ride along the top corner of the upper plate Use the fillet guide roll for lap welds on plate over thick If making fillet welds install the double guide rolls which are designed to ride against both the vertical and horizontal members of the joint with sufficient clearance between the rolls to clear tack welds Obtain the proper position of the electrode with respect to the joint by adjusting the hex screw above either guide roll Adjust the flux hose to deposit flux directly onto the wire at the joint Do not allow flux to fall ahead of the guide roll Loosen the lock screw X on the pivot assembly S al lowing the head to swing freely about the pivot shaft The combination of the off center weight of the head and the downward pressure
187. k Remove either the nozzle or the guide block at the end of the nozzle Load the wire reels with Innershield electrode per instructions in Sec T3 2 2 For Feed drums and reels see Sec T2 5 7 A and B Remove the U shaped ingoing guide from the top of the wire straightener Turn the straightener ad justing knob for minimum straightening Straighten the first 10 of electrode and insert the ends through their respective holes and down through the straightener and ingoing guides to the drive rolls Press the Inch Down button until both wires start to feed through the rolls Turn the straightener knob away from minimum straightening and slide the U shaped guide along the wires to its original position Lock the thumb screw Inch the electrode through the drive rolls and adjust the straightener until the wire is straight Mark this position so it can be quickly reset after the next loading of the reels The straightener will do a good straightening job if the reels are properly installed as described under Reel Installation Contact tips Insulation Insulating tube Nozzle Travel Direction gle ipa Work Travel Direction The Lincoln Electric Company Cleveland Ohio 44117 1199 Sec T2 5 3 K239 and L2 5 3 Continued Tip contact block Insulation Tip insulator m Tip insulating tube Socket head screw G MAINTENANC
188. l 92Jy July 1992 Assembly and Installation ELECTRICAL INSTALLATION CONT D The Lincoln Electric Company Cleveland Ohio 44117 1199 Sec T2 3 4 A oo NO ON et t xog 03300 6 43 O 3439 943 Jeq Jepun pob nus 151 591492 2 243 101392240 5 194029 204 PN 0078 9 Oqe 009 70 91138 9ujus93 SiN OU Sj 929041 01 3224009 914 03 322440 919 03 129uu0 1240 10 POJIBULOI eq 1 n 5 943 saden 9 N 41295 2 uo 01 3294402 541414 wujus83 9 4 9 4 pee 3294002 541336 9 pas 3294109 81483 031402 51 yl 299044 aq 150 21 05 29904 41238 90141913 9211048 941 Jebu 2402 943 pes 914603 9234052 43 3294499 uoj328uuo2 dn ede 4 91902 eq pinoys pes s 8506 5 143 299 JUBALO 201 959jd 91493 0 243 910 0403 23914 yjom 93 329 1 3 320000 06004110 3143 305 9148 16 5 pee yJo
189. l the backup tang lifts off the surface 3 Remove the 3 8 9 5 mm set screw C in the body A 4 Remove the contact tip clamping nut D and the contact tip Remove the brass thread protecting collar E Remove the window cover F from unit Slide the center guide G up out of the pivot body until the tang is above the window 8 Place the Linc Fill guide assembly into the nozzle win dow and then lower the center guide tube G back down to its original position ON tA 92Jy K148 with water cooling attachment K148 amp K149 1 Assembly and Installation 9 Line up the spot at the top of the center guide tube G with the 3 8 9 5 mm tapped hole in the upper pivot block A and put the 3 8 9 5 mm set screw C back into the hole and tighten securely 10 Line up the lower spot in the center guide tube G with the 3 8 9 5 mm set screw Item 4 and tighten this securely 11 Replace the brass thread protecting collar It s important that this protecting collar be pulled up against its locating shoulder otherwise the tip locking nut will not clamp the tip securely 12 Replace the contact tip and its clamping nut D and tighten securely 13 Assemble the proper combination of extension guides Items 12 13 and 14 with locking nut Item 11 for the welding procedure to be used 14 If Submerged Arc welding is being used
190. lamps back together and tighten The stationary mem ber should be positioned as shown in Figure 3 Figure 3 Installation 2 The lower hose clamp must be placed and tightened in a position where it does not touch the outboard long stickout arm of the K149 nozzle Position the moving member to the desired flux coverage and then tighten the wing screw Use middle or lower tapped hole depending upon E S O The arm can be lowered to cover 4 00 inch electrical stickout Connect flux hose from hopper to the flux entry port on the concentric flux cone arm cut the hose length to suit C K129 Type Twinarc Nozzle Unscrew the hose clamps far enough so that they can be slipped up over the tip holder clamping nut Position the stationary member as shown in Figure 4 and then tighten the hose clamps Position the moving member to the desired height and tighten the wing screw Since the tips and the wire come out of the noz zle at 7 there will be some occasions where the cone will have to be tilted as shown Provi sions have been made to accomplish this by re moving the furthermost screw from the tip on each side of the cone then tilting the cone and putting the two screws back into the rear holes of the cone Retighten all four screws See Fig ure 4 Connect the flux hose from the hopper to the flux entry port of the concentric cone arm cut the hose length to suit Flux cone positi
191. lectrode Cable Cable Assembly Controls to Head Includes For K338 Parts Break Down see P 100 H a K216 L5231 B 512020 9 512024 2 L5231 C K235 Il Il Specify Length 0 9 27 2007 100 100 FLUX CORED WIRE STRAIGHTENER SINGLE ARC 1 16 thru 5 32 Electrodes Indicates a Change This Printing ITEM DESCRIPTION PARTNO am 123456789 09 27 2007 Wire Straightener Includes M10214 Body Assembly M10311 Bearing M9300 55 Washer S9262 140 Lock Washer E106A 3 5 16 18 HN CF000029 Socket Head Screw T9447 13 Rollpin T9967 30 Connecting Link T12141 Wire Guide 12551 8 32 x 50 RHS CF000033 Retainer Plate T12145 Wire Guide T12126 Adjusting Knob S12547 Adjusting Screw T12102 h mb h N dl 4 D P 100 L CROSS SEAM ADJUSTER je 74 N N 4 1 a Change This Cross Seam Adjuster Assembly Includes Clamping Ring S SES NC 5 DAMAS MAS SA MSS Z 2 23 2 ASAS IRA 7 N E oat 2 77 as 2 9 2 2 2 N 2 2 N 262 _ 2 Y PART NO M10802 M10787 P 100 L CR A PLATE LA 22277 4 FACE PLATE QTY I SS 1234 56
192. les to the K215 assembly per Table 1 3 Depending on the power source and process to be used the jumpers on the NA 5 Voltage Board may have to be changed As shipped the NA 5 is connected for use with the DC 400 DC 600 DC 1000 or DC 1500 type power sources For other power sources refer to the appropriate connection diagram and Sec T3 6 4 Connect work leads of sufficient size and length per Table 1 between the Work stud on the power source and the work Be sure the connection to the work makes a tight and clean metal to metal contact Assembly and Installation Sec T2 3 1 Continued D ELECTRODE POLARITY Polarity is changed by operating the polarity switch on the power source if so equipped or by interchanging the welding leads on the power source output studs IMPORTANT WHEN CHANGING POLARITY ON IN STALLATIONS USING THE DISCONTINUED K224 SOLID STATE REMOTE CONTROL Turn generator off and allow it to come to a complete stop before changing polarity The polarity switch on the solid state remote field control and the power source polarity must be set to the same polarity Failure to do so will result in blowing the fuse in the solid state remote field control and loss of generator output The polarity of the NA 5 control circuit 1 shipped connected for electrode positive If electrode negative 1 required two leads inside the NA 5 control must be reversed Proceed as follows Turn off the input power to t
193. lly switches Weld Con trols wire speed and voltage Actual settings depend upon the application requirements Setting the start time to 0 00 seconds will bypass the Start Mode controls durng the weld cycle D Available options for applications with particularly difficult starting 1 K238 High Frequency Generator See Sec T2 5 8 2 K237 Linc Fill Starting Relay See Sec T2 5 12 Sec T3 5 2 Setting Travel Starting and Stopping Standard machines can be connected for a variety of starting and stopping sequences 96 STARTING SEQUENCES On the Fly Travel Starting When shipped all models are connected for On the travel starting The sequence follows 1 With the electrode NOT touching the work press the Start button This starts both the wire feed and travel motors 2 When the electrically electrode touches the work to start the arc there is relative motion bet ween the end of the electrode and the work This scratching type contact helps assure consistent arc striking This sequence is recommended for most welding in cluding 1 Roundabouts and any other weld which ends at its starting point A K337 Weld Timer Module to con trol the welding cycle duration can be installed 2 Welds started on a run out tab 3 For improved arc striking on any application Standstill Travel Starting All models can be reconnected so the travel remains
194. lock and the mating surface on the copper current bar are bright clean and flat This junction carries the full weld ing current After the contact block is in place and the two socket head screws are retightened tighten the screws holding the pressure springs Nozzle Rotation The nozzle can be set so the elec trodes are in line with the joint for highest speed and 17 32 Dia 5 Holes BRACKET SUPPORT DETAIL Materials 3 8x4 00x 23 HRS Bracket Support User to make The Lincoln Electric Company Cleveland Ohio 44117 1199 penetration straddle the joint for a wide bead and shal low penetration or skewed across the joint for special conditions To rotate the nozzle loosen the two 14 20 socket head screws that hold the body of the nozzle to the mounting base and rotate the nozzle to the desired angle If the desired angle is not readily obtained re move the socket head screws entirely and relocate them in alternate holes provided Any desired angle can be obtained in this manner Retighten the screws when properly adjusted MAINTENANCE The greatest contact jaw wear takes place on the center contact block The side pressure jaws are made from a special long wearing material Replace the center con tact block when it has such a groove worn that there is no pressure on the electrode from the side pressure jaws When replacing the center contact block be certain the surface between it and the copper bar 1 bright s
195. loose To lock N so there is no movement tighten socket head screw X Place Handle on One of Two Positions HORIZONTAL HEAD ADJUSTER ONLY Fig T3 2 3 8 February 1982 The Lincoln Electric Company Cleveland Ohio 44117 1199 ROUTINE EQUIPMENT OPERATION CONT D Sec T3 3 1 Controls and Their Functions CONTROLS ON THE FRONT OF THE NA 5 CONTROL BOX A Exposed Controls lockable cover down l 92Jy Wire Speed Meter 5 Reads the SET or AC TUAL wire speed in inches minute The jumper on the meter P C board must be properly positioned for the gear ratio and drive rolls being used see table on wiring diagram Volts Meter 5 Reads the SET or ACTUAL welding voltage Inch Up Button 2 Pushing this button will inch the electrode up Inch Down Button 2 Pushing this will inch the electrode down With NA 5 controls above Code 8300 the electrode will automatically stop when it makes electrical contact with the work and the flux solenoid if used will activate until the inch down button is released Units below Code 8300 do not have this automatic stop feature Start Button 3 When this is pushed the elec trode will feed down with the wire speed and vol tage controlled by the Arc Striking Controls START CONTROLS SPEED amm YATS a ARC STRIKING CONTROLS AUTOMATIC WIRE FEEDER 10 Operating Instructions Under the conditions noted in
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197. m Figure 2 SO 0094 CORRECT PATTERN INCORRECT PATTERN INCORRECT PATTERN Full bearing face Bearing not riding Bearing not riding contact flat against surface flat against surface February 1982 The Lincoln Electric Company Cleveland Ohio 44117 Sec T2 2 4 C Continued File as Sec L2 2 4 C for IM 278 The out of squareness between the carriage and the beam can be corrected by shimming the lower bearing assembly bar Add shims in this area if necessary INCLINED OPERATION OF CARRIAGE 1 Beam should have knurled type driving flange 2 When the tilt is 5 or under no counter weight system is required as far as the loading on the carriage drive motor is concerned However see caution below 3 Beam tilt angles of greater than 5 will require a counter weight system as shown The amount of counter weight will depend on the tilt angle and carriage loading Pulley Carriage Beam Weight 4 Beamtilt angles should be limited to 10 or less CAUTION When the carriage is used in an inclined type of operation the unit is free to roll whenever the travel release handle is pulled down This may happen even if a counterbalance is used unless the wire reel and flux hopper when used are mounted off the carriage in which case their changing weight does not affect the counterbalance Each carriage is shipped with the gear ratio specified for the model ordered
198. minals per the appropriate con nection diagram shown below Such as L E Part No S12021 11 4 socket receptacle for 512020 3 4 pin plug with S12024 1 cable clamp e DOG 32 x zo I m NONNOI 7915 NONNOI 8 01123135 310933 OY VOB 23738 310 34 79495 2 SIVNIIS AYZ REMOTE SWITCH PROC SWITCH 1 SIGNALS PROC amp SIGNAL REMOTE 24 VOLT PROC 3 SIGNAL DC SELECTION PROC 2 SIGNAL SIGNAL i SWITCH COMMON CONNECTIONS FOR SWITCH SIGNALS CONNECTIONS FOR 24 VOLT SIGNALS CAUTION The switch common and the 24 volt signal common terminals are not electrically common with each other and are therefore not interconnectable Although the kit s Remote Selection Board is fuse protected impro per signals or connections may possibly cause damage to the circuit 4 Exclusive Remote Selection While Welding The Multi procedure board inside the kit control box can be configured to permit the kit s panel selector switch to be fully functional while welding or it can be configured to disable the panel selector switch thus per mitting remote selection of weld procedures See Figure 3 The panel selector switch is fully functional in either configuration when not welding The Lincoln Electric Company Cleveland Ohio 44117 1199 Sec T2 5 19 Continued
199. mm NEN EN 1 Hex Head Screw 1 4 20x 75 2 Lockwasher E106A 2 3 Hex Nut 1 4 20 4 Cable Clamp M8501 7 Head Mounting and Lift Mechanism See P 101 Q Lift Hand Stud 113872 Roller 18128 Roll Pin T9967 30 8 Carriage Frame Assembly G1322 1 X X 9 Gear Box Mounting Plate M12550 1 X X 10 Swivel Motor Mount 15772 2 11 Shim 0179 Thick Not Shown T10778 1 As Read X X 11 Shim 0598 Thick Not Shown T10778 2 4 11 Shim 1875 Thick Not Shown S10040 66 2 IX 12 Hex Head Bot 2 1 12 Hex Head Bolt 1 2 13x1 25 2 X 13 Lockwasher E106A 5 2 X X 14 Plain Washer S9262 1 2 XIX 15 Spring 15338 1 XX 16 Motor and Gear Box Assembly See P 132 D 1 XIX 17 Socket Head Cap Screw 79447 11 XIX 18 Lockwasher E106A 2 3 19 Socket Head Screw 2 XX 20 Spacer 562 Thick Sues 4 xx 20 Spacer 562 Thick S10262 5 4 XX 21 Shim 010 Thick 21 Shim 002 Thick Read X X Read X X 05 20 2005 132 2 132 2 TC 3 GENERAL ASSEMBLY 21326 2 29 80B 05 20 2005 P 132 C 3 P 132 C 3 Use only the parts marked X in the column under the heading number called for in the model index page Indicates a Change This Printing ITEM DESCRIPTION PART NO QTY 11231456 789 22 Lower Bearing Bar Assembly Includes 22 Lower Bearing Bar Assembly Includes Bearing Bearing 23 Drive Wheel Rack Tooth Std Below Code 9000 Option Above 9000
200. mooth and clean This joint must carry up to 1 500 amperes User to supply 1 2 13 1 00 Hex screw amp lockwasher NECESSARY INSULATION Section insulation ES 24 m 1 amp Bracket support Fiber tube Steel washer Bolt Lock washer Fiber washer Bracket assembly base METHOD FOR MOUNTING SECOND ELECTRODE REEL February 1982 The Lincoln Electric Company Cleveland Ohio 44117 1199 Assembly and Installation K239 INNERSHIELD TWINARC KIT Sec T2 5 3 K239 File as Sec L2 5 3 K239 for IM 278 K239 Innershield Twinarc Kit In Innershield welding two 3 32 flux cored elec trodes are fed through a single wire feeder Both wires must be the same size standard model of the NA 2 NA 3 or 5 with a 95 1 wire feed gear ratio can be converted for welding The K239 kit includes the nozzle equipped for water cool ing drive rolls drive roll locating collar idle roll assembly ingoing and outgoing guide tubes wire straightener wire reel and wire reel mounting shaft and insulation Spacing between the electrodes is fixed A REEL INSTALLATION l See K129 for mounting suggestions for the second electrode reel The reel support bracket must be made by the fixture builder to fit the particular installation For optimum operation the two wire reels should be mounted in the same
201. mp Electrode Cable K338 L6211 D 512020 27 512023 12 512024 1 L6211 F 512020 17 512023 10 512024 4 L6211 G Cable Asbly Controls to Head NA 5S Includes Multi Conductor Control Cable Flux Includes Polarized Pin Connector Polarized Receptacle Connector Cable Clamp Multi Conductor Control Cable Motor Includes Polarized Pin Connector Polarized Receptacle Connector 0 This part is obsolete and no longer available K335 L6211 B 512020 16 512023 8 512024 4 L6211 D 512020 27 512023 12 S S y 4 Ny ld ld id Ny A ld SH aS a a 4 09 27 2007 P 100 H b P 100 H b CABLE ASSEMBLIES POWER SOURCE TO CONTROLS amp CONTROLS TO HEAD Indicates a Change This Printing ITEM DESCRIPTION PART NO QTY 1lalalalsielz 8o Cable Clamp Multi Conductor Shielded Cable Tach Includes Polarized Pin Connector Polarized Receptacle Connector Cable Clamp Electrode Cable S12024 1 L6211 F 512020 17 512023 10 512024 4 L6211 G NA 4 WITH CURRENT CONTROL SWITCH Cable Assembly Power Source to Controls Includes Multi Conductor Control Cable Includes Polarized Socket Connector Connector Clamp Electrode Cable Cable Assembly Controls to Head Includes For K235 Parts Break Down see P 100 H a NA 5R Cable Assembly Power Source to Controls Includes Multi Conductor Control Cable Includes Polarized Socket Connector Connector Clamp E
202. n I C set the head and nozzle for the proper electrode angle per procedural requirements Inch the electrode out of the tips to the proper E S O Place the nozzle into the welding position Loosen the clamps and rotate Installation the concentric flux cone unit approximately 40 to 45 Retighten the clamps Loosen wing screw allowing the cone assem bly to slide down within 12 of an inch of touching the piece to be welded See Figure 5 B Flux Hopper Mounting for Horizontal Fillets For horizontal fillet welding the flux hopper will not function properly if it is fastened to the face plate of the NA 3 or NA 5 The hopper should be mounted directly above the flux entry of the con centric flux cone unit Flux hose angles should be no greater than 35 from the vertical plane to insure good flux flow from hopper to cone C UsageOnDeep Narrow Grooved Welds For narrow deep groove welding it may be neces sary to remove the copper cone from the moving arm February 1982 The Lincoln Electric Company Cleveland Ohio 44117 1199 MECHANICAL INSTALLATION CONT D Sec 12 2 11 File as Sec L2 2 11 for IM 278 File as Sec E2 7 7 for IM 245 K29 Vertical Head Adjuster ASSEMBLY Automatic welding applications frequently require rais ing and lowering the head assembly The Vertical Head Adjustment provides a quick simple and easy method of doing this A height variation of four inches can be achieved wi
203. n wrench NECESSARY INSULATION Section AA tube Exchange broken ceramics with the new ones insulation im Steel washer Screw hollow lok screws n cU Replace nozzle tips Bracket Lock washer Fiber washer Bracket assembiy base METHOD FOR MOUNTING SECOND ELECTRODE REEL April 1988 The Lincoln Electric Company Cleveland 44117 1199 Assembly and Installation K225 SUBMERGED ARC TWINARC KIT Sec T2 5 3 K225 File as Sec L2 5 3 K225 for IM 278 K225 Submerged Arc Twinarc Kit In Twinarc submerged arc welding two 5 64 3 32 s solid wires are fed through a single wire feeder Both wires must be the same size An 35 NA 4 or NA 5 with 142 1 gear ratio should be used The 95 1 gear ratio may be required for maximum usable currents and wire feed speeds especially with 5 64 electrode The Twinarc assembly includes a wire reel insulated reel mounting bracket drive rolls drive roll locating collar an idle roll assembly wire straightener dual wire guides nozzle and contact block The contact assembly has two spring loaded jaws These press the electrode against the center spacer block for good electrical contact to keep the nozzle cool and to maintain contact at a given point so electrical stickout remains con stant during welding Spacing between the wires is fixed by the size of the center contact block A REEL INSTALLATION 1 See drawing below for mo
204. ncy Unit as near to the head as possible but at least two feet away from the NA 5 con trol box 2 Connect electrode welding cables from the High Fre quency Unit to the automatic head and to the K215 input cable assembly at the 5 control box M14156 3 Connect work welding cables from the High Frequency Unit to the power source and to the work per M14156 4 Remove the cover from the High Frequency Untt Install the appropriate connector for the control lead conduit in the hole provided to the right of the terminal strip 5 Loosen the screws holding the NA 5 control box cover closed and open the the door to gain access to the termi nal strip Assembly and Installation Sec 2 5 8 Continued 6 Remove the plastic hole plug from the hole on the left side of the NA 5 control box Install the appropriate connector forthe control lead conduit 7 Install a shielded five conductor control cable having 18 AWG or larger control leads from the H gh Fre quency Unit to the NA 5 control box The shielding must be grounded to the control boxes Connect the leads as follows a High Freq terminal strip 31 to NA 5 control termi nal strip 31 b High Freq terminal strip 87 to NA 5 control termi nal strip 87 c High Freq terminal strip 681 to NA 5 control ter minal strip 681 d High Freq terminal strip 510 to NA 5 control ter minal strip 610 e High Freq grounding stud to NA 5 control box grounding s
205. nd Ohio 44117 1199 Assembly and Installation Sec T2 5 3 K129 L2 5 3 and E2 7 5 Continued 17 32 Dia 5 Holes 4 Insert the other guide tube in the outgoing side of the face plate Place the nozzle assembly over the guide tube Here again the tube and the nozzle as sembly are keyed to insure proper line up of the holes Insert and tighten the two socket head screws and fasten the nozzle securely 5 Fasten the electrode cables one on top and one on the bottom of the electrode terminal with a 2 13 nut and bolt Use two 4 0 cables for currents up to 1000 amperes at 80 duty cycle Use three 4 0 ca bles for 1000 1300 amperes use four 4 0 cables for 1300 1500 amperes E ADJUSTMENTS 1 When using an 5 connect the calibration jumper lead to pin 95S on the wire speed meter board per the table on the wiring diagram BRACKET SUPPORT DETAIL Materiais 3 8 4 00 23 H R S F MAINTENANCE For 045 wire Unscrew the locking collar and replace the contact tip when it no longer provides accurate wire placement or good electrical contact Keep replacement tips in stock For 1 16 5 64 and wire the tips can be replaced di rectly Before installing the new tip or contact tip holder 1 Make sure the threads and the bottom surface of 2 The ingoing tubes must be lined up with the drive roll grooves or poor wire feeding will be encoun tered Therefore do not change this adjustment once
206. nd any corners or touching grounded metal equipment If it must be fed long distances use insulated friction free guides rather than long tubes G WIRE STRAIGHTENER The NA 3S NA 3SF NA 4 NA 5S and NA 5SF models are shipped with a solid electrode straightener for 5 64 and larger wire The NA 3N NA 3NF 5 and NA 5NF models are shipped with one of the following 1 A flux cored wire straightener for 045 thru 5 32 Cored electrode It can also be used with 5 64 and 3 32 solid wire For solid wires above 3 32 use the 8269 1 Solid Wire Straightener 2 A tightly wound spring type wire guide for 035 thru 1 16 solid electrodes The various optional Twinarc assemblies also include a twin wire straightener or wire guide as appropriate After the head is installed fit the wire straightener or wire guide over the ingoing guide tube on top of the drive roll box The ingoing guide has a radius at the entrance shoulder the outgoing guide is chamfered The ingoing radius guide tube MUST be used at the wire straightener 22 EA 222 INGOING OUTGOING Turn the straightener so it points toward the wire reel Tighten the two clamps supplied to hold it in position For 035 1 16 Solid Electrode July 1992 For Flux Cored Solid Electrode Electrode Installation The Lincoln Electric Company Cleveland Ohio 44117 1199 Sec 2 2 3 Control Box Installation The control box can be mounted
207. nelectric com
208. ng currents generally under 600 amps Higher currents can be used but result in faster tip wear The outer flux cone deposits flux right around the arc for full coverage with minimum flux con sumption Contact tips for the electrode diameter specified on the order 5 4 thru are shipped with each nozzle differ ent contact tip is required for each electrode size used Nozzles ordered for and electrodes also include a contact tip adapter Screw the adapter into the nozzle and the tip into the adapter Installation Nozzles ordered for feeding and electrode diameters include a liner Insert the liner as shown in the following photo Do NOT usethe liner when the I D of the outgoing tube is larger than 125 These larger I D guide tubes are shipped with some wire feeders built to feed and all wire feeders built to feed larger electrodes NOTE Changing to a different diameter wire may neces sitate changing drive rolls and the ingoing and outgoing guide tubes See P 100 D for the correct parts 970c Slip one end of the rubber flux hose shipped with the noz zle onto the valve tube below the flux hopper Fit the short insulating tube in the other end of the hose and then insert into the hole in the nozzle body Do not push the tube in far enough to touch the nozzle Connect the electrode cable from the control box to the contact noz zle Place one cable on top and one below the connection ta
209. ng information for the equipment being used 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 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 Vent hollow castings or containers before heating cutting or welding They may explode 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 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 cir cuits This can create fire hazards or overheat liftin
210. nge This Printing For K247 HC Models above code 7500 use the parts marked X in Column 3 DESCRIPTION PARTNO QTY 12 IER e Eus 15388 LE ON Shim Swivel Motor Mount T10778 2 E 5 Choke Coil M8424 Cable To Travel Receptacle in Control Box Includes M8377 Plug 510272 Wire Reel Support 13154 Control Mounting Parts Insulation Tube T7305 19 Insulation Washer S10773 12 Insulation Spacer S10300 Adapter Plate S15082 Hex Head Screw 1 4 20 x 75 Plain Washer S9262 98 Lockwasher E106A 2 xx ___ Carriage Type Number For amp NA2 For amp 4 For amp 4 Gear Ratio K23 F K247 amp HC F Fast 144 1 K23 M K247 amp HC M Medium 324 1 23 247 8 HC S Slow 648 1 3 8 82 P 101 Q Supersedes P 52 D P 101 Q Supersedes P 52 D HEAD MOUNTING AND LIFT MECHANISM Indicates a Change This Printing For K23 and K236 Models Below Code 7500 use the parts marked X in column 1 For K247 and K247 HC Models Above Code 7500 and K325 and K325 HC Models use the parts marked X in column 2 ITEM DESCRIPTION PART NO Lom Head Mounting and Lift Mechanism Includes all Below 13116 15460 Mounting and Lift Mechanism Includes all Below B d G
211. odule Permits setting of weld time for an adjustable period Elim inates need to press stop button Instructions are included with kit The Timer units are adjustable by means of thumb wheel switches over the following ranges K337 10 0 00 to 9 99 sec K337 100 00 0 to 99 9 sec February 1982 Sec T2 5 11 K336 Remote Interface Module Permits connection of customer furnished remote start stop and inch momentary contact closure or momentary 24 volt signals Also used when a single remote signal is desired to start or stop multiple heads Installation and application instructions are included with the kit 92Jy NOTE This Module replaces the earlier K336 Remote Pushbutton Interface Module February 1982 K373 Analog Interface Procedure Control This kit mounts on the right side of the 5 control box with three screws and connects to the NAS procedure kit receptacle and terminal strip This control provides circuit 1solated interface for 0 to 10 volts DC analog signal levels linearly representing O to 10096 of the rated range of the wire speed and voltage con tro of the 5 system Comprehensive installation and operation instructions are included with the control April 1988 Sec T2 5 12 Cont Linc Fill Starting Relay K237 When using the Linc Fill Starting Relay Kit it is also nec essary to use a K334 Optional Start Control Do not use the starting relay circuit when using high frequency Install the k
212. ol 5 Open the 5 control box door and locate the 12 cav ity harness receptacle lying near the lower right rear corner of the box Remove the receptacle s jumper plug T 13498 1 and save for future re use Figure 2 _ 96 Assembly and Installation Sec T2 5 19 Continued NOTE 1 If the Multi Procedure Kit is removed from the NA 5 both the Warning label and the jumper plug removed in Steps 2 and 5 above must be replaced on the NA 5 2 Access to the circuit board mounting screws located between the NA 5 and kit control boxes is obtained by removing the kit s top mounting screw and hinging the box down If weld procedure selection is to be done only with the kit s panel selector switch the Multi Procedure Kit installa tion is now complete If it is desired to employ remote signals for weld procedure selection refer to Section C below MULTI PROCEDURE BOARD REMOTE SELECTION BOARD 1 8 AMP FUSE TERMINALS EXTERNAL SWITCHES TERMINALS FOR EX TERNAL 24V SIGNALS VITSE BLUE JUMPER LEAD shown connected to p Figure 3 C PROCEDURE SELECTION WITH REMOTE SIGNALS 1 Procedure Selection The Multi Procedure Kit circuitry is such that the pro cedure selection is performed on a priority basis in which the selection of a higher weld procedure number overrides the selection of any lower weld procedure number Therefore selecti
213. ol P C Board mounted on the back of the box in the lower right hand comer and change the jumper plug from the pin to the S pin Burnback and Electrode Back Up The primary consideration in setting the arc stopping sequence is to prevent the electrode from sticking in the puddle This is easily done with the machine as shipped The standard sequence when the optional Crater Controls are not used follows 1 Press the Stop button 2 The wire feed motor stops and the Burnback time delay starts 3 The arc continues to burn the electrode back from the puddle until the arc goes out or the time set on the thumbwheel switch elapses This control should be set for just enough burnback time to prevent crater sticking There are two other ways this circuit can be connected One will cause the wire to retract with a contactor drop out delay at the end of the weld and the second will cause the wire to retract during burnback time and there will be no contactor drop out delay at the end of the weld If either one of these alternate methods of stopping the weld is desired the connections on the logic board can be easily changed To change the stopping sequence turn the input AC power off at the power source remove the screw hold The Lincoln Electric Company Cleveland Ohio 44117 1199 ing the inner panel and swing the panel open Change the connections older models or switch positions newer models on the lo
214. on shown without Figure 5 The Lincoln Electric Company Cleveland Ohio 44117 1199 Figure 4 D All Nozzles After the installation to any of the three nozzles has been completed a continuity check should be made between the copper flux cone and the nozzle body This can be done by using an ohmmeter or test light If meter reads zero determine where the short is and correct the situation otherwise the copper cone will be at electrode potential and if it should touch the ground during the welding operation the cone will be damaged The Lincoln Electric Company Cleveland Ohio 44117 1199 Sec T2 2 8 L2 2 8 and 2 7 8 Continued 92Jy GENERAL OPERATING COMMENTS A Nozzle positions for Horizontal Fillets 1 K148 or K148 with K149 After the concentric flux unit has been fastened to the nozzle body per Section I A or B set the nozzle to the proper electrode angle dic tated by the procedure Loosen the two hold down clamps which fasten the nozzle to the face plate rotate the entire nozzle assembly ap proximately 40 to 45 and then retighten the clamps Inch the electrode out of the nozzle to the proper E S O Position the wire into the joint configuration then slide the concentric cone down so that it is approximately 12 of an inch away from the vertical and the horizontal surfaces to be welded Tighten the wing screw See Figure 5 K129 After mounting the concentric cone to the noz zle per Sectio
215. on of Weld Procedure 3 overrides the selection of Weld Procedure 2 and Weld Procedure 4 overrides the selection of any other weld procedure s The circuit also provides that if Weld Procedure 2 3 or 4 is not selected then Weld Proce dure 1 is automatically selected The Lincoln Electric Company Cleveland Ohio 44117 1199 2 Remote Selection Signals The Remote Selection Board of the Multi Procedure Kit permits remote selection of Weld Procedures 2 3 and 4 by user supplied external signals and provides protective isolation of the kit s control circuitry from these signals The external signals can be switch closure or 24 volt signals per the following SWITCHES Maintained closure of contacts rated for 24 volts 10 milliamperes DC service 24 VOLT SIGNALS Application of a 24 volt 10 AC or DC signal capable of 10 milliamperes per input 3 Remote Signal Connections a Turn off the input power to the NA 5 and remove the Multi Procedure Kit side cover panel by remov ing the two lower panel screws b Route leads from the external selection signals into the Multi Procedure box through the cable clamp provided or appropriate user provided replacement box connector NOTE A plug buttoned hole cluster is also provided on later units to accept mounting of an MS 3102A 18 type box receptacle c Using 250 x 032 quick connect female lead termi nals connect the remote leads to the proper Remote Selection Board ter
216. orrect drive rolls and guide tubes or b Be sure that the drive rolls and guide tubes are incorrect pressure setting stamped with the wire diameter being used Replace if necessary Check for proper pressure setting c Worn drive rolls c Replace or reverse if split type d Partially flashed or melted contact tip d Replace contact tip 2 Variable hunting arc CAUSE WHAT TO DO a Contact tip worn or incorrect size a Replace contact tip b Worn or undersized work cables or poor b Inspect and repair or replace as necessary connections to work c Loose electrode connections c The following connections must be tight Electrode cable to wire feeder and power source work cable to power source and work contact tip to nozzle d Rusty electrode d Replace electrode 3 Unit will not feed wire Digital meters are not lit CAUSE WHAT TO DO a CONTROL POWER switch OFF a Turn switch ON b Circuit breaker is tripped b Reset breaker c Power Fuse blown c Replace fuse d 115 V AC supply from power source d Check that the power source is ON If so check power source AC fuse 4 Arc can be struck but unit then shuts down while welding or power source output is too low to establish an arc ACTUAL VOLTS meter reading is low or zero when start 1 pressed CAUSE WHAT TO DO AA 2 AA o AAA A a Leads 21 and 67 may not be connected for the cor a Check the white work and black electrode l
217. oss Shaft Assembly 324 1 Ratio Only Includes Items 199 through 202 S10080 6 1 Cross Shaft Assembly 628 1 Ratio Only Includes Items 199 through 202 S10080 8 1 199 Cross Shaft 224 1 Ratio Only S10075 3 9 1 5 199 Cross Shaft 324 1 Ratio Only 510075 4 1 199 Cross Shaft 648 1 Ratio Only S10075 2 1 200 Input Worm Gear 144 1 Ratio Only S10087 3 PHHH 200 Input Worm Gear 224 1 and 648 1 Ratio u 1 1 201 e 202 Woodruff Key 405 1 X Output Shaft Assembly 144 1 Ratio Only Includes Items 203 through 208 S10083 3 0 X Output Shaft Assembly 324 1 Ratio Only Includes Items 203 through 208 S10083 4 Output Shaft Assembly 648 1 Ratio Only Includes Items 203 through 208 S10083 2 1 203 _ 0020 8008 204 Output Shaft Worm Gear 144 1 Ratio Only S10076 3 0 1 204 Output Shaft Worm Gear 324 1 Ratio Only S10076 4 1 204 Output Shaft Worm Gear 648 1 Ratio Only S10076 2 1 205 Ball Bearing M9300 27 1 x 206 Ball Bearing T10776 1 207 Snap Ring S9776 5 1 208 Woodruff Key 606 1 209 Motor Base Gasket T8364 1 210 Round Head Screw Motor Base to Gear Case 10 24 x 3 4 3 211 Lock Washer Motor Base to Gear Base E106A 1 3 HH 213 Slotted Pipe Plug 510780 5 0 1 Gear Box Lubricant T8484 1 order a gear box assembly without a motor add W to this assembly number Q This part is obsolete and no longer available 02 20 2002 NSS Not sold separately 101 2 3 4 5 and LAF
218. otor armature should be 120 to 160 ohms October 1997 nor 761 OO 15 TERMINAL BIRIP _ QSGILLATION SPEEP L some motors may not have thermostats these units will have a jumper across terminala 732 and 732 703 Um ko Ream COLOR CODE Brown Gr GREEN ANS ELECTRICAL SYMBOLS PER E 1537 on SWITCH 3 hm MOTOR THERMOSTA LEGEND 10047 WFD The Lincoln Electric Company Cleveland Ohio 44117 1199 1 1 a4 Moana TED TOoWASUOS OF umi To T 0047 MFD 25 SOKRA SPREADARC SPREADARC _________ wua CONNECTION DIAGRAM M 13447 The Lincoln Electric Company Cleveland Ohio 44117 1199 Assembly and Installation EW2357 A SPEED FEED DRUMS WARNING FALLING EQUIPMENT can cause injury For top lifting inches 2 2 5 7 File as Sec 1 2 5 10 for IM 278 General Installation The drum must be set on a turntable which permits it to turn freely allowing the wire to be paid off without tangling Turntables can be purchased from a manufacturer or made by the user See Figure 1 A turntable consist of a stationary plate on the floor 1 a rotating plate turntable 2 centered on a large bearing 3 and a post 4 and arm s 5 for the eyelet s 6 At least one low friction insulated eyelet is
219. ows l The arc length remains constant during oscillation to give more uniform penetration 2 There are controls for dwell periods at the end of the stroke to provide smoother bead edges 3 The travel speed of the arc is uniform across the bead The control circuitry of the new Spreadarc uses solid state electronics The dwell time and oscillation speed controls are calibrated for easy setting The length of the oscillation travel distance is easily adjustable from four inches to one quarter inch by repositioning stops which activate sealed snap action limit switches control box containing the electrical controls is mounted on the side of the unit opposite the head mount ing The operating controls consist of 1 On off switch 2 pilot light 3 Circuit breaker protects control circuit and motor from short circuit conditions 4 Oscillation speed The nameplate dial is calibrated directly in inches per minute 5 Front and rear dwell controls Each has the name plate dial calibrated directly in seconds Specifications Input voltage 115 volts 50 or 60 hertz Input current 1 0 ampere maximum Weight 62 pounds without head Maximum allowable additional weight to be mounted on Spreadarc 70 pounds one NA 3 NA 4 or NA 5 head with flux hopper Oscillation track 0 25 to 4 0 inches Oscillation speed 10 120 in min Dwell at either end of travel 10 to
220. ox If the control box is to be mounted so the 4 foot cables are not sufficient install a K335 or K338 Control to Head Ex tension cable of the length ordered up to 30 feet The K335 for the NA 5S head includes motor tachometer and flux hopper lead extensions with polarized plugs on each end and electrode cables The K338 for the NA 5N NF and SF heads is the same as the K335 without the flux hopper lead extension The NA 5N and NA SS also include two 4 foot lengths of electrode cable Bolt the terminals of one end of the cable pair to the wire contact assembly and the terminals of the other end to the electrode leads to the K215 Power Source to Control cable assembly Properly insulate the bolted con nection When the K335 or K338 extension cables are used between the controls and heads the 4 foot lengths of elec trode cable are not used If currents or duty cycle higher than 1000 amperes at 80 duty cycle will be used add additional electrode cable per Table 1 The F models do not include the 4 foot lengths of elec trode cable as standard If not using a K335 or K338 for the NA 5NF or NA SSF order an appropriate length of the needed electrode cable Connect it between the wire contact assembly and the K215 cable assembly as described above TABLE 1 Below 1000 amps Two 4 0 1000 to 1300 amps hree 4 0 1300 to 1500 amps T 92Jy SEC T2 3 ELECTRICAL INSTALLATION Assembly and Installation K 215
221. p distance controlled by the time setting If other modes of burnback and electrode backup are desired refer to Sec T3 5 2 Burnback voltage and wire speed will be at the settings of the previous mode until the arc goes out Start Controls 12 Optional On some appli cations and procedures it is desirable to weld at a different wire speed and voltage at the start of a weld for a short period of time before swiching to the weld wire speed and volts When the op tional Start Controls are installed this can be done The start wire speed and voltage can be higher or lower than the weld values and are completely independent of other control settings Setting the start time to 0 00 seconds will bypass the start mode controls during the welding cycle Install the optional Start Controls per the instruc tions included with the kit Note that the same kit can be used for either Start Controls or Crater Controls and proper function depends on correct installation Although the timer can be set for 9 99 seconds the majority of applications will require only 0 25 to 2 00 seconds A good rule to follow for the initial settings of the Start Controls is to set them at the same settings as the Weld Controls wire speed and voltage The time delay can be set for about one second After the first test weld the controls can be re adjusted as desired Weld Timer 14 Optional With this option the weld duration is set by the Weld
222. r smaller reels to prevent instability Assembly and Installation Sec T2 5 7 B Continued File as Sec L2 5 10 B for IM278 The Lincoln Electric Company Cleveland Ohio 44117 1199 INSTALLATION INSTRUCTIONS SPEED FEED REELS Installation of Automatic Brakes The high electrode feed speeds generally 2300 inches per minute may require the use of a turntable with an automatic brake to stop the reel rotation from overrun at the end of the weld For more information on brakes and for instructions on how to install them visit the Lincoln Electric website at http www lincolnelectric com knowledge articles content speedfeeddrum asp and view the Speed Feed document Wire Feeding The position of the reel with respect to the wire feeder will vary from job to job Proper placement of the wire is important to minimize the complications during wire feeding Improper Installation Improper installation can Pull kinks into the wire feeder which can not be straightened Cause milling of the electrode resulting in clogged guide tubes and liners Overload the wire feed drive motor Minimum 10 in 25 4 cm diameter pulleys 3 2008 Precautions B To prevent installation complications observe the following precautions See Figure 3 I Pull the electrode as short a distance as possible 2 Guide the electrode through friction free insulated eyelets which are properly spaced Do not pull the w
223. r 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 Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot 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 Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling 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 When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 LINCOLN RE 4 b 4 C 56 5 4 5 6 51 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
224. r source output voltage before the arc strikes The Volts potentiometer is not effec tive on R3S machines Proper setting of both of these controls is very important in order to have the best arc striking Weld Controls 4 The Wire Speed and Volts potentiometers control the welding procedure Burnback and Electrode Back Up Time 8 This control determines the length of time of burnback delay after the stop circuit is energized Depending on the connections on the logic board it may also determine the length of time the wire feed motor reverses after the stop button is pushed before it stops The NA 5 as shipped from the factory is connected to stop the wire feed motor immediately with adjustable burnback delay when the stop button is pushed The time delay control therefore should be adjusted to just the point where there is no sticking of the electrode in the crater at the end of the weld If the circuit is con nected so the wire reverses at the end of the weld the distance the wire reverses after the welding The Lincoln Electric Company Cleveland Ohio 44117 1199 arc goes out is controlled by the time setting and the Inch Wire Speed The higher the Inch Wire Speed setting the faster the wire reverses If the wire does not back up far enough at the end of the weld increase the time setting and or turn the Inch Wire Speed to a higher setting However the inch speed should be set for best arc striking and the backu
225. re and excessively high currents increase jaw wear When arcing occurs in the jaws or the wire becomes loose in the jaws remove the jaws and dress them down by filing When an excessive amount of material is worn off replace the jaws Contact jaws manufactured after April 1979 have replaceable contact inserts refer to P 101 N The contact jaws must be kept inline with the wire guides To align the contact jaws loosen the stationary contact jaw Item 25 of P 101 N Release the tension on the mov able contact jaw 21 by loosening the screws holding The Lincoln Electric Company Cleveland Ohio 44117 1199 the strap spring Item 18 Place a straight 14 piece of bare 54 wire up through the wire guide and into the drive rolls Adjust the stationary contact jaw so the electrode touches the jaw at the center of the groove for the entire length of the jaw Tighten the screws Remove the piece of bare wire Apply the tension to the movable contact jaw by tightening the screws holding the strap spring Be cer tain the movable contact jaw moves freely after these screws are tightened C K233 Small Wire Contact Nozzle For Models NA 3 NA 4 and 5 For submerged arc welding with 035 thru diameter electrodes Unless a separate K219 Flux hopper kit was ordered a T10642 11 flux hose must be purchased 57748 35 hose tip must also be purchased sepa rately Installation Depending upon the electrode size spec
226. rom standard to high capacity or from high capacity to standard by changing bearings and a few spacers The maximum equipment to be used with each type of car 15 shown in the following tables K325 STANDARD CARRIAGE Carriage bearing width 472 Singlehead and control Single wire reel Vertical adjuster Single head and control Two wirereels Vertical adjuster Horizontal adjuster Fluxhopper Noauxiliary equipment Horizontal adjuster Flux hopper 75165 of auxiliary equip ment centrally located over carriage K325HC HIGH CAPACITY CARRIAGE Carriage bearing width 866 Twoheads and controls Four wire reels cen trally located over carriage Vertical adjuster Horizontal adjuster Flux hopper Noauxiliary equipment Three heads and controls Three wire reels Vertical adjuster Horizontal adjuster Flux hopper No auxiliary equipment Twoheads and controls Two wire reels Vertical adjuster Horizontal adjuster Flux hopper 1501 5 of auxiliary equipment centrally located over carriage It is important that the mounting of the heads control boxes wire reels and other equipment be done in such a manner that there is a minimum overhung weight The head mountings are to be such that the heads are within the dimensions shown in Figure 1 Figure 1 92Jy INSTALLATION All carriages are factory assembled to fit an
227. s Controls for optimum arc striking The optimum strike control settings for most processes will be typ ically 4 5 volts higher than the Weld Mode Voltage Setting and 40 5096 of the Weld Mode Wire Feed Speed Setting possibly lower if cold starting is used b If striking is still not satisfactory refer to Sec T3 5 2 for information on wire feed motor acceleration c If installed adjust the Start Controls to set the welding procedures for the time set on the timer to provide the bead size penetration or other factor as needed for the application refer to Sec T3 5 1 Operating Instructions Sec T3 4 Continued Setup Instructions d If installed adjust the Crater Controls to set the welding procedures for the set time after the stop button is pressed to provide the bead size or fill the crater as needed for the application refer to Sec T3 2 2 e Set the Burnback Time to provide the stopping characteristics needed April 1988 The Lincoln Electric Company Cleveland Ohio 44117 1199 The Lincoln Electric Company Cleveland Ohio 44117 1199 Operating Instructions SEC T3 5 STARTING AND STOPPING SEQUENCES Sec T3 5 1 Means of Arc Striking NA 5 codes utilize hot start arc striking which operates as follows 1 With the electrode not touching the work press the Start button 2 The electrically hot electrode inches down as set by the Inch Wire Speed
228. s de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes 5 Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les zones ou l on pique le laitier Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s 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 loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de lev age c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas for
229. s do not have a Weld a Eg owns mode light nor Mode Selector Switch The meters always display the procedure set by the selected procedure con trols Maximum versatility is obtained when the 5 is con nected to a DC 400 through DC 1500 type power source or SAF 600 and SA 800 with the Solid State Remote Field Control When used with a SAM or R3S power source the voltage range of the required procedures may exceed the range covered by the power source remote control and it would therefore be impossible to obtain the range of set procedures without readjustments at the power source B INSTALLATION TO THE NA 5 1 Turn off all input power to the NA 5 at the power source 2 Remove the four screws securing the corners of the 16722 Warning label on the right side of the NA 5 con trol box and remove the Warning label to expose the 1 inch square access hole REMOUNT THE WARNING LABLE WITH ITS MOUNTING SCREWS ABOVE THE DECAL ON THE MULTI PROCEDURE KIT SIDE COVER PANEL 3 Remove the top most screw from the right side of theNA 5 control box and save for use in Step 4 below 4 Route the Multi Procedure Kit plug harness into the 5 control box through the square access hole Then align the Multi Procedure Kit s top and two bottom mounting holes with the holes in the NA 5 box side pe and secure with the removed top screw and the two uU t screws provided with the kit wW 1 27 jc e m
230. s installed Drive in the roll pin C which comes with the adjuster D With the draw bolt J and hex nut H in place fit the head F to the stub shaft on the bottom of the horizontal adjuster D Tighten nut H Driveinthe roll pin removed in step 1 Place the crank housing on the adjuster D in the more convenient of the two positions indicated in the sketch by removing the two screws rotating the housing 180 and tightening the screws Place Handle on One of Two Positions Two Screws and Rotate Housing The Lincoln Electric Company Cleveland Ohio 44117 1199 February 1982 The Lincoln Electric Company Cleveland Ohio 44117 Sec T2 3 1 Wiring the Equipment Have electrician install and service this equipment Turn the input power off at the fuse box before working on equipment Do not touch electrically hot parts can kill A INPUT POWER REQUIRED The only power required for operation of the control is 115 volts AC 50 or 60 Hz All power sources covered in Sec T2 3 4 provide the re quired power If there is no connection diagram available for a particular power source the power source is not suitable for use with the 5 B CONNECTION OF HEAD TO CONTROLS All heads include a 4 foot motor and motor tachometer cable Insert the plugs on these cables into the matching receptacles on the side of the control b
231. screw the flux hose clamp Item 10 onto the extension housing K148 Nozzie Installation To install the nozzle on the head insert the outgoing wire guide from the head into the nozzle assembly Place the combined assembly in position on the bottom of the wire feed roll box Clamp it in place using the two clamps sup plied with the head Before pulling the clamps up tight the nozzle must be posi tioned relative to the travel direction as shown in Figure 1 This position is set so accidental contact between the work and the nozzle will not compress the contact pressure spring If positioned otherwise such accidental contact may cause arcing inside the contact tip After the nozzle is positioned in the proper relationship with the travel direction the connector tab for the electrode cables can be moved to any of four positions 90 apart To change the tab remove the two 1 4 20 hex head screws Tap the connector tab to loosen it from the tapered collar on the nozzle body Turn the tab to the desired position Replace and tighten the 1 4 20 screws CON Operation The same contact 513763 is used for 3 32 2 4 mm through 3 16 4 8 mm diameter electrodes 16388 1 used for 062 1 6 mm and 5 64 2 0 mm electrode Loading of Wire Straighten the start end of the coil for at least eight inches pass the end down through the appropriate wire straighten er Inch the wire through the wire feeder and the nozzle The L
232. se Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonctionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines souder parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se prot ger contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle partie du corps Un coup d arc peut tre plus qu un coup de soliel donc a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du ray onnement de l arc et des projections quand on soude ou quand on regarde l arc Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libre
233. sed a low level DC voltage signal is applied between the electrode and work which permits the wire to inch down normally When the electrode makes electrical contact with the work it shorts out this signal causing the wire feed to automatically stop and the flux solenoid to activate until the inch down button is released Inch up will not be affected by this circuit This voltage signal is supplied by the 24 volt trans former on the NA 5 Voltage P C board only when the inch down button is pressed The level of the signal appearing between the electrode and work will be de pendent on the impedance present across these points including the power source output stud impedance If this impedance is less than 500 ohms the applied signal level may be too low to permit the electrode to inch down B Electrode Backup If while starting or welding the electrode stubs or shorts to work the resulting loss of arc voltage will cause the electrode to momentarily back up until the arc vol tage is re established then change back to normal feed direction NOTE The cold starting circuitry will cause the NA 5 to feed in the wrong direction when the start button is pressed if the ACTUAL arc voltage as read on the NA 5 voltmeter does not exceed typically about 6 5 volts Usual causes for this situation are No wire loaded through the NA 5 head and nozzle assembly except when using the K148 nozzle 2 No power source weld cabl
234. sion Sec T2 2 7 File as Sec L2 2 7 for IM 278 File as Sec M2 2 7 for IM 279 This nozzle can be used with the NA 3 NA 4 and NA 5 wire feeders K148A is designed for 3 32 and s wire sizes K148B is designed for 5 32 and 3 16 wire K148C is designed for 068 to 3 64 wire Current Ratings A Without Linc Fill Attachment Innershield welding 600 amps 100 duty no water cooling 1100 amps 100 duty with water cooling Submerged arc welding 1100 amps 100 duty no water cooling B With K 149 Linc Fill Attachment Innershield or Submerged Arc 1100 amps 100 duty no water cooling Water Cooling Attachment When using currents over 600 amperes at high duty cycles water cooling always increases contact up life The cooling attachment is ordered as a separate item Part No T12928 Installation instructions are included in the kit The Magnum Water Cooler 20 saves water and is recom mended for most applications The other solution is to con nect the attachment to the water supply and the drain with rubber tubing obtained locally Water flow should be between 1 2 1 gallon 1 9 3 8 L of tap water minute K149 Installation 1 Install the K149 attachment before mounting the K148 nozzle on the welder 2 Place a small C clamp on the spring supporting members A and B in such a manner that the spring can be com pressed Look up the hole in the end of contact tip and tighten the C clamp unti
235. ssembly P 132 F Wire Feed Drive Motor P 135 C Control Box Assembly P 135 D Control Box Door Assembly P 135 E 0110 II 6 4 135 K349 Multi Procedure P 135 G Pulsed Power Feeder Conversion Kit Below Code 9100 Order K442 3 Pulsed Power Feeder Conversion Kit Above Code 9100 Order K442 1 6 2 97 100 100 WIRE FEED GEAR BOX Gear ratio is stenciled on the side of the gear case and on top of Item 12 Indicates a Change This Printing ITEM DESCRIPTION PARTNO am 123456789 Gear Box Asbly Includes Items 1 21 95 1 Ratio L5199 3 Gear Box Asbly Includes Items 1 21 55 1 or 57 1 Ratio L5199 2 Gear Box Asbly Includes Items 1 21 142 1 Ratio L5199 1 Gear Box Case G1328 Gear 512504 Snap Ring 59776 23 Woodruff Key 304 Snap Ring 59776 16 Set Screw New Design Pipe Plug Old Design 511604 26 510780 5 0 Bevel Shaft Assembly 512511 Woodruff Key 304 gt Plain Washer 59262 121 Spur Shaft Assembly S12510 5 16 18 HN CF000029
236. ssembly M13936 Insulation 114468 Decal S11893 2 Nameplate Above Code 11000 112800 OO OND OT 00 Digital Meter P C Board Above Code 8990 Only 14490 P C Board Spacer Above Code 8990 Only M14537 High Speed Decal 21 to 1 Not Shown 520166 AN A Na ld al 06 09 2008 135 135 CONTROL BOX Indicates a Change This Printing DESCRIPTION PARTNO am Control Welded Assembly Code 8205 Only S16707 Control Box Welded Assembly All Other Codes S16991 1 Relay 522182 Plug Button 113597 1 Thread Cutting Screw S9225 36 Lock Washer T9695 1 10 24 HN CF000010 Reed Switch and Mounting Plate Assembly Includes Below Code 9100 amp Above 9338 S16705 Reed Switch Assembly Below Code 9100 12334 35 Reed Switch and Mounting Plate Assembly Includes Above Code 9100 See Note 1 M15269 Reed Switch Stud Assembly Above Code 9100 See Note 1 M15268 Number Plate 110726 139 Number Plate 110726 138 Resistor S10404 75 10 24x5 00 RHS CF000045 Insulating Washer T4479 A Transformer S16711 Transformer Code 8205 Only S16712 Transformer S17101 Cable Tie Mount Not Shown 113941 Harness Includes Below Code 11000 Not Shown G1554 Harness Includes Above Code 11000 Not Shown G1554 1 Terminal Strip S14530 5 Jumper for Terminal Strip T13962 Fuse 1 2 Amp 12
237. starting leave the electrode or less away from the work b When using 4 starting for some sub merged arc welding inch the electrode down until it touches the work and the flux valve opens Press the Start button 10 While welding turn the cross seam adjuster hand wheel as needed to keep the arc in the joint At the end of the weld press the Stop but ton If needed press the Inch Up button to get the electrode up out of the way Remove the work and reload the fixture NOTE When the contact tip in the end of the nozzle wears during repetitive welding it must be replaced Check the contact tip for wear if weld quality seems to be deteriorating 88My February 1982 Operating Instructions Sec T3 2 2 Loading the 50 60 Pound Reel To remove the wire reel from its shaft grasp the spring loaded knob and pull it out This straightens the knob so it seats into the shaft when released Lay the reel flat on the floor and remove the cover plate Place a coil of wire on the reel so it unwinds properly as the reel rotates a Be sure the coil is placed so the spring loaded arms will not interfere with the later removal of the coil tie wires b When loading 035 and 045 L 50 wire be certain the coil is placed on the reel so the spring loaded arms are at the center of the slots in the cardboard coil liner This provides the positive compression of the coil neede
238. stubbing occurs when the start time expires the start wire speed may be set too low or the start voltage is set too high The lead from the Starting Relay and the nozzle contact as sembly which accompanies the kit is 15 ft of 12 wire This has been found to give the proper amount of bypass current If the length of lead s nt with the kit is not the desired length for the relay to guide assembly lead a new lead can be made per the table below Any of these leads should give the same amount of bypass current Assembly and Installation Sec T2 5 12 Cont 8 11fee 10 14 feet 13 17 feet 16 22 feet 20 28 feet 32 45 feet 51 71 feet February 1982 Sec T2 5 13 K334 Start and Crater Controls Easily installed procedure and timer boards to permit adjust ment of wire speed and voltage Can be installed to function at either the start of the weld or at the end for crater filling Instructions are included with the kit February 1982 Sec T2 5 14 Current Relay S13605 Useful for fixture builders and others who need a signal indicating that welding current is flowing Relay contacts 2 and 4 will close and remain closed when welding Mounts inside the NA 5 control box using the two holes provided on the bottom left side with 6 screws and nuts not provided The electrical connections of the current relay leads and terminals are not provided to be made per diagram below RELAY COIL LEADS TO NA 5
239. t removed it will gather around the nozzle of the gun and impede or shut off the flux flow when making relatively long welds or welding continuously The magnetic particles can also cause porosity in the weld Fit the magnetic separator into the funnel or hopper Pour the flux to be reclaimed into the top pan of the separator The separator is designed so the flux flows around three permanent magnets The magnets remove all magnetic par ticles When the magnets become covered with their full load they automatically stop the flux flow When the flux flow stops remove the separator from the funnel or hopper Turn it over and open the panel that covers the magnets Remove the magnetic particles with brushing or an air blast Be careful to protect yourself and others in the area from flying particles The magnetic separator is used with all Lincoln mild steel fluxes 760 761 780 781 860 and 880 Do not use the magnetic separator with any stainless steel alloy or hardsurfacing flux except H 535 The magnetic separator removes some of the alloying elements from these fluxes thus changing their characteristics July 1983 Sec T2 5 18 K310 Flux Screen The unit was designed to fit the top of either the standard fill funnel of a continuous flux feed system of a K58 mag netic separator The unit has a steel screen with 065 to 075 openings and an air vibrator attached to the frame The vibrator can be used with air line pressures ran
240. te power source the power source and or process in use connection diagram 6 Speedmeter readings and or wire feed speed are not accurate CAUSE WHAT TO DO a The Speedmeter Calibration Jumper is connected a Select the correct pin to match the drive roll and to the wrong pin head ratio being used See Section IC2 b Improper drive rolls b Drive rolls must match wire size 7 Travel Burnback or other modes do not sequence properly CAUSE WHAT TO DO a Jumpers on the Logic Board may be connected a Consult the manual or wiring diagram for the incorrectly various alternate pin connections 88My Troubleshooting Guide Sec T6 6 Continued IB OUT OF RANGE SHUTDOWN If the NA 5 voltage control is unable to supply the SET value of arc voltage while welding the automatic shutdown circuit will activate This protection circuit immediately re turns the NA 5 control to idle state within a few seconds after the arc voltage discrepancy occurs Typical causes for the activation of this protective shutdown circuit are as follows See Sec IA 4 for remedies a SET value of arc voltage is outside the power source range b Power source voltage control not set for c Misconnection of NA 5 control cable leads to power source d Incorrect weld polarity connections or settings at 5 or power source e Lost connection of 5 voltage sensing leads 67 and 21 between arc and voltage control or blo
241. tement toxique ou autres produits irritants Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 PR CAUTIONS DE S RET POUR LES MACHINES SOUDER TRANSFORMATEUR REDRESSEUR Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre 2 Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi 3 Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place NOTES The Lincoln Electric Company Index Cleveland Ohio 44117 1199 PRODUCT DESCRIPTION A new concept in automatic welding a wire feeder which when used with an appropriate Lincoln power source takes the guesswork from procedure setting and procedure control Designed to achieve higher quality control and weld quality levels more easily The arc voltage and wire feed speed can be set on digital meters before the arc is struck and the procedure remains precisely set day in and day out on production Jobs SEC T1 INDEX Sec T2 Installation Mechanical Installation 2 2222 Haar RR RE REOR du ECL Eu ob ERE PX Se
242. ter center and outer drive roll on the shaft and tighten the hex nut securely D NOZZLE INSTALLATION 1 Place the new swivel type idle roll into position tighten the pivot screw and then assemble the ten sion spring and screw a On the NA 2 and NA 2F tighten the tension screw until the nut bottoms against the shoulder of the screw b On the NA 3 4 or 5 with wire in the system tighten the tension screw to the 045 32 position on the indicator plate 2 Insert one of the guide tubes in the top hole of the face plate use either one of the guide tubes sup plied both are identical Place the dual ingoing wire guide over this guide tube The two parts are keyed together so hole line up is automatic Then place the two L shaped locking clamps T8400 into position line up the two flat surfaces of the guide tube so they are parallel with outside di ameter of the drive and tighten the two locking screws 3 Turn the nozzle upside down Insert the two long wire guide tubes that were shipped loose into the nozzle body so they fit into the internal recessed holes the mounting block Place the contact tip or the contact tip holder into position at the end of the nozzle being sure the guide tubes fit into the recessed holes in the contact tip Line up the holes in the contact tip or holder with the holes in the in coming end and lock it in position with the clamp ing nut The Lincoln Electric Company Clevela
243. terface Idle Mode selector switch set to ANALOG SIGNAL position the procedure control is returned to the analog signals as described in D 2 above E MAINTENANCE Every three months inspect the control box If needed blow dirt out using low pressure dry air No other maintenance should be required If the Analog Procedure Override control knobs are removed the following procedure must be used to maintain proper override control when the knobs are replaced 1 Rotate control shafts fully CCW as viewed from shaft end 2 Position knob on shaft so marker line of knob is in line with the bottom left marker line on the nameplate 3 Tighten the knob set screw 4 Rotate knob to the position 96My Assembly and Installation F MAJOR COMPONENTS PARTS LIST Spare Parts Recommended Required for 10 units Per Unit for 2 Years Analog Interface P C 31605 Board Assembly Analog Interface Board 517139 Insulation Transformer Assembly 17305 Idle Mode Selector T10800 13 Switch Lead Harness 14165 315 Assembly Harness Grommet T9274 3 Control Knob T10491 Nameplate M14422 Security Panel M14287 Lock Tab T10045 40 Side Cover Panel 17147 bh Judgment is required for machine orders for larger quantities These suggested spare parts are not to be considered as a multiple tor each group of 10 Failure unlikely replaced only if physically damaged or lost N The Lincoln Electric
244. th this attachment B INSTALLATION 92 Check the for the following items l Head adjustment lock A 1 4 diameter roll pin th 13 2 75 hex head lock screw WM and washers D in Vertical head lift adjuster E To install proceed as follows 1 Be sure nut is tight Drive out roll pin 2 While holding the head loosen nut H and lower the head F from the head support E 3 Loosen the nut K on the draw bolt L now re move the stationary mount E not shown in Fig 2 4 Slide the clamp ring A over the end of the mount ing bracket M Drive the roll pin B into clamp ring when the hole in the ring lines up with the groove in the mounting bracket M Two adjustable clamps and their respective screws Assembly and Installation 6 Tighten the clamp ring A with the open slot in the up position using the Y clamping C 7 Slide the vertical head adjustment unit E into the mounting bracket M Tighten the draw bolt nut K 8 Install one adjustable clamp D on each side of the clamp ring A 9 If a horizontal adjuster is to be used install it now per instructions in Sec T2 2 12 10 Raisethe welding head or horizontal adjuster back into position on the up and down lift shaft N Drive the 46 roll pin back into its original posi tion 11 Tighten draw bolt nut H A
245. the eight hex head screws 17 holding the top and bot tom tracks in place and remove the tracks by sliding them off the track support 18 Allow the top bearing to rest on the track support Do not loosen the screws holding the motor in place because it has been factory set to give the proper clearance bet ween the rack and pinion Inspect the four bearings to see that they rotate freely and are not ex cessively worn Install the new tracks or switched tracks on the track support making certain that they are seated on the edges of the track support Re assemble all parts except for the top and bottom track shields and limit switch bracket To adjust the eccentrics on the bottom bear ings tighten the 5 13 screws until snug Rotate ec centric nuts to bring bottom bearings snug against the track Hold eccentric nuts from turning and tighten 12 13 screws Check for proper pressure by turning outer race of bottom bearings by hand They must slip but there must be no vertical play in the carriage assembly Readjust eccentrics if neces sary Lubricate tracks and bearings and install top and bottom track shields and limit switch bracket Motor brushes With normal service these brushes should last for many years Check brushes every two years or whenever the unit is disassembled for changing tracks Replace the brushes before the length is reduced to less than 25 inch Motor gear reducer When the motor
246. thermostat a jumper T13962 must be installed on the terminal strip at positions 732 and 732 See wiring dia gram M13447 on next page October 1997 05 3 1 2 9 Sec 2 5 6 and 1 2 5 6 Continued 2 Printed Circuit Board The P C board has light emitting diodes mounted at various locations to aid in troubleshooting a problem The lights and their on functions are as follows A indicates front limit switch LS1 is activated B indicate rear limit switch LS2 is activated C indicates positive field voltage D indicates negative field voltage E indicates voltage to motor armature will be dim when speed control is set at minimum 3 Voltage Measurements All voltages are 10 a b 31 32 terminal strip 115 volts AC 32 731A terminal strip 115 volts AC 0 if motor thermostat or circuit 1s open 726 727 terminal strip 105 to 120 volts DC polarity depending on travel direction 739 741 terminal strip 90 to 100 volts DC oscillation speed at maximum 12 to 25 volts DC oscillation speed at minimum 701 702 terminal strip 13 to 15 volts DC limit switches not activated 701 703 terminal strip 13 to 15 volts DC limit swtiches not activated 4 Resistance Measurements b 726 727 terminal strip Motor field should be 1200 to 1500 ohms 739 741 terminal strip M
247. tinued Table T 3 5 RECONNECTING THE TRAVEL SEQUENCE Travel Stops Older Models Newer Models With the Start Button With Arc Striking With Arc Striking With Start Button With Start Button NOTE Indicates switch in position With the Stop Button With Arc Stopping With Stop Button With End Crater Fill Time with Optional procedure module installed in crater receptacle After Bumback Time with Optional procedure module installed in crater receptacle Lead 691 Lead 692 Lead 691 Lead 692 Lead 691 Lead 692 Lead 691 Lead 692 Lead 691 Lead 692 m Indicates switch in down y position Indicates switch position does not matter Operating Instructions Switch 1 Switch 2 the Optional Procedure Module is installed in the crater receptacle DIP switch position 1 on Switch 2 should be in the UP position as shown Additionally remove 583C to 584C Jumper Plug from the Procedure Board If the Procedure Module is not installed the switch should be in the down position and the 583C to 584C Jumper Plug should be re installed on the Procedure Board 96 February 1996 The Lincoln Electric Company Operating Instructions Cleveland Ohio 44117 1199 SEC T3 6 VOLTAGE CONTROL RESPONSE The NA 5 is provided with selectable voltage control re sponse Proper setting depends on the power source and process being used Refer to the appropriate power source conn
248. tructions are in cluded in the kits WATER FLOW SWITCH INSTALLATION Installation of a switch which permits welding only when cooling water is flowing in the nozzle is highly recommended The switch must operate at the 3 gallon per minute level 1 For the 5 Install a K336 Remote Interface Module Then connect a flow switch with normally closed contacts between the Common Terminal and the Weld Stop Terminal of the interface module If water is not flowing the weld cannot Assembly and Installation Sec T2 5 3 and L2 5 3 Continued be started The switch should be suitable for a low level voltage of 24 volts and 10 milliamps Two suitable switches are as follows Delaval Switch Number FS925 Gems Sensor Division SPDT N C Farmington Connecticut 06302 Hoban Engineering Corp Switch Number 1074 N W Ist Avenue 200 B 2 A Boca Raton Florida 33432 SPST 2 For the NA 3 Use a switch with normally closed contacts The two switches listed under the NA 5 are suitable Connect the switch to terminals 528 and 582 on the 3 terminal strip If welding starts current flows when no water is flowing the 3 shuts down 3 For the NA 2 Use a switch with normally open contacts Two suitble switches are as follows McDonnell amp Miller ITT Switch Number FS6 3500 N Spaulding Avenue SPDT Chicago Illinois 60618 Switch Number 2600 0811 SPDT Hays Manufacturing Co Division of Zurn Ind
249. tud 8 Remove the 67 black lead from the NA 5 terminal strip electrode polarity connection and tape the terminal of the removed lead 9 Connect a 18 AWG or larger electrode sensing lead from the bolted electrode lead connection per 14156 to the appropriate NA 5 terminal strip polar ity connection replacing the 67 black lead referred to in Electrode Polarity Sec T2 3 1 D OPERATION When the 5 Start button is pushed 115 volts is applied to leads 31 and 87 energizing the High Fre quency Unit When the welding arc is established 110 volts DC is applied to 610 and 681 which energizes 1CR in the High Frequency Unit This opens the 1CR normally closed contact which is in series with the 115 volt AC input power circuit and de energizes the High Frequency Unit WARNING When using the High Frequency Unit the hot starting start sequence is to be used see of Arc Striking Sec T3 5 1 Cold starting is not to be used do not allow the electrode to touch the work when inching down because this results in the High Frequency Unit becom ing energized when the electrode touches the work E MAINTENANCE The only routine maintenance required on the High Fre quency Unit is to inspect the spark gaps monthly and to main the setting specified on the spark gap cover plate WARNING Use extreme caution when this adjustment is made The volt
250. udes Multi Conductor Control Cable Electrode Cable K97 L4112 1 L4112 2 Cable Assembly Controls to Head Includes Electrode Cable 63 inches long L2286 191 NA 3 ALL MODELS NA 4 w CURRENT CONTROL RHEOSTAT AND NA 5 ALL MODELS EXCEPT R Cable Assembly Power Source to Controls Includes Multi Conductor Control Cable Includes Polarized Socket Connector Connector Clamp Electrode Cable K215 L5267 B S12020 8 512024 2 L5267 C Cable Asbly Controls to Head NA 3N NF amp SF Includes Multi Conductor Control Cable Motor Includes Polarized Pin Connector Polarized Receptacle Connector Cable Clamp Electrode Cable K234 L5318 D S12020 15 512023 9 512024 4 L5118 E Cable Asbly Controls to Head 3 amp NA 4 Includes Multi Conductor Control Cable Flux Valve Includes Polarized Pin Connector Polarized Receptacle Connector Cable Clamp Multi Conductor Control Cable Motor Includes Polarized Pin Connector Polarized Receptacle Connector Cable Clamp Electrode Cable K235 L5318 B 0 S12020 16 512023 8 512024 4 L5318 D 12020 15 512023 9 512024 4 L5318 E Cable Asbly Controls to Head NA 5N NF amp SF Includes Multi Conductor Control Cable Motor Includes Polarized Pin Connector Polarized Receptacle Connector Cable Clamp Multi Conductor Shielded Cable Tach Includes Polarized Pin Connector Polarized Receptacle Connector Cable Cla
251. ug wires distributor cap or magneto wire as appropriate LINCOLN before welding Exposure to EMF fields in welding may have other health effects which are now not known 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 Never coil the electrode lead around your body 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 Connect the work cable to the workpiece as close as possible to the area being welded Do not work next to welding power source 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 o
252. unting suggestions for the second electrode reel The reel support bracket must be made by the fixture builder to fit the par ticular installation The wire reels should be lo cated so the wire straightener knob points toward the wire reels B INITIAL PREPARATION l Remove the following parts from the wire feed unit The wire straightener The complete nozzle Both the upper and lower guide tubes The drive roll assembly including the drive roll locating collar e The idle roll assembly See Sec 2 5 3 K129 Cog tm C TWINARC ASSEMBLY Parts listed on P 101 L 1 Place the drive rolls on the shaft per the following sketch and tighten the hex locking nut 2 Place the new swivel type idle roll assembly into position tighten the pivot screw and then assemble the tension spring and screw Adjust the idle roll Apply a little grease or oil to the O D of sleeve Key and carefully slide it Drive roll Nut into the dust seal Drive roll Drive roll locating collar 92Jy ON pressure adjustment screw for the wire diameter to be used while welding Insert one of the guide tubes into the top hole of the face plate both guide tubes supplied are identical Place the dual wire straightener over this guide tube The two parts are keyed together so hole line up is automatic Then place the two L shaped locking clamps into position line up the two flat surfaces of t
253. ustries Erie Pennsylvania 16512 Remove the jumper from 20 to 26 on the terminal strip in the NA 2 control box Connect the normally open contacts of the switch to these terminals The switch will prevent ICR from pulling in if no water is flowing E ADJUSTMENTS 1 When using an 5 connect the calibration jumper lead to pin 95S on the wire speed meter board per the table on the wiring diagram 2 Nozzle Rotation The proper lineup of the elec trodes with the seam should be specified by the pro 3 4 Internal stickout Visible stickout Electrical stickout i The Lincoln Electric Company Cleveland Ohio 44117 1199 cedures To rotate the nozzle loosen the two 4 20 socket head screws which hold the body of the noz zle to the mounting base and rotate the nozzle to the desired angle If a greater angle is required remove the socket head screws entirely and relocate them in the alternate holes provided Any desired angle can be obtained in this manner Tighten the screws when properly adjusted Electrode Spacing Drag Angle and Electrode Stickout As shown in the following sketch the electrode spacing drag angle as the electrode leaves the guide block and the internal electrical stickout is fixed The electrical stickout is Ya great er than the visible stickout Set the stickout as specified by the procedures F LOADING THE ELECTRODE l 5 8 Spacing ne Drag an Wor
254. vailable 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 Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Refer to http www lincolnelectric com safety for additional safety information SAFETY PRECAUTIONS DE S RETE Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc T Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s 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 couch pour lesquelles une grande partie du corps peut tre en contact avec la mas
255. washer Wire Guide 3 32 Electrode Wire Guide 5 64 Electrode Wire Guide 1 16 Electrode Wire Guide 045 Electrode Wire Guide 035 Electrode O A mb Nozzle Insert 1 16 5 64 and 3 32 Electrode 1 2 13 S10157 1 19447 8 Spring Bracket Assembly M10547 o Retaining Spring 59776 12 Socket Head Screw T9447 10 Extension Guide Arm M10554 K233 515106 052 Note A 515106 3 32 Note A S10493 1 T10570 1 2 13x1 1 2 S10798 0 T12336 T9447 11 1 512775 3 32 512775 5 64 S12775 1 16 S12775 052 S12775 045 0 12775 035 0 K104 S11027 6 0 112335 A S10773 41 2 S9262 23 2 E106A 2 2 512774 3 32 512774 5 64 512774 1 16 512774 045 512774 035 I Hex Head Cap Screw 1 4 20x1 2 Flat Washer 59262 23 0 This part is obsolete and no longer available 05 13 2002 101 101 K96 HORIZONTAL ADJUSTER IP 11 N 7 i aug Li uU O Li E gt acer um a ze eei 1 M10224 6 16 78B Indicates a Change This Printing ITEM DESCRIPTION PARTNO am 12134 516 78 9 Horizontal Adjuster Includes all Below Cross Adjustment Block Cross Adjustment Screw Assembl End Cover Plate S10509 38 Head Lift Adjustment Shaft Assembly 510097 Thrust Washer S926
256. ween the screws to prevent rota tion remove the hex nut Item 10 which holds the gear to the shaft Remove the flat washer Item 1 1 3 Pull the gear from the shaft using the screws as a pul ling device 4 Be certain the woodruff key Item 5 is properly lo cated on the shaft Turn the adapter plate mounting screws into the new fiber gear from the stenciled side and place the gear on the shaft Replace the flat washer tighten the hex nut and remove the adapter plate mounting screws from the gear 5 After noting the relation of the adapter plate with the motor leads remove the adapter plate from the motor Support the pinion properly and with the proper size punch drive the roll pin which holds the pinion out of the shaft Pull the pinion off Install the new pinion and replace the roll pin Replace the adapter plate in its original location 6 Cover the teeth of the motor pinion and the input gear with a non fluid type lubricant Lincoln Spec E2322 This can be scooped from the cavity of the gear case 7 Reassemble the motor on the gearbox being certain the gears mesh properly and the adapter plate locating bead is in its cavity Replace and tighten the four screws and the lockwashers removed in Step 1 8 Jumper on wire speed meter P C board must be prop erly positioned for the gear ratio and drive rolls being used See table on wiring diagram July 1983 Sec T6 2 3 Wire Drive Mechanism Drive mechanisms
257. wer Bearing Bar Assembly 510299 2 Lower Bar Assembly M12980 2 2 X Lower Fn ME Bar Assembly M12980 1 2 Thin 510262 5 4 X Spacer Thick S10262 2 8 X Spacer Thick S10262 4 2 X Lockwasher Lower Bearing Bar Mounting E106A 4 4 pr Head Screw SE pr e Head Screw 19447 49 2 X Head Mounting and Lift L3116 1 X Head Mounting and Lift 15460 1 _Head Mounting Parts See P 101 Q 1 1 MENU Lift Handle M12968 ie Lift Handle Stud T13872 x Soba xp pex x pe po abe ef e Hex Head Bolt 1 2 13 x 1 25 E106A 5 10379 Lockwasher Upper Spring Bracket Hex Head Bolt 3 8 16 x 75 Set Screw Lift Handle and Stud Mounting S11604 11 2 Hex Nut Locking Set Screw 3 8 16 1 Roll Pin Lift Handle Mounting T9967 30 1 X Roller Mounts Item C thru Crank Bracket 18128 1 XX Gear Box Mounting Plate M8485 1 X X Flat Head Screw 5 16 18 x 625 4 XX Drive Wheel 1 Key Drive Wheel to Motor 1 X X Spacer 1 XIX Lockwasher 1 Nut Drive Wheel to Moto 105 1 X X X erre Swivel Motor Mount S15772 2 1869 2 XXX 2 02 2 X X 1 2 XX 06 06 2001 P 101 P 1 b P 101 P 1 b Supersedes P 52 C 1 Supersedes P 52 C 1 For K23 amp K236 Models below code 7500 use the parts marked X in Column 1 For K247 Models above code 7500 use the parts marked X in Column 2 Indicates a Cha
258. wn 8 fuse on voltage P C boards built since early 1983 With NA 5 units above Code 8300 the conditions of d and e above would result in the wrong wire feed direction when the weld 1 started In the case of full range control power sources such as the DC 600 this protective shutdown circuit could prevent welding under the conditions of c d and e above by holding the power source output at minimum possibly providing too low of a power source output to even estab lish an arc With 5 units above Code 8300 condition c could cause repeated feed direction reversals which may blow the Field fuse in the 5 Power P C Board Although out of range shutdown can occur with all power sources when working with very low or very high arc vol tages it is most likely to occur when using the R3S models with the somewhat limited voltage range of the various taps For instance if the R3S 400 triangle tap setting 1s for 31 volts the range of control from the remote circuit is approximately 7 volts i e 2712 to 34 volts at nominal input voltage If the 5 controls are set for 29 volts and the input voltage to the R3S goes up it may not be possible for the 5 control circuit to hold the 29 volts so the welding will shut down By changing to the 27 volt triangle setting the range will be approximately 2312 to 30 4 volts and at high input voltage there will be sufficient control to hold the SET arc voltage On these m

Lincoln Electric IM305-C Welding System User Manual

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