Lincoln Electric IM278-D Welder User Manual


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WIRING DIAGRAMS
L6489-1
A
ELECTRODE TO POWER SOURCE
WORK
517
67
593
592
592
539S
582 581
539S
634 642 641
5K
STOP
SWITCH
START
SWITCH
WIRE FEED
SPEED CONTROL
INCH UP
SWITCH
INCH DOWN
SWITCH
576 575
POWER SOURCE
OUTPUT CONTROL
10K
77
AM
517
-
+
VM
67
-
+
21
625
532
532
25
TRAVEL
SWITCH
HAND
OFF
AUTO
2
532
531A
631
532
32
531
31
53187
FLUX OR
WATER
SOLENOID
WIRE FEED MOTOR
627
539
531
531A
626
541
ARM
531
87
FLUX CONNECTOR
C
B
A
531
87
532
25
531
GND.
GND.GND.
A
B
C
D
539
627
626
A
B
C
D
GND.
E
541
539
627
626
GND.
541
A
B
C
D
E
GND.
F
G
H
I
2
4
31
32
75
21
76
77 77
76
75
21
32
31
4
2
MOTOR CONNECTOR
CONTROL CABLE TO
POWER SOURCE
585
510
589
510
682
510
532
625
CONTROL POWER
SWITCH
31
67
21
77
76
75
681
689
528
582
581
4
87
32
626
627
539
539S
510
2
541A
541
532
592
562
635
636
637
525
539
528
531A
67
21
TRAVEL
CONNECTOR
24
1
10
2
3
4
5
6
7
8
9
11
12
*
510A
2
1
10
7
9
12
6
8
11
510
610
631
532
539
541
627
626
*
539
525
539S
593
629
539
525
587
CONTROL P.C.BD.
*
586
1
2
3
4
5
6
7
8
9
250
610
510
525
629
539
636
635
641
642
75
77
1
2
3
4
6
7
8
9
11
12
76
*
75
76
*
1
2
3
4
6
7
9
10
11
12
77
635
584(S)
629
515
539
525
583(S)
75
76
*
1
2
3
4
6
7
9
10
11
12
77
635
584(C)
629
515
539
525
583(C)
5
588
1
4
6
3
2
9
8
575
576
681
634
592
682
510A
*
LOGIC
P.C.BD.
9
8
510A
510A
4
6
528
689
11 582
12 581
2 585
3 589
5562
1637
7587
10 586
531A
N.D.
TERMINAL
STRIP
N.E.
CR1
FLUX
RELAY
CR2
TRAVEL
RELAY
CR3
CONTACTOR
RELAY
N.F.
F2
F1
F3
N.G.
JUMPER
CONNECTOR "A"
JUMPER
CONNECTOR "B"
N.A.
690
694
691
692
693
*
N.B.
WORK TO POWER SOURCE
N.D. 87-531 115VAC - 1/2A SWITCHED.
N.G. THIS FUSE NOT PRESENT ON EARLIER CONTROL P.C.
BOARD MODELS.
N.B. THESE LEADS ARE NOT PRESENT ON LOGIC P.C. BOARDS
WITH DIP SWITCHES.
Methods of BurnbackMethods of Travel
Start/stop with switches
Lead #691 to P6
Lead #692 to P5
Start/stop with current
Lead #691 to P6
Lead #692 to P7
Start with current
Stop with stop switch
Lead #691 to P5
Lead #692 to P7
Start with start switch
Stop after crater fill
(Crater fill board installed)
Lead #691 to P8
Lead #692 to P9
For earlier logic P.C.
Boards with jumpers
tcennoCseY
Lead #694 to P10
tcennoCoN
Lead #694 to P8
Wire feed stop & contactor
delay
Lead #693 to P3
Lead #690 to P4
Inch up & contactor delay
Lead #693 to P1
Lead #690 to P4
Inch up & no contactor
delay
Lead #693 to P1
Lead #690 to P2
Crater board installed?
SWITCH #1
1234
SWITCH #2
1234
SWITCH #1
1234
SWITCH #2
1234
For Logic P.C. Boards with
dip switches
(Remove jumper connector "B"
from 584(c) to 583(c))
(Install jumper connector "B"
from 584(c) to 583(c))
For earlier logic P.C.
Boards with jumpers
Connect
Connect
SWITCH #1
1234
SWITCH #2
1234
SWITCH #1
1234
SWITCH #2
1234
For Logic P.C. Boards with
dip switches
Connect
Connect
SWITCH #1
1234
SWITCH #2
1234
SWITCH #1
1234
SWITCH #2
1234
N.A. WHEN START P.C. BOARD IS INSTALLED, JUMPER CONNECTOR "A" IS REMOVED.
Use of crater fill board
For earlier logic P.C.
Boards with jumpers
Connect
Connect
SWITCH #1
1234
SWITCH #2
1234
SWITCH #1
1234
SWITCH #2
1234
For Logic P.C. Boards with
dip switches
Connect
SWITCH #1
1234
SWITCH #2
1234
5641
N.F. JUMPER LEAD TO BE CONNECTED TO PIN "H" AT ALL TIMES.
UNIT SHIPPED WITH LEAD IN THIS POSITION.
1/2A SLOW BLOW FUSE
3/10A FUSE
3/10A FUSE
641
518
N.C.
11
22
33
44
1
2
3
4
CURRENT TRANSFORMER
518
539S528
CR4
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
9
10
11
12
INDICATES CONNECTOR CAVITY NUMBERS
*
CAVITY NUMBERING SEQUENCE
(COMPONENT SIDE OF P.C. BOARD)
NA-4 SHIPPED WITH LOGIC P.C. BOARD
SET FOR INDICATED MODE OF TRAVEL
AND BURNBACK.
NA-4 WITH CURRENT CONTROL RHEOSTAT
ELECTRICAL SYMBOLS PER E1537.
VARIABLE VOLTAGE P.C.BD.
N.C. 531-532 115VAC; 531-25 115VAC (SWITCHED) - 250 VA
5 AMP
CIRCUIT
BREAKER
CURRENT SENSOR
P. C. BOARD
588
515
635
539
629
525
584(C)
583(C)
76
77
75
515
635
539
629
525
584(S)
583(S)
76
77
75
11
12
9
8
10
5
6
4
3
7
START P.C.BD. (OPTIONAL)
CRATER FILL P.C.BD.
(OPTIONAL)
*
11
12
9
8
10
5
6
3
4
1
*
7
N.E. ON EARLIER UNITS, LEAD #689 WAS LOCATED BETWEEN #31 and #67
(FORMERLY #5), LEAD #510 WAS LOCATED BETWEEN #87 & #32, AND
LEAD #31 WAS LOCATED NEXT TO #681. CAREFULLY NOTE LEAD POSITIONS
BEFORE MAKING ANY CONNECTIONS TO TERMINAL STRIP.
GND
539
8
GND
8
GND10
GND
2
N.J.
GND
2
N.J.
N.H.
N.H. THIS LEAD PRESENT ON CODE 10318 AND HIGHER.
N.K.
N.J. THESE LEADS ARE NOT PRESENT ON EARLIER START
AND CRATER FILL P.C. BOARDS.
N.K. ALL FUSES WERE REPLACED WITH PTC RESETTABLE
FUSES ON LATER CONTROL P.C. BOARDS.
DOOR
SUBPANEL
1234
SWITCH EXAMPLE
SWITCH POSITION 1 IS UP
SWITCH POSITION 2 IS DOWN
SWITCH POSITIONS 3 AND 4 ARE NOT APPLICABLE
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside
the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.
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