Lincoln Electric IM305-C Welding System User Manual


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G1553
A
DIGITAL METER
VOLTMETER BOARD
SPEED-
METER
BOARD
5
1
0
5
1
9
6
0
2
6
0
1
2
5 3
4
1
6
5
1
8
5
1
0
5
1
7
5
1
0
P
6
0
2
6
0
1
5
1
0
P
5
1
0
P
6
0
2
6
0
1
5
1
0
5
1
0
5
1
9
5
1
0
P
6
0
2
6
0
1
DIGITAL METER
2
5 3
4
1
6
WORK
WELDING
NOZZLE
ARM.
E
L
E
C
T
R
O
D
E
B
L
U
E
B
L
A
C
K
W
H
I
T
E
R
E
D
5
4
1
5
3
9
6
2
6
6
2
7
6
7
5
2
5
A
5
5
5
5
1
0
A
TACH.
PICK-UP
P.C. BD.
CONTROL
POWER
SOURCE
A
B
C
87
531
GND
A
B
C
D
E
F
541
539
627
626
67
A
B
C
D
MOTOR RECEPTACLE
525A
555
510A
A
B
C
D
E
F
TACH. RECEPTACLE
G
H
I
2
4
31
32
21
A
B
C
GREEN
531
87
FLUX OR WATER
SOLENOID
INPUT RECEPTACLE
S12778
S12515
S12514
S12515
S13161-052
S13161-5/64
S14904(OUTER)
S14905(INNER)
S12514
S14904(OUTER)
S14905(INNER)
57F 57/1
57 57/1
95 95/1
95S 95/1
142 142/1
142/1
142T
SINGLE .035-.052
SINGLE 1/16-3/32
SINGLE 3/32-5/32
SINGLE 1/16-3/32
TWIN .045-.052
SINGLE 3/32-7/32
TWIN 3 32
/
TWIN 1/16-5/64
TWIN 5/64-1/8
40-778 I.P.M.
38-762 I.P.M.
22-428 I.P.M.
23-456 I.P.M.
15-289 I.P.M.
15-300 I.P.M.
PIN RATIO PART NUMBER RANGE RANGE
USE OF PIN "S" JUMPER CONNECTION.
5
4
1
5
3
9
6
2
7
8
7
3
2
5
3
1
5
3
2
5
3
1
B
3
1
RF BYPASS
P.C. BOARD
621
87
667
531
626
WHITE
627
6
2
6
6
1
0
6
8
1
5
0
0
5
0
0
5
2
8
6
8
9
+
-
2
5
1
6
3
4
532
531A
631
610
531B
500
1/2A SLOW BLOW
POWER P. C. BOARD
POWER FUSE
1/2A SLOW BLOW
FIELD FUSE
539
627
541
626
1
2
3
4
5
6
528
500
CR4
COUPLED
MAGNETICALLY
ELECTRODE CABLE
TO POWER SOURCE
REED SWITCH ACTUATED BY
WELDING CURRENT
*
*
2
4
8
6
3
7
9
5
1
587
525
510
540
500
525
510
500
500
*
ORANGE
ORANGE
RED
WHITE
RED
TS2
5
2
8
E
L
E
C
T
6
7
TS1
5
0
0
W
O
R
K
2
1
531A
R1
631
531B
POLARITY CONNECTIONS WHICH MATCH ELECTRODE AND WORK CABLE POLARITY CONNECTIONS TO POWER SOURCE.
HI-FREQUENCY INSTALLATION INSTRUCTIONS FOR RE
QUIRED #67 ELECTRODE VOLTAGE SENSING LEAD CONNECTION.
NOTE: NA-5 MOTORS INSULATED FOR HIGH FREQUEN
CY STARTING DO NOT HAVE THIS CONNECTION. REFER TO
"COM" TAB, UNLESS SPECIFIED ON THE POWER SOURCE CONNECTION DIAGRAM TO BE CONNECTED TO THE "AUTO" TAB
TO DISABLE THE "COLD" STARTING FEATURE.
AND TAPED CONNECTION
532
531
531A
CB1
5
0
0
5
0
0
5
2
8
6
8
9
6
2
1
6
6
7
TERMINAL
STRIP JUMPER
CIRCUIT
POLARITY
TERMINALS
610
R
ELECTRODE
500
*
*
682
681
585
610
2
LOGIC
P.C. BOARD
*
*
BLUEBLUE
W
H
I
T
E
R
E
D
R
E
D
B
L
U
E
B
L
U
E
Y
E
L
L
O
W
Y
E
L
L
O
W
B
L
A
C
K
B
L
A
C
K
6
0
1
6
0
2
T1
587
O
R
A
N
G
E
O
R
A
N
G
E
B
R
O
W
N
B
R
O
W
N
T2
500
12
540
10
525
9
510
14
13
628
1
520
8 510P
7
510P
METER
6
632
2
512
3
511
5 511A
4 510P
15
586
11
*
CONTROL
P.C. BOARD
F
S
555
510A
525A
VOLTAGE P.C. BOARD
516
9
514
2
635
4
564A
510P
8
10
525
3
510
7
500 6
5
530
1
667
11
621
12
6
A
B
4
C
5
592
3
687
2
688
1
3
531B
8
532
9
637
4
511
1
511A 2
7
500
6
5
*
FAST BLOW
FUSE
1 8 AMP
/
S
F
*
B
D
A
*
BYPASS COM
AUTO
*
4 2
1
3
6
8
8
6
8
8
A
5
2
5
5
0
0
FILTER P.C. BOARD
LEAD PLUG
500
560
1
564
2
500
3
515
4
635
5
520
6
632 7
510P
8
9
W
W
10
564A
11
12
*
PROCEDURE KIT
RECEPTACLE
JUMPER PLUG
ELECTRICAL SYMBOLS PER E1537
CAVITY NUMBERING SEQUENCE
*
N.M.
N.L.
N.E.
563
N.N.
1
584C
2
564
583S
4
5
500
6
515
3 500
1
5
4
6
3
589
581
1
582
4
628
2
530 3
687
5
688
6
5 563
9
563
6
561
8
560
7
588
4
584S
3
566
2
565
1
583C
4
3
2
1
5
6
6
3
7
5
2
8
5
8
6
5
8
7
5
9
2
6
8
9
*
REMOTE INTERFACE
MODULE (OPTIONAL)
MOCMOCUP
DOWN
START
STOP
SWITCHES
RED
RED
N.L.
24V.
SIGNALS
*
1
6
5
4
2
3
581A
500
586
592
582
515
N.F.
W
H
I
T
E
W
H
I
T
E
R
E
D
R
E
D
N.D.
N.H
FLUX RECEPTACLE
J4
A
B
C
GND
D
532
25
531
J3
J2
J1
WORK CABLE TO
POWER SOURCE
TS
3
N.K.
N.J.
5A CIRCUIT
BREAKER
25
TRAVEL SW.
S2
532
531
31 32
POWER SW.
S1
"HOT" LIGHT
LT1
DOWN
592
500
S4
INCH
UP
S3
586
500
625
N.A. SPEEDMETER BOARD CALIBRATION JUMPER IS TO BE CONNECTED FOR NA-5 HEAD AND DRIVE ROLL
EMPLOYED PER CHART BELOW: (CONNECTED TO PIN "
95" OR "21" WHEN SHIPPED.
21
21/1
S12778
SINGLE .035-.052
100-2070 I.P.M.
= EARLIER SPEEDMETER BOARDS DID NOT HAVE THESE PINS.
= SINGLE "21" PIN ON HIGH SPEED BOARD ONLY.
N.B. REMOVE START RECEPTACLE JUMPER PLUG FROM PROCEDURE BOARD TO INSTALL OPTIONAL PROCEDURE
MODULE AS START PROCEDURE CONTROL. IF MODULE IS REMOVED, REPLACE JUMPER PLUG.
N.C. REMOVE CRATER RECEPTACLE JUMPER PLUG FROM PROCEDURE BOARD TO INSTALL OPTIONAL PROCEDURE
MODULE AS CRATER PROCEDURE CONTROL AND CONNECT LOGIC BOARD LEAD #694 TO PIN #P10.
IF MODULE IS REMOVED, REPLACE JUMPER PLUG AND LOGIC BOARD LEAD #694 TO PIN #P8.
N.D. CONTROL BOARD JUMPER LEAD CONNECTED TO PIN "F" WHEN SHIPPED. SEE OPERATING MANUAL FOR
N.E. VOLTAGE BOARD RED JUMPER LEAD CONNECTED TO PIN "S" AND WHITE JUMPER LEAD CONNECTED TO
N.G. 531-532 115VAC
531-25 115VAC (SWITCHED)
250 VA
N.J. CONNECT #67 BLACK (ELECTRODE) LEAD AND #21 WHITE (WORK) LEAD TO APPROPRIATE TERMINAL STRIP
N.K. LEAD CONNECTED TO MOTOR FRAME WHICH IS ELECTRICALLY COMMON WITH ELECTRODE DRIVE ROLL AND DRIVEN ELECTRODE.
N.L. REMOVE JUMPER PLUG TO INSTALL OPTIONAL KIT. IF KIT IS REMOVED, REPLACE JUMPER PLUG.
N.M. NOT PRESENT ON EARLIER VOLTAGE P.C. BOARDS.
N.N. BLUE JUMPER LEAD NOT PRESENT ON EARLIER VOLTA
GE P.C. BOARDS. THE JUMPER IS TO BE CONNECTED TO THE
B
L
U
E
W
H
I
T
E
R
E
D
582
STOP
S6
581A
682
ELECTRODE LEAD BOLTED
142T
95S
57F
TIMER BOARD
(START TIME USE)
6
5
5
5
0
0
I
O
5
1
5
1
2
4
1
4
1
3
9
6
7
1
8
1
0
1
1
3
5
2
1
5
5
0
0
5
1
0
P
5
1
5
5
2
0
6
3
5
6
3
2
5
8
4
S
5
8
3
S
5
8
4
C
5
8
3
C
5
8
8
5
6
3
5
6
4
5
6
4
A
START RECEPT.
*
1
0
5
6
1
2
1
4
1
5
1
1
8
9
7
1
1
3
2
4
3
5
2
0
5
1
5
5
1
0
P
5
0
0
5
8
3
S
5
8
4
S
5
8
8
5
8
8
A
6
3
5
6
3
2
6
5
5
J
U
M
P
E
R
P
L
U
G
S
{
{
*
1
0
5
6
1
2
1
4
1
5
1
1
8
9
7
1
1
3
2
4
3
5
2
0
5
1
5
5
1
0
P
5
0
0
5
8
8
5
8
8
A
6
3
5
6
3
2
6
5
5
5
8
4
C
5
8
3
C
CRATER RECEPT.
OPTIONAL PROCEDURE MODULE
USED FOR START CONTROL
5
4
3
2
1
6
5
8
1
A
5
8
1
5
6
5
5
6
6
5
6
1
5
6
0
*
N.B.
N.C.
5
6
4
3
2
1
5
0
0
6
5
5
5
1
5
I
O
*
5
6
4
3
2
1
500
655
515
I
O
WELD TIME
RECEPT.
TIMER BOARD
6
5
5
5
0
0
I
O
5
1
5
OPTION BOARD
5
6
4
3
2
1
6
5
5
5
0
0
I
O
5
1
5
TIMER
RECEPT.
OPTIONAL PROCEDURE MODULE
USED FOR CRATER CONTROL
(CRATER TIME USE)
TIMER BOARD
(BURNBACK TIME)
5
0
0
6
5
5
5
1
5
I
O
START
S5
5
0
0
5
8
1
A
581A
5
1
6
5
1
4
5
1
2
5
1
1
5
1
0
P
6
0
1
6
0
2
5
1
7
5
1
9
6
5
5
5
0
0
I
O
5
1
5
WELD TIMER BOARD
(OPTIONAL)
N.A.
SET-ACTUAL
S7
PROCEDURE BOARD
*
BURNBACK
RECEPT.
531B
532
592
(COMPONENT SIDE OF P.C. BOARD)
SPEEDMETER NA-5 HEAD DRIVE ROLL WIRE SIZE RATED SPEED
5
6
2
S
5
6
2
S
5
6
2
C
5
6
2
C
142
95
57
1
2
3
4
1
2
3
4
5
6
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
9
10
11
12
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
12
6
1
J29
N.H. 531-87 115 VAC (SWITCHED) 1/2 AMP.
PIN "B" WHEN SHIPPED, FOR USE TYPICALLY WITH DC-[ ]
TYPE POWER SOURCES. REFER TO CONNECTION
DIAGRAM FOR ALTERNATE CONNECTIONS, AND JUMPER CONNECTIONS FOR R3S, SAM AND SAF OR SA
POWER SOURCES WITH K224. EARLIER VOLTAGE BOARDS DO NOT CONTAIN PIN "D".
1/8 AMP FUSE
OPTIONAL PULSE POWER
TRAVEL RECEPT.
J5
1
5
6
2
5
8
3
6
5
5
5
1
5
5
0
0
5
8
4
5
8
8
5
8
8
A
6
3
2
6
3
5
5
2
0
5
1
0
P
9
1
0
8
3
2
6
4
1
2
5
1
1
*
7
P29 (C)
J29 (C)
J28 (C)
(CRATER FILL USE)
OPTION BOARD
5
6
4
3
2
1
6
5
5
5
0
0
I
O
5
1
5
TIMER
RECEPT.
1
5
6
2
5
8
3
6
5
5
5
1
5
5
0
0
5
8
4
5
8
8
5
8
8
A
6
3
2
6
3
5
5
2
0
5
1
0
P
9
1
0
8
3
2
6
4
1
2
5
1
1
*
7
(START USE)
J28 (S)
J29 (S)
P29 (S)
P28 (S)
3
1
J28
6
P28 (C)
CABLE
TO
532
87
610
532
585
589
FLUX RELAY MODULE
CR1
31
4
2
610
CR2
31
4
2
RELAY MODULE
RELAY MODULE
N.P.
532
TRAVEL
CONTACTOR
4
2
625
682
CR3
3
1
4
2
610
N.P.
N.P.
N.P. EARLIER RELAYS HAD SAME TERMINAL NUMBERS BUT IN A DIFFERENT ORIENTATION.
METHODS OF TRAVEL
START/STOP WITH SWITCHES
LEAD #691 to P6
LEAD #692 to P5
LEAD #691 to P6
LEAD #692 to P7
STOP WITH STOP SWITCH
LEAD #691 to P5
LEAD #692 to P7
START WITH START SWITCH
STOP AFTER CRATER TIME
LEAD #691 to P6
LEAD #692 to P9
FOR EARLIER LOGIC P.C.
BOARDS WITH JUMPERS
CONNECT
CONNECT
SWITCH #1
1 234
SWITCH #2
1 234
SWITCH #1
1 234
SWITCH #2
1 234
FOR LOGIC P.C. BOARDS WITH
CONNECT
CONNECT
SWITCH #1
1 234
SWITCH #2
1 234
SWITCH #1
1 234
SWITCH #2
1 234
FOR EARLIER LOGIC P.C.
BOARDS WITH JUMPERS
YES
CONNECT
LEAD #694 TO P10
NO
CONNECT
LEAD #694 TO P8
CRATER BOARD INSTALLED?
SWITCH #1
1 234
SWITCH #2
1 234
SWITCH #1
1 234
SWITCH #2
1 234
FOR LOGIC P.C. BOARDS WITH
DIP SWITCHES
DIP SWITCHES
FOR EARLIER LOGIC P.C.
BOARDS WITH JUMPERS
SWITCH #1
1 2 3 4
SWITCH #2
1 234
SWITCH #1
1 2 3 4
SWITCH #2
1 234
FOR LOGIC P.C. BOARDS WITH
DIP SWITCHES
1 2 3 4 1 234
METHODS OF BURNBACK
CONNECT
LEAD #690 TO P4
LEAD #693 TO P3
CONNECT
LEAD #690 TO P4
LEAD #693 TO P1
CONNECT
LEAD #690 TO P2
LEAD #693 TO P1
1 2 3 4
SAMPLE SWITCH
SWITCH POSITION 1 IS UP
SWITCH POSITION 2 IS DOWN
SWITCH POSITIONS 3 AND 4 ARE NOT APPLICABLE
NA-5 SHIPPED CONNECTED FOR INDICATED METHODS OF TRAVEL & BURNBACK.
START WITH START SWITCH
LEAD #691 to P6
LEAD #692 to P8
CONNECT
SWITCH #1
1 234
SWITCH #2
1 234
START/STOP WITH WELD CURRENT
START WITH WELD CURRENT
(OPTIONAL PROCEDURE MODULE
INSTALLED IN CRATER RECEPTACLE)
(OPTIONAL PROCEDURE MODULE
INSTALLED IN CRATER RECEPTACLE)
STOP AFTER BURN-BACK TIME
N.F. LOGIC BOARD DIP SWITCHES OR JUMPERS TO BE SET
TO SUIT DESIRED APPLICATIONS PER CHARTS BELOW:
WIRE FEED STOP WITH
CONTACTOR DELAY
INCH UP WITH CONTACTOR DELAY
INCH UP WITH NO CONTACTOR
DELAY
USE OF OPTIONAL CRATER MODULE
N.R.
N.R.
N.R.
N.R. POTENTIOMETERS AND SWITCHES MOUNTED ON P.C. BOARD ARE CONNECTED TO FRAME, FOR ESD.
(NOT PRESENT ON EARLIER BOARDS)
N.S. THE FIELD FUSE WAS REPLACED WITH A PTC RESETTABLE FUSE ON LATER MODEL POWER BOARDS.
N.S.
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