Lincoln Na5 Service Manual

							OPERATING INSTRUCTIONSB-8B-8
Wire Feed Motor AccelerationELECTRIC SHOCKcan kill.
• Turn off input power to the welding power source
using the disconnect
switch before working on
this equipment.
The NA-5 has two different speeds of
controlled wire feed motor acceleration.  As
shipped, the unit is connected for fast
acceleration which is best for most
applications.  To change to the slower
acceleration, turn off all input power to the
NA-5 control box.  Open the control box.
Locate the Control PC Board mounted on
the back of the box in the lower right hand
corner.  Change the jumper plug from the “F”
pin to the “S” pin as shown in Figure B.2. 
Burnback and Electrode Backup
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 stopping sequence when the
optional “Crater Controls” are not used is as
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.  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 holding the inner panel,
and swing the panel open.  Change the
connections (older models) or switch
positions (newer models) on the logic board
as shown in Table B.2.
Optional “Crater Controls”
This option is recommended for applications
where the ending bead size must be
controlled, applications when the crater must
be filled, roundabouts, and any 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 Controls” 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 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 and then retract at strike mode speed for the remainder of burnbacktime.
NA-5
JUMPER 
 PLUG
FIGURE B.2 – ACCELERATION JUMPER PLUGS. 
WARNING
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							TABLE  B.2 – STOPPING SEQUENCE SETTINGS.
When “Stop” Button is Pressed Older Models Newer Models*
Feed motor stops and  Lead #693 to Pin 3
electrode burns back with  Lead #690 to Pin 4
contactor delay (standard)
Feed motor inches up and  Lead #693 to Pin 1
electrode burns back with Lead #690 to Pin 4
contactor delay
Feed motor inches up and  Lead #693 to Pin 1
contactor opens Lead #690 to Pin 2
(no burnback)
*NOTE:
VOLTAGE CONTROL
RESPONSE
The NA-5 is provided with selectable voltage
control response. Proper setting depends on
the power source and process being used.
Refer to the appropriate power source
connection diagram for the proper
connection of the jumpers located on the
NA-5 Voltage P.C. Board, shown in Figure
B.3.
To change the voltage control response:
1. 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
Voltage P.C. Board per the
appropriate power source connection
diagram.
1234
Switch #2
1234Switch #2
1234Switch #2
OPERATING INSTRUCTIONSB-9B-9
NA-5
Indicates switch in up   position
Indicates switch in down   position
Indicates switch position does not matter
NA-5
VOLTAGE
A D
B
RED
JUMPER
 PLUG
WHITE
JUMPER
 PLUG
FIGURE B.3 – VOLTAGE CONTROL RESPONSE JUMPER PLUG LOCATIONS. 
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							AUTOMATIC SHUTDOWN
If the NA-5 voltage control is unable to
supply the “Set” value of the arc voltage
while welding, the automatic shutdown
circuit will activate.  This protection circuit
immediately returns the NA-5 control to idle
state within a few seconds after the arc
voltage discrepancy occurs.
Typical causes that activate 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 the power source.
4. Incorrect weld polarity connections, or settings, at NA-5 or power source.
5. Lost connection of NA-5 voltage sensing leads (#67 and #21) between
arc and voltage control or a blown 1/8
amp fuse on voltage PC boards built
since 1983.
With NA-5 units above Code 8300, the
conditions of causes 4 and 5 above would
result in the wrong wire feed direction when
the weld is started.  See the section on 
Cold
Start Circuitry.
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 causes 3, 4 and 5
above by holding the power output at
minimum, possibly providing 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 the section
on 
Cold Start Circuitry.
Although out of range shutdown can occur
with all power sources when working with
very low or very high arc voltages, it is most likely to occur when using the R3S models
with the somewhat limited voltage ranges 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
approximately 7 volts, i.e. 27.5 to 34.5 volts
at nominal input voltage.  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 NA-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 23.5 to 30.5
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:
1. Move the NA-5 voltage set point 2 volts lower than the desired
procedure and make a test weld.
a. If the NA-5 still shuts down, go to step 2 below.
b. 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 significant change in input
voltage.  Skip the following step.
2. Move the NA-5 voltage setting set point 2 volts higher than the desired
procedure and make a test weld.
a. If the NA-5 keeps welding, change the R3S triangle setting
to the next lower voltage and
reset the NA-5 set point to the
desired procedure. The R3S is
now set properly unless there is
a significant change in input
voltage.  Skip the following step.
b.  If the NA-5 still shuts down, refer to the following paragraph and
other causes previously listed.
OPERATING INSTRUCTIONSB-10B-10
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							OPERATING INSTRUCTIONSB-11B-11
NA-5
In some cases, it is also possible to hold the
“Actual” button pressed while starting the
arc.  Before the NA-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 negative (-) voltage, the
polarity connections or settings at the NA-5
or power source are wrong.  
This same general procedure can be used
on the 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 voltage.  If the NA-5
continues to weld at one of these voltages,
it can be determined what change in the
range controls of the power source are
required so it can supply the desired voltage.
COLD START CIRCUITRY 
NA-5 controls above Code 8300 contain
circuitry added to the voltage PC 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 exceeds approximately
6.5 VDC.  However, if this voltage level is
not exceeded, or drops below approximately
3.5 VDC, 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 coldstart circuitry by replacing the old L-6257 voltage boardwith the new G-1556 voltage board.  This new boardwill mount and connect in the same manner as the oldboard, except the third harness connector (previouslyconnected to a jumper plug) must be connected to thelower receptacle of the new voltage board.
NOTE: HI-FREQ starting cannot be used
with converted units below Code 8300. A. Auto Stop 
When the “Inch Down” button is pressed, 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.  The “Inch
Up” button is not affected by this circuit.
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 voltage is
re-established and then change back to the
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 the
situation are:
1. No wire loaded through the NA-5 head and nozzle assembly (except
when using the K148 Contact
Nozzle).
2. No power source weld cable connection to the NA-5 head or work.
3. Incorrect electrode polarity connections at the NA-5 or power
source. 
4. Little or no output voltage from the power source.
5. An open voltage sensing lead #67 or #21 to the NA-5 control box or a
blown 1/8 amp fuse on a voltage PC
board built since 1983.
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							OPERATING INSTRUCTIONSB-12B-12
NA-5
SECURITY OF WELD
PROCEDURE SETTINGS
There are two means provided to prevent or
limit unauthorized 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 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  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 select switch knob.
c. Remove the felt seal and square spacer tube mounted behind
each control knob.
d. Open the control box. Disconnect, then remove, the
procedure control PC board
assembly and its panel insulation. 
e. Install a 1/2 in. long, pan or round head, #4 sheet metal screw into
the 0.10 in. diameter hole located beneath each square so the head
is on the back side of the panel
(inside the control box).
f. Remount the PC board assembly and its panel insulation.
Reconnect the PC board and
close and secure the control box. 
g. Remount the rotary select switch knob and replace 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
15% 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.  
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							TABLE OF CONTENTS
- ACCESSORIES SECTION - 
NA-5
Accessories  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
 . . . . . . . . . . . Section C
General  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
 . . . . . . . . . C-2
Listing of Accessories  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3 K29 Vertical Lift Adjuster  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
K58 Magnetic Separator  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
K96 Horizontal Adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
K129 Submerged Arc Small Wire Twinarc
® . . . . . . . . . . . . . . . . . C-3
K148 Contact Nozzle and K149 Linc-FillTM
Long Stickout Extension  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
K218 Horizontal Fillet/Lap Attachment  . . . . . . . . . . . . . . . . . . . . C-3
K219 Flux Hopper Kit  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
K223 Solenoid Kit  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
K225 Submerged Arc Twinarc Kit  . . . . . . . . . . . . . . . . . . . . . . . C-4
K238 High Frequency Unit  . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4
K239 Twinarc Kit for Innershield
®Electrodes  . . . . . . . . . . . . . . . C-4
K278 SpreadarcTM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4
K281 Solid Wire Straightener for Tiny Twinarc  . . . . . . . . . . . . . . C-4
K285 Concentric Flux Cone  . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4
K310 Flux Screen  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4
K325 TC-3 Travel Carriage  . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4
K334 Start and Crater Controls  . . . . . . . . . . . . . . . . . . . . . . . . . C-5
K336 Remote Interface Module  . . . . . . . . . . . . . . . . . . . . . . . . . C-5
K337 Weld Timer Module  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5
K349 Multi-Procedure Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5
S-22022 or S-22182 Current Relay  . . . . . . . . . . . . . . . . . . . . . . C-5
Speed-Feed Drum  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5
Speed-Feed Reel  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5
Section CSection C
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							C-2ACCESSORIESC-2
NA-5
Product NumberProduct Name
K29 VERTICAL LIFT ADJUSTER
K58 MAGNETIC SEPARATOR
K96 HORIZONTAL  ADJUSTER
K129 SUBMERGED ARC SMALL WIRE TWINARC
K148 CONTACT NOZZLE
K149 LINC-FILL LONG STICKOUT EXTENSION
K218 HORIZONTAL FILLET/LAP ATTACHMENT
K219 FLUX HOPPER KIT
K223 SOLENOID KIT
K225 SUBMERGED ARC TWINARC KIT
K238 HIGH FREQUENCY UNIT
K239 TWINARC KIT FOR INNERSHIELD ELECTRODES
K278 SPREADARC
K281 SOLID WIRE STRAIGHTENER FOR TINY TWINARC
K285 CONCENTRIC FLUX CONE
K310 FLUX SCREEN
K325 TC-3 TRAVEL CARRIAGE
K334 START AND CRATER CONTROLS
K336 REMOTE INTERFACE MODULE
K337 WELD TIMER MODULE
K349 MULTI-PROCEDURE KIT
S22022 or S22182 CURRENT RELAY
SPEED-FEED DRUMS
SPEED-FEED REELS
GENERAL
This section contains a listing and short
description of the accessories that are available with the NA-5 automatic welding
system.
TABLE  C.1  –  NA-5  AUTOMATIC  WELDING  SYSTEM  ACCESSORIES.
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							ACCESSORIESC-3C-3
NA-5 
LISTING OF ACCESSORIES
K29 VERTICAL LIFT ADJUSTER
When mounted in the NA-5 head mounting
system, the K29 Vertical Lift Adjuster
provides quick hand crank adjustment of the
vertical head position. It also has some
horizontal adjustability as described in Sec.
T3.2.3 of operator’s manual IM305.
Installation instructions are shipped with
each K29 Vertical Lift Adjuster kit, are
contained in the IM305 manual, and can be
ordered as Sec. T2.2.11.
K58 MAGNETIC SEPARATOR
Useful with any submerged arc equipment.
The unit removes foreign magnetic particles
from reused submerged arc welding flux.
Operating instructions are included with the
kit.
K96 HORIZONTAL ADJUSTER
When mounted in the NA-5 head mounting
system, the K96 Horizontal Adjuster
provides quick hand crank adjustment of the
horizontal head position. Installation
instructions are shipped with each K96
Horizontal Adjuster kit, are contained in the
IM305 manual, and can be ordered as Sec.
T2.2.12.
K129 SUBMERGED ARC SMALL
WIRE TWINARC
®
The Twinarc system provides for the feeding
of two small solid wires through a single wire
feeder. The Twinarc assembly includes a
wire reel, reel brake, shaft and mounting
bracket, drive roll, idle roll assembly, dual
wire guides, and nozzle and contact tip or
contact tip holder. Instructions are shipped
with each kit, are contained in the IM305
manual, and can be ordered as Sec. T2.5.3
K129.
K148 CONTACT NOZZLE AND
K149 LINC-FILL
TMLONG
STICKOUT EXTENSION
This Innershield and submerged arc nozzle
is designed for 0.062 through 3/16 in.
(1.57 through 4.76 mm) wire at high
currents. When long stickout [2 to 5 (50.80
to 127.00 mm)] is required, the K149
Linc-Fill Long Stickout Extension is
recommended along with the K237 Linc-Fill
Starting Relay. Instructions are contained in
the IM305 manual and can also be ordered
as Sec. T2.2.7.
K218 HORIZONTAL
FILLET/LAP ATTACHMENT
This special contact assembly automatically
guides the electrode when making
submerged arc horizontal fillet and lap welds
to ensure accurate bead placement without
expensive fixtures and clamps. Installation,
operating, and maintenance instructions are
shipped with each kit, are contained in the
IM305 manual, and can also be ordered as
Sec. T2.5.4.
K219 FLUX HOPPER KIT
This flux hopper, which has an electric flux
valve, can be mounted on NA-5N and
NA-5NF heads for submerged arc welding.
Installation instructions are included with
each kit. The operator and maintenance
instructions are contained in the IM305
manual and can also be ordered as
Sec. T2.5.9.
K223 SOLENOID KIT
The solenoid kit includes a valve to control
water flow when using the cooling
attachment on the K148 or K239 contact
nozzle assembly. It opens when the start
button is pressed and can be wired to close
either when the stop button is pressed or
when the arc goes out. Installation
instructions are shipped with each kit.
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							ACCESSORIESC-4C-4
K225 SUBMERGED
ARC TWINARC KIT
The Twinarc kit provides for the feeding of
two 5/64, 3/32, or 1/8 in. (1.98, 2.38, or
3.18 mm) solid wires through a single wire
feeder. The electrode wire must be the
same size. The assembly includes a wire
reel, insulated reel mounting bracket, wire
straightener, dual wire guides, nozzle, and
contact block. Installation, operating, and
maintenance instructions are shipped with
each kit, are contained in the IM305 manual,
and can be ordered as Sec. T2.5.3 K225.
K238 HIGH FREQUENCY UNIT
This unit supplies high frequency to the
welding leads for more positive starts, which
may be required for certain difficult starting
applications. Factory-installed insulation is
required. Instructions are shipped with each
unit. Installation instructions are contained
in the IM305 manual and can be ordered as
Sec. T2.5.8.
K239 TWINARC KIT FOR
INNERSHIELD
®ELECTRODES
This kit provides for welding with two
Innershield electrodes. Two 3/32 in.
(2.38 mm) flux-cored electrodes are fed
through a single wire feeder. Both wires
must be the same size. The K239 kit
includes the nozzle equipped for water
cooling, 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.
Instructions are included in the kit, are
contained in the IM305 manual, and can
also be ordered as Sec. T2.5.3 K239.
K278 SPREADARCTM
The primary application for this accessory is
for hardfacing buildup using a Twinarc
nozzle. The combination “Spreadarc-
Twinarc” covers large areas quickly with
smooth beads of minimum admixture with
the base metal. Flux cored electrode, openarc, and submerged arc procedures can be
used. Instructions are shipped with the kit,
are contained in the IM305 manual, and can
also be ordered as Sec. T2.5.6.
K281 SOLID WIRE
STRAIGHTENER FOR
TINY TWINARC
This wire straightener will straighten 0.045
through 3/32 in. (1.14 through 2.38 mm) wire
diameters. It is recommended for welding
procedures requiring long stickout and
where wire position accuracy is essential.
Instructions are shipped with the kit, are
contained in the IM305 manual, and can be
ordered as Sec. T2.5.5.
K285 CONCENTRIC FLUX CONE 
The concentric flux cone was designed to
fit on the K148 Contact Nozzle alone, the
K148 Contact Nozzle with a K149 Linc-Fill
Long Stickout Extension, the K129
Submerged Arc Small Wire Twinarc, and
the K391 nozzles.  (The maximum electrical
stickout when using the K149 Linc-Fill Long
Stickout Extension will be 4 in. [101.6 mm.]).
Use of this attachment results in the flux
being fed concentrically around the
electrodes.  Installation, operating, and
maintenance instructions are shipped with
each kit, are contained in the IM305 manual,
and can be ordered as Sec. T2.2.8 K285.
K310 FLUX SCREEN
Useful for any submerged arc equipment. It
removes foreign magnetic particles from
reused submerged arc welding flux.
Operating instructions are included in the kit.
K325 TC-3 TRAVEL CARRIAGE
The K325 Travel Carriage carries the control
box and wire drive head, in either direction,
on a beam of suitable length and
mechanical specifications. Two models are
available: Standard and High Capacity.
NA-5
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							ACCESSORIESC-5C-5
NA-5
K334 START AND CRATER
CONTROLS 
Easily installed procedure and timer boards
to permit adjustment of wire speed and
voltage.  Can be installed to function at
either the start of the weld or at the end for
crater filling.  Installation, operating, and
maintenance instructions are shipped with
each kit and can be ordered as Sec. T2.5.13
K334.
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.  This module replaces the earlier
K336 Remote Pushbutton Interface Module.
Installation and application instructions are
shipped with each kit and can be ordered as
Sec. T2.5.11 K336.
K337 WELD TIMER MODULE 
Permits setting of weld time for an adjustable
period.  Eliminates need to press the “Stop”
button.  Instructions are included in the kit. 
K349 MULTI-PROCEDURE KIT 
The K349 Multi-Procedure Kit provides three
additional weld mode procedure settings of
wire feed speed and voltage, allowing the
choice of four NA-5 weld mode procedures.
Installation, operating, and maintenance
instructions are shipped with each kit, are
contained in the IM305 manual, and can be
ordered as Sec. T2.5.19 K349.
S22022 OR S22182 CURRENT
RELAY MODULES
The current relay is useful to fixture builders
and others who need a signal indicating that
welding current is flowing.  Installation,
operating, and maintenance instructions are
shipped with each kit. The S22022 relay
module is suitable for dry circuit applications
and it is rated at 2 Amps, 115 VAC or 28
VDC. This relay has both normally open and
normally closed contacts. The S22182 relay
module is suitable for applications requiring
at least 10 mA current and it is rated at 3
Amps, 115 VAC or 28 VDC. This relay only
has normally open contacts.  
SPEED-FEED DRUM
These drums must be set on a turntable
which permits them to freely turn in a
clockwise direction.  Installation, operating,
and maintenance instructions are contained
in the IM305 manual and can be ordered as
Sec. T2.5.7-A.
SPEED-FEED REEL
These reels require dereeling equipment
that permits the reel to rotate freely as the
electrode is used.  Installation, operating,
and maintenance instructions are contained
in the IM305 manual and can be ordered as
Sec. T2.5.7-B.
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