SVM131-A
July, 1997
NA-5
AUTOMATIC WELDING SYSTEMS
For use with the following models:
NA-5N
NA-5NF
NA-5S
NA-5SF
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.
SERVICE MANUAL
World's Leader in Welding and Cutting Products
Premier Manufacturer of Industrial Motors
Sales and Service through Subsidiaries and Distributors Worldwide
22801 St. Clair Ave. Cleveland, Ohio 44117-1199 U.S.A. Tel. (216) 481-8100
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ii
ii
SAFETY
ARC RAYS can burn.
ELECTRIC SHOCK can kill.
3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.
4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
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.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:
FUMES AND GASES
can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
fumes and gases.When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
fumes and gases away from the breathing zone. When
welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
3.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
5.b. Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors to
form phosgene, a highly toxic gas, and other irritating
products.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.
5.c. 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.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
5.d. 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.
3.j. Also see Items 6.c. and 8.
5.e. Also see item 1.b.
Mar ‘95
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iii
SAFETY
WELDING SPARKS can
cause fire or explosion.
CYLINDER may explode
if damaged.
6.a. Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
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.
process used and properly operating
regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.
7.c. Cylinders should be located:
•Away from areas where they may be struck or subjected to
physical damage.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact can
cause overheating and create a fire hazard.
•A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even though they have
been “cleaned”. For information, purchase “Recommended
Safe Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.
FOR ELECTRICALLY
powered equipment.
6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate circuits.
This can create fire hazards or overheat lifting chains or
cables until they fail.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.
6.h. Also see item 1.c.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Mar ‘95
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iv
iv
SAFETY
5. Toujours porter des lunettes de sécurité dans la zone de
PRÉCAUTIONS DE SÛRETÉ
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.
Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv-
antes:
6. Eloigner les matériaux inflammables ou les recouvrir afin
de prévenir tout risque d’incendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé
de la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter
toujours tout contact entre les parties sous tension et
la peau nue ou les vétements mouillés. Porter des
gants secs et sans trous pour isoler les mains.
b. Faire trés attention de bien 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 couché
pour lesquelles une grande partie du corps peut être
en contact avec la masse.
8. S’assurer que la masse est connectée le plus prés 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 éloignés de la zone de travail, on
augmente le risque de voir passer le courant de soudage
par les chaines de levage, câbles de grue, ou autres
circuits. Cela peut provoquer des risques d’incendie ou
d’echauffement des chaines et des câbles jusqu’à ce qu’ils
se rompent.
c. Maintenir le porte-électrode, la pince de masse, le
câble de soudage et la machine à souder en bon et sûr
état defonctionnement.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de
tôles galvanisées plombées, ou cadmiées ou tout autre
métal qui produit des fumeés toxiques.
d. Ne jamais plonger le porte-électrode dans l’eau pour
le refroidir.
e. Ne jamais toucher simultanément les parties sous
tension des porte-électrodes connectés à deux
machines à souder parce que la tension entre les deux
pinces peut être le total de la tension à vide des deux
machines.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les
vapeurs du solvant pour produire du phosgéne (gas
fortement toxique) ou autres produits irritants.
f. Si on utilise la machine à souder comme une source
de courant pour soudage semi-automatique, ces
precautions pour le porte-électrode s’applicuent aussi
au pistolet de soudage.
11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie
du corps.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du ray-
onnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.
1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
l‘arc.
2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
3. Avant de faires des travaux à l’interieur de poste, la debranch-
er à l’interrupteur à la boite de fusibles.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan-
talons sans revers, et chaussures montantes.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
Mar. ‘93
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v
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MASTER TABLE OF CONTENTS FOR ALL SECTIONS
Page
i-iv
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrode Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Source Connection Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . .
A-2
A-4
A-6
A-8
A-8
Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section B
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operator’s Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Controls and Their Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setup Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting and Stopping Sequences . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting Travel Starting and Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . .
Voltage Control Response . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Automatic Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cold Start Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Security of Weld Procedure Settings . . . . . . . . . . . . . . . . . . . . . . . . . . .
B-2
B-2
B-3
B-4
B-5
B-6
B-9
B-10
B-11
B-12
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section C
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Listing of Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C-2
C-3
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section D
Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Welding Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optional Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D-2
D-3
D-6
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section E
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Input Power Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power and Voltage Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control, Logic and Procedure Boards . . . . . . . . . . . . . . . . . . . . . . . .
E-2
E-2
E-3
E-4
Optional start, Crater Fill and Weld Timer Boards . . . . . . . . . . . . . . .
SCR Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
E-5
E-6
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section F
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section G
Parts Listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NA-5
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vi
vi
NOTES
NA-5
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Section A
Section A
TABLE OF CONTENTS
- INSTALLATION SECTION -
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Box Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Welding Head Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Input Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Box to Welding Head Connections . . . . . . . . . . . . . . . . .
Power Supply to Control Box Connections . . . . . . . . . . . . . . . . .
Electrode Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Source Connection Diagrams . . . . . . . . . . . . . . . . . . . . . . . .
Figure A.8 — Connection of NA-5 (All) to a DC-600 . . . . . . . . . .
Figure A.9 — Connection of NA-5 (All) to a DC-650 Pro . . . . . . .
Figure A.10 — Connection of NA-5 (All) to a R3S-400, -600
or -800 with no Line Voltage Compensator (Obsolete) . . . . . .
Figure A.11 — Connection of NA-5 (All) to a SAM-400 Motor
Generator or Engine Welder . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure A.12 — Connection of NA-5 (All) to a SAM-650
A-2
A-4
A-4
A-4
A-5
A-6
A-6
A-6
A-7
A-8
A-8
A-9
A-10
A-11
A-12
Engine Welder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure A.13 — Connection of NA-5 to DC-1000 or DC-1500 . . . .
Figure A.14 — Connection of NA-5 to DC-400 or CV-400 . . . . . .
A-13
A-14
A-15
NA-5
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A-2
A-2
INSTALLATION
TECHNICAL SPECIFICATIONS – NA-5
MINIMUM ELECTRICAL INPUT REQUIREMENTS
115 VAC @ 3 amps 50/60 Hz power
REQUIRED WELDING POWER SOURCE
NA-5
DC Constant Voltage
WIRE FEED SPEED and GEAR RATIOS
FEED SPEED RANGE
in./min (m/min)
MAX. WIRE SIZE in. (mm)
GEAR RATIO
CORED WIRE
0.052 (1.3)
3/32 (2.4)
SOLID WIRE
21:1
57:1
100 - 2070 (2.54 - 52.6)
38 - 7.78 (0.96 - 19.8)
22 - 456 (0.56 - 11.6)
15 - 300 (0.38 - 7.62)
0.052 (1.3)
1/16 (1.6)
1/8 (3.2)
95:1
5/32 (4.0)
142:1
5/32 (4.0)
7/32 (5.6)
PHYSICAL DIMENSIONS
LENGTH
in. (mm)
WIDTH
in. (mm)
HEIGHT
in. (mm)
WEIGHT
lbs (kg)
MODEL
NA-5 Control Box
9.02 (229)
17.87 (454)
15.05 (382)
30 (13)
NA-5
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A-3
A-3
INSTALLATION
FIGURE A.1 – BASIC CONTROL AND WIRE DRIVE SYSTEM.
CONTROL BOX
HEAD MOUNTING PARTS
(WITH INSULATION
AND HARDWARE)
CONTROL
CABLE
TO
POWER
SOURCE
WIRE
STRAIGHTENER
TACHOMETER
CABLE
4 FT (1.2 M) CABLE
(DRIVE MOTOR TO
CONTROL BOX)
MOTOR
4 FT (1.2 M) ELECTRODE CABLES
[(TWO 4/0) CONTACT ASSEMBLY
TO CONTROL BOX]
CROSS
SEAM
ADJUSTER
GEAR BOX
CONTACT
ASSEMBLY
(OPTIONAL)
NA-5
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A-4
A-4
INSTALLATION
1. Align the mounting holes in adapter
plate M-13945 to the holes in the
travel carriage.
MECHANICAL
INSTALLATION
2. Install four hex head screws through
the adapter plate and into the travel
carriage.
WARNING
ELECTRIC SHOCK
can kill.
3. Secure the control box to the adapter
plate with four lock washers and four
bolts, two from the bottom and two
from the back.
• Turn off input power to
the welding power source
using the disconnect
switch before working on
this equipment.
Before mounting the control box onto a
fixture, you must provide mounting holes in
the fixture per the measurements provided
in Figure A.3 or dimension print S16717.
When placing the mounting holes, ensure
the controls and meters are convenient to
the operator.
INTRODUCTION
This section covers the basic requirements to
install the control box and welding head
shown in Figure A.1. This section will give
you mounting hole alignments, component
mounting clearances, and any special
instructions or precautions that must be fol-
lowed when installing the control box and
mounting head.
FIGURE A.2 – CONTROL BOX
CARRIAGE MOUNTING.
CONTROL BOX INSTALLATION
The control box can be mounted either on
the standard travel carriage or on a separate
fixture. It is electrically grounded by a lead
in the input cable assembly.
ADAPTER
PLATE
TRAVEL
To install the control box on the standard
travel carriage, use mounting kit T14469 and
perform the following steps. Also refer to
Figure A.2.
CARRIAGE
CONTROL
BOX
NA-5
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A-5
A-5
INSTALLATION
To install the control box on a fixture,
perform the following steps and refer to
Figure A.3.
WELDING HEAD INSTALLATION
The welding head can be mounted either
with the standard head mounting hardware
or with the horizontal head and/or vertical lift
adjusters. Design the installation of your
welding head so it meets the adjustability
requirements of your welding application.
Refer to Section C, Accessories, for more
information regarding the adjustable
mounting hardware.
1. Align the mounting holes on the back
and/or bottom of the control box with
the holes you put in the fixture
according to the measurements
provided in Figure A.3.
2. Secure the control box to the fixture
using lock washers and hex head
screws at each of the mounting holes.
The welding head and electrode are
electrically “hot” when welding. They must
be insulated from ground.
FIGURE A.3 – CONTROL BOX
FIXTURE MOUNTING.
Standard head mounting hardware and
insulation are shipped with the NA-5
welding head. If you are mounting the
welding head on a separate fixture, provide
the mounting holes for the standard head
mount as specified in Figure A.4. For best
arc striking, use a rigid mounting that
prevents the head from moving when the
electrode strikes the work.
VIEW FROM BACK
0.41
(10.41)
0.28 (7.11) SLOTS
4 PLACES
0.562 DIA (14.27)
2 HOLES
12.75
(323.85)
1.34
(34.04)
FIGURE A.4 – WELDING HEAD
MOUNTING HOLES.
13.77
(349.76)
1.71
(43.43)
12.00
(304.8)
APPROXIMATE
INSULATOR
0.531 DIA.
(13.49)
SIZE
2.88
(73.15)
1.09
(27.68)
0.43
(10.92)
1/4-20
THREAD HOLES
2.62
(66.55)
4.265
(108.33)
VIEW FROM BOTTOM
12.00
(304.8)
4.5
1.71
(43.43)
(114.30)
NOTE: DIMENSIONS ARE IN INCHES
WITH MILLIMETERS IN
3.50
(88.9)
PARENTHESES.
1/4-20 THREAD HOLES
FRONT
NOTE: DIMENSIONS ARE IN INCHES
WITH MILLIMETERS IN
PARENTHESES.
NA-5
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A-6
A-6
INSTALLATION
When mounting the welding head to the
standard travel carriage, (see 305-B sec.
T2.2.4) mount it so only a minimum of
overhang weight exists. Mount the head so
it stays within the dimension shown in Figure
A.5.
nection diagrams for connecting automatic
welding systems to various welding power
sources.
INPUT POWER REQUIREMENTS
350 volt-amperes of 115 VAC 50/60 Hz
power is required for the wire feed motor and
controls. Another 250 volt-amperes may be
required depending on the travel circuit.
FIGURE A.5 – MOUNT TO CARRIAGE
OVERHANG DIMENSION.
CONTROL BOX TO WELDING
HEAD CONNECTIONS
19 IN.
(483 MM)
All welding heads include a 4 ft (1.2 m)
motor cable and motor tachometer cable.
Insert the plugs on these cables into the
matching receptacles on the side of the
control box.
If the 4 ft (1.2 m) cables are not sufficient,
install a K335 or K338 control to head
extension cable of the length ordered [up to
30 ft (9.1 m)]. 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-5S also include two 4 ft
(1.2 m) lengths of electrode cable. Bolt the
terminals at one end of the the cable pair to
the wire contact assembly and the terminals
at the other end to the electrode leads on the
power source to control cable assembly.
Properly insulate the bolted connection.
When the K335 or K338 extension cables are
used between the controls and heads, the 4 ft
(1.2 m) lengths of electrode cable are not
used. If currents or duty cycles higher than
1000 amps at 80% duty cycle will be used,
add additional electrode cable per Table A.1.
ELECTRICAL
INSTALLATION
WARNING
ELECTRIC SHOCK
can kill.
• Do not touch electrically
live parts such as output
terminals or internal
wiring.
TABLE A.1
80% Duty Cycle
Below 1000 amps
Two 4/0
This section provides information on proper
wiring procedures for the NA-5 welding sys-
tem. This section also provides basic con-
1000 to 1300 amps Three 4/0
1300 to 1500 amps Four 4/0
NA-5
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A-7
A-7
INSTALLATION
The “F” models do not include the 4 ft (1.2
m) lengths of electrode cable as standard.
If you are not using a K335 or K338 exten-
sion cable for the NA-5NF or NA-5SF, order
an appropriate length of the needed elec-
trode cable. Connect it between the wire
contact assembly and the control cable
assembly as described above.
Insert the polarized connector of the K215
or K597* control cable into the matching
receptacle on the side of the control box.
With the power source off, connect the
control cable assembly to the power
source as follows:
1. If using the multi-process 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 (Figures
A.8 to A.14).
POWER SUPPLY TO CONTROL
BOX CONNECTIONS
At the NA-5 control box, in order to activate
the NA-5 weld current sensing switch, the
electrode cables of the control cable
assembly must be placed under the clamp
bar on the left-hand side of the control box,
as shown in Figure A.6. This is required
for proper operation of the reed switch.
The nuts holding the clamp bar in place
need only to be pulled up snug. Do not
overtighten. 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.
2. Connect the K215 control cable
leads to the power source terminal
strip exactly as specified on the
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 cycles higher than 1000 amps
at 80% duty cycle will be used, add
additional electrode cables to the
K215 assembly per Table A.1.
3 Depending on the power source and
the 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, and
DC-1500 type power sources. For
other power sources, refer to the
appropriate connection diagram and
to IM305 Sec. T3.6.
FIGURE A.6 – CONTROL BOX
ELECTRICAL CONNECTIONS.
CLAMP
BAR
4. Connect work leads of sufficient size
and length per Table A.1. between
the “To 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.
FROM
POWER
SOURCE
*The K597 cable assembly has a 14-pin MS-type
connector for use with later model Lincoln CV power
sources.
TO
WELDING
HEAD
NA-5
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A-8
A-8
INSTALLATION
FIGURE A.7 – TERMINAL STRIP
ELECTRODE POLARITY
LOCATION.
WARNING
ELECTRIC SHOCK
can kill.
• Turn off input power to
the welding power
source
using
the
disconnect
switch
before working on this
equipment.
TERMINAL
STRIPS
Polarity is changed at the power source.
The polarity of the NA-5 control circuit is
shipped connected for electrode positive. If
electrode negative is required, two leads
inside the NA-5 control must be reversed.
Proceed as follows:
POWER SOURCE
CONNECTION DIAGRAMS
1. Turn off the input power to the NA-5
control box by turning off the welding
power source.
The following section contains the wiring
diagrams necessary to connect the
applicable power source to the control box.
If there is no diagram, refer to power source
manual.
2. Open the control box door and locate
the terminal strips on the back of the
control box in the lower left-hand
corner as shown in Figure A.7.
WARNING
3. On the right end of the lower terminal
strip, interchange the black and white
leads going to the terminals marked
(+) and (-). The black lead (#67)
must be connected to the same
polarity as the electrode welding lead;
i.e. if the electrode is positive,
connect the black lead to the (+)
terminal on the terminal strip. The
white lead (#21) is connected to the
opposite polarity terminal.
ELECTRIC SHOCK
can kill.
• Turn off input power to
the welding power
source
using
the
disconnect
switch
before working on this
equipment.
NA-5
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A-9
A-9
INSTALLATION
FIGURE A.8 – CONNECTION OF NA-5 (ALL) TO A DC-600.
P
TO NA-5 INPUT
CABLE PLUG
B
.A.
NOTE:
DIAGRAM SHOWS ELECTRODE CONNECTED POSITIVE.
A
TO CHANGE POLARITY, TURN POWER OFF, REVERSE THE
ELECTRODE AND WORK CABLES AT THE POWER SOURCE
AND POSITON THE SWITCH ON POWER SOURCE TO PROPER
POLARITY. REFER TO NA-5 OPERATING MANUAL FOR REQUIRED
NA-5 CONTROL BOX POLARITY CONNECTIONS.
P
CONNECT TO CABLES FROM NA-5
WIRE CONTACT ASSEMBLY
B
CONNECT
TO WORK
ALL CODES:
TURN OFF INPUT POWER
DC-600 CODES 8046-8200:
FOR SUB ARC:
ADJUST THE POWER SOURCE: DC-600:
1. SET MODE SWITCH TO CV SUB ARC.
2. WHITE LEAD ON CONTROL PC BOARD IS CONNECTED TO PIN "M".
1. CONNECT ELECTRODE CABLES TO TERMINAL OF DESIRED POLARITY.
2. SET TOGGLE SWITCH TO SAME POLARITY AS THE ELECTRODE CABLE
CONNECTION.
FOR ALL OPEN ARC PROCESSES EXCEPT MR-203 ELECTRODES:
1. SET MODE SWITCH TO CV INNERSHIELD.
3. SET TOGGLE SWITCH TO "REMOTE".
4. SET MODE SWITCH TO THE DESIRED POSITION FOR THE PROCESS TO BE USED.
2. WHITE LEAD ON CONTROL PC BOARD IS CONNECTED TO PIN "M".
FOR NR-203 ELECTRODES:
1. SET MODE SWITCH TO CV INNERSHIELD.
2. WHITE LEAD ON CONTROL PC BOARD IS CONNECTED TO PIN "I".
DC-600 CODES 8000-8045:
FOR SUB ARC:
1. SET MODE SWITCH TO CV SUB ARC.
2. WHITE LEAD ON CONTROL PC BOARD IS CONNECTED TO PIN "M" AND BLUE
LEAD IS CONNECTED TO "W".
DC-600 CODES ABOVE 8200:
FOR SUB ARC:
1. SET MODE SWITCH TO CV SUB ARC.
FOR ALL OPEN ARC PROCESSES:
2. SET MODE SWITCH TO CV INNERSHIELD.
FOR ALL OPEN ARC PROCESSES EXCEPT NR-302 AND NR-203 ELECTRODES:
1. SET MODE SWITCH TO CV INNERSHIELD.
2. WHITE LEAD ON CONTROL PC BOARD IS CONNECTED TO PIN "M" AND BLUE
LEAD IS CONNECTED TO "W".
FOR OPTIMUM PERFORMANCE WITH NA-5, DC-600'S WITH CODES 8288 AND
ABOVE ARE PREFERRED. FOR ADDITIONAL INSTALLATION INSTRUCTIONS,
SEE NA-5 OPERATING MANUAL.
FOR NR-203 AND NR-302 ELECTRODES:
1. SET MODE SWITCH TO CV INNERSHIELD.
2. WHITE LEAD ON CONTROL PC BOARD IS CONNECTED TO PIN "I"
AND BLUE LEAD IS CONNECTED TO "S".
N.A. ON EARLIER DC-600'S, #67 TERMINAL WAS ALSO ON THE TERMINAL STRIP.
N.B. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS.
N.C. EXTEND LEAD #21 USING #14 OR LARGER INSULATED WIRE PHYSICALLY SUITABLE FOR THE INSTALLATION. AN S-16586 - [ ] REMOTE VOLTAGE SENSING WORK
LEAD IS AVAILABLE FOR THIS PURPOSE. CONNECT IT DIRECTLY TO THE WORK PIECE KEEPING IT SEPARATE FROM THE WELDING WORK CABLE CONNECTION
TO THE WORK PIECE. FOR CONVENIENCE, THIS EXTENDED #21 LEAD SHOULD BE TAPED ALONG THE WELDING WORK CABLE.
N.D. TAPE UP BOLTED CONNECTION.
N.E. CONNECT THE NA-5 CONTROL CABLE GROUNDING LEAD TO THE FRAME TERMINAL MARKED
SOURCE MUST BE PROPERLY GROUNDED.
NEAR THE POWER SOURCE TERMINAL STRIP. THE POWER
N.F. IF USING AN OLDER K-215 CONTROL CABLE: CONNECT LEAD #75 TO #75 ON TERMINAL STRIP, CONNECT LEAD #76 TO #76 ON TERMINAL STRIP, CONNECT
LEAD #77 TO #77 ON TERMINAL STRIP.
N.G. THE JUMPERS ON THE NA-5 VOLTAGE BOARD MUST BE CONNECTED AS FOLLOWS: CONNECT RED JUMPER TO PIN "S". CONNECT WHITE JUMPER TO PIN "B".
N.H. CONNECT A JUMPER FROM "N" TO "P". THERE IS NO NPS TERMINAL STRIP ON DC-600 CODES ABOVE 8200.
N.J. FOR PROPER NA-5 OPERATION, THE ELECTRODE CABLES MUST BE SNUGGED UNDER THE CLAMP BAR ON THE LEFT SIDE OF THE NA-5 CONTROL BOX.
CLEVELAND, OHIO U.S.A.
NA-5
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A-10
A-10
INSTALLATION
FIGURE A.9 – CONNECTION OF NA-5 (ALL) TO A DC-650 PRO
P
P
CONTROL
CABLE
TO NA-5 INPUT
CABLE PLUG
P
6
TO NA-5 INPUT
CABLE PLUG
A
CONNECT TO CABLES FROM
NA-5 WIRE CONTACT ASSEMBLY
A
CONNECT TO CABLES FROM NA-5
WIRE CONTACT ASSEMBLY
R
CONNECT
TO WORK
NOTE: ABOVE DIAGRAMS SHOW ELECTRODE CONNECTED POSITIVE. TO CHANGE POLARITY, TURN POWER OFF, REVERSE THE ELECTRODE
AND WORK CABLES AT THE POWER SOURCE AND POSITION THE SWITCH ON THE POWER SOURCE TO PROPER POLARITY. REFER TO
NA-5 OPERATING MANUAL FOR REQUIRED NA-5 CONTROL BOX POLARITY CONNECTIONS.
DC650 PRO POWER SOURCE SETTINGS
1. TURN OFF INPUT POWER.
2. CONNECT ELECTRODE CABLES TO TERMINALS OF DESIRED POLARITY.
3. SET TOGGLE SWITCH TO SAME POLARITY AS ELECTRODE CABLE CONNECTION.
4. SET TOGGLE SWITCH TO REMOTE.
5. SET MODE SWITCH TO DESIRED POSITION FOR THE PROCESS TO BE USED.
6. CONNECT NEGATIVE OUTPUT CABLES TO MATCH MODE SWITCH SETTING.
N.A. WELDING CABLES MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION.
N.B. EXTEND LEAD #21A BY REMOVING LEAD #21A FROM THE TERMINAL STRIP AND CONNECTING IT TO A #14 OR LARGER INSULATED WIRE PHYSICALLY SUITABLE FOR
THE INSTALLATION.
N.C. EXTEND LEAD #21 USING A #14 OR LARGER INSULATED WIRE PHYSICALLY SUITABLE FOR INSTALLATION.
N.D. CONNECT EXTENDED LEAD DIRECTLY TO THE WORK PIECE KEEPING IT SEPARATE FROM THE WELDING WORK CABLE CONNECTION TO THE WORK PIECE. FOR
CONVENIENCE, THIS EXTENDED LEAD SHOULD BE TAPED ALONG THE WELDING WORK CABLE.
N.E. TAPE UP CONNECTION.
N.F. FOR PROPER NA-5 OPERATION, THE ELECTRODE CABLES MUST BE SNUGGED UNDER THE CLAMP BAR ON THE LEFT SIDE OF THE NA-5 CONTROL BOX.
N.G. CONNECT NEGATIVE OUTPUT CABLES TO STUDS TO MATCH DC650 PRO MODE SWITCH SETTING.
N.H. THE JUMPERS ON THE NA-5 VOLTAGE BOARD MUST BE CONNECTED AS FOLLOWS: CONNECT RED JUMPER TO PIN "S", CONNECT WHITE JUMPER TO PIN "B".
N.J. IF USING AN OLDER K-215 CONTROL CABLE, CONNECT LEAD #75 TO #75 ON TERMINAL STRIP, CONNECT LEAD #76 TO #76 ON THE TERMINAL STRIP, CONNECT
LEAD #77 TO #77 ON THE TERMINAL STRIP.
N.K. CONNECT THE NA-5 CONTROL CABLE GROUNDING LEAD TO THE FRAME TERMINAL MARKED
NEAR THE POWER SOURCE TERMINAL STRIP.
CLEVELAND, OHIO U.S.A.
NA-5
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A-11
A-11
INSTALLATION
FIGURE A.10 – CONNECTION OF NA-5 (ALL) TO A R3S-400, -600, OR -800
WITH NO LINE VOLTAGE COMPENSATOR (OBSOLETE).
B
B
B
POSITIVE
NOTE: ABOVE DIAGRAM SHOWS ELECTRODE CONNECTED POSITIVE. TO CHANGE POLARITY, TURN POWER OFF, REVERSE THE ELECTRODE AND WORK CABLES AT THE
POWER SOURCE AND POSITION THE SWITCH ON POWER SOURCE TO PROPER POLARITY. REFER TO NA-5 OPERATING MANUAL FOR REQUIRED NA-5 CONTROL
BOX POLARITY CONNECTIONS.
R3S POWER SOURCE SETTINGS
TURN POWER SOURCE OFF.
NA-5 SETTINGS
FOR SUB ARC:
1. RED LEAD ON VOLTAGE PC BOARD IS CONNECTED TO PIN "S".
2. WHITE LEAD ON VOLTAGE PC BOARD IS CONNECTED TO PIN "A".
FOR ALL PROCESSES:
1. CONNECT ELECTRODE CABLE TO TERMINAL OF DESIRED POLARITY.
2. SET THE POLARITY SWITCH TO THE SAME POLARITY AS THE ELECTRODE
CABLE CONNECTION.
3. SET TOGGLE SWITCH TO REMOTE.
4. INSTALL VOLTAGE TRIANGLE IN A POSITION AS CLOSE AS POSSIBLE TO
THE DESIRED ARC VOLTAGE.
FOR ALL OPEN ARC PROCESSES:
1. RED LEAD ON VOLTAGE PC BOARD IS CONNECTED TO PIN "F".
2. WHITE LEAD ON VOLTAGE PC BOARD IS CONNECTED TO PIN "A".
FOR ADDITIONAL INSTALLATION INSTRUCTIONS, SEE NA-5 OPERATING MANUAL.
N.A. ADD JUMPER FROM #75 TO #76, USING INSULATED COPPER WIRE.
N.B. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS.
N.C. EXTEND LEAD #21 USING #14 OR LARGER INSULATED WIRE PHYSICALLY SUITABLE FOR THE INSTALLATION. AN S -16586 [ ] REMOTE VOLTAGE-SENSING WORK LEAD
IS AVAILABLE FOR THIS PURPOSE. CONNECT IT DIRECTLY TO THE WORK PIECE, KEEPING IT SEPARATE FROM THE WELDING WORK CABLE CONNECTION TO THE
WORK PIECE. FOR CONVENIENCE, THIS EXTENDED #21 LEAD SHOULD BE TAPED ALONG THE WELDING WORK CABLE.
N.D. TAPE UP BOLTED CONNECTION.
N.E. CONNECT THE NA-5 CONTROL CABLE GROUNDING LEAD TO THE FRAME TERMINAL MARKED
MUST BE PROPERLY GROUNDED.
, NEAR THE POWER SOURCE TERMINAL STRIP. THE POWER SOURCE
N.F. IF USING AN OLDER K-215 CONTROL CABLE: CONNECT LEAD #75 TO #75 ON TERMINAL STRIP, CONNECT LEAD #76 TO #77 ON TERMINAL STRIP, CONNECT
LEAD #77 TO #76 ON TERMINAL STRIP, AND ADD JUMPER PER N.A.
N.G. ON EARLIER R3S MACHINES, #67 AND #1 TERMINALS WERE ALSO ON THE TERMINAL STRIP.
N.H. THE UPPER TERMINAL STRIP (#75, #76, #77) WAS NOT PRESENT ON EARLY R3S MACHINES. THOSE MACHINES ARE NOT COMPATIBLE WITH THE NA-5 SINCE THERE
CAN BE NO ADJUSTMENT OF VOLTAGE BY THE NA-5.
N.J. FOR PROPER NA-5 OPERATION, THE ELECTRODE CABLES MUST BE SNUGGED UNDER THE CLAMP BAR ON THE LEFT SIDE OF THE NA-5 CONTROL BOX.
CLEVELAND, OHIO U.S.A.
NA-5
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A-12
A-12
INSTALLATION
FIGURE A.11 – CONNECTION OF NA-5 (ALL) TO A SAM-400 MOTOR
GENERATOR OR ENGINE WELDER.
BOLT TO CABLES
FROM NA-5
P
WIRE CONTACT
ASSEMBLY
N.B.
N.B.
NOTE: TO CHANGE POLARITY, TURN POWER OFF, AND POSITION THE SWITCH ON POWER SOURCE TO PROPER POLARITY. REFER TO NA-5 OPERATING MANUAL FOR
REQUIRED NA-5 CONTROL BOX POLARITY CONNECTIONS.
SAM POWER SOURCE SETTINGS
TURN POWER SOURCE OFF.
NA-5 SETTINGS
FOR SUB ARC:
1. RED LEAD ON VOLTAGE PC BOARD IS CONNECTED TO PIN "S".
2. WHITE LEAD ON VOLTAGE PC BOARD IS CONNECTED TO PIN "A".
FOR SUB ARC:
1. SET THE ELECTRODE POLARITY SWITCH TO THE VARIABLE VOLTAGE
POSITION OF THE POLARITY DESIRED FOR THE PROCESS BEING USED.
2. SET THE TOGGLE SWITCH TO CONSTANT VOLTAGE.
3. SET THE CONSTANT VOLTAGE CONTROL TO NUMBER 7 AND THE
CURRENT CONTROL TO 500.
FOR ALL OPEN ARC PROCESSES:
1. RED LEAD ON VOLTAGE PC BOARD IS CONNECTED TO PIN "F".
2. WHITE LEAD ON VOLTAGE PC BOARD IS CONNECTED TO PIN "A".
FOR ALL OPEN ARC PROCESSES:
1. SET THE ELECTRODE POLARITY SWITCH TO THE CONSTANT VOLTAGE
POSITION OF THE POLARITY DESIRED FOR THE PROCESS BEING USED.
2. SET THE TOGGLE SWITCH TO CONSTANT VOLTAGE.
3. SET THE CONSTANT VOLTAGE CONTROL TO NUMBER 5.
FOR ADDITIONAL INSTALLATION INSTRUCTIONS, SEE NA-5 OPERATING MANUAL.
N.A. REMOVE SAM PORTABLE FIELD CONTROL AND CONNECT NA-5 CONTROL CABLE.
N.B. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS.
N.C. EXTEND LEAD #21 USING #14 OR LARGER INSULATED WIRE PHYSICALLY SUITABLE FOR THE INSTALLATION. AN S-16586-[ ] REMOTE VOLTAGE-SENSING WORK LEAD
IS AVAILABLE FOR THIS PURPOSE. CONNECT IT DIRECTLY TO THE WORK PIECE, KEEPING IT SEPARATE FROM THE WELDING WORK CABLE CONNECTION TO
WORK PIECE. FOR CONVENIENCE, THIS EXTENDED #21 LEAD SHOULD BE TAPED ALONG THE WELDING WORK CABLE.
N.D. TAPE UP BOLTED CONNECTION.
N.E. CONNECT THE NA-5 CONTROL CABLE GROUNDING LEAD TO THE FRAME TERMINAL MARKED
MUST BE PROPERLY GROUNDED.
, NEAR THE POWER SOURCE TERMINAL STRIP. THE POWER SOURCE
N.F. IF USING AN OLDER K-215 CONTROL CABLE: CONNECT LEAD #76 TO #75 ON TERMINAL STRIP, CONNECT LEADS #75 AND #77 TO #76 ON TERMINAL STRIP.
N.G. ON EARLIER SAM MACHINES, #1 TERMINAL WAS ALSO ON THE TERMINAL STRIP.
N.H. FOR PROPER NA-5 OPERATION, THE ELECTRODE CABLES MUST BE SNUGGED UNDER THE CLAMP BAR ON THE LEFT SIDE OF THE NA-5 CONTROL BOX.
CLEVELAND, OHIO U.S.A.
NA-5
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A-13
A-13
INSTALLATION
FIGURE A.12 – CONNECTION OF NA-5 (ALL) TO A SAM-650 ENGINE WELDER.
POWER SOURCE
TO NA-5 INPUT
CABLE PLUG
NOTE: TO CHANGE POLARITY, TURN POWER OFF, AND
POSITION THE SWITCH ON POWER SOURCE TO
PROPER POLARITY. REFER TO NA-5
OPERATING MANUAL FOR REQUIRED
NA-5 CONTROL BOX POLARITY CONNECTIONS.
BOLT TO CABLES
FROM NA-5
"TAP"
WIRE CONTACT
ASSEMBLY
P
P
P
. .
NA-5 SETTINGS
SAM POWER SOURCE SETTINGS
TURN POWER SOURCE OFF.
FOR SUB ARC:
1. RED LEAD ON VOLTAGE PC BOARD IS CONNECTED TO PIN "S".
2. WHITE LEAD ON VOLTAGE PC BOARD IS CONNECTED TO PIN "A".
FOR SUB ARC:
1. SET THE ELECTRODE POLARITY SWITCH TO THE POLARITY DESIRED FOR THE
PROCESS BEING USED.
2. SET THE TOGGLE SWITCH TO CONSTANT VOLTAGE.
3. SET THE CONSTANT VOLTAGE CONTROL TO NUMBER 7.
4. CONNECT THE TAP CABLE TO THE "300-575, MAX, SLOPE" STUD.
FOR ALL OPEN ARC PROCESSES:
1. RED LEAD ON VOLTAGE PC BOARD IS CONNECTED TO PIN "F".
2. WHITE LEAD ON VOLTAGE PC BOARD IS CONNECTED TO PIN "A".
FOR ALL OPEN ARC PROCESSES:
1. SET THE ELECTRODE POLARITY SWITCH TO THE POLARITY DESIRED FOR THE
PROCESS BEING USED.
2. SET THE TOGGLE SWITCH TO CONSTANT VOLTAGE.
3. SET THE CONSTANT VOLTAGE CONTROL TO NUMBER 5.
4. CONNECT THE TAP CABLE TO THE "450-MAX, MED SLOPE" STUD.
FOR ADDITIONAL INSTALLATION INSTRUCTIONS, SEE NA-5 OPERATING MANUAL.
N.A. REMOVE SAM PORTABLE FIELD CONTROL AND CONNECT NA-5 CONTROL CABLE.
N.B. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS.
N.C. EXTEND LEAD #21 USING #14 OR LARGER INSULATED WIRE PHYSICALLY SUITABLE FOR THE INSTALLATION. AN S-16586- [ ] REMOTE VOLTAGE-SENSING WORK
LEAD IS AVAILABLE FOR THIS PURPOSE. CONNECT IT DIRECTLY TO THE WORK PIECE, KEEPING IT SEPARATE FROM THE WELDING WORK CABLE CONNECTION
TO THE WORK PIECE. FOR CONVENIENCE, THIS EXTENDED #21 LEAD SHOULD BE TAPED ALONG THE WELDING WORK CABLE.
N.D. TAPE UP BOLTED CONNECTION.
N.E. CONNECT THE NA-5 CONTROL CABLE GROUNDING LEAD TO THE FRAME TERMINAL MARKED
SOURCE MUST BE PROPERLY GROUNDED.
NEAR THE POWER SOURCE TERMINAL STRIP. THE POWER
N.F. IF USING AN OLDER K-215 CONTROL CABLE: CONNECT LEAD #76 TO #75 ON TERMINAL STRIP, CONNECT LEADS #75 AND #77 TO #76 ON TERMINAL STRIP.
N.G. ON EARLIER SAM MACHINES, #1 TERMINAL WAS ALSO ON THE TERMINAL STRIP.
N.H. FOR PROPER NA-5 OPERATION, THE ELECTRODE CABLES MUST BE SNUGGED UNDER THE CLAMP BAR ON THE LEFT SIDE OF THE NA-5 CONTROL BOX.
CLEVELAND, OHIO U.S.A.
NA-5
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A-14
A-14
INSTALLATION
FIGURE A.13 – CONNECTION OF NA-5 TO DC-1000 OR DC-1500.
INPUT CABLE PLUG
POWER SOURCE
CONTROL
CABLE
P
BOLT TO CABLES FROM
NA-5 WIRE CONTACT
ASSEMBLY
CONNECT TO WORK
THE DIAGRAM SHOWS ELECTRODE CONNECTED POSITIVE. TO CHANGE POLARITY, TURN POWER OFF, REVERSE THE ELECTRODE AND WORK LEADS AT THE
POWER SOURCE, POSITION THE POSITIVE-NEGATIVE SWITCH ON THE POWER SOURCE TO CORRESPOND TO THE POLARITY OF THE ELECTRODE CABLE CONNECTION.
REFER TO NA-5 OPERATING MANUAL FOR REQUIRED NA-5 CONTROL BOX POLARITY CONNECTIONS.
N.A. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS.
N.B. EXTEND LEAD 21 USING #14 OR LARGER INSULATED WIRE PHYSICALLY SUITABLE FOR THE INSTALLATION. AN S-16586-[ ] REMOTE VOLTAGE-SENSING WORK LEAD
IS AVAILABLE FOR THIS PURPOSE. CONNECT IT DIRECTLY TO THE WORK PIECE KEEPING IT SEPARATE FROM THE WELDING WORK CABLE CONNECTION TO
WORK PIECE. FOR CONVENIENCE, THIS EXTENDED #21 LEAD SHOULD BE TAPED ALONG THE WELDING WORK CABLE.
N.C. TAPE UP BOLTED CONNECTION.
N.D. CONNECT THE NA-5 CONTROL CABLE GROUND LEAD TO THE FRAME TERMINAL MARKED
MUST BE PROPERLY GROUNDED.
NEAR THE POWER SOURCE TERMINAL STRIP. THE POWER SOURCE
N.E. IF USING AN OLDER AUTOMATIC CONTROL CABLE WITH LEADS 75, 76, 77; CONNECT LEAD 75 TO #75 ON TERMINAL STRIP, CONNECT LEAD #76 TO #74 ON TERMINAL
STRIP, CONNECT LEAD #77 TO #73 ON TERMINAL STRIP.
N.F. CONNECT THE JUMPERS ON THE NA-5 VOLTAGE BOARD AS FOLLOWS: CONNECT RED JUMPER TO PIN "S". CONNECT WHITE JUMPER TO PIN "B".
N.G. SET THE DC-1000 OR DC-1500 CONTROLS AS FOLLOWS: SET THE CONTROL SWITCH TO "OUTPUT CONTROL REMOTE".
FOR SUBMERGED ARC PROCESSES, SET THE MODE SWITCH TO "C.V. SUBMERGED ARC". FOR OPEN ARC PROCESSES, SET THE MODE
SWITCH TO "C.V. INNERSHIELD"
N.H. FOR PROPER OPERATION, THE ELECTRODE CABLE MUST BE SNUGGED UNDER THE CLAMP BAR ON THE LEFT SIDE OF THE NA-5 CONTROL BOX.
N.J. TERMINALS #73 AND #74 WERE NOT PRESENT ON DC-1500 MACHINES BELOW CODE 8294. THESE EARLIER CODE MACHINES ARE NOT SUITABLE FOR
USE WITH THE NA-5.
N.K. ALTERNATIVE 500 AMP POSITIVE TERMINAL CONNECTION PROVIDED ON DC-1000 MODELS ABOVE CODE 9500 ONLY.
N.L. ALTERNATE SUBMERGED ARC MODE AVAILABLE FOR IMPROVED ARC STABILITY IN HIGH CURRENT, LARGE PUDDLE, SLOW TRAVEL PROCEDURES BY MAKING
SPECIAL CONNECTIONS ON BOTH DC-1500 AND NA-5.
ON DC-1500 CONTROL BOARD (G-1530-2 AND SUPERSEDING) REMOVE RED AND BLUE JUMPERS FROM "FR" PINS AND RECONNECT TO CORRESPONDING "SR" PINS.
ON NA-5 VOLTAGE BOARD (G-1556-1 AND SUPERSEDING) WHITE JUMPER MUST BE CONNECTED TO PIN "D".
NA-5 PIN "D" CONNECTION MAY ALSO BE USED FOR SOME PROCEDURES ON DC-1500 WITHOUT CONTROL BOARD JUMPERS, DC-1500 WITH CONTROL BOARD
JUMPERS ON "FR" PINS OR DC-1000.
CLEVELAND, OHIO U.S.A.
NA-5
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A-15
A-15
INSTALLATION
FIGURE A.14 – CONNECTION OF NA-5 TO DC-400 OR CV-400.
POWER SOURCE
TO NA-5 INPUT CABLE PLUG
C
B
N.E.
A
CONTROL
CABLE
32
31
2
N.H.
N.D. AND N.H.
4
GND
21
POSITIVE
NEGATIVE
N.D.
N.B. AND N.C.
BOLT TO CABLES FROM NA-5
WIRE CONTACT ASSEMBLY
N.A.
CONNECT TO WORK
THE DIAGRAM SHOWS ELECTRODE CONNECTED POSITIVE. TO CHANGE POLARITY, TURN POWER OFF, REVERSE THE ELECTRODE AND WORK LEADS AT THE
POWER SOURCE AND POSITION THE SWITCH ON POWER SOURCE (IF EQUIPPED), TO PROPER POLARITY. REFER TO NA-5 OPERATING MANUAL FOR REQUIRED
NA-5 CONTROL BOX POLARITY CONNECTIONS. ALSO REFER TO NOTE N.H.
FOR ADDITIONAL INSTALLATION INSTRUCTIONS, SEE NA-5 OPERATING MANUAL.
N.A. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS.
N.B. EXTEND LEAD #21 USING #14 AWG OR LARGER INSULATED WIRE PHYSICALLY SUITABLE FOR THE INSTALLATION. AN S-16586- [LENGTH] REMOTE
VOLTAGE-SENSING WORK LEAD IS AVAILABLE FOR THIS PURPOSE. CONNECT IT DIRECTLY TO THE WORK PIECE KEEPING IT ELECTRICALLY SEPARATE
FROM THE WELDING WORK LEAD CIRCUIT AND CONNECTION. FOR CONVENIENCE, THIS EXTENDED #21 LEAD SHOULD BE TAPED TO THE WELDING
WORK LEAD. (IF THE LENGTH OF WORK LEAD CIRCUIT IS SHORT, AND CONNECTIONS CAN BE EXPECTED TO BE RELIABLE, THEN CONTROL CABLE
LEAD #21 DOES NOT NEED TO BE EXTENDED AND CAN BE DIRECTLY CONNECTED TO TERMINAL #21 ON THE TERMINAL STRIP. NOTE THAT THIS IS
NOT THE PREFERRED CONNECTION BECAUSE IT ADDS ERROR TO THE NA-5 VOLTMETER READING.)
N.C. TAPE UP BOLTED CONNECTION.
N.D. CONNECT THE CONTROL CABLE GROUND LEAD TO THE FRAME TERMINAL MARKED
NEAR THE POWER SOURCE TERMINAL STRIP. THE POWER
SOURCE GROUNDING TERMINAL (MARKED AND LOCATED NEAR THE POWER SOURCE INPUT POWER CONNECTIONS) MUST BE PROPERLY CONNECTED
TO ELECTRICAL GROUND PER THE POWER SOURCE OPERATING MANUAL. .
N.E. THE JUMPERS ON THE NA-5 VOLTAGE BOARD MUST BE CONNECTED AS FOLLOWS: CONNECT RED JUMPER TO PIN "S". CONNECT WHITE JUMPER TO PIN "B".
WHEN USING NA-5 CONTROLS ABOVE CODE 8300 WITHOUT THE OPTIONAL DC-400 DIODE KIT OR CV-400, CVI-500 DIODE OPTIONS:
THE NA-5 INCH DOWN BUTTON WILL NOT OPERATE UNLESS A JUMPER IS CONNECTED BETWEEN THE TWO TAB TERMINALS, LABELED "AUTO",
LOCATED ABOVE THE TRANSFORMER ON THE NA-5 VOLTAGE PC BOARD. THIS JUMPER, HOWEVER, WILL DISABLE THE COLD STARTING/AUTO STOP
FEATURE OF THE NA-5, PERMITTING ONLY HOT STARTING TECHNIQUES TO BE USED.
N.G. FOR PROPER NA-5 OPERATION, THE ELECTRODE CABLES MUST BE SNUGGED UNDER THE CLAMP BAR ON THE LEFT SIDE OF THE NA-5 CONTROL BOX.
N.H.* IF LEAD #21 IS TO BE CONNECTED TO THE TERMINAL STRIP, CONNECT TO THE #21 TERMINAL THAT MATCHES WORK POLARITY. THIS CONNECTION MUST
BE CHANGED WHENEVERTHE ELECTRODE POLARITY IS CHANGED.
* DOES NOT APPLY TO DC-400 BELOW CODE 9200 WITH POLARITY SWITCH.
CLEVELAND, OHIO U.S.A.
NA-5
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A-16
A-16
NOTES
NA-5
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Section B
Section B
TABLE OF CONTENTS
- OPERATING INSTRUCTIONS SECTION -
Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section B
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operator’s Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Controls and Their Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exposed Controls (With Lockable Cover Down) . . . . . . . . . . . . .
Controls Under the Lockable Security Cover . . . . . . . . . . . . . . .
Setup Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting and Stopping Sequences . . . . . . . . . . . . . . . . . . . . . . . . . .
Means of Arc Striking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting Travel Starting and Stopping . . . . . . . . . . . . . . . . . . . . . . . .
Starting Sequences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stopping Sequences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reconfiguring the Travel Sequences . . . . . . . . . . . . . . . . . . . . .
Voltage Control Response . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Automatic Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cold Start Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Security of Weld Procedure Settings . . . . . . . . . . . . . . . . . . . . . . . .
B-2
B-2
B-3
B-3
B-3
B-4
B-5
B-5
B-6
B-6
B-6
B-6
B-9
B-10
B-11
B-12
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B-2
B-2
OPERATING INSTRUCTIONS
1. Be sure there is enough electrode in
the machine to complete the weld.
SAFETY PRECAUTIONS
2. If submerged arc welding, fill flux
hopper with new or freshly screened
flux. All reused flux must be screened
100% through an 8 mesh screen
[0.065 to 0.075 in. (1.6 to 1.9 mm)
opening]. Turn the switch on the
hopper to “On.”
WARNING
ELECTRIC SHOCK
can kill.
• Do not touch electrical-
ly live parts or elec-
trode with skin or wet
clothing.
3. Start the power source.
4. Turn the “Power Control” switch on the
wire feeder control to “On.”
• Insulate yourself from
work or ground.
• Always wear dry insu-
lating gloves.
5. Position the welding head at the start
of the weld. Be sure the travel carriage
or other travel mechanism is set to
move in the proper direction.
FUMES AND GASES
can be dangerous.
6. Set the travel switch to “Automatic
Travel.” When set to “Hand Travel”,
the travel system operates without
welding.
•
•
Keep your head out of
fumes.
Use ventilation or
exhaust to remove
fumes from breathing
zone.
7. For best starts, cut the electrode to a
sharp point.
8. Press the “Inch Down” button to feed
the electrode out of the nozzle.
WELDING SPARKS
can cause fire or
explosion.
a. For most applications, when hot
starting, leave the electrode
1/4 in. (6.4 mm) or more away
from the work.
• Keep flammable mater-
ial away.
b. When cold starting some
submerged arc welding, inch the
electrode down until it touches the
work and the flux valve opens.
• Do not weld on con-
tainers that have held
combustibles.
ARC RAYS
can burn.
9. Press the “Start” button.
10. While welding, turn the cross seam
adjuster handwheel as needed to keep
the arc in the joint.
•
Wear eye, ear, and
body protection.
11. At the end of the weld, press the
“Stop” button.
Observe additional Safety Guidelines
detailed in the beginning of this manual.
12. If needed, press the “Inch Up” button
to get the electrode up and out of the
way. Remove the work and reload the
fixture.
OPERATOR’S
INSTRUCTIONS
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.
Once the system is properly set up, the
operator can make production welds
without readjusting the controls using the
following simple instructions:
NA-5
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B-3
B-3
OPERATING INSTRUCTIONS
4. INCH UP AND INCH DOWN. Press to
CONTROLS AND
THEIR FUNCTIONS
inch electrode up or down.
5. MODE SELECTOR SWITCH AND
LIGHTS. Used to preset the voltage
and wire feed speed for the various
modes of operation (Strike, Start,
Weld, and Crater).
The operator controls for the NA-5 are
illustrated in Figure B.1. Refer to the figure
and the following explanations of the
controls.
EXPOSED CONTROLS (WITH
LOCKABLE COVER DOWN)
6. SET-ACTUAL BUTTON. When
pressed, will display the actual wire
speed and voltage in the wire speed
and volts meters. When the button is
not pressed, the set wire speed and
voltage is displayed.
1. CIRCUIT BREAKER. Protects the
circuit from severe wire feed motor
overloads and short circuits. Press to
reset.
7. START. Begins welding cycle.
2. CONTROL POWER. Turns input
control power “On” and “Off.” Also
used as an emergency “Off” in case
of malfunction.
8. STOP. Initiates the stopping cycle at
the end of the weld.
9. TRAVEL. Turn to “Off” for no travel,
“Hand Travel” for travel without
welding, and “Automatic Welding” for
welding operations.
3. ELECTRODE
“HOT”
LIGHT.
Comes on when the “Start button” is
pressed and the electrode circuit
becomes electrically hot.
10. VOLTS METER. Displays the set or
actual voltage for each mode (Strike,
Start, Weld, Crater).
FIGURE B.1 – NA-5 CONTROLS.
11. WIRE SPEED METER. Displays the
set or actual wire speed for each
mode (Strike, Start, Weld, Crater).
CONTROLS UNDER THE
LOCKABLE SECURITY COVER
12. ARC STRIKING CONTROLS. Sets
the wire speed until the welding
current begins to flow and controls
the power source voltage during arc
striking.
11
10
15
17
13. BURNBACK AND ELECTRODE
BACKUP TIME. Controls the length
of burnback delay time after the stop
circuit is energized.
16
12
14. WELD CONTROLS. Controls the
voltage and wire speed during the
welding mode.
13
7
15. CRATER CONTROLS (OPTIONAL).
Sets the ending current and voltage
for an adjustable period of time.
3
16. START CONTROLS (OPTIONAL).
Sets the starting current and voltage
for an adjustable period of time.
1
6
4
14
9
8
17. WELD TIME (OPTIONAL). Controls
2
5
the time of the weld mode.
NA-5
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B-4
B-4
OPERATING INSTRUCTIONS
5. Set the head position relative to the
work as required for the fixture,
application, and procedures. See
IM305 Sec. T3.2.3.
SETUP INSTRUCTIONS
Use the following steps to set up the NA-5
welding system prior to welding:
1. If using a multi-process power source
(SAM, DC-400, DC-600, DC-1000,
OR DC-1500 type), make con-
nections and settings per the power
source connection diagram (Figures
A.8 to A.14) for the process being
used.
6. Rotate the 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.
7. Refer to the instructions for the wire
contact assembly being used. See
IM305 Sec. T2.2.6, T2.2.7, T2.5.3, or
T2.5.4.
AUTO TAB
When using the NA-5 with the DC-
400 or CV-400 power source, the
auto tab jumper on the NA-5 voltage
PC 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 NA-5 is disabled and only the
hot starting technique can be used. If
the cold start technique is to be used,
the optional Diode must be installed
on the DC-400 or CV-400.
8. The mount for standard 50 and 60 lb
(22.7 and 27.2 kg) electrode coils
includes
a
two-position brake
assembly. Generally the brake should
be at the inner position (nearest to
the wire reel shaft) for wire feed
speeds below 400 in./min (10 m/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.
2. Set the power source and NA-5
circuit polarity per information on
Electrode Polarity in Section A,
Installation.
3. Depending on the procedures and
applications, decide:
9. Load the wire reel per IM305 Sec.
T3.2.2 or install the Speed-Feed
drum or reel per Sec. T2.5.7-A or -B.
a. The means of arc striking and
whether to start the travel with
the “Start” button or the arc.
10. Straighten the first 6 in. (152.4 mm)
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 and
feed the wire through the nut, down
through the straightener, and into the
drive rolls. Screw the nut back onto
the straightener. Feed the 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
using the K231 contact nozzle
because the nozzle relies on the
small curvature of the electode for
proper electrical contact within the
contact tip.
b. Whether the initial bead size or
penetration requires use of the
optional “Start Controls.”
See the Starting and Stopping
Sequences section.
4. Depending upon the procedures and
applications:
a. Select the arc and travel stopping
sequence. See the Starting and
Stopping Sequences section.
b. Decide if the control of the ending
bead size or crater fill requires
the use of optional “Crater
Controls”. See the Starting and
Stopping Sequences section.
NA-5
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B-5
B-5
OPERATING INSTRUCTIONS
11. Set the travel speed as specified by
STARTING AND STOPPING
SEQUENCES
the procedures. With the wire feeder
travel switch set to “Hand Travel”, the
travel runs without welding, permitting
accurate measurement of travel
speed. When using a Lincoln travel
carriage, adjust the speed with the
rheostat and the direction with the
toggle switch on the carriage control
panel.
MEANS OF ARC STRIKING
The NA-5 Codes utilize “hot start” arc
striking which operates as follows:
1. With the electrode not touching the
work, press the “Start” button.
12. Connect the work lead to the work or
a suitable piece of scrap. Clip the
end of the electrode to a sharp point.
2. The electrically “hot” electrode
inches down as set by the “Inch Wire
Speed” control.
13. Preset the “Start” (if used), “Weld”,
and “Crater” (if used) controls to the
wire speed and voltage specified in
the procedure.
3. When the electrode makes contact
with the work, the arc strikes and the
circuit automatically switches from
“Strike” settings to “Weld” (or “Start”,
if used) settings.
14. Make several test welds, readjusting
the controls in the following order:
NA-5 models above Code 8300 offer both
“hot start” arc striking, as described
above, or “Cold Start” arc striking which
operates as follows:
a. Set the “Arc Striking”, “Inch Wire
Speed”, and “Volts” controls for
optimum arc striking.
The
optimum strike control settings for
most processes will be typically 4
to 5 volts higher than the weld
mode voltage setting and 40% to
50% of the weld mode wire feed
speed setting (possibly lower if
cold starting is used).
1. Press the “Inch Down” button until the
tip of the electrode 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 possible poor starting.
b. If striking is still not satisfactory,
refer to the section on Setting
Travel Starting and Stopping or
IM305 Sec. T3.5.2 for information
on wire feed motor acceleration.
2. The arc establishes when the “Start”
button is pressed, and the circuit
automatically switches to “Weld” (or
“Start”, is 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.
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.
Use either the standard “on-the-fly” travel
starting or rewire the controls for “standstill”
travel starting as described in the Setting
Travel Starting and Stopping section.
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.
Optional “Start Controls”
Recommended for applications where
penetration, bead size, and other
characteristics must be carefully controlled
at the start.
e. Set the “Burnback
Time” to
provide the stopping char-
acteristics needed.
NA-5
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B-6
B-6
OPERATING INSTRUCTIONS
The starting sequence is as described above
except that 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 automatically
switches to the “Welding Controls” wire
speed and voltage. Actual settings depend
on application requirements.
3. Any application for improved arc
striking.
“Standstill” Travel Starting
All models can be reconnected so the travel
remains at a standstill until the arc starts.
“Standstill” travel starting is used when the
electrode must be started at a precise
location.
Available options for applications with
particularly difficult starting.
For consistent arc striking with “Standstill”
travel starting, always clip the end of the
electrode to a sharp point before starting.
1. K238 High Frequency Generator -
See IM305 Sec. T2.5.8.
STOPPING SEQUENCES
SETTING TRAVEL
STARTING AND STOPPING
As shipped, the travel stops when the “Stop”
button is pressed, producing a small crater
area.
Standard machines can be connected for a
variety of starting and stopping sequences.
When the end of the weld overlaps the
beginning, changing the stopping sequence
to stop the travel later spreads the crater
over a longer area.
STARTING SEQUENCES
“On-the-Fly” Travel Starting
RECONFIGURING THE TRAVEL
SEQUENCES
When shipped, all models are connected for
“On-the-Fly” travel starting. The starting
sequence is as follows:
WARNING
1. With the electrode NOT touching the
work, press the “Start” button. This
starts both the wire feed and travel
motors.
ELECTRIC SHOCK
can kill.
• Turn off input power to
the welding power source
using the disconnect
switch before working on
this equipment.
2. When the electrically “hot” electrode
touches the work to start the arc,
there is relative motion between the
end of the electrode and the work.
This “scratching” type contact helps
assure consistent arc striking.
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 in the wiring diagram
for the NA-5 being used. Table B.1 also
shows information on reconfiguring the
travel sequences.
This sequence is recommended for most
welding applications including:
1. Roundabouts and any other weld
which ends at its starting point. A
K337 Weld Timer Module to control
the welding cycle duration can be
installed.
2. Welds started on a run-out tab.
NA-5
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B-7
B-7
OPERATING INSTRUCTIONS
TABLE B.1 – TRAVEL SEQUENCE LEAD AND SWITCH POSITIONS.
Travel Starts
Travel Stops
Older Models
Newer Models*
With “Start”
Button
With “Stop”
Button
Lead #691 to Pin 6
Lead #692 to Pin 5
1
1
1
2
3
4
4
4
1
1
1
2
3
4
4
4
Switch #1
Switch #2
With Arc Striking With Arc Stopping
With Arc Striking With Stop Button
Lead #691 to Pin 6
Lead #692 to Pin 7
2
3
2
3
Switch #1
Switch #2
Lead #691 to Pin 5
Lead #692 to Pin 7
2
3
2
3
Switch #1
Switch #2
With “Start”
Button
With End Crater
Fill Time (With
optional procedure
module installed in
Lead #691 to Pin 6
Lead #692 to Pin 9
1
2
3
4
1
2
3
4
Switch #1
Switch #2
1
crater receptacle )
With “Start”
Button
After Burnback
Time (with
Lead #691 to Pin 6
Lead #692 to Pin 8
1
2
3
4
1
2
3
4
optional procedure
module installed
in crater
Switch #1
Switch #2
1
receptacle )
1
*NOTE:
If 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 pro
cedure 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 reinstalled on the procedure board.
Indicates switch in up position
Indicates switch in down position
Indicates switch position does not matter
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B-8
B-8
OPERATING INSTRUCTIONS
Wire Feed Motor Acceleration
The standard stopping sequence when the
optional “Crater Controls” are not used is as
follows:
WARNING
1. Press the “Stop” button.
ELECTRIC SHOCK
can kill.
2. The wire feed motor stops and the
“Burnback Time Delay” starts.
• Turn off input power to
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.
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.
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.
FIGURE B.2 – ACCELERATION
JUMPER PLUGS.
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.
JUMPER
PLUG
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.
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.
*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 burnback
time.
NA-5
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B-9
B-9
OPERATING INSTRUCTIONS
TABLE B.2 – STOPPING SEQUENCE SETTINGS.
When “Stop” Button
is Pressed
Older Models
Newer Models*
1
2
3
4
Feed motor stops and
electrode burns back with
contactor delay (standard)
Lead #693 to Pin 3
Lead #690 to Pin 4
Switch #2
1
2
3
4
Feed motor inches up and
electrode burns back with
contactor delay
Lead #693 to Pin 1
Lead #690 to Pin 4
Switch #2
Feed motor inches up and
contactor opens
Lead #693 to Pin 1
Lead #690 to Pin 2
1
2
3
4
(no burnback)
Switch #2
*NOTE:
Indicates switch in up position
Indicates switch in down position
Indicates switch position does not matter
FIGURE B.3 – VOLTAGE CONTROL
RESPONSE JUMPER PLUG
LOCATIONS.
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.
RED
JUMPER
PLUG
To change the voltage control response:
1. Turn off all input power to the NA-5
control.
WHITE
JUMPER
PLUG
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.
B
D
A
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B-10
B-10
OPERATING INSTRUCTIONS
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:
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”.
1. Move the NA-5 voltage set point 2
volts lower than the desired
procedure and make a test weld.
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.
a. If the NA-5 still shuts down, go to
step 2 below.
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.
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.
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.
2. Move the NA-5 voltage setting set
point 2 volts higher than the desired
procedure and make a test weld.
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.
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.
Although out of range shutdown can occur
with all power sources when working with
very low or very high arc voltages, it is most
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B-11
B-11
OPERATING INSTRUCTIONS
In some cases, it is also possible to hold the
A. Auto Stop
“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.
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
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.
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:
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.
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.
*Units below Code 8300 can be provided with the cold
start circuitry by replacing the old 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 (previously
connected to a jumper plug) must be connected to the
lower receptacle of the new voltage board.
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.
NOTE: HI-FREQ starting cannot be used
with converted units below Code 8300.
NA-5
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B-12
B-12
OPERATING INSTRUCTIONS
beneath each square so the head
is on the back side of the panel
(inside the control box).
SECURITY OF WELD
PROCEDURE SETTINGS
f. Remount the PC board assembly
and its panel insulation.
Reconnect the PC board and
close and secure the control box.
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.
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.
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:
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.
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.
j. With finger pressure on the knob
against the felt seal, carefully
retighten the set screw of each
knob.
d. Open
the
control
box.
Disconnect, then remove, the
procedure control PC board
assembly and its panel insulation.
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.
e. Install a 1/2 in. long, pan or round
head, #4 sheet metal screw into
the 0.10 in. diameter hole located
NA-5
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Section C
Section C
TABLE OF CONTENTS
- ACCESSORIES SECTION -
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section C
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Listing of Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
K29 Vertical Lift Adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
K58 Magnetic Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
K96 Horizontal Adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C-2
C-3
C-3
C-3
C-3
C-3
®
K129 Submerged Arc Small Wire Twinarc . . . . . . . . . . . . . . . . .
TM
K148 Contact Nozzle and 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C-3
C-3
C-3
C-3
C-4
C-4
C-4
C-4
C-4
C-4
C-4
C-4
C-5
C-5
C-5
C-5
C-5
C-5
C-5
®
K239 Twinarc Kit for Innershield Electrodes . . . . . . . . . . . . . . .
TM
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
S-22022 or S-22182 Current Relay . . . . . . . . . . . . . . . . . . . . . .
Speed-Feed Drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Speed-Feed Reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NA-5
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C-2
C-2
ACCESSORIES
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.
Product Number
Product Name
K29
VERTICAL LIFT ADJUSTER
MAGNETIC SEPARATOR
HORIZONTAL ADJUSTER
SUBMERGED ARC SMALL WIRE TWINARC
CONTACT NOZZLE
K58
K96
K129
K148
K149
K218
K219
K223
K225
K238
K239
K278
K281
K285
K310
K325
K334
K336
K337
K349
S22022 or S22182
LINC-FILL LONG STICKOUT EXTENSION
HORIZONTAL FILLET/LAP ATTACHMENT
FLUX HOPPER KIT
SOLENOID KIT
SUBMERGED ARC TWINARC KIT
HIGH FREQUENCY UNIT
TWINARC KIT FOR INNERSHIELD ELECTRODES
SPREADARC
SOLID WIRE STRAIGHTENER FOR TINY TWINARC
CONCENTRIC FLUX CONE
FLUX SCREEN
TC-3 TRAVEL CARRIAGE
START AND CRATER CONTROLS
REMOTE INTERFACE MODULE
WELD TIMER MODULE
MULTI-PROCEDURE KIT
CURRENT RELAY
SPEED-FEED DRUMS
SPEED-FEED REELS
NA-5
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C-3
C-3
ACCESSORIES
K148 CONTACT NOZZLE AND
K149 LINC-FILLTM LONG
STICKOUT EXTENSION
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.
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.
K58 MAGNETIC SEPARATOR
K218 HORIZONTAL
FILLET/LAP ATTACHMENT
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.
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.
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.
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.
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.
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.
NA-5
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C-4
C-4
ACCESSORIES
arc, 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.
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.
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.
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.
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
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.
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.
K278 SPREADARCTM
K325 TC-3 TRAVEL CARRIAGE
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, open
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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C-5
C-5
S22022 OR S22182 CURRENT
ACCESSORIES
K334 START AND CRATER
CONTROLS
RELAY MODULES
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.
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.
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.
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
K337 WELD TIMER MODULE
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.
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.
NA-5
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C-6
C-6
NOTES
NA-5
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Section D
Section D
TABLE OF CONTENTS
- MAINTENANCE SECTION -
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section D
Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ground Fault Fuse Protection . . . . . . . . . . . . . . . . . . . . . . . . . .
Welding Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wire Drive Gear Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wire Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing Wire Feed Gear Ratios . . . . . . . . . . . . . . . . . . . . . . . .
Wire Drive Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wire Straighteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optional Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contact Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wire Reel Mounting for 50 or 60 lb (22.7 or 27.2 kg) Coils . . . . .
Travel Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vertical Lift Adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Horizontal Adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High Frequency Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spreadarc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D-2
D-2
D-2
D-3
D-3
D-3
D-4
D-4
D-5
D-5
D-6
D-6
D-6
D-6
D-6
D-6
D-6
D-6
NA-5
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D-2
D-2
MAINTENANCE
If a complete or partial short occurs in the
field circuit, or if there is a defect on the PC
board, a 1/2 amp slow-blow type fuse will
blow. This field circuit fuse is mounted on the
power PC board, shown in Figure D.2, inside
the control box. Before replacing the fuse,
check the motor field for a short condition.
Normal resistance is approximately 700
ohms.
CONTROL BOX
GENERAL
Inspect the control box every 3 months. If
needed, blow dirt out using low pressure air.
No further maintenance should be required.
CIRCUIT PROTECTION
With NA-5 controls above Code 8300, the
field circuit fuse may blow 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 Automatic
Shutdown in Section B, Operating
Instructions.)
The circuit breaker mounted on the left side
of the control box protects the control circuit
from short circuit conditions and from severe
wire feed overloads. If it is open, determine
and correct the cause for the overload. To
reset the circuit breaker, push in the red
button shown in Figure D.1.
FIGURE D.1 – CIRCUIT BREAKER
RESET BUTTON.
FIGURE D.2 – POWER PC BOARD
FUSE LOCATIONS.
NA-5 POWER
FIELD
1/2 AMP
SLOW-BLOW
FUSE
POWER
1/2 AMP
SLOW-BLOW
FUSE
The power supply for the electronic circuitry
is protected by a 1/2 amp slow-blow type fuse
shown in Figure D.2. It is located on the
power PC board inside the control box.
CIRCUIT
BREAKER
RESET BUTTON
NA-5
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D-3
D-3
MAINTENANCE
The 1/8 amp fast-blow fuse, shown in Figure
D.3, on a voltage PC board built since 1983,
protects the NA-5 circuitry from damage
which may result from a ground or case
faulted control lead. If the fuse blows, the
NA-5 voltage sensing lead circuit will be
opened (Refer to Automatic Shutdown in
Section B, Operating Procedures) and the
Troubleshooting Guide.
NA-5 circuit common (#510). Such a
condition typically exists when the NA-5
polarity connections are set for electrode
negative.
WELDING HEAD
WIRE DRIVE GEAR BOX
Once a year, recoat all gear teeth with a
non-fluid molydisulfide type grease such as
Non-Fluid Oil Corporation’s A-29 Special/MS
Lubricant. For access to the gears in the first
chamber, remove the adapter plate and
motor assembly as shown in Figure D.4.
FIGURE D.3 – VOLTAGE BOARD FUSE
LOCATION.
1/8 AMP
FAST-BLOW
FUSE
FIGURE D.4 – WIRE DRIVE MOTOR
GEAR BOX.
DRIVE MOTOR
BRUSH ACCESS
HEX HEAD
SCREW
ADAPTER
PLATE AND
MOTOR
ASSEMBLY
FIRST
CHAMBER
PIPE
PLUG
WIRE DRIVE
GEARBOX
SECOND
CHAMBER
GROUND FAULT FUSE
PROTECTION
SLOT HEAD
SCREW
To lubricate the gears in the second
chamber, remove one of the pipe plugs and
feed grease until it comes in contact with the
bevel gear teeth. Then, rotate the output
shaft by hand until all teeth are lubricated.
A 1/8 amp fast-blow fuse, shown in Figure
D.3, is located on the voltage PC board.
This fuse will protect the NA-5 circuitry from
damage resulting from a ground or case
faulted control lead when the arc voltage
potential exists between ground and the
NA-5
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D-4
D-4
MAINTENANCE
FIGURE D.5 – CHANGING THE WIRE
WIRE DRIVE MOTOR
FEED GEAR RATIO
Periodically inspect the wire drive motor
brushes, Figure D.4. Replace the brushes
as needed.
HEX NUT (11)
PLAIN WASHER (9)
CHANGING WIRE FEED GEAR
RATIOS
INPUT
HELICAL
GEAR (12)
SLOT HEAD
SCREWS
(MOUNTING
SCREWS)
WIRE
FEED
Four wire size conversion kits are available
to modify the wire feeder for different size or
type electrodes. The kits include drive rolls
and guide tubes for the wire specified, as
shown in Table D.1.
GEARBOX
TABLE D.1 - CONVERSION KITS
WOODRUFF
KEY (8)
Wire Type in. (mm)
Conversion Kit
3/32-7/32 (2.38-5.56)
Solid or Cored
T13724-A
1/16-3/32 (1.59-2.38)
Solid or Cored
T13724-B
T13724-C
T13724-D
0.035-0.052 (0.89-1.32)
Solid
1. Remove the four screws that mount
the adapter plate and motor assembly
to the gear box. Remove the adapter
plate and motor assembly from the
gear box.
0.045-0.052 (1.14-1.32)
Cored
Refer to Table D.2. 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 Figures D.4,
D.5 and D.6).
2. Take the two long screws removed in
step 1 and screw one into each of the
tapped holes located on the face of
fiber input helical gear (12). Insert the
screws through the full thickness of
the gear, and using a screwdriver
wedged between the screws to
prevent rotation, remove hex nut (11)
that holds the gear to the shaft.
Remove plain washer (9).
NOTE: Any item numbers in parentheses
on Figure D.5 refer to item numbers in the
task description breakdown.
TABLE D.2 – WIRE FEED GEAR RATIOS.
Feed Speed
Max Wire Size
in. (mm)
Gear
Range
Ratio
in/min (m/min)
Cored Wire
Solid Wire
0.052 (1.3)
1/16 (1.6)
1/8 (3.2)
21:1
57:1
100-2070 (2.54-52.58)
40-778 (1.02-19.76)
22-456 (0.56-11.58)
15-300 (0.38-7.62)
0.052 (1.3)
3/32 (3.0)
5/32 (4.0)
5/32 (4.0)
95:1
142:1
7/32 (5.6)
NA-5
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D-5
D-5
MAINTENANCE
3. Pull the gear from the shaft using the
screws as a pulling device.
FIGURE D.6 – DRIVE MOTOR PINION
GEAR REMOVAL.
4. Be certain woodruff key (8) is properly
located on the shaft. Screw the
adapter plate and motor assembly
mounting screws into the new fiber
input helical gear from the stenciled
side and place the gear on the shaft.
Replace plain washer (9), tighten the
hex nut (1), and remove the adapter
plate and motor assembly mounting
screws from the gear.
WIRE
DRIVE
MOTOR
SHAFT
5. After noting the relation of the adapter
plate with the motor leads, remove
the adapter plate from the wire drive
motor. See Figure D.6. Support the
pinion properly and, with the proper
size punch, drive the roll pin that
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.
ADAPTOR
PLATE
PINION
MOUNTING
SCREW (X3)
ROLL PIN
6. Cover the teeth of the motor pinion
and the input gear with a non-fluid
molydisulfide type grease such as
Non-Fluid Oil Corporation’s A-29
Special/MS Lubricant. This grease
can be scooped from the cavity of the
gear case.
The electrode is driven by gripping
between the grooved drive rolls and
spring-loaded idle roll. Replace the drive
rolls when they become worn. The drive rolls
for 1/16 in. (1.6 mm) and larger diameter
electrodes have two sets of teeth so they
can be reversed once before they must be
replaced.
7. Reassemble the motor on the gear
box; make sure the gears mesh
properly and the adapter plate
locating bead is in its cavity. Replace
and tighten the four screws removed
in step 1.
WIRE STRAIGHTENERS
Solid Electrode
8. Jumper on wire speed meter PC
board must be properly positioned for
the gear ratio and drive rolls being
used (See the wiring diagram for the
wire speed meter PC board.)
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 necessary, 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 bushing over.
WIRE DRIVE MECHANISM
Drive mechanisms for three wire size ranges
are available: 0.035 through 0.052 in.
(0.9 through 1.3 mm), 1/16 through 3/32 in.
1.6 through 2.4 mm), and 3/32 through
7/32 in. (2.4 through 5.6 mm). If changing to
wire sizes outside this range, change the
drive rolls and the incoming and outgoing
guide tubes. Also change the gear ratio as
necessary.
Flux-Cored Electrode
Severe wear at the “V” 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
wire milling.
NA-5
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D-6
D-6
MAINTENANCE
2. Check the carriage drive gear teeth.
If the teeth are badly worn, replace
the drive gear.
OPTIONAL FEATURES
CONTACT ASSEMBLIES
3. After 5,000 hours of operation, the
motor and the first reduction gear
should be removed from the gear box,
and all the gear teeth should be
recoated with a good grade of
graphite grease.
A 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 location or good electrical contact. See
Sec. T2.2.6, Sec. T2.2.7, or Sec. T2.5.3 of
the IM305 manual for specific instructions to
replace contact tips and to perform
maintenance on other various contact
assemblies.
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 and head lift screw. Apply a
thin layer of grease to the outside diameter
of the head lift tube and the inside diameter
of the long hole in the head lift body. 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 in
grease.
WIRE REEL MOUNTING FOR
50 OR 60 LB (22.7 OR
27.2 KG) 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.
TRAVEL CARRIAGE
Periodically:
1. Disengage the release handle and
see that the carriage moves freely
along the beam.
HORIZONTAL ADJUSTER
Twice a year, apply a thin coat of grease to
all sliding surfaces. Every year, replace the
grease in the gear cavity with a medium
grease.
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.
HIGH FREQUENCY GENERATOR
3. Add a few drops of oil to the clutch
handle bearings.
Inspect the spark gaps monthly and maintain
the setting specified on the spark gap cover
plate.
4. Add a few drops of oil into each of the
cups at the travel mounting pivot
point.
SPREADARC
(No change of lubrication is required
for cold temperature operation.)
Refer to the maintenance information
provided in IM305 Sec. T2.5.6.
Once a year:
1. Check the motor brushes. If 0.25 in.
(6.35 mm) or shorter, replace with
new brushes.
NA-5
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E-1
E-1
THEORY OF OPERATION
TABLE OF CONTENTS
-THEORY OF OPERATION SECTION-
Theory of Operation..................................................................................................................Section E
General Description..........................................................................................................................E-2
Input Power Circuits .........................................................................................................................E-2
Power and Voltage Boards...............................................................................................................E-3
Control, Logic and Procedure Boards ..............................................................................................E-4
Optional start, Crater Fill and Weld Timer Boards............................................................................E-5
SCR Operation.................................................................................................................................E-6
NA-5
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E-2
E-2
THEORY OF OPERATION
GENERAL DESCRIPTION
The NA-5 is a fully automatic wire feed
control unit. It is designed for multiple
process CV operation and can be used
with a variety of wire feeder heads, con-
tact nozzles and welding processes.
The NA-5 control unit enables the oper-
ator to preset wire feed speed and arc
voltage on digital meters. These preset
conditions are internally monitored and
remain constant until changed by the
operator.
FIGURE E.1 Input Circuits
TACH FEEDBACK (MOTOR RPM)
CONTACTOR CLOSURE (#2 AND #4)
ARC VOLTS (SET & ACTUAL)
REMOTE VOLTAGE CONTROL (A, B, C)
1/2 AMP
F501
WORK SENSING (#21)
115VAC
SET VOLTAGE
(#67)
ODE SENSING
VOLTAGE
BOARD
R
T
C
E
L
TACH
TRAVEL
RECEPTACLE
D
C
FLUX
RECEPTACLE
E
S
U
P
A
R
3
MOTOR
A
C
CR
N
D
V
O
L
P
L
Y
S
2
CR
H
U
T
T
A
INCH
DOWN
SWITCH
A
G
E
START
STOP
SWITCH
V
O
L
R
M
A
T
V
O
L
V
O
L
D
O
W
N
F
I
E
L
D
SWITCH
1
CR
T
T
A
G
E
T
U
R
E
A
G
E
A
G
E
OPTIONAL
START
BOARD
VOLTS
SPEED
START
TIMER
P
DC SUPPLY VOLTAGE
INPUT
POWER
SWITCH
R
O
C
E
D
U
R
E
STRIKE
CIRCUIT
BREAKER
P
F2
B
O
A
R
D
R1(2 OHMS)
OPTIONAL
CRATER
BOARD
O
CRATER
TIMER
STRIKE/WELD PROCEDURE
ENABLE
LOGIC
BOARD
#31
W
CONTROL
CABLE
RECEPTACLE
115
VAC
E
OPTIONAL
WELD
TIMER
R
#32
F1
B
O
A
R
D
WELD
BURNBACK
TIMER
FIELD DIRECTION
MOTOR
SIGNAL
F
E
E
D
VOLTS
SPEED
ARMATURE
E
N
A
B
L
WELD
CURRENT
REED SWITCH
G
A
T
T1
T2
E
E
S
I
G
N
A
L
S
I
G
N
A
L
115VAC
SET SPEED
1
0
V
A
C
36VAC (18+18VAC)
22VAC
S
10VDC REFERENCEVOLTAGE
DC VOLTAGE
TACH FEEDBACK (MOTOR RPM)
VOLT
METER
BOARD
SPEED
METER
BOARD
CONTROL
BOARD
WIRE FEED SPEED (SET & ACTUAL)
INCH
UP
SWITCH
DIGITAL
METER
DIGITAL
METER
INPUT POWER CIRCUITS
motor. The voltage board receives
115VAC and transforms and rectifies it
to 24VDC for the "work touch sensing"
circuit. The T1 and T2 transformer pri-
maries are also supplied with 115VAC
via the F1 (1/2amp) fuse on the power
board. The T1 and T2 secondary wind-
ings offer a variety of isolated AC sup-
ply voltages to the power, logic and
meter boards.
The NA-5 control unit is supplied with
115VAC power usually from the welding
power source. The 115VAC power is
connected to the control box circuitry
through the control cable receptacle,
the input power switch and a 5 amp cir-
cuit breaker.
The 115VAC is applied through a 2 ohm
resistor to the power board where is
rectified and controlled to supply arma-
ture and field voltage to the wire drive
NOTE: Unshaded areas of block logic diagrams are the subject of discussion.
NA-5
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E-3
E-3
THEORY OF OPERATION
FIGURE E.2 Power and Voltage Boards
TACH FEEDBACK (MOTOR RPM)
CONTACTOR CLOSURE (#2 AND #4)
ARC VOLTS (SET & ACTUAL)
REMOTE VOLTAGE CONTROL (A, B, C)
1/2 AMP
F501
WORK SENSING (#21)
115VAC
SET VOLTAGE
(#67)
ODE SENSING
VOLTAGE
BOARD
R
T
C
E
L
TACH
TRAVEL
RECEPTACLE
D
C
FLUX
RECEPTACLE
E
S
U
P
A
R
3
MOTOR
A
C
CR
N
D
V
O
L
P
L
Y
S
2
CR
H
U
T
T
A
INCH
DOWN
SWITCH
A
G
E
START
STOP
SWITCH
V
O
L
R
M
A
T
V
O
L
V
O
L
D
O
W
N
F
I
E
L
D
SWITCH
1
CR
T
T
A
G
E
T
U
R
E
A
G
E
A
G
E
OPTIONAL
START
BOARD
VOLTS
SPEED
START
TIMER
P
DC SUPPLY VOLTAGE
INPUT
POWER
SWITCH
R
O
C
E
D
U
R
E
STRIKE
CIRCUIT
BREAKER
P
F2
B
O
A
R
D
R1(2 OHMS)
OPTIONAL
CRATER
BOARD
O
CRATER
TIMER
STRIKE/WELD PROCEDURE
ENABLE
LOGIC
BOARD
#31
W
CONTROL
CABLE
RECEPTACLE
115
VAC
E
OPTIONAL
WELD
TIMER
R
#32
F1
B
O
A
R
D
WELD
BURNBACK
TIMER
FIELD DIRECTION
MOTOR
SIGNAL
F
E
E
D
VOLTS
SPEED
ARMATURE
E
N
A
B
L
WELD
CURRENT
REED SWITCH
G
A
T
T1
T2
E
E
S
I
G
N
A
L
S
I
G
N
A
L
115VAC
SET SPEED
1
0
V
A
C
36VAC (18+18VAC)
22VAC
S
10VDC REFERENCEVOLTAGE
DC VOLTAGE
TACH FEEDBACK (MOTOR RPM)
VOLT
METER
BOARD
SPEED
METER
BOARD
CONTROL
BOARD
WIRE FEED SPEED (SET & ACTUAL)
INCH
UP
SWITCH
DIGITAL
METER
DIGITAL
METER
POWER AND VOLTAGE
BOARDS
The AC voltages that are received by
the power board are rectified and regu-
lated. These DC voltages are supplied
to the motor, voltage board and control
board. The two SCR-controlled
115VDC supplies power the motor
armature and field circuits.
The voltage board also generates a low
DC voltage that is applied to the elec-
trode during the inch down mode.
When the electrode makes contact with
the work piece, this low voltage is
"loaded down", signaling the control cir-
cuitry to stop the wire feed motor. This
feature allows the operator to utilize the
"work touch sensing" feature.
The actual arc voltage is sensed at leads
#67(electrode) and #21(work) which are
coupled to the voltage board. The pre-
set voltage requirements are also sent to
the voltage board. This information is
compared and processed on the voltage
board and the resultant correction signal
is sent to the Lincoln CV power source
via the remote voltage leads (A,B,C).
The preset and actual arc voltage infor-
mation is also sent to the voltage meter
board where it is processed and dis-
played on the digital meter.
If for any reason the actual welding arc
voltage does not match the set weld
voltage
(+/- 0.5Volts) the NA-5 will shutdown.
This feature insures that the actual
welding voltage is the same as the pre-
set voltage during the welding cycle.
This circuitry is incorporated on the volt-
age board.
NOTE: Unshaded areas of block logic diagrams are the subject of discussion.
NA-5
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E-4
E-4
THEORY OF OPERATION
FIGURE E.4 Control Logic and Procedure Boards
TACH FEEDBACK (MOTOR RPM)
CONTACTOR CLOSURE (#2 AND #4)
ARC VOLTS (SET & ACTUAL)
REMOTE VOLTAGE CONTROL (A, B, C)
1/2 AMP
F501
WORK SENSING (#21)
115VAC
SET VOLTAGE
(#67)
ODE SENSING
VOLTAGE
BOARD
R
T
C
E
L
TACH
TRAVEL
RECEPTACLE
D
C
FLUX
RECEPTACLE
E
S
U
P
A
R
3
MOTOR
A
C
CR
N
D
V
O
L
P
L
Y
S
2
CR
H
U
T
T
A
INCH
DOWN
SWITCH
A
G
E
START
STOP
SWITCH
V
O
L
R
M
A
T
V
O
L
V
O
L
D
O
W
N
F
I
E
L
D
SWITCH
1
CR
T
T
A
G
E
T
U
R
E
A
G
E
A
G
E
OPTIONAL
START
BOARD
VOLTS
SPEED
START
TIMER
P
DC SUPPLY VOLTAGE
INPUT
POWER
SWITCH
R
O
C
E
D
U
R
E
STRIKE
CIRCUIT
BREAKER
P
F2
B
O
A
R
D
R1(2 OHMS)
OPTIONAL
CRATER
BOARD
O
CRATER
TIMER
STRIKE/WELD PROCEDURE
ENABLE
LOGIC
BOARD
#31
W
CONTROL
CABLE
RECEPTACLE
115
VAC
E
OPTIONAL
WELD
TIMER
R
#32
F1
B
O
A
R
D
WELD
BURNBACK
TIMER
FIELD DIRECTION
MOTOR
SIGNAL
F
E
E
D
VOLTS
SPEED
ARMATURE
E
N
A
B
L
WELD
CURRENT
REED SWITCH
G
A
T
T1
T2
E
E
S
I
G
N
A
L
S
I
G
N
A
L
115VAC
SET SPEED
1
0
V
A
C
36VAC (18+18VAC)
22VAC
S
10VDC REFERENCEVOLTAGE
DC VOLTAGE
TACH FEEDBACK (MOTOR RPM)
VOLT
METER
BOARD
SPEED
METER
BOARD
CONTROL
BOARD
WIRE FEED SPEED (SET & ACTUAL)
INCH
UP
SWITCH
DIGITAL
METER
DIGITAL
METER
board to proceed from the "strike" settings to the optional
start board if used, or to the welding wire speed and arc
voltage parameters.
CONTROL, LOGIC AND
PROCEDURE BOARDS
The logic board interprets and processes the signals it
receives from the various PC boards, switches and con-
trols. The logic board also houses a DC power supply
(+5 -10) which is derived from the 22VAC received from
the T2 transformer. This DC voltage is also used on the
procedure board.
The control board receives information from the logic
board, the procedure board and the tach feedback cir-
cuit. The control board then applies the appropriate gate
signal to the SCR power supply on the power board.
This variable and regulated DC voltage is applied to the
motor armature thus controlling the speed of the wire
feed motor. The preset and actual wire feed speed infor-
mation is sent to the speed meter board where it is
processed and displayed on the digital meter.
The procedure board incorporates the many options
available with the NA-5. The "strike" and "weld" controls
are part of the procedure board and are not optional.
The wire feed speed and arc voltage settings for the vari-
ous modes are "programmed" through the procedure
board and are then sent to the logic, voltage and control
boards at the appropriate times during the welding cycle.
The burnback time is also coupled through the procedure
board. 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 pressed.
Upon receiving voltage reference level commands from
the procedure and voltage boards, or the user-operated
switches, the logic board sends the appropriate com-
mand signals to the control and power boards to drive
the wire feed motor to the proper speed and direction.
When the "start" signal is received by the logic board the
power source contact relay (3CR) is energized along
with the travel relay (2CR) and the flux relay (1CR). The
"inch down" and "stop" switches signal the logic board
which then directs the control and power boards to apply
the appropriate armature and field voltages to the wire
drive motor. The "inch up" switch, which is connected
directly to the control board, dictates that the wire drive
motor reverse direction, backing the electrode wire away
from the work piece. When the welding current closes
the reed switch the logic board directs the procedure
NOTE: Unshaded areas of block logic diagrams are the subject of discussion.
NA-5
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E-5
E-5
THEORY OF OPERATION
FIGURE E.3 Optional Start, Crater Fill and Weld Timer Boards
TACH FEEDBACK (MOTOR RPM)
CONTACTOR CLOSURE (#2 AND #4)
ARC VOLTS (SET & ACTUAL)
REMOTE VOLTAGE CONTROL (A, B, C)
1/2 AMP
F501
WORK SENSING (#21)
115VAC
SET VOLTAGE
(#67)
ODE SENSING
VOLTAGE
BOARD
R
T
C
E
L
TACH
TRAVEL
RECEPTACLE
D
C
FLUX
RECEPTACLE
E
S
U
P
A
R
3
MOTOR
A
C
CR
N
D
V
O
L
P
L
Y
S
2
CR
H
U
T
T
A
INCH
DOWN
SWITCH
A
G
E
START
STOP
SWITCH
V
O
L
R
M
A
T
V
O
L
V
O
L
D
O
W
N
F
I
E
L
D
SWITCH
1
CR
T
T
A
G
E
T
U
R
E
A
G
E
A
G
E
OPTIONAL
START
BOARD
VOLTS
SPEED
START
TIMER
P
DC SUPPLY VOLTAGE
INPUT
POWER
SWITCH
R
O
C
E
D
U
R
E
STRIKE
CIRCUIT
BREAKER
P
F2
B
O
A
R
D
R1(2 OHMS)
OPTIONAL
CRATER
BOARD
O
CRATER
TIMER
STRIKE/WELD PROCEDURE
ENABLE
LOGIC
BOARD
#31
W
CONTROL
CABLE
RECEPTACLE
115
VAC
E
OPTIONAL
WELD
TIMER
R
#32
F1
B
O
A
R
D
WELD
BURNBACK
TIMER
FIELD DIRECTION
MOTOR
SIGNAL
F
E
E
D
VOLTS
SPEED
ARMATURE
E
N
A
B
L
WELD
CURRENT
REED SWITCH
G
A
T
T1
T2
E
E
S
I
G
N
A
L
S
I
G
N
A
L
115VAC
SET SPEED
1
0
V
A
C
36VAC (18+18VAC)
22VAC
S
10VDC REFERENCEVOLTAGE
DC VOLTAGE
TACH FEEDBACK (MOTOR RPM)
VOLT
METER
BOARD
SPEED
METER
BOARD
CONTROL
BOARD
WIRE FEED SPEED (SET & ACTUAL)
INCH
UP
SWITCH
DIGITAL
METER
DIGITAL
METER
OPTIONAL START, CRATER
FILL AND WELD TIMER
BOARDS
When installed, the optional start board
dictates to the procedure board the
starting wire feed speed and arc volt-
age. This condition can be operator set
for a predetermined period of time.
These parameters can be set either
higher or lower than those of the weld-
ing procedure to control penetration,
bead shape, or other factors at the start
of the weld. The start circuit becomes
active when the weld current sensing
reed switch is closed.
is pressed. This optional feature is
helpful in controlling bead shape and
filling craters at the end of a weld.
The weld timer permits setting of weld
time for an adjustable period of time.
This feature eliminates the need to
press the "stop" switch.
The crater fill board is used by the oper-
ator to adjust the finishing wire feed
speed and voltage either higher or
lower than the welding procedure for an
adjustable period of time. This circuit
becomes active when the "stop" switch
NOTE: Unshaded areas of block logic diagrams are the subject of discussion.
NA-5
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E-6
E-6
THEORY OF OPERATION
SCR OPERATION
A silicon controlled rectifier (SCR) is a three terminal
device used to control rather large currents to a load.
An SCR acts very much like a switch. When a gate
signal is applied to the SCR it is turned ON and there
is current flow from anode to cathode. In the ON state
the SCR acts like a closed switch. When the SCR is
turned OFF there is no current flow from anode to
cathode thus the device acts like an open switch. As
the name suggests, the SCR is a rectifier, so it passes
current only during positive half cycles of the AC sup-
ply. The positive half cycle is the portion of the sine
wave in which the anode of the SCR is more positive
than the cathode.
these terminals must be slightly greater than 0.6V.
Once the SCR has fired it is not necessary to continue
the flow of gate current. As long as current continues
to flow from anode to cathode the SCR will remain on.
When the anode to cathode current drops below a
minimum value, called holding current, the SCR will
shut off. This normally occurs as the AC supply volt-
age passes through zero into the negative portion of
the sine wave. If the SCR is turned on early in the
positive half cycle, the conduction time is longer
resulting in greater SCR output. If the gate firing
occurs later in the cycle the conduction time is less
resulting in lower SCR output.
When an AC supply voltage is applied to the SCR, the
device spends a certain portion of the AC cycle time in
the on state and the remainder of the time in the off
state. The amount of time spent in the ON state is
controlled by the Gate.
An SCR is fired by a short burst of current into the
gate. This gate pulse must be more positive than the
cathode voltage. Since there is a standard PN junc-
tion between gate and cathode, the voltage between
INPUT
CATHODE
OUTPUT
NOTE: AS THE GATE
PULSE IS APPLIED
LATER IN THE CYCLE
THE SCR OUTPUT
IS DECREASED.
ANODE
GATE
GATE
FIGURE E.4 SCR Operation
NA-5
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SECTION F-1
SECTION F-1
TROUBLESHOOTING & REPAIR
TABLE OF CONTENTS
-TROUBLESHOOTING AND REPAIR SECTION-
Troubleshooting and Repair......................................................................................................Section F
How to Use Troubleshooting Guide......................................................................................................F-2
PC Board Troubleshooting Procedures................................................................................................F-3
Troubleshooting Guide .........................................................................................................................F-4
PC Board LED Definitions ..................................................................................................................F-36
PC Board LED Sequence Table.........................................................................................................F-37
Test Procedures .................................................................................................................................F-38
DC Power Supply Test....................................................................................................................F-38
T1 and T2 Transformer Test ...........................................................................................................F-42
Voltage Board Transformer Test.....................................................................................................F-45
Wire Feed Drive Motor Test ............................................................................................................F-48
External Resistance Test (Leads #21 and #67)..............................................................................F-50
Out of Voltage Range Shut Sown Test ...........................................................................................F-52
Tach Board Feedback Test.............................................................................................................F-55
VoltmeterAccuracy Test ..................................................................................................................F-57
Wire Speed Accuracy Test..............................................................................................................F-60
Meter Circuit Accuracy Test ............................................................................................................F-64
Replacement Procedures...................................................................................................................F-71
PC Board(s) Removal and Replacement ........................................................................................F-71
Digital Meter and Meter PC Board Removal and Replacement......................................................F-73
Tach PC Board Removal and Replacement ...................................................................................F-77
Wire Drive Motor Removal and Replacement.................................................................................F-81
Retest After Repair.............................................................................................................................F-85
NA-5
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F-2
F-2
TROUBLESHOOTING & REPAIR
HOW TO USE TROUBLESHOOTING GUIDE
WARNING
Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician and
machine operator and will invalidate your factory warranty. For your safety and to avoid
Electrical Shock, please observe all safety notes and precautions detailed throughout this
manual.
__________________________________________________________________________
out removing the case wrap-around cover.
This Troubleshooting Guide is provided to
help you locate and repair possible machine
malfunctions. Simply follow the three-step
procedure listed below.
Step 3. RECOMMENDED COURSE OF
ACTION
The last column labeled “Recommended
Course of Action” lists the most likely com-
ponents that may have failed in your
machine. It also specifies the appropriate
test procedure to verify that the subject
component is either good or bad. If there
are a number of possible components,
check the components in the order listed to
eliminate one possibility at a time until you
locate the cause of your problem.
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled “PROBLEM
(SYMPTOMS)”. This column describes
possible symptoms that the machine may
exhibit. Find the listing that best describes
the symptom that the machine is exhibiting.
Symptoms are grouped into the following
categories: wire feeding problems, mode
function problems, function problems and
welding problems.
All of the referenced test procedures
referred to in the Troubleshooting Guide are
described in detail at the end of this chap-
ter. Refer to the Troubleshooting and Repair
Table of Contents to locate each specific
Test Procedure. All of the specified test
points, components, terminal strips, etc. can
be found on the referenced electrical wiring
diagrams and schematics. Refer to the
Electrical Diagrams Section Table of
Contents to locate the appropriate diagram.
Step 2. PERFORM EXTERNAL TESTS.
The second column labeled “POSSIBLE
AREAS OF MISADJUSTMENT(S)” lists the
obvious external possibilities that may con-
tribute to the machine symptom. Perform
these tests/checks in the order listed. In
general, these tests can be conducted with-
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the
tests/repairs safely, contact the Lincoln Electric Service Department for technical trou-
bleshooting assistance before you proceed call 216-383-2531 or 1-800-833-9353.
_____________________________________________________________
NA-5
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F-3
F-3
TROUBLESHOOTING & REPAIR
PC BOARD TROUBLESHOOTING PROCEDURES
- Remove the P.C. Board from the static-
shielding bag and place it directly into the
equipment. Don’t set the P.C. Board on or
near paper, plastic or cloth which could have
a static charge. If the P.C. Board can’t be
installed immediately, put it back in the static-
shielding bag.
WARNING
ELECTRIC SHOCK can kill.
Have an electrician install
and service this equip-
ment. Turn the input power
OFF at the fuse box before
working on equipment. Do
not touch electrically hot
- If the P.C. Board uses protective shorting
jumpers, don’t remove them until installation
is complete.
parts.
_______________________________
CAUTION: Sometimes machine failures
appear to be due to PC board failures. These
problems can sometimes be traced to poor
electrical connections. To avoid problems
when troubleshooting and replacing PC
boards, please use the following procedure:
- If you return a P.C. Board to The Lincoln
Electric Company for credit, it must be in the
static-shielding bag. This will prevent further
damage and allow proper failure analysis.
4. Test the machine to determine if the fail-
ure symptom has been corrected by the
replacement PC board.
1. Determine to the best of your technical
ability that the PC board is the most likely
component causing the failure symptom.
NOTE: It is desirable to have a spare (known
good) PC board available for PC board trou-
bleshooting.
2. Check for loose connections at the PC
board to assure that the PC board is prop-
erly connected.
NOTE: Allow the machine to heat up so that
all electrical components can reach their oper-
ating temperature.
3. If the problem persists, replace the sus-
pect PC board using standard practices to
avoid static electrical damage and electri-
cal shock. Read the warning inside the
static resistant bag and perform the follow-
ing procedures:
5. Remove the replacement PC board and
substitute it with the original PC board to
recreate the original problem.
a. If the original problem does not reap-
pear by substituting the original
board, then the PC board was not the
problem. Continue to look for bad
connections in the control wiring har-
ness, junction blocks, and terminal
strips.
P.C. Board can be dam-
aged by static electricity.
- Remove your body’s stat-
ic charge before opening
the static-shielding bag.
Wear an anti-static wrist
strap. For safety, use a 1
Meg ohm resistive cord
connected to a grounded
part of the equipment
frame.
ATTENTION
Static-Sensitive
Devices
Handle only at
Static-Safe
Workstations
b. If the original problem is recreated by
the substitution of the original board,
then the PC board was the problem.
Reinstall the replacement PC board
and test the machine.
Reusable
Container
Do Not Destroy
- If you don’t have a wrist
strap, touch an unpainted,
grounded, part of the
equipment frame. Keep touching the frame to
prevent static build-up. Be sure not to touch
any electrically live parts at the same time.
6. Always indicate that this procedure was
followed when warranty reports are to be
submitted.
NOTE: Following this procedure and writing
on the warranty report, “INSTALLED AND
SWITCHED PC BOARDS TO VERIFY
PROBLEM,” will help avoid denial of legiti-
mate PC board warranty claims.
- Tools which come in contact with the P.C.
Board must be either conductive, anti-static or
static-dissipative.
NA-5
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F-4
F-4
TROUBLESHOOTING & REPAIR
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENTS(S)
RECOMMENDED
COURSE OF ACTION
WIRE FEEDING PROBLEMS
The wire feeds whenever the input
power switch is in the “ON” position.
1. Check the “Start” switch (S5).
Make sure it is not stuck closed.
1. Check light 7B on the logic board.
It should NOT be on. If light 7B is
ON remove lead #518A from the
“Start” switch. If the light remains
ON the logic board may be faulty.
If the light goes OFF check the
switch and associated leads.
See wiring diagram and Figure
F.1.
2. Check the “Inch Down” switch
(S4). Make sure it is not stuck
closed.
3. Check the “Inch Up” switch (S3)
Make sure it is not stuck closed.
4. Check to make sure that jumper 2. Check light 7J on the logic board.
lead #693 is connected to the
proper pin on the logic board.
See wiring diagram.
It should NOT be on. If light 7J is
ON remove lead #592 from the
“Inch Down” switch. If the light
remains ON the logic board may
be faulty. If the light goes OFF
check the switch and associated
leads. See wiring diagram and
Figure F.1.
3. |Disconnect lead #586 from the
“Inch Up” switch. If the problem
is resolved check the switch and
associated leads. See wiring dia-
gram.
4. Check lights 7B, 7J and 7E.
They should all be OFF. If lights
7B and 7J are OFF and light 7E
is ON the logic board may be
faulty. See Figure F.1.
5. Disconnect plug “A” from the logic
board. If the wire feed stops the
logic board may be faulty. See
Figure F.1.
6. If the feed does not stop with plug
“A” disconnected, disconnect plug
“E” from the logic board. If the
wire feed stops with plug “E” dis-
connected the logic board may be
faulty. If the wire feed does NOT
stop with plug “E” disconnected
the power board may be faulty.
Replace. See Figure F.1.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
NA-5
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F-5
F-5
TROUBLESHOOTING & REPAIR
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENTS(S)
RECOMMENDED
COURSE OF ACTION
WIRE FEEDING PROBLEMS
The wire does not feed. Pressing
any of the switches (buttons) will
NOT feed the wire. The motor does
NOT run.
1. Make sure input power switch is 1. Check the lights (LEDS) locate on
ON.
the PC boards. Some should be
lit. See Table F.1. If none of the
lights are lit perform the T1 and
2. Check the circuit breaker (CB1).
Reset if tripped.
T2
Transformer
Test.
3. Make sure 115VAC is being
applied to the control box through
the control cable receptacle.
Leads #31 and #32.
2. If the appropriate lights are lit
(see Table F.1.) and the wire
does NOT feed perform the Wire
Drive Motor Test.
4. Check the two fuses on the
power board. Replace if blown. If
fuse F101 immediately fails when
replaced contact your local
3. If only some of the appropriate
lights on the power board are lit
the power board may be faulty.
Lincoln Authorized Field Service 4. If all of the appropriate lights are
Facility.
lit, except light 1D on the power,
board, check resistor R1. Normal
resistance is 2 ohms. See wiring
diagram.
5. Make sure the motor cable is con-
nected to the motor receptacle on
the NA-5 control box.
5. If fuse F101 immediately fails
when input power is applied,
unplug all of the PC boards
except the power board. If the
fuse still fails the power board
may be faulty. If the fuse does
not fail reconnect the PC boards
one at a time until the faulty
board is located. Also check and
inspect the wiring harness for
“short” or “grounds”. Reconnect
the PC boards in the following
order: control, voltage,logic,pro-
cedure,option,timer, remote inter-
face,speedmeter and voltmeter.
NOTE: Some of the above PC
boards are optional and may not
be used in all NA-5 control units.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
NA-5
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F-6
F-6
TROUBLESHOOTING & REPAIR
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENTS(S)
RECOMMENDED
COURSE OF ACTION
WIRE FEEDING PROBLEMS
The wire will not feed and the circuit 1. Check for a mechanical restric-
1. Perform the Wire Drive Motor
breaker (CB1) trips when the inch
down, inch up or the start buttons
are pressed. The wire drive motor
does not turn.
tion in the wire feeding path.
Test.
2. Make sure the proper input volt- 2. The power board may be faulty.
age (115VAC) is applied to the
NA-5 control unit.
See Table F.1.
3. Check the motor control cable for
“shorts’ or “grounds”.
3. Check the F102 field fuse on the
power board. Replace if faulty.
Note: Frequent motor polarity
changes can cause the fuse to
fail. This can be caused by the
following:
•A welding procedure with
frequent electrode to puddle
shorting.
•A power source output too
low to establish an arc.
When the inch up button is press the 1. The welding head is designed to
wire feeds down. When the inch
down button is pressed the wire
feeds up.
feed wire in the proper direction
when it is installed as shipped
from the factory. If the nozzle
and wire straightener aare rotated
about the axis of the gearbox
outpu shaft, the wire may feed in
the opposite direction.
Interchange leads #626 and #627
at the terminal strip (TS2) inside
the control box. See wiring dia-
gram.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
NA-5
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F-7
F-7
TROUBLESHOOTING & REPAIR
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENTS(S)
RECOMMENDED
COURSE OF ACTION
WIRE FEEDING PROBLEMS
The wire will not feed when the inch 1. If a DC400, Pulse Power 500 or a 1. Disconnect the white #21 lead
down button is pressed. The wire
does inch up OK and feeds down
when the start button is pressed.
CV400 power source is used a
Diode Kit must be installed in the
power source.
from the NA-5 polarity terminal
strip (TS1). See wiring diagram.
With the inch down button
pressed read the ACTUAL volts
on the NA-5 digital voltmeter.
The digital meter should read
over 19 volts and the wire should
inch down. If not, perform the
Voltage Board Transformer
Test. If the test is OK the voltage
board may be faulty. Replace.
2. Check to see if light 7J on the
logic board is ON while the inch
down button is pressed. If it does
NOT light check the inch down
button and associated leads.
See wiring diagram.
•(For codes below 8300) If
light 7J DOES light when
the inch down button is
pressed the logic board
may be faulty.
2. If the voltage is over 19 volts
and the wire DOES inch down
with the #21 lead disconnected
reconnect the #21 lead to the
terminal strip and read the
ACTUAL volts with the inch
down button pressed. If the
voltage is less than 8 volts per-
form the #21 - #67 External
Resistance Test. If the resis-
tance test is OK the voltage
board may be faulty. Replace.
•(For codes above 8300)
Jumper the AUTO tabs on
the voltage board and press
inch down button. If the
wire does NOT feed down
the logic board may be
faulty.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
NA-5
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F-8
F-8
TROUBLESHOOTING & REPAIR
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENTS(S)
RECOMMENDED
COURSE OF ACTION
WIRE FEEDING PROBLEMS
The wire will not inch down but does 1. Check to make sure that light 7J, 1. The logic board may be faulty.
inch up properly. The wire does not
feed in either direction when the start
button is pressed.
on the logic board, is lit when the
inch down button is pressed. If
not check the inch down switch
and associated leads. See wiring
diagram.
Replace.
2. The power board may be faulty.
Replace.
2. Check to make sure that light 7B,
on the logic board, is lit when the
start button is pressed. If not
check the start button and associ-
ated leads. See wiring diagram.
The wire will not inch down but does 1. For codes below 8300 make sure 1. Jumper the AUTO tabs on the
inch up properly. When the start
button is pressed the wire feeds up
instead of down.
the jumper plug is securely
installed in the harness receptacle
near the voltage board.
voltage board. (Above code
8300) Press the inch down but-
ton. If the wire inches down the
voltage board may be faulty.
Replace.
2. Check to make sure light 7E, on
the logic board, is on when the
inch down button is pressed. If
light 7E is ON the power board
may be faulty.
If the wire does NOT inch down
the logic board may be faulty.
Replace.
3. Check the 1/8 amp fuse on the
voltage board . Replace if faulty.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
NA-5
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F-9
F-9
TROUBLESHOOTING & REPAIR
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENTS(S)
RECOMMENDED
COURSE OF ACTION
WIRE FEEDING PROBLEMS
NA-5 units above code 8300 with
“cold starting”.
The wire feeds up instead of down
when the start button is pressed.
The wire inches up and down prop-
erly.
1. Make sure the electrode wire is
fed into the welding tip.
1. Jumper the #2 and #4 leads at
the Lincoln CV power source.
Open circuit voltage should be
present at both the power source
and at the ACTUAL voltmeter
reading on the NA-5. If open cir-
cuit voltage is present at the
power source but NOT at the NA-
5 ACTUAL voltmeter reading per-
form the #21-#67 External resis-
tance Test.
2. Check the 1/8 amp fuse on the
voltage board. Replace if faulty.
3. Make sure electrode polarity is
correct and the same as the #67
and #21 leads at terminal strip
(TS1). See wiring diagram.
4. Make sure the welding power
source is producing welding arc 2. With the start button pressed light
voltage.
7K should be lit. If it is not the
logic board may be faulty.
3. Check contactor relay 3CR.
Leads #2 and #4 are closed by
relay 3CR. Make sure the relay is
functiioning properly.
4. Check the control cable between
the power source and the NA-5
control unit. See wiring diagram.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
NA-5
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F-10
F-10
TROUBLESHOOTING & REPAIR
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENTS(S)
RECOMMENDED
COURSE OF ACTION
WIRE FEEDING PROBLEMS
NA-5 units above code 8300 with
“cold starting”.
1. Check the 1/8 amp fuse on the
voltage board. Replace if faulty.
1. Perform the #21-#67 External
ResistanceTest.
While pressing the inch down button
the wire does not stop when it touch- 2. While pressing the inch down but- 2. Check the continuity of leads
es the work.
ton with the wire touching the
work piece, observe light 7G on
the logic board. If the light goes
on but the wire does NOT stop
feeding the logic board may be
faulty.
#667 and #621 to the voltage
board. See wiring diagram.
3. The logic board may be faulty.
4. The voltage board may be faulty.
The wire will NOT inch up but does 1. With the unit at idle (no buttons
1. Check the inch up switch (button)
for proper operation. Also check
associated leads for loose or
faulty connections. See wiring
diagram.
inch down and weld properly.
pressed) observe lights 1D, on
the power board, and light 7E, on
the logic board. 1D should be
ON. 7E should be OFF.
2. If 1D is OFF replace the power
board.
3. If 7E is ON replace the logic
board.
The wire feeds UP when either inch 1. While pressing the inch down but- 1. Check the inch up and inch down
button is pressed.
ton observe light 7E on the logic
board. It should be ON.
switches (buttons) for proper oper-
ation and wiring. See wiring dia-
gram.
2. If light 7E is ON, while the inch
down button is pressed, the
power board may be faulty.
Replace.
3. If light 7E remains OFF, while
the inch down button is pressed,
the logic board may be faulty.
Replace.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
NA-5
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F-11
F-11
TROUBLESHOOTING & REPAIR
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENTS(S)
RECOMMENDED
COURSE OF ACTION
WIRE FEEDING PROBLEMS
The wire feeds down when either
inch button is pressed.
1. Wth the unit at idle (no buttons
pressed) observe light 7E on the
logic board. It should be OFF.
1. Check the inch up and inch down
switches (buttons) for proper oper-
ation and wiring. See wiring dia-
gram.
2. If light 7E is ON the logic board
may be faulty. Replace.
3. If light 7E is OFF the power board
may be faulty. Replace.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
NA-5
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F-12
F-12
TROUBLESHOOTING & REPAIR
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENTS(S)
RECOMMENDED
COURSE OF ACTION
MODE FUNCTION PROBLEMS
The speed and voltage controls do 1. Check lights 1A and 1B located
1. If lights 1A and /or 1B are OFF
perform the DC Power Supply
Test.
not function. All of the mode lights
function properly.
on the power board. They should
both be ON.
2. If both lights 1A and 1B are ON
the control board may be faulty.
Replace.
2. Perform the T1 and T2
Transformer Test.
3. The power board may be faulty.
Replace.
All the mode lights function properly. 1. The control board may be faulty.
None of the speed controls operate
properly.
Replace.
All the mode lights function properly. 1. The voltage board may be faulty.
None of the voltage controls operate
properly.
Replace.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
NA-5
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F-13
F-13
TROUBLESHOOTING & REPAIR
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENTS(S)
RECOMMENDED
COURSE OF ACTION
MODE FUNCTION PROBLEMS
Only the strike mode functions, when 1. The logic board may be faulty.
the unit is at idle, regardless of the
selector switch position.
Replace.
2. The procedure board may be
faulty.
Only the strike mode functions while 1. While the unit is welding check
. If light 7D is NOT lit, when weld
current is present, connect a
jumper wire from terminal #528 to
#500 on terminal strip TS1. See
wiring diagram. If light 7D does
light check the CR4 reed switch
and associated leads and connec-
tions. See wiring diagram.
welding. The unit stays in the strike
mode and does not progress through
the welding sequence.
light 7D on the logic board. It
should be ON when welding cur-
rent is present. If light 7D is ON
the logic board may be faulty.
3. If light 7D is NOT lit when weld
current is present make sure the
weld cables have been properly
routed through the cable clamp
on the left side of the control box.
2. If 7D does NOT light, with the
jumper wire in place, check the
#528 lead and the #500 lead
between the TS1 terminal strip
and the logic board. See wiring
diagram.
3. The logic board may be faulty.
Replace.
The strike light is OFF and neither
strike control functions. The other
mode lights work. The unit will not
feed wire when the start button is
pressed.
1. Check light 7D on the logic board. 1. If light 7D is ON check the CR4
If it is off the logic board may be reed switch and associated leads.
faulty. Replace.
See wiring diagram.
2. If the start light is on all the time
the start board (if used) may be
faulty. Replace or install jumper
plug in procedure board.
3. If the crater light is on all the time
the crater board (if used) may be
faulty. Replace or install jumper
plug in procedure board.
4. If the weld light is on all the time
the logic board may be faulty.
Replace.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
NA-5
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F-14
F-14
TROUBLESHOOTING & REPAIR
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENTS(S)
RECOMMENDED
COURSE OF ACTION
MODE FUNCTION PROBLEMS
The strike light does not light. The 1. The procedure board may be
strike controls (voltage and wire feed
speed) do function normally.
faulty. Replace.
The strike light comes on but the
strike controls (voltage and wire feed
speed) do not function normally.
1. The procedure board may be
faulty. Replace.
The start light does not light. The
start controls (voltage and wire feed
speed) may or may not function nor-
mally. The NA-5 is at idle with the
selector switch in the “Start” position.
1. Make sure the start option board 1. Check the lead harness between
is installed correctly.
the start option board and the
procedure board for loose or
faulty connections. See wiring
diagram.
2. The procedure board may be
faulty. Replace.
The start light is ON but the start
controls (voltage and wire feed
speed) do not function. The NA-5 is
at idle with the selector switch in the
“Start” position.
1. If no other mode lights are lit the 1. Check the lead harness between
start option board may be faulty.
Replace.
the start option board and the
procedure board for loose or
faulty connections. See wiring
diagram.
2. If the strike light is also lit (along
with the start light) the logic board
may be faulty.
3. If the weld and or crater lights are
also lit (along with the start light)
the procedure board may be
faulty.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
NA-5
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F-15
F-15
TROUBLESHOOTING & REPAIR
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENTS(S)
RECOMMENDED
COURSE OF ACTION
MODE FUNCTION PROBLEMS
When the start button is pressed and 1. Make sure the start option is in- 1. Check the lead harness between
the unit is welding, the start mode is
skipped.
stalled properly in the NA-5.
the start option boards and the
procedure board for loose or
faulty connections. See wiring
diagram.
2. Make sure the start timer is set
for a time greater than zero sec-
onds.
3. If the weld light goes ON as soon
as (but not before) the arc is
struck and the start timer is set
for a time greater than zero sec-
onds, the start timer board may
be faulty.
4. If the weld light goes ON before
the arc is struck replace the start
option board with the jumper
plug. If the weld light continues
to go ON before the arc is struck
the logic board may be faulty.
Replace.
5. With the jumper plug installed: If
the weld light does NOT go ON
until the arc is struck the start
option board may be faulty.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
NA-5
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F-16
F-16
TROUBLESHOOTING & REPAIR
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENTS(S)
RECOMMENDED
COURSE OF ACTION
MODE FUNCTION PROBLEMS
When welding the start timer does
not time out. The unit stays in the
start mode.
1. When the weld is stopped check 1. Check the lead harness between
to see if the crater (if used) or
burnback timer is functioning
properly. If the crater and or burn-
back timer IS functioning properly
the start timer may be faulty.
the start option boards and the
procedure board for loose or
faulty connections. See wiring
diagram.
2. If the start, crater and burnback
timers are not working properly
the procedure board may be
faulty.
The crater light does not light. The 1. Make sure the crater option
1. Check the lead harness between
the crater option boards and the
procedure board for loose or
faulty connections. See wiring
diagram.
crater controls (voltage and wire
feed speed) may or may not func-
tion. The NA-5 is at idle with the
selector switch in the ”Crater” pos-
tion.
boards are installed correctly.
2. The procedure board may be
faulty. Replace.
The crater light is ON but the crater 1. If no other lights are lit the crater 1. Check the lead harness between
controls (voltage and wire feed
speed) do not function. The NA-5 is
at idle with the selector switch in the
“Crater” position.
option board may be faulty.
Replace.
the crater option boards and the
procedure board for loose or faulty
connections. See wiring diagram.
2. If the strike light is also lit (along
with the crater light) the logic
board may be faulty.
3. If the weld and or start lights are
also lit (along with the crater light)
the procedure board may be
faulty.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
NA-5
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F-17
F-17
TROUBLESHOOTING & REPAIR
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENTS(S)
RECOMMENDED
COURSE OF ACTION
MODE FUNCTION PROBLEMS
At the end of the weld the crater light 1. Make sure the crater option is
1. Check the lead harness between
the crater boards and the proce-
dure board for loose or faulty con-
nections. See wiring diagram.
does NOT light.
installed properly in the NA-5.
2. Make sure the crater timer is set
for a time greater than zero sec-
onds.
3. The crater option and or timer
board may be faulty. Replace.
4. The logic board may be faulty.
At the end of the weld the crater
timer does not time out. The unit
stays in the crater mode.
1. Replace the crater option board 1. Check the lead harness between
with the jumper plug. Set the
burnback timer for any time
the crater boards and the proce-
dure board for loose or faulty con-
nections. See wiring diagram.
greater than zero seconds. If the
unit then stops after the weld and
burnback time, the crater timer
board may be faulty. Replace.
2. If the unit does not stop the pro-
cedure board may be faulty.
No burnback/retract occurs at the
end of the weld.
1. Make sure the burnback timer is 1. Check the lead harness between
set for a time greater than zero
ohms.
the burnback module and the pro-
cedure board for loose or faulty
connections.
2. Be sure the jumper leads or dip
switches on the logic board are
comfigured correctly for the burn-
back/retract desired. See wiring
diagram.
3. The burnback timer module may
be faulty. Replace.
4. The procedure board may be
faulty.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
NA-5
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F-18
F-18
TROUBLESHOOTING & REPAIR
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENTS(S)
RECOMMENDED
COURSE OF ACTION
MODE FUNCTION PROBLEMS
The burnback timer does not time
out properly.
1. Test if the other timers (start,
weld, crater) function properly. If
they time out correctly the burn-
back module may be faulty.
Replace.
1. Check the lead harness between
the burnback module and the pro-
cedure board for loose or faulty
connections.
2. If the other timers (start, weld,
crater) do NOT function correctly
the procedure board may be
faulty.
The weld light does not light. The
weld controls (voltage and wire feed
speed) may or may not function.
The NA-5 is at idle with the selector
switch in the “Weld” position.
1. The procedure board may be
faulty. Replace.
The weld light is ON but the weld
controls (voltage and wire feed
speed) do not function. The NA-5 is
at idle with the selector switch in the
“Weld” postion.
1. If the option boards (start and
crater) are not installed make
sure the jumper plugs are
installed in the procedure board.
2. If the strike light is also lit (along
with the weld light) the logic
board may be faulty.
3. The procedure board may be
faulty. Replace.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
NA-5
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F-19
F-19
TROUBLESHOOTING & REPAIR
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENTS(S)
RECOMMENDED
COURSE OF ACTION
MODE FUNCTION PROBLEMS
During the welding sequence the
weld light does not go ON.
1. If the optional start timer is
installed determine if the start
mode is timing out. If the
sequence stays in the “start”
mode the start timer may be
faulty.
2. If the start module is OK and the
weld light does not go ON the
logic board may be faulty.
Replace.
3. If a start module is NOT used
make sure the jumper plug is
installled in the procedure board
receptacle.
While welding the weld mode is
omitted in the welding sequence.
The weld timer is set for a longer
time than zero seconds.
1. The weld timer module may be
faulty. Replace.
1. Check the lead harness between
the weld timer and the procedure
board for loose or faulty connec-
tions.
The weld timer does not time out.
the unit stays in the weld mode.
1. Set the burnback timer for a value 1. Check the lead harness between
greater than zero seconds. Start
the weld sequence and then stop
it with the stop button. Check to
see if the unit returns to the nor-
mal idle state.(Strike light ON and
“Hot Electrode” light OFF).
• If the weld mode ends and
the unit returns to the nor-
mal idle state, the weld
the weld timer and the procedure
board for loose or faulty connec-
tions.
timer module may be
faulty.
• If the unit does NOT return
to the normal idle state the
procedure board may be
faulty.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
NA-5
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F-20
F-20
TROUBLESHOOTING & REPAIR
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENTS(S)
RECOMMENDED
COURSE OF ACTION
FUNCTION PROBLEMS
The start button does not initiate the 1. If the crater and or start option
1. If light 7C is ON check the stop
button and associated leads for
“shorts” or “grounds”. Light 7C
should be on ONLY when the
stop button is pressed.
power source output or the wire
feed. The mode selector switch is in
the strike position and the mode
strike light is lit.
boards are NOT used the jumper
plugs must be installed in the pro-
cedure board receptacles.
2. With the unit at idle check light 7C
on the logic board. It should be
OFF. Also check light 7B on the
logic board. With the start button
pressed light 7B should go ON. If
lights 7C and 7B are functioning
normally the logic board may be
faulty.
2. If light 7B does NOT go on, when
the start button is pressed, check
the start switch (button) and asso-
ciated leads for loose or faulty
connections. See wiring diagram.
3. Check the lead harness between
the logic board and the procedure
board for loose or faulty connec-
tions. See wiring diagram.
The start button initiates the power 1. If the wire inches up properly, but 1. If the wire does not feed when the
source output, but the wire does not
feed.
does not feed when the start but-
ton is pressed, the logic board
may be faulty.
inch up button is pressed perform
the Wire Drive Motor Test.
2. If the wire does NOT feed, when
the inch up button is pressed,
check light 1E on the power
board. It should go ON when the
inch up button is pressed. If light
1E does not go on when the inch
up button is pressed the control
board may be faulty.
3. The power board may be faulty.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
NA-5
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F-21
F-21
TROUBLESHOOTING & REPAIR
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENTS(S)
RECOMMENDED
COURSE OF ACTION
FUNCTION PROBLEMS
The start button initiates the wire
feed, but does not activiate the
power source output.
1. Make sure that lead #690 is con- 1. The CR3 relay may be faulty.
nected to the proper pin on the
logic board. On newer logic
Check or replace.
boards the dip switches must be 2. Check the #2 and #4 leads
in the proper position. See wiring
diagram.
between the CR3 relay and the
control cable receptacle. See
wiring diagram.
2. Make sure the power source is
capable of producing welding
output voltage. Jumper #2 and
#4 at the power source’s terminal
strip. This should produce open
circuit voltage at the output termi-
nals. If open circuit voltage is not
present the power source may be
faulty.
3. Check or replace the control
cable between the NA-5 and the
power source.
4. With the start button pressed
check light 7K on the logic board
and the “Electrode Hot” light.
Both lights should be on. If the
lights are OFF unplug the burn-
back timer. If the problem is
resolved the burnback timer may
be faulty. Replace.
5. The logic board may be faulty.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
NA-5
Download from Www.Somanuals.com. All Manuals Search And Download.
F-22
F-22
TROUBLESHOOTING & REPAIR
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENTS(S)
RECOMMENDED
COURSE OF ACTION
TRAVEL FUNCTION PROBLEMS
The travel function will not operate
regardless of the travel switch posi-
tion.
1. Check the travel switch for proper 1. With the travel switch (S2) in the
operation. Also check associat-
ed leads for loose or faulty con-
nections.
hand travel position, and the
115VAC input power applied to
the NA-5 unit, check for 115VAC
at the travel receptacle. 115VAC
should be present at leads #531
to #532. 115VAC should also be
present at leads #25 to #531. If
either of these two voltages are
missing or not correct check the
lead harness, switch (S2) and
travel receptacle for loose or
faulty connections. See wiring
diagram.
2. Check the travel receptacle and
associated leads for loose or
faulty connections.
3. Make sure the travel unit is oper-
ational.
2. If the above voltages are correct
the problem is in the travel unit or
connecting cable.
The travel will not function with the
travel switch in the “Hand” travel
position. The unit operates properly
with the travel switch in the “Auto”
position.
1. Check the travel switch and asso- 1. The travel switch may be faulty.
ciated leads for loose or faulty
connectioins.
Check or replace.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
NA-5
Download from Www.Somanuals.com. All Manuals Search And Download.
F-23
F-23
TROUBLESHOOTING & REPAIR
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENTS(S)
RECOMMENDED
COURSE OF ACTION
TRAVEL FUNCTION PROBLEMS
The travel will not function with the
travel switch in the “Auto” postion.
The travel operates correctly with the
travel switch in the “Hand” position.
1. Make sure the jumper leads #691 1. If light 7H, located on the logic
and #692 are connected properly
to the correct pins on the logic
board. See wiring diagram.
board, does light when the auto-
matic travel is active check the
CR2 relay. Normal coil resis-
tance is 10,000 ohms. The con-
tacts (terminals 2 and 4) should
“close” when 110VDC is applied
to the relay coil (terminals 1 +
and 3 -).
2. Check the travel switch (S2) and
associated leads for loose or
faulty connections. See wiring
diagram.
3. Check light 7H located on the
logic board. This light should be
ON when the “Auto” travel is
active. If light 7H does not light
the logic board may be faulty.
The travel runs continuously when
the travel switch is in the “Auto” posi-
tion.
1. Make sure the jumper leads #691 1. The 2CR relay may be faulty.
and #692 are connected properly
to the correct pins on the logic
board. See wiring diagram.
The contacts (terminals 2 and 4)
may be stuck closed.
2. Check the associated leads for
misconnections. See wiring dia-
gram.
2. Check light 7H on the logic board.
If light 7H is always ON the logic
board may be faulty.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
NA-5
Download from Www.Somanuals.com. All Manuals Search And Download.
F-24
F-24
TROUBLESHOOTING & REPAIR
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENTS(S)
RECOMMENDED
COURSE OF ACTION
FUNCTION PROBLEMS
After pressing the stop button, the
electrode “Hot” light goes OFF, but
the electrode wire remains electrical-
ly hot. (The welding voltage is
always present). The wire stops
feeding.
1. Carefully disconnect the #2 lead 1. The 3CR relay may be faulty.
from the power source terminal
strip. The welding voltage should
be disabled. If the welding volt-
age is still present the power
source is faulty.
The contacts (terminals 2 and 4)
may be stuck closed.
2. Check the associated leads for
misconnections. See wiring dia-
gram.
2. Check or replace the control
cable between the power source
and the NA-5 unit.
After pressing the stop button, the
weld light remains on and the wire
continues to feed.
1. If a crater option module is used, 1. If, while pressing the stop button,
check to make sure the logic
board jumper (#694) is on pin
P10.
light 7C does NOT go on, check
the stop button and associated
leads.
2. While pressing the stop button
observe light 7C located on the
logic board. It should be lit. If
light 7C is ON and the wire feed-
ing and welding does not stop,
the logic board may be faulty.
The set and actual speed meter
readings match within a few IPM, but
both are in error.
1. Made sure the calibration jumper 1. Remove the drive motor end cap
on the speedmeter board is con-
nected properly. See Operation
Section.
and the tach cover plate from the
end of the wire drive motor.
Check to make sure the slotted
disc is secure and aligned and
rotates freely through the center
of the module pick-up.
2. Perform the Wire Speed
Accuracy Test
3. Perform the Meter Circuit
Accuracy Test.
4. The control board may be faulty.
Replace.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
NA-5
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F-25
F-25
TROUBLESHOOTING & REPAIR
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENTS(S)
RECOMMENDED
COURSE OF ACTION
FUNCTION PROBLEMS
The set speed and actual speed
meter readings do not match within a
few IPM. One or both readings may
be erratic.
1. Contact your local Lincoln
1. Check the lead and switch conti-
nuity of the SET speedmeter cir-
cuit. See wiring diagram.
Authorized Field Service Facility.
2. Check the lead and switch conti-
nuity of the ACTUAL speedmeter
circuit. See wiring diagram.
3. Perform the Wire Speed
Accuracy Test
4. Perform the Meter Circuit
Accuracy Test.
5. The control board may be fault
The set speed is adjustable and
steady. The actual speed is uncon-
trollable. The meter displays the
actual speed correctly.
1. Contact your local Lincoln
1. While the motor is running care-
fully unplug the 15 pin molex from
the control board.
Authorized Field Service Facility.
A. If the motor continues to
run the power board may
be faulty. Replace.
B. If the motor stops the
control board may be
faulty. Replace.
2. Perform the Wire Drive Motor
Test.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
NA-5
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F-26
F-26
TROUBLESHOOTING & REPAIR
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENTS(S)
RECOMMENDED
COURSE OF ACTION
FUNCTION PROBLEMS
The set speed is adjustable and
steady. The actual speed reading is
incorrect and or erratic.
1. Check that the jumper plug is
installed securely in the harness
receptacle near the voltage
1. Remove the drive motor end cap
and the tach cover plate from the
end of the wire drive motor.
board. Codes below 8300 only.
Check to make sure the slotted
disc is secure and aligned and
rotates freely through the center
of the module pick-up.
2. Check for loose or faulty connec-
tions on leads #510A, #525A and
#555 between the tach receptacle
and the control board.
2. Perform the Tach Board
Feedback Test.
3. Check the tach cable from the
tach board to the tach receptacle. 3. If the Tach Board Feedback
The shield in the cable should
NOT be grounded to the case.
Test is OK the control board may
be faulty. Replace.
1. Check the voltage sensing leads
for continuity. (zero ohms). #21
should have continuity to the
The set volts and actual volts read- 1. Put the Lincoln power source in
ings match within a few tenths of a
volt while welding. However both
readings are inaccurate.
the machine control mode.
Check to see if the power supply
can be set for the arc voltage
required for the process. If not,
the power source may be faulty.
work piece and #67 should have
continuity to the wire feed head
assembly. See wiring diagram.
2. Perform the Voltmeter Accuracy
2. The control cable may be faulty.
Check or replace.
Test.
3. Perform the Meter Circuit
Accuracy Test.
4. The voltage board may be faulty.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
NA-5
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F-27
F-27
TROUBLESHOOTING & REPAIR
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENTS(S)
RECOMMENDED
COURSE OF ACTION
FUNCTION PROBLEMS
The actual volts reading does NOT 1. NA-5 units with a G1556-2 (or
1. If the actual reading is the prob-
lem check the actual volts switch
and associated leads. See wiring
diagram.
match the set volts reading within a
few tenths of a volt. One reading
may be erratic. The NA-5 does not
shut off.
higher) voltage board do not con-
trol the actual strike voltage to
match the set strike voltage. The
actual strike voltage is a function
of the set strike voltage and the
OCV contrtol characteristics of
the welding power source.
2. If the set reading is the problem
check the set volts switch and the
asociated leads. See wiring dia-
gram.
NA-5 controls with a G1556-3 (or
higher) voltage board must have 3. Perform the Voltmeter Accuracy
the jumper plug connected to the
4-cavity receptacle on the board,
unless the pulsed power filter
board option is connected.
Test
4. Perform the Meter Circuit
Accuraty Test.
2. Make sure the shutdown
“BYPASS” pins are not jumpered
together on the NA-5 voltage
board.
5. The voltage board may be faulty.
3. Check the voltage sensing leads
for continuity. (zero ohms). #21
lead should have continuity to the
work piece and #67 lead should
have continuity to the wire feed
head assembly. See wiring dia-
gram.
4. Put the Lincoln welding power
source in the machine control
mode. Check to see if the power
supply can be set for the arc volt-
age required for the process. If
not, the power supply may be
faulty.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
NA-5
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F-28
F-28
TROUBLESHOOTING & REPAIR
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENTS(S)
RECOMMENDED
COURSE OF ACTION
FUNCTION PROBLEMS
The NA-5 repeatedly shutsdown
while welding.
1. Make sure the power source
polarity switch is set for the cor-
rect electrode polarity.
1. Perform the Out of Voltage
Range Shutdown Test.
2. The voltage board may be faulty.
2. Make sure the #67 and #21 leads
are connected to the TS1 termi-
nal strip for the correct electrode
polarity. See wiring diagram.
3. Make certain the voltage control
switch on the Lincoln CV power
source is set in the “Remote”
position.
4. Make sure the #21 lead has con-
tinuity (zero ohms) to the work
piece.
5. Make sure the #67 lead has con-
tinuity (zero ohms) to the wire
feed head assembly.
6. Check the 1/8 amp fuse on the
NA-5 voltage board. Replace if
faulty.
7. The control cable may be faulty.
Check or replace.
8. Be sure the welding power
source is compatable with the
NA-5.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
NA-5
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F-29
F-29
TROUBLESHOOTING & REPAIR
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENTS(S)
RECOMMENDED
COURSE OF ACTION
FUNCTION PROBLEMS
The circuit breaker trips when the
inch up, inch down, or start buttons
are pressed.
1. The power board may be faulty. 1. Perform the Wire Drive Motor
Replace.
Test.
2. Perform the DC Power Supply
Test.
The circuit breaker trips and or the
fuse (F101) blows when the NA-5 is
turned on. (input power applied).
1. Contact your Local Lincoln
1. If fuse F101 or the circuit breaker-
immediately fails when input
power is applied, unplug all of
the PC boards except the power
board. If the fuse still fails the
power board may be faulty. If
the fuse does not fail reconnect
the PC boards one at a time until
the faulty board is located. Also
check and inspect the wiring har-
ness for “short” or “grounds”.
Reconnect the PC boards in the
following order: control,
Authorized Field Service Facility.
voltage,logic,procedure,option-
timer, remote interface,speedme-
ter and voltmeter.
NOTE: Some of the above PC
boards are optional and may not
be used in all NA-5 control units.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
NA-5
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F-30
F-30
TROUBLESHOOTING & REPAIR
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENTS(S)
RECOMMENDED
COURSE OF ACTION
FUNCTION PROBLEMS
The circuit breaker trips after the
wire has been feeding for a period of
time. Welding is normal.
1. Check to make sure there are not 1. Perform the DC Power Supply
any mechanical restrictions in the
wire feeding path which could
cause excessive loading on the
wire drive motor.
Test.
2. Perform the Wire Drive Motor
Test.
3. The power board may be faulty.
The 1/8 amp fuse on the voltage
board repeatedly fails.
1. Check to make sure the PC
boards are NOT grounded to the
case of the NA-5. This can hap-
pen due to metallic dust build-up.
1. Remove the input power to the
NA-5 and replace the 1/8 amp
fuse. Locate and remove the #21
and #67 leads from the TS1 ter-
minal strip.
A. Make a resistance check
from the following leads
to the NA-5 case ground-
ing screw. Lead #510A,
510P, 500, 515 and 525.
B. The resistances should
be above 1000 ohms. If
any tests are below 1000
ohms that circuit has low
resistance to case
ground. Isolate faulty
leads or PC board. See
wiring diagram and
schematic.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
NA-5
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F-31
F-31
TROUBLESHOOTING & REPAIR
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENTS(S)
RECOMMENDED
COURSE OF ACTION
STARTING/WELDING PROBLEMS
The arc voltage appears to rise too 1. Increase the strike and or start
1. The voltage board may be faulty.
Replace.
slowly. The wire stubs or blasts off
at the start of the weld sequence.
voltage settings.
Once the arc is established the weld- 2. Put the output control switch (on
ing is OK.
the power source) in the
“Machine Control” position.
Jumper the “BYPASS “ pins on
the NA-5 voltage board. Control
the arc voltage from the power
source. If the problem is NOT
remedied the power source may
be at fault. If the problem is
solved the NA-5 may be at fault.
3. If the start response jumper, on
the voltage board, is in the “B”
position, change to the “A” posi-
tion. If the “A” position cures the
starting problem the voltage
board may be faulty.
The voltage seems too high or flares 1. Decrease the strike and or start 1. The voltage board may be faulty.
excessively at the start of the weld
sequence. Once the arc is estab-
lished the welding is OK.
voltage settings.
Replace.
2. Put the output control switch (on
the power source) in the
“Machine Control” position.
Jumper the “BYPASS” pins on
the voltage board. Control the
arc voltage from the power
source. If the problem is NOT
remedied the power source may
be at fault. If the problem is
solved the NA-5 may be at fault.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
NA-5
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F-32
F-32
TROUBLESHOOTING & REPAIR
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENTS(S)
RECOMMENDED
COURSE OF ACTION
WELDING PROBLEMS
The arc is unstable or oscillating.
1. Check the welding cables for
loose or faulty connections.
1. The NA-5 voltage board may be
faulty. Replace.
2. Make sure the electrode and gas
(if used) is correct for the process
being used.
3. Put the output control switch (on
the power source) in the
“Machine Control” position.
Jumper the “BYPASS “ pins on
the NA-5 voltage board. Control
the arc voltage from the power
source. If the problem is NOT
remedied the power source may
be at fault. If the problem is
solved the NA-5 may be at fault.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
NA-5
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F-33
F-33
TROUBLESHOOTING & REPAIR
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENTS(S)
RECOMMENDED
COURSE OF ACTION
FUNCTION PROBLEMS
The flux or gas/water solenoid does 1. Make sure the switch on the flux 1. If light 7G, located on the logic
not function (open).
hopper is in the ON position.
board, does light when the flux
(gas/water) solenoid is normally
active, check the CR1 relay.
Normal coil resistance is 10,000
ohms. The contacts (terminals 2
and 4) should “close” when
2. Check light 7G located on the
logic board. This light should be
on when the flux valve would nor-
mally be active. If light 7G does
not light the logic board may be
faulty.
110VDC is applied to the relay coil
(terminals 1 + and 3 -).
2. Check the wiring harness for
loose or faulty connections
between the CR1 relay, the logic
board, the TS2 terminal strip and
the flux receptacle. See wiring
diagram.
The flux or gas/water solenoid con- 1. Check light 7G located on the
1. Check the CR1 relay. The con-
tacts (terminal 2 and 4) should
“close” only when 110VDC is
applied to the relay coil. (termi-
nals 1+ and 3-). If the contacts
are “closed” continuously replace
the CR1 relay.
tinuously remains open.
logic board. This light should be
lit only when the flux valve would
normally be active. If light 7G is
lit continuously the logic board
may be faulty.
2. Check to make sure the solenoid
is not stuck in the open position.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
NA-5
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F-34
F-34
TROUBLESHOOTING & REPAIR
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENTS(S)
RECOMMENDED
COURSE OF ACTION
WELDING PROBLEMS
The arc is unstable or oscillating.
1. Check the welding cables for
loose or faulty connections.
1. The NA-5 voltage board may be
faulty Replace.
2. Make sure the electrode and gas
(if used) is correct for the process
being used.
3. Put the Lincoln power source in
the machine control
mode.Jumper the “BYPASS” pins
on the NA-5 voltage board.
Adjust the weld voltage at the
power source for the process
being used. If the problem is
NOT resolved the power source
may be faulty.
The welding arc is variable or “hunt- 1. Make sure the welding parame- 1. Put the Lincoln power source in
ing”.
ters are correct for the welding
procedure being used.
the machine control mode.
Jumper the “BYPASS” pins on the
NA-5 voltage board. Adjust the
weld voltage at the power source
for the process being used. If the
problem is resolved check or
replace the control cable or the
NA-5 voltage board may be faulty.
2. Check the welding cables for-
loose or faulty connections.
3. Check the wire feeding path for
restrictions.
4. The contact tip may be worn.
Check or replace.
2. Perform the Wire Drive Motor
Test.
5. The welding power source may
be faulty. Check or replace.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
NA-5
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F-35
F-35
TROUBLESHOOTING & REPAIR
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENTS(S)
RECOMMENDED
COURSE OF ACTION
WELDING PROBLEMS
Poor arc striking with sticking or
“blast offs”. The weld bead is ropey
and has porosity.
1. Make sure the welding parame- 1. Put the Lincoln power source in
ters (voltages and wire feed
speed) and techniques are cor-
rect for the welding procedure
being used.
the machine control mode.
Jumper the “BYPASS” pins on the
NA-5 voltage board. Adjust the
weld voltage at the power source
for the process being used. If the
problem is resolved check or
replace the control cable or the
NA-5 voltage board may be faulty.
2. Check the welding cables for
loose or faulty connections.
3. The contact tip may be worn.
Check or replace.
4. The welding power source may
be faulty. Check or replace.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
NA-5
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F-36
F-36
TROUBLESHOOTING & REPAIR
PC BOARD LED (LIGHT) DEFINITIONS
LED Number
Functions Indicated By PC Board LEDS
1A
1B
1C
1D
1E
1F
+15VDC Analog Supply Present
-10VDC Analog Supply Present
Down Field Voltage Applied
Up Field Voltage Applied
Armature Voltage Applied
115VDC Relay Supply Present
7A
7B
7C
7D
7E
7G
7H
7J
+15VDC Logic Supply Present
"Start" Switch Pressed
"Stop" Switch Pressed
Welding Current Present
Signal to Apply Down Field Voltage
Signal to Operate Flux or Water Solenoid
Signal to Operate Travel Circuit
"Inch Down" Switch Pressed
7K
Signal to Operate Power Source Output Contactor
LED LIGHT LOCATIONS
LED LIGHT LOCATIONS
NA-5 LOGIC
LED 1E
LED 7E
LED 7B
LED 1C
LED 1D
LED 7J
LED 7C
LED 7D
LED 1A
LED 1B
LED7A
LED 1F
LED 7K
LED 7H
LED 7G
NA-5
POWER
NA-5
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F-37
F-37
TROUBLESHOOTING & REPAIR
PC BOARD LED (LIGHT) SEQUENCE TABLE ABOVE CODE 8300
INDICATOR LIGHTS
CONDITIONS FOR LIGHT "ON"
Light
No.
Location
(PC Board)
Idle
Mode
"Inch Up" "Inch Down" "Start"
"Stop"
Switch
Burnback Weld Arc
Switch
Switch
Switch
Mode
Establish
Pressed
Pressed
Pressed
Pressed
1A
1B
1C
1D
1E
1F
Power
Power
Power
Power
Power
Power
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON*
ON
ON
ON
ON
ON
ON
ON
ON
ON
7A
7B
7C
7D
7E
7G
7H
7J
Logic
Logic
Logic
Logic
Logic
Logic
Logic
Logic
Logic
ON
ON
ON
ON*
ON
ON
ON
ON
ON
ON
ON
ON*
ON
ON
ON**
ON**
ON
ON*
7K
ON
ON
ON* only while switch is pressed
ON** dependent on travel mode
NA-5
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F-38
F-38
TROUBLESHOOTING & REPAIR
DC POWER SUPPLY TEST
WARNING
Service and repair should be performed only by Lincoln Electric factory trained per-
sonnel. Unauthorized repairs performed on this equipment could result in danger to
the technician or the machine operator and will invalidate your factory warranty. For
your safety and to avoid electrical shock, please observe all safety notes and precau-
tions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform
the tests/repairs safely, contact the Lincoln Electric service department for technical
troubleshooting assistance before you proceed.
Call (216) 383-2531 or (800) 833-9353 (WELD).
_____________________________________________________________
TEST DESCRIPTION
This will help determine if the power and logic boards are supplying the correct DC voltages
to the NA-5 circuitry.
This procedure takes approximately 16 minutes to perform.
MATERIALS NEEDED
5/16" Nutdriver
Volt/Ohmmeter (Multimeter)
Wiring diagram
NA-5
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F-39
F-39
TROUBLESHOOTING & REPAIR
DC POWER SUPPLY TEST (continued)
TEST PROCEDURE
1. Remove input power to the NA-5.
5. Perform the power supply checks as
described in Table F.1 If any of the
readings are incorrect (out of range)
or missing the power or logic board
may be faulty. See wiring diagram.
Note: Do not unplug the molex con-
nectors.
2. Using the 5/16" nutdriver open the
control box PC board access door.
3. Locate the power, logic, voltage,
control and procedure boards. See
Figure F.1
Also check associated leads and
plugs for loose or faulty connec-
tions.
4. Apply 115VAC to the NA-5 wire
feeder at the correct pins. See
wiring diagram.
POWER
BOARD
VOLTAGE
BOARD
LOGIC
BOARD
CONTROL
BOARD
PROCEDURE
BOARD
FIGURE F.1 P.C. BOARD LOCATIONS
NA-5
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F-40
F-40
TROUBLESHOOTING & REPAIR
DC POWER SUPPLY TEST (continued)
TABLE F.1 DC POWER SUPPLY CHECKS
CHECK POINT
LOCATION
TEST
DESCRIPTION
CONNECTOR
PLUG PIN NO.
LEAD NO.
NORMAL
ACCEPTABLE
VOLTAGE
READING
CONTROL PC
BOARD
CONNECTOR
PLUG
CHECK +15VDC
SUPPLY FROM
POWER BOARD
TO
PIN 10 +
PIN 9 -
525 +
510 -
14.0 - 16.0 VDC
14.0 - 16.0 VDC
9.0 - 11.0 VDC
9.0 - 11.0 VDC
90 - 135 VDC
510 -
CONTROL BOARD
525 +
VOLTAGE PC
BOARD 12 PIN
CONNECTOR
PLUG
CHECK +15VDC
SUPPLY FROM
POWER BOARD
TO
PIN 3 +
PIN 7 -
525 +
510 -
VOLTAGE BOARD
510 -
525 +
VOLTAGE PC
BOARD 12 PIN
CONNECTOR
PLUG
CHECK -10VDC
SUPPLY FROM
POWER BOARD
TO
PIN 6 -
PIN 7+
500 -
510 +
VOLTAGE BOARD
510 +
500 -
CONTROL PC
BOARD
CONNECTOR
PLUG
CHECK -10VDC
SUPPLY FROM
POWER BOARD
TO
PIN 14 -
PIN 9 +
500 -
510 +
510 +
CONTROL BOARD
500 -
LOGIC PC
BOARD J1
CONNECTOR
PLUG
CHECK +110VDC
SUPPLY FROM
POWER BOARD
TO
PLUG J1 PIN 1+
PLUG J1 PIN 2 -
610 +
500 -
610 +
500 -
LOGIC BOARD
NA-5
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F-41
F-41
TROUBLESHOOTING & REPAIR
DC POWER SUPPLY TEST (continued)
TABLE F.1 DC POWER SUPPLY CHECKS (continued)
CHECK POINT
LOCATION
TEST
DESCRIPTION
CONNECTOR
PLUG PIN NO.
LEAD NO.
NORMAL
ACCEPTABLE
VOLTAGE
READING
PROCEDURE
PC BOARD
J19 CONNECTOR
PLUG
CHECK +15VDC
SUPPLY FROM
LOGIC BOARD
TO
PLUG J19
PIN 5 +
515 +
500 -
14.0 - 16.0 VDC
PLUG J19
PIN 15 -
PROCEDURE BOARD
515 +
500 -
VOLTMETER
BOARD
CHECK +5VDC
SUPPLY
TEST POINT1.
TP5 +
TP5 +
PRODUCED
ON THE
VOLTMETER
BOARD
4.75 - 5.25 VDC
TEST POINT1.
510P -
LEAD 510P -
SPEEDMETER
BOARD
CHECK +5VDC
SUPPLY
TEST POINT1.
TP5 +
TP5 +
4.75 - 5.25 VDC
PRODUCED
ON THE
SPEEDMETER
BOARD
TEST POINT1.
510P -
LEAD 510P -
1.Scrape encapsulation from test points.
NA-5
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F-42
F-42
TROUBLESHOOTING & REPAIR
T1 and T2 TRANSFORMER TEST
WARNING
Service and repair should be performed only by Lincoln Electric factory trained per-
sonnel. Unauthorized repairs performed on this equipment could result in danger to
the technician or the machine operator and will invalidate your factory warranty. For
your safety and to avoid electrical shock, please observe all safety notes and precau-
tions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform
the tests/repairs safely, contact the Lincoln Electric service department for technical
troubleshooting assistance before you proceed.
Call (216) 383-2531 or (800) 833-9353 (WELD).
_____________________________________________________________
TEST DESCRIPTION
This test will help the technician to determine if the T1 and/or T2 transformers are functioning
properly.
This procedure takes approximately 15 minutes to perform.
MATERIALS NEEDED
115VAC power supply
Volt-Ohmmeter (Multimeter)
5/16" Nutdriver
Slot head screwdriver
NA-5
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F-43
F-43
TROUBLESHOOTING & REPAIR
T1 and T2 TRANSFORMER TEST (Continued)
5. Using the 115VAC supply carefully
PROCEDURE
apply 115VAC to the T1 primary
leads #531B and #532.
1. Remove all input power to the NA-5.
6. Check for approximately 10VAC at
the yellow secondary leads (#601
and #602). See wiring diagram.
2. Using 5/16" nutdriver open the con-
trol box PC board access door.
3. Locate the T1 and T2 transformers.
See Figure F.2
4. Locate and remove the two sets of
primary leads (#531B and #532)
from the upper terminal strip TS2.
Label leads for reassembly. See
wiring diagram and Figure F.2
POWER
BOARD
UPPER
TERMINAL
STRIP
LOGIC
BOARD
T1 TRANSFORMER
T2 TRANSFORMER
FIGURE F.2 T1 AND T2 TRANSFORMERS
NA-5
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F-44
F-44
TROUBLESHOOTING & REPAIR
T1 and T2 TRANSFORMER TEST (Continued)
7. Check for approximately 22VAC at
the blue secondary leads. The blue
secondary leads are connected to
the logic board. See wiring diagram.
13. Check for approximately 115VAC
at the orange secondary leads.
The orange leads are connected to
the power board. See wiring dia-
gram.
8. Check for approximately 18VAC at
the white to red leads. The white
and red leads are connected to the
power board. See wiring diagram.
14. Check for approximately 24VAC at
the brown secondary leads. See
wiring diagram.
9. Check for approximately 36VAC at
the red to red leads. Both red leads
are also connected to the power
board. See wiring diagram.
15. If all the secondary voltages are
correct the T2 transformer is func-
tioning properly.
16. If any or all of the secondary volt-
ages are low or not present the T2
transformer may be faulty.
10. If all the secondary voltages are
correct the T1 transformer is func-
tioning properly.
17. Reconnect the primary leads
(#531B and #532) to the TS2 termi-
nal strip.
11. If any or all of the secondary volt-
ages are low or not present the T1
transformer may be faulty.
18. Close and secure the access door.
12. Using the 115VAC supply carefully
apply 115VAC to the T2 primary
leads #531B and #532.
NA-5
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F-45
F-45
TROUBLESHOOTING & REPAIR
VOLTAGE BOARD TRANSFORMER TEST
WARNING
Service and repair should be performed only by Lincoln Electric factory trained per-
sonnel. Unauthorized repairs performed on this equipment could result in danger to
the technician or the machine operator and will invalidate your factory warranty. For
your safety and to avoid electrical shock, please observe all safety notes and precau-
tions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform
the tests/repairs safely, contact the Lincoln Electric service department for technical
troubleshooting assistance before you proceed.
Call (216) 383-2531 or (800) 833-9353 (WELD).
_____________________________________________________________
TEST DESCRIPTION
This test will aid the technician in determining if the transformer on the voltage board is func-
tioning properly.
This procedure takes approximately 15 minutes to perform.
MATERIALS NEEDED
5/16" Nutdriver
Phillips head screwdriver
115VAC power supply
Volt/Ohmmeter
NA-5
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F-46
F-46
TROUBLESHOOTING & REPAIR
VOLTAGE BOARD TRANSFORMER TEST (Continued)
4. Remove the molex type plugs from
TEST PROCEDURE
the voltage board.
1. Remove all input power to the NA-5.
5. Using the phillips head screwdriver
remove the voltage board from the
control box.
2. Using the 5/16" nutdriver open the
control box PC board access door.
6. Locate the transformer and test
points on the voltage board. See
Figure F.4
3. Locate the voltage board. See
Figure F.3
VOLTAGE
BOARD
FIGURE F.3 VOLTAGE BOARD LOCATION
NA-5
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F-47
F-47
TROUBLESHOOTING & REPAIR
VOLTAGE BOARD TRANSFORMER TEST (Continued)
24VAC
SECONDARY
TEST POINTS
{
PIN #9
PIN #8
VOLTAGE BOARD
TRANSFORMER
FIGURE F.4 TRANSFORMER TEST POINTS
7. Using the 115VAC supply carefully
apply 115VAC to pins #8 and #9 in
the nine pin molex plug cavity on the
voltage board. See Figure F.4
Make sure the board and leads are
insulated from each other and any
metal conductors.
10. If the secondary voltage is low or
not present the transformer may be
faulty.
11. Carefully remove the 115VAC sup-
ply from the voltage board.
12. Install the voltage board and con-
nect the molex plugs.
8. Using the voltmeter check for
approximately 24VAC at the sec-
ondary test points. See Figure F.4
13. Close and secure the access door.
Note: The secondary voltage will vary
with the input primary voltage. The
insulating material will have to be
removed from the secondary test
points to insure that the meter probes
make good electrical contact.
9. If the secondary voltage is correct
the transformer is functioning proper-
ly.
NA-5
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F-48
F-48
TROUBLESHOOTING & REPAIR
WIRE FEED DRIVE MOTOR TEST
WARNING
Service and repair should be performed only by Lincoln Electric factory trained per-
sonnel. Unauthorized repairs performed on this equipment could result in danger to
the technician or the machine operator and will invalidate your factory warranty. For
your safety and to avoid electrical shock, please observe all safety notes and precau-
tions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform
the tests/repairs safely, contact the Lincoln Electric service department for technical
troubleshooting assistance before you proceed.
Call (216) 383-2531 or (800) 833-9353 (WELD).
_____________________________________________________________
TEST DESCRIPTION
This test will determine if the wire drive motor is able to function when supplied with the cor-
rect voltages..
This procedure takes approximately 17 minutes to perform.
MATERIALS NEEDED
Variable DC voltage supply 0 to 90 VDC
Isolated DC voltage supply 0 to 120 VDC
Volt/Ohmeter
NA-5
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F-49
F-49
TROUBLESHOOTING & REPAIR
WIRE FEED DRIVE MOTOR TEST (Continued)
TEST PROCEDURE
MOTOR APPLIED
VOLTAGE TEST
1. Remove the wire feed motor connec-
tor from the NA-5 control box.
1. Carefully connect the isolated 120
VDC supply (SUPPLY TURNED
OFF) to pins C and D on the motor
connector.
2. Using the ohmmeter, measure the
resistances per the table below. Also
see Figure F.5.
2. Carefully connect the variable 0 to 90
VDC supply (SUPPLY TURNED
OFF) to pins A and B on the motor
connector. (See Table F.1.)
3. If the motor resistance test is good,
proceed to the Motor Applied Voltage
Test.
3. Apply field voltage first (pins C and
D) to the motor. Then, slowly apply
the armature voltage to pins A and B.
(See Table F.1).
FIGURE F.5 WIRE FEED DRIVE MOTOR
CONNECTOR PINS.
MOTOR
CONNECTOR
PINS
4. The motor should run, and the speed
should vary with changes to the
armature voltage.
#67
#541
#539
F
5. If the motor does NOT run and
change speed correctly, the motor or
gear box may be faulty.
E
A
B
D
C
6. To stop the motor, REMOVE THE
ARMATURE VOLTAGE FIRST (pins
A and B).
#627
#626
TEST POINTS
RESISTANCE
DC VOLTAGE
0 to 90 VDC
Lead #539 to lead #541
armature
4 to 5 ohms
Lead #626 to lead #627
field winding
750 to 850 ohms
90 to 120 VDC
NONE
All leads
to
500,000 ohms
min.
motor shell
(Except lead #67)
Lead #67 to motor
shell
zero ohms
Not Applicable
NA-5
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F-50
F-50
TROUBLESHOOTING & REPAIR
EXTERNAL RESISTANCE TEST (LEADS #21 AND #67)
WARNING
Service and repair should be performed only by Lincoln Electric factory trained per-
sonnel. Unauthorized repairs performed on this equipment could result in danger to
the technician or the machine operator and will invalidate your factory warranty. For
your safety and to avoid electrical shock, please observe all safety notes and precau-
tions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform
the tests/repairs safely, contact the Lincoln Electric service department for technical
troubleshooting assistance before you proceed.
Call (216) 383-2531 or (800) 833-9353 (WELD).
_____________________________________________________________
TEST DESCRIPTION
This test will help the technician to determine if the external voltage sensing leads are con-
nected properly and intact.
This procedure takes approximately 8 minutes to perform.
MATERIALS NEEDED
Volt-Ohmmeter (Multimeter)
5/16" Nutdriver
3/4" wrench
Wiring diagram
NA-5
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F-51
F-51
TROUBLESHOOTING & REPAIR
EXTERNAL RESISTANCE TEST (LEADS #21 AND #67) (Continued)
PROCEDURE
1. Make sure the electrode wire is fed
through the wire contact assembly
tip but NOT touching the "work"
piece.
6. Using the ohmmeter check the resis-
tances per the following table F.2
7. Reconnect the welding cable leads
to the contact assembly.
2. Disconnect input power to the NA-5.
8. If any of the resistances are not cor-
rect per Table F.2 check the associ-
ated leads, cables and circuits for
"opens" or "shorts". See wiring dia-
gram.
3. Make sure the drive motor cable and
power source control cables are
properly connected to the NA-5 con-
trol box.
4. Using the 5/16" nutdriver open the
control box PC board access door.
9. Close and secure the control box
access door.
5. Locate the TS1 terminal strip. See
wiring diagram.
TABLE F.2 EXTERNAL VOLTAGE SENSING LEADS TEST POINTS
TEST POINTS
EXPECTED
RESISTANCES
COMMENTS AND
CONDITIONS
Lead #667
to
Zero or less than
1 ohm
Electrode wire must be in
contact assembly tip
Electrode wire
Lead #621 to
work piece
Zero or less than
1 ohm
Polarity switches must be
in the correct positions
Lead #667 to
#621
Greater than 15K
ohms
Using the 3/4" wrench
disconnect the welding
cable(s) from the
contact assembly
NA-5
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F-52
F-52
TROUBLESHOOTING & REPAIR
OUT OF VOLTAGE RANGE SHUT DOWN TEST
WARNING
Service and repair should be performed only by Lincoln Electric factory trained per-
sonnel. Unauthorized repairs performed on this equipment could result in danger to
the technician or the machine operator and will invalidate your factory warranty. For
your safety and to avoid electrical shock, please observe all safety notes and precau-
tions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform
the tests/repairs safely, contact the Lincoln Electric service department for technical
troubleshooting assistance before you proceed.
Call (216) 383-2531 or (800) 833-9353 (WELD).
_____________________________________________________________
TEST DESCRIPTION
This test will help determine if the out-of-voltage range shut down circuitry is functioning prop-
erly.
This procedure takes approximately 18 minutes to perform.
MATERIALS NEEDED
5/16" Nutdriver
Jumper wire
Lincoln CV Power Source
NA-5
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F-53
F-53
TROUBLESHOOTING & REPAIR
OUT OF VOLTAGE RANGE SHUT DOWN TEST (Continued)
TEST PROCEDURE
4. Connect to a Lincoln Electric CV
power source per connection dia-
gram. See the Installation section
of this manual.
1. Remove input power to the NA-5
2. Using the 5/16" nutdriver open the
control box PC board access door.
3. Locate the voltage PC board.
Jumper together the "BYPASS" and
“Common” pins on the NA-5 voltage
PC board. See Figure F.6 (On older
voltage boards these pins may be
labeled "B"). This should disable the
shut down circuit.
1/8 AMP FUSE
JUMPER
TOGETHER
FIGURE F.6 VOLTAGE BOARD AND PIN LOCATIONS
NA-5
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F-54
F-54
TROUBLESHOOTING & REPAIR
OUT OF VOLTAGE RANGE SHUT DOWN TEST (Continued)
5. Start welding and observe the
ACTUAL voltage reading on the NA-
5 digital meter. The actual voltage
must match the SET voltage within
+/- 0.5VDC. If it does NOT, the NA-
5 is designed to shut down.
9. If the ACTUAL voltage reading is dif-
ferent from the SET voltage reading,
the power source may not be capa-
ble of producing the required arc
voltage, the control cable may be
faulty or misconnected, or the NA-5
voltage PC board may be faulty.
6. If the NA-5 continues to shut down
with the "BYPASS" pins jumpered
together, the voltage PC board may
be faulty.
10. After all tests are complete, remove
the input power to the wire feeder
and remove the jumper wire you
placed on the "BYPASS' pins on
the voltage PC board. Close and
secure the access door.
7. If the ACTUAL voltage reading is
zero, the sensing leads may be
faulty.
Perform the External
Resistance Test. Also check the
1/8 amp fuse on the voltage PC
board.
8. Check the polarity switche in the
Lincoln power source and its associ-
ated leads. Set the switches to the
same polarity as the electrode. See
the Wiring Diagram.
NA-5
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F-55
F-55
TROUBLESHOOTING & REPAIR
TACH BOARD FEEDBACK TEST
WARNING
Service and repair should be performed only by Lincoln Electric factory trained per-
sonnel. Unauthorized repairs performed on this equipment could result in danger to
the technician or the machine operator and will invalidate your factory warranty. For
your safety and to avoid electrical shock, please observe all safety notes and precau-
tions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform
the tests/repairs safely, contact the Lincoln Electric service department for technical
troubleshooting assistance before you proceed.
Call (216) 383-2531 or (800) 833-9353 (WELD).
_____________________________________________________________
TEST DESCRIPTION
This procedure will aid the technician to determine if the tach board is functioning properly.
This procedure takes approximately 10 minutes to perform.
MATERIALS NEEDED
5/16" Nutdriver
Phillips head screwdriver
Analog volt/ohmmeter (Multimeter)
Wiring diagram
NA-5
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F-56
F-56
TROUBLESHOOTING & REPAIR
TACH BOARD FEEDBACK TEST (Continued)
PROCEDURE
between 4.5 - 10.5VDC. (The motor
1. Remove input power to the NA-5.
must be running.) This is the feed-
back voltage from the tach PC board
to the control PC board. This volt-
age is dependent upon motor speed.
2. Using the 5/16" nutdriver open the
control box PC board access door.
3. Locate leads #510A, #525A and
#555 on the control board.
7. If the feedback voltage is missing or
does not vary with motor speed, the
tach PC board may be faulty. Also
check for loose or faulty connec-
tions.
4. Apply 115VAC to the NA-5 wire
feeder at the correct pins. See
wiring diagram.
8. After the completion of the tests
remove the 115VAC power and
close and secure the access door.
5. Check leads #525A(+) to #510A(-)
for the presence of 15VDC. This is
the supply voltage from the control
PC board to the tach PC board. If
the voltage is present, proceed to
the next step. If the voltage is miss-
ing check the associated wiring and
then perform the DC Power Supply
Test.
6. With the motor running (activate
either inch switches or the start
switch) and check leads #555(+) to
#510A(-) for the presence of
NA-5
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F-57
F-57
TROUBLESHOOTING & REPAIR
VOLTMETER ACCURACY TEST
WARNING
Service and repair should be performed only by Lincoln Electric factory trained per-
sonnel. Unauthorized repairs performed on this equipment could result in danger to
the technician or the machine operator and will invalidate your factory warranty. For
your safety and to avoid electrical shock, please observe all safety notes and precau-
tions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform
the tests/repairs safely, contact the Lincoln Electric service department for technical
troubleshooting assistance before you proceed.
Call (216) 383-2531 or (800) 833-9353 (WELD).
_____________________________________________________________
TEST DESCRIPTION
This test will help determine if the NA-5 voltmeter is providing accurate readings.
This procedure takes approximately 10 minutes to perform.
MATERIALS NEEDED
Digital volt/ohmmeter with at least 3-1/2 digits and +/-0.5% accuracy
NA-5
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F-58
F-58
TROUBLESHOOTING & REPAIR
VOLTMETER ACCURACY TEST (Continued)
TEST PROCEDURE
Perform the following checks with the
NA-5 connected to a Lincoln CV weld-
ing power source according to the prop-
er connection diagram. See the
Installation Section of this manual.
3. Place a jumper wire between leads
#2 and #4 located on CR3 relay.
See Figure F.8 This this should
energize the output terminals of the
Lincoln CV welding power source.
An open circuit voltage should be
present at the welding output termi-
nals. The test voltmeter reading
should match the ACTUAL volts
meter reading on the NA-5 within +/-
0.5VDC (typically +/- 0.2VDC). If it
does not, check the integrity and
1. Connect the test voltmeter (see
Materials Needed) between the
"work" and the electrode cable con-
nection at the welding head. See
Figure F.7
2. Using the 5/16" nutdriver open the
control box PC board access door.
placement
of
the
voltage
sensing leads #21 and #67 and
associated wiring. Perform the
Meter Circuit Accuracy Test.
ELECTRODE CABLES
CONNECT VOLTMETER
TO ELECTRODE
CONNECTION
POINT
FIGURE F.7 TEST METER CONNECTION POINTS
NA-5
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F-59
F-59
TROUBLESHOOTING & REPAIR
VOLTMETER ACCURACY TEST (Continued)
CR3 RELAY
FIGURE F.8 CR3 RELAY
4. Remove the jumper wire from leads
#2 and #4.
5. Remove the test voltmeter and,
while welding, compare the SET
volts and ACTUAL volts meter read-
ings. Depending upon the arc volt-
age characteristics of the process
being welded, the ACTUAL reading
may vary somewhat about an aver-
age value. The average ACTUAL
reading should match the SET read-
ing within +/- 0.5 VDC. If not, refer
to the Meter Circuit Accuracy Test.
6. If no further tests are required,
remove all test equipment and close
and secure the access door.
NA-5
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F-60
F-60
TROUBLESHOOTING & REPAIR
WIRE SPEED ACCURACY TEST
WARNING
Service and repair should be performed only by Lincoln Electric factory trained per-
sonnel. Unauthorized repairs performed on this equipment could result in danger to
the technician or the machine operator and will invalidate your factory warranty. For
your safety and to avoid electrical shock, please observe all safety notes and precau-
tions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform
the tests/repairs safely, contact the Lincoln Electric service department for technical
troubleshooting assistance before you proceed.
Call (216) 383-2531 or (800) 833-9353 (WELD).
_____________________________________________________________
TEST DESCRIPTION
This test will help determine if the NA-5 is providing the proper wire feed per inches of revolu-
tion of the drive roll.
This procedure takes approximately 20 minutes to perform.
MATERIALS NEEDED
Ruler or other linear measuring device
5/16" Nutdriver
NA-5
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F-61
F-61
TROUBLESHOOTING & REPAIR
WIRE SPEED ACCURACY TEST (Continued)
TEST PROCEDURE
Perform the following checks with the
NA-5 connected to a Lincoln CV weld-
ing power source according to the prop-
er connection diagram. See the
Installation Section of this manual.
1. Check to make sure the speedmeter
calibration jumper is connected to
the proper calibration pin for the
head and drive roll system being
used. See Table F.3
TABLE F.3
SPEEDMETER
CALIBRATION
HEAD
RATIO
DRIVE ROLL
PART NUMBER
WIRE SIZE RANGE
RATED SPEED
RANGE (IPM)
21*
21/1
S12778
S19113
Single .035 - .052 Solid
Single .045 - .052 Cored
100 - 2070
57F**
57**
57/1
57/1
S12778
S12515
Single .035 - .052
Single 1/16 - 3/32
40 - 778
38 - 762
95
95/1
95/1
S12514
Single 3/32 - 5/32
22 - 428
23 - 456
95S***
S12515
S19113
S13161-052
S13161-5/64
S14904 (Outer)
S14905 (Inner)
Single 1/16 - 3/32
Single .045 - .052 Cored
Twin .045 -.052
Twin 1/16 - 5/64
Twin 3/32
142
142/1
142/1
S12514
Single 3/32 - 7/32
Twin 5/64 - 1/8
15 - 289
15 - 300
142T***
S14904 (Outer)
S14905 (Inner)
* Present on HI -Speed NA-5 speedmeter board only. ** Early speedmeter pins were labeled 55F and 55,
respectively.
*** Early speedmeter PC boards did not include these calibration pins.
NA-5
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F-62
F-62
TROUBLESHOOTING & REPAIR
WIRE SPEED ACCURACY TEST (Continued)
2. Check for the proper wire feed inch-
es per revolution of the drive roll.
A. Set the Strike speed control to
any setting between 50 and 125
IPM. While pressing the INCH
DOWN button measure the pre-
cise length of wire fed by exactly
10 revolutions of the drive roll.
The measured length should be
within the range specified in
Table F.4 for the drive roll and
wire size employed.
B. If the measured length is not
within the specified lengths
there may be a problem with the
wire or wire feeding path. See
the Troubleshooting Guide
(Feeding Problems) in this sec-
tion of the manual. Also check
for correct drive roll tension
adjustment.
TABLE F.4
DRIVE ROLL PART
WIRE SIZE RANGE
INCHES OF WIRE FED PER
10 REVOLUTIONS OF
DRIVE ROLL
NUMBER
S12778
S19113
Single .035 - .052 Solid
Single .045 - .052 Cored
Single 1/16 - 3/32
Single 3/32 - 5/32
Twin .045 - .052
53 - 54
53 - 55
51 - 53
49 - 51
53 - 55
53 - 55
51 - 52
S12515
S12514
S13161-052
S13161-5/64
Twin 1/16 - 5/64
S14904 (Outer)
S14905 (Inner)
Twin 3/32
S12514
Single 3/32 - 7/32
Twin 5/64 - 1/8
49 - 52
51 - 53
S14904 (Outer)
S14905 (Inner)
NA-5
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F-63
F-63
TROUBLESHOOTING & REPAIR
WIRE SPEED ACCURACY TEST (Continued)
3. Check for the proper drive roll revo-
lutions per minute. (RPM)
B. If the readings do not match the
number in Table F.5 refer to the
A. Adjust the STRIKE speed con-
trol to obtain the SET speed
specified for the speedmeter
calibration pin and head ratio
specified per Table F.5 While
pressing the INCH down button
count the drive roll revolutions in
60 seconds. The drive roll revo-
lutions and actual speed reading
should match Table F.5
Meter Circuit Accuracy Test.
TABLE F.5
SPEEDMETER
CALIBRATION
PIN
HEAD
RATIO
SET SPEEDMETER
READING (IPM)
READING (IPM)
DRIVE ROLL
RPM
ACTUAL
SPEEDMETER
21*
21/1
0.27 (IPM X 1000)
50 +/- 2
0.27 +/- 0.01
(IPM X 1000)
57F**
57**
57/1
57/1
268
262
249
265
250
260
50 +/- 1
50 +/- 1
50 +/- 1
50 +/- 1
50 +/- 1
50 +/- 1
268 +/- 2
262 +/- 2
249 +/- 2
265 +/- 2
250 +/- 2
260 +/- 2
95
95/1
95S***
142
95/1
142/1
142/1
142T***
* Present on HI -Speed NA-5 speedmeter board only. ** Early speedmeter pins were labeled 55F and 55,
respectively.
*** Early speedmeter PC boards did not include these calibration pins.
NA-5
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F-64
F-64
TROUBLESHOOTING & REPAIR
METER CIRCUIT ACCURACY TEST
WARNING
Service and repair should be performed only by Lincoln Electric factory trained per-
sonnel. Unauthorized repairs performed on this equipment could result in danger to
the technician or the machine operator and will invalidate your factory warranty. For
your safety and to avoid electrical shock, please observe all safety notes and precau-
tions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform
the tests/repairs safely, contact the Lincoln Electric service department for technical
troubleshooting assistance before you proceed.
Call (216) 383-2531 or (800) 833-9353 (WELD).
_____________________________________________________________
TEST DESCRIPTION
This test will help determine if the NA-5 meter circuit is functioning properly.
The Speed Meter Circuit tests take approximately 15 minutes to perform.
The Volt Meter Circuit tests take approximately 15 minutes to perform.
MATERIALS NEEDED
Digital volt/ohmmeter with at least 3-1/2 digits and +/- 0.5% accuracy
5/16" Nutdriver
NA-5
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F-65
F-65
TROUBLESHOOTING & REPAIR
METER CIRCUIT ACCURACY TEST (Continued)
5. Test for AC supply to the volt-
TEST PROCEDURE
meter PC board.
1. Remove input power to the NA-5.
• Check for 8 to 11VAC from lead
#601 to #602. See Figure F.9
2. Using the 5/16" nutdriver open the
control box PC board access door.
Note: The coating will have to be
removed from the test points to ensure
accurate voltmeter readings. If the cor-
rect AC voltage is not present check for
loose or faulty connects with the associ-
ated leads. See wiring diagram.
3. Locate the voltmeter PC board. See
Figure F.9
4. Apply input power to the NA-5.
517
518
TP4
TP5
601
510C
510
602
L6685-[ ] METER
FIGURE F.9 VOLTMETER PC BOARD AND TEST POINTS
NA-5
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F-66
F-66
TROUBLESHOOTING & REPAIR
METER CIRCUIT ACCURACY TEST (Continued)
6. Test for DC volts on the voltmeter
7. Test Digital Voltmeter Accuracy
PC board.
• Use a test meter with at least 3-
1/2 digits and +/- 0.5% accuracy.
• Check for 4.75 to 5.25VDC from
TP5 to lead #510C. See Figure
F.9
• Connect the + probe to TP4 and
the - probe to lead 510C. Do NOT
disconnect plug.
Note: The coating will have to be
removed from the test points to ensure
accurate voltmeter readings.
Note: The coating will have to be
removed from the test points to ensure
accurate meter readings.
• If the display is NOT lit and the
correct DC voltage is present at
TP5 to lead #510C, the digital
meter may be faulty. Replace the
meter.
• With the NA-5 voltmeter reading
SET values of STRIKE voltage,
adjust the strike voltage control
until the test meter matches the
settings in the table below.
• If the AC voltage IS present at
leads #601 to #602 and the DC
voltage is missing, the voltmeter
PC board may be faulty.
• If the NA-5 digital voltmeter does
not match the readings, the digital
meter may be faulty.
NA-5 SET VOLTS READING
TEST VOLTMETER READING
15.0VDC
30.0VDC
60.0VDC
.150 +/- .004VDC
.300 +/- .004VDC
.600 +/- .006 VDC
NA-5
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F-67
F-67
TROUBLESHOOTING & REPAIR
METER CIRCUIT ACCURACY TEST (Continued)
8. Test Voltmeter PC Board Accuracy
• Use a test meter with at least 3-
1/2 digits and +/- 0.5% accuracy.
• Connect the + probe to lead #517
and the - probe to lead #510C.
Do not disconnect plug.
Note: The coating will have to be
removed from the test points to ensure
accurate meter readings.
• With the NA-5 voltmeter reading
SET values of STRIKE voltage,
adjust the strike voltage control
until the NA-5 voltmeter matches
the settings in the table below.
• If the test meter does not match
the readings, the voltmeter PC
board may be faulty.
NA-5 SET VOLTS READING
TEST VOLTMETER READING
15.0VDC
30.0VDC
60.0VDC
1.50VDC +/- .04
3.00VDC +/- .04
6.00VDC +/- .06
NA-5
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F-68
F-68
TROUBLESHOOTING & REPAIR
METER CIRCUIT ACCURACY TEST (Continued)
9. Locate the speedmeter PC board.
See Figure F.10
12. Test for DC volts on the speed-
meter PC board.
10. Apply input power to the NA-5.
• Check for 4.75 to 5.25VDC from
TP5 to lead #510P. See Figure
F.10
11. Test for AC supply to the speed-
meter PC board.
Note: The coating will have to be
removed from the test points to ensure
accurate meter readings.
• Check for 8 to 11VAC from lead
#601 ot #602. See Figure F.10
• If the display is NOT lit and the
correct DC voltage is present at
TP5 to lead #510P, the digital
meter may be faulty. Replace the
meter.
• If the AC voltage IS present at
leads #601 to #602 and the DC
voltage is missing, the speedme-
ter PC board may be faulty.
Note: The coating will have to be
removed from the test points to ensure
accurate voltmeter readings. If the cor-
rect AC voltage is not present check for
loose or faulty connects with the associ-
ated leads. See wiring diagram.
TP4
TP5
510P
601
602
510
NA5 SPEED METER L6233
FIGURE F.10 SPEEDMETER PC BOARD AND TEST POINTS
NA-5
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F-69
F-69
TROUBLESHOOTING & REPAIR
METER CIRCUIT ACCURACY TEST (Continued)
13. Test Speedmeter Digital Meter
Accuracy
• Use a test meter with at least 3-
1/2 digits and +/- 0.5% accuracy.
• Connect the + probe to TP4 and
the - probe to lead 510P. Do NOT
disconnect plug.
Note: The coating will have to be
removed from the test points to ensure
accurate meter readings.
• With the NA-5 speedmeter read-
ing SET values of STRIKE speed,
adjust the strike wire speed con-
trol until the test meter matches
the settings in the table below.
• If the NA-5 digital speedmeter
does not match the readings, the
digital meter may befaulty.
NA-5 SET SPEED READING
(IPM)
TEST VOLTMETER READING
150 (1.50*)
300 (3.00*)
.150 +/- .004VDC
.300 +/- .004VDC
*For Hi-Speed NA-5 speedmeter (IPM X 1000).
NA-5
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F-70
F-70
TROUBLESHOOTING & REPAIR
METER CIRCUIT ACCURACY TEST (Continued)
14. Test Speedmeter PC Board
Accuracy
• If the test meter does not match
the readings, the speedmeter PC
board may be faulty.
• Use a test meter with at least 3-
1/2 digits and +/- 0.5% accuracy.
15. When the testing is complete close
and secure the access door.
• Connect the + probe to lead #519
(Jumper lead) and the - probe to
lead #510P. Do not
nect plug.
discon-
Note: The coating will have to be
removed from the test points to ensure
accurate meter readings.
• With the NA-5 speedmeter read-
ing SET values of STRIKE speed ,
adjust the strike wire speed con-
trol until the NA-5 speedmeter
matches the settings in the table
below.
SPEEDMETER
CALIBRATION PIN
NA-5 SET SPEED READING
TEST VOLTMETER
READING
(IPM)
21*
57F
57
2.07*
778
762
428
456
289
300
6.00 +/- .06
6.00 +/- .06
6.00 +/- .06
6.00 +/- .06
6.00 +/- .06
6.00 +/- .06
6.00 +/- .06
95
95S
142
142T
* For Hi-Speed NA-5 speedmeter (IPM X 1000)
NA-5
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F-71
F-71
TROUBLESHOOTING & REPAIR
PC BOARD(S) REMOVAL AND REPLACEMENT
WARNING
Service and repair should be performed only by Lincoln Electric factory trained per-
sonnel. Unauthorized repairs performed on this equipment could result in danger to
the technician or the machine operator and will invalidate your factory warranty. For
your safety and to avoid electrical shock, please observe all safety notes and precau-
tions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform
the tests/repairs safely, contact the Lincoln Electric service department for technical
troubleshooting assistance before you proceed.
Call (216) 383-2531 or (800) 833-9353 (WELD).
_____________________________________________________________
DESCRIPTION
The following procedure will aid the technician in removing and replacing the printed circuit
boards for maintenance or replacement.
This procedure takes approximately 17 minutes to perform.
MATERIALS NEEDED
Phillips head screwdriver
5/16" Nutdriver
NA-5
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F-72
F-72
TROUBLESHOOTING & REPAIR
PC BOARD(S) REMOVAL AND REPLACEMENT (Continued)
PROCEDURE
Before starting the following procedure,
refer
to
the
PC
Board
Troubleshooting Procedures at the
beginning of this section.
1. Remove the input power to the NA-
5.
2. Using the 5/16" nutdriver open the
control box PC board cover.
3. Carefully remove the molex type
plugs (and leads) connected to the
PC board that is to be removed.
4. Using the phillips head screwdriver,
remove the PC board mounting
screws.
5. Carefully remove the PC board.
REPLACEMENT PROCEDURE
1. Using the phillips head screwdriver
and mounting screws carefully posi-
tion and install the new PC board.
2. Reconnect the molex type plugs
(and leads) into the new PC board.
3. Close and secure the access door.
NA-5
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F-73
F-73
TROUBLESHOOTING & REPAIR
DIGITAL METER AND METER PC BOARD REMOVAL AND REPLACEMENT
WARNING
Service and repair should be performed only by Lincoln Electric factory trained per-
sonnel. Unauthorized repairs performed on this equipment could result in danger to
the technician or the machine operator and will invalidate your factory warranty. For
your safety and to avoid electrical shock, please observe all safety notes and precau-
tions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform
the tests/repairs safely, contact the Lincoln Electric service department for technical
troubleshooting assistance before you proceed.
Call (216) 383-2531 or (800) 833-9353 (WELD).
_____________________________________________________________
DESCRIPTION
The following procedure will help the technician remove the digital meters and meter PC
boards for repair or replacement.
This meter PC Board portion of this procedure takes approximately 8 minutes to perform.
The total Meter PC Board and Meter Replacement procedure takes approximately 15 minutes to perform.
MATERIALS NEEDED
5/16" Nutdriver
Phillips head screwdriver
NA-5
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F-74
F-74
TROUBLESHOOTING & REPAIR
DIGITAL METER AND METER PC BOARD REMOVAL AND REPLACEMENT
METER PC BOARD REMOVAL
PROCEDURE
5. Carefully remove the meter PC
board.
1. Remove input power to the NA-5.
2. Using the 5/16" nutdriver open the
control box PC board access door.
Note insulation placement for reassem-
bly. Also make sure the plug on the
back of the PC board plugs into the
prongs on the meter when you
reassemble.
3. Locate and unplug the meter PC
board that is to be removed. See
Figure F.11
4. Using the 5/16" nutdriver remove the
four PC board mounting nuts. See
Figure F.11
SPEED METER BOARD
METER BOARD
MOUNTING
NUTS
PC BOARD
PLUG PRONGS
FIGURE F.11 METER PC BOARD, MOUNTING NUTS AND PLUG
NA-5
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F-75
F-75
TROUBLESHOOTING & REPAIR
DIGITAL METER AND METER PC BOARD REMOVAL AND REPLACEMENT
DIGITAL METER REMOVAL
PROCEDURE
1. Using the phillips head screwdriver
remove the four screws from the
meter bezel. See Figure F.12
4. Using the 5/16" nutdriver, remove
the two nuts, screws and lockwash-
ers holding the digital meter to the
cover assembly.
2. Carefully remove the bezel assem-
bly.
5. Carefully remove the digital meter.
3. Carefully remove the meter shield
assembly.
MOUNTING
INSULATOR
DIGITAL
METER
METER SHIELD
ASSEMBLY
METER SHIELD
METER BEZEL
FIGURE F.12 METER BEZEL AND SCREW LOCATIONS
NA-5
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F-76
F-76
TROUBLESHOOTING & REPAIR
DIGITAL METER AND METER PC BOARD REMOVAL AND REPLACEMENT
REPLACEMENT PROCEDURE
1. With the 5/16" nutdriver, fasten the
digital meter to the cover assembly
with two screws, nuts and lockwash-
ers.
2. Using the phillips head screwdriver,
reattach the meter shield and bezel
assembly.
3. Position the insulation and plug the
PC meter board into the digital
meter.
4. Mount the meter PC board using the
four nuts previously removed.
5. Reattach the molex plug.
6. Close and secure the access door.
NA-5
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F-77
F-77
TROUBLESHOOTING & REPAIR
TACH PC BOARD REMOVAL AND REPLACEMENT
WARNING
Service and repair should be performed only by Lincoln Electric factory trained per-
sonnel. Unauthorized repairs performed on this equipment could result in danger to
the technician or the machine operator and will invalidate your factory warranty. For
your safety and to avoid electrical shock, please observe all safety notes and precau-
tions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform
the tests/repairs safely, contact the Lincoln Electric service department for technical
troubleshooting assistance before you proceed.
Call (216) 383-2531 or (800) 833-9353 (WELD).
_____________________________________________________________
DESCRIPTION
The following procedure will help the technician remove the Tach PC board and related com-
ponents for repair or replacement.
This procedure takes approximately 9 minutes to perform.
MATERIALS NEEDED
5/16" Nutdriver
Slot head screwdriver
Phillips head screwdriver
3/8" Wrench
NA-5
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F-78
F-78
TROUBLESHOOTING & REPAIR
TACH PC BOARD REMOVAL AND REPLACEMENT (Continued)
5. Using the phillips head screwdriver,
PROCEDURE
remove the two screws from the
pick-up assembly cover . See
Figure F.14. Remove the cover.
1. Remove input power to the NA-5.
2. With the 5/16" nutdriver locate and
remove the four screws holding the
tach cover to the wire feed drive
motor. See Figure F.13
6. Hold the nut in place with the 3/8"
wrench. With the phillips head
screwdriver, remove the locking
screw from the rotating disc. See
Figure F.15
3. Using the 5/16" nutdriver remove the
two screws from the connection box
cover.
4. Locate and disconnect the in-line
connectors from leads #510A,
#525A and #555.
TACH COVER
MOUNTING
SCREWS (x4)
PICKUP
ASSEMBLY
WIRE
DRIVE
MOTOR
FIGURE F.13 DRIVE MOTOR, TACH COVER, AND CONNECTION BOX
NA-5
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F-79
F-79
TROUBLESHOOTING & REPAIR
TACH PC BOARD REMOVAL AND REPLACEMENT (Continued)
SCREWS
TACHASSEMBLY
COVER
FIGURE F.14 PICK-UP ASSEMBLY AND COVER
7. Carefully remove the rotating disc
and tach PC board together. Note
spacer washers underneath the disc.
8. If tach PC board is to be removed
carefully remove leads from connec-
tion box and cover plate.
PHILLIPS
SCREW DISC
NUT
TACH
PC BOARD
FIGURE F.15 ROTATING DISC, NUT AND TACH BOARD
NA-5
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F-80
F-80
TROUBLESHOOTING & REPAIR
TACH PC BOARD REMOVAL AND REPLACEMENT (Continued)
REASSEMBLY
1. Upon reassembly the spacers must
be used to assure that the disc
rotates freely and smoothly within
the sensor "window" on the printed
circuit board. Note the tach PC
board must be held in place when
aligning the rotating disc in the sen-
sor window. Press down on the tach
PC board with your finger to simulate
the cover.
2. Use the 3/8" wrench to hold the nut
in place. Attach the rotating disc
with the phillips head screw.
3. Thread leads #510A, #525A and
#555 through the cover plate and
into the connection box. Attach to
their respective in-line connectors.
4. Replace the connection box cover.
5. Replace the pick-up assembly cover.
6. Reattach the tach cover to the wire
feed drive motor.
NA-5
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F-81
F-81
TROUBLESHOOTING & REPAIR
WIRE DRIVE MOTOR REMOVAL AND REPLACEMENT
WARNING
Service and repair should be performed only by Lincoln Electric factory trained per-
sonnel. Unauthorized repairs performed on this equipment could result in danger to
the technician or the machine operator and will invalidate your factory warranty. For
your safety and to avoid electrical shock, please observe all safety notes and precau-
tions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform
the tests/repairs safely, contact the Lincoln Electric service department for technical
troubleshooting assistance before you proceed.
Call (216) 383-2531 or (800) 833-9353 (WELD).
_____________________________________________________________
DESCRIPTION
This procedure will aid the technician in the removal and replacement of the drive motor to
the gear box and also associated wiring to the control box.
This procedure takes approximately 35 minutes to perform.
MATERIALS NEEDED
7/16" Wrench
5/16" Nutdriver
Large slot head screwdriver
NA-5
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F-82
F-82
TROUBLESHOOTING & REPAIR
WIRE DRIVE MOTOR REMOVAL AND REPLACEMENT (Continued)
MOTOR REMOVAL
PROCEDURE
6. Using the 5/16" nutdriver remove the
clamp holding the connection box to
the drive motor.
1. Remove input power to the NA-5.
2. Remove the motor and tach cable
from the NA-5 control box.
7. Carefully remove the connection box
being careful not to stretch the leads.
3. Perform the Tach Board Removal
Procedure.
4. Using the slot head screwdriver
remove the two screws mounting the
tach housing to the drive motor.
Remove the tach housing from the
drive motor.
5. Using the phillips head screwdriver
remove the cover plate adaptor.
See Figure F.16
TACH HOUSING
COVER PLATE
ADAPTER
WIRE
DRIVE
MOTOR
FIGURE F.16 DRIVE MOTOR AND TACH HOUSING
NA-5
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F-83
F-83
TROUBLESHOOTING & REPAIR
WIRE DRIVE MOTOR REMOVAL AND REPLACEMENT (Continued)
8. Remove leads #67, #627, #626,
#539 and #541 from the terminal
strip in the connector box.
11. Carefully remove the adapter plate
and motor assembly (with pinion
attached).
9. Using the 7/16" wrench, remove two
1/4-20 bolts holding the adapter
plate and motor assembly to the wire
feed gear box. (Older models may
have slot head 1/4-20 bolts). See
Figure F.17
12. With a slot head screwdriver,
remove the adapter plate from the
drive motor.
10. Using the large slot head screwdriv-
er, remove the two slot head screws
that go through the wire feed gear
box and into the adapter plate.
HEX HEAD
BOLT
ADAPTER
PLATE AND
MOTOR
ASSEMBLY
WIRE DRIVE
GEARBOX
SLOT HEAD
SCREW
FIGURE F.17 DRIVE MOTOR
NA-5
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F-84
F-84
TROUBLESHOOTING & REPAIR
WIRE DRIVE MOTOR REMOVAL AND REPLACEMENT (Continued)
MOTOR REPLACEMENT
PROCEDURE
1. Attach the adapter plate to the drive
motor using the slot head screwdriv-
er.
2. Carefully install the replacement
motor (with correct pinion) and
mount the adapter mounting plate
using the 1/4-20 bolts and slot head
screws previously removed.
3. Attach leads #67, #627, #626, #539
and #541 to their respective termi-
nals in the connector box.
4. Carefully position the connector box
and clamp to the drive motor and
using the 5/16' nutdriver secure in
position. Be sure NOT to "pinch"
any leads.
5. Using the phillips head screwdriver
mount the cover plate adaptor to the
drive motor.
6. Using the slot head screwdriver
attach the tach housing to the drive
motor.
7. Perform
the
Tach
Board
Replacement Procedure.
8. Assemble the motor and tach cables
to the NA-5 control box.
NA-5
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F-85
F-85
TROUBLESHOOTING & REPAIR
RETEST AFTER REPAIR
If a failed test indicates that any mechanical part that could affect the machine's electrical characteristics must be
replaced or if any electrical components are repaired or replaced, the machine must be retested and must meet
the following standards.
Wire Feed Speed per following table:..........................
Gear Ratio
Wire Speed Range in/min (m/min)
21/1
57/1
95/1
100-2070 (2.54-52.58)
38-778 (.97-19.76)
22-456 (.56-11.58)
15-300 (.38-7.62)
142/1
LEDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Must operate per PC Board LED Definitions table in
Troubleshooting Section.
Flux or Water Solenoid . . . . . . . . . . . . . . . . . . . .Must operate when "Start" switch is pressed.
Relay 3CR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Must operate and "close" power source contactor.
Relay 2CR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Must operate and activate external travel circuit, if used.
Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Refer to Voltmeter Accuracy Test.
Wire Speed Meter . . . . . . . . . . . . . . . . . . . . . . . .Refer to Wire Speed Accuracy Test.
Voltage control and shutdown . . . . . . . . . . . . . . .Refer to Out of Voltage Range Shut Down Test.
NA-5
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F-86
F-86
NOTES
NA-5
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G-1
G-1
ELECTRICAL DIAGRAMS
TABLE OF CONTENTS
-ELECTRICAL DIAGRAMS SECTION-
Electrical Diagrams....................................................................................................................Section G
Wiring Diagram ....................................................................................................................................G-2
Logic PC Board (L6242-1) Schematic .................................................................................................G-3
Logic PC Board (L6242-2 & above) Schematic ...................................................................................G-4
Power PC Board (L6252-1) Schematic................................................................................................G-5
Power PC Board (L6252-2 & above) Schematic..................................................................................G-6
Voltage PC Board Schematic ..............................................................................................................G-7
Control Circuit Schematic ....................................................................................................................G-8
Procedure Board Schematic................................................................................................................G-9
Option & Timer Board Schematics.....................................................................................................G-10
Meter PC Board Schematic & Layout ................................................................................................G-11
Miscellaneous PC Board Layouts......................................................................................................G-12
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NOTES
NA-5
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G-2
G-2
ELECTRICAL DIAGRAMS
Wiring Diagram
1 5 5 G 3
564A
OPTIONAL PULSE POWER
FILTER P.C. BOARD
LEAD PLUG
581A
OPTIONAL PROCEDURE MODULE
USED FOR CRATER CONTROL
FLUX RELAY MODULE
87
N.P.
532
4
ELECTRODE CABLE
TO POWER SOURCE
2
POWER P. C. BOARD
N.F.
OPTIONAL PROCEDURE MODULE
USED FOR START CONTROL
TIMER BOARD
(CRATER TIME USE)
1
2
3
4
5
6
626
LOGIC
585
610
CR1
DIGITAL METER
DIGITAL METER
P.C. BOARD
1
3
*
541
627
N.L.
TRAVEL
TIMER BOARD
(START TIME USE)
RELAY MODULE
1
583C
*
*
625
SPEED-
142
95
142T
95S
57F
*
*
2
587
565
566
584S
588
560
561
563
563
2
3
4
REED SWITCH ACTUATED BY
WELDING CURRENT
539
VOLTMETER BOARD
4
2
1
3
METER
BOARD
532
N.P.
N.P.
4
8
525
510
500
540
525
4
TIMER
RECEPT.
2
1/2A SLOW BLOW
FIELD FUSE
57
6
5
3
2
4
1
688
687
530
628
N.M.
589
N.A.
6
3
7
7
8
*
610
CR2
*
528
500
MAGNETICALLY
COUPLED
1
3
P28 (C)
J28 (C)
N.R.
CR4
TIMER
RECEPT.
CONTACTOR
RELAY MODULE
6
9
5
9
2
4
516
514
4
1
4
1
1/2A SLOW BLOW
POWER FUSE
6
2
5
3
6
2
5
3
9
5
510
500
500
582
581
*
2
P28 (S)
J28 (S)
TRAVEL RECEPT.
J5
1
/
8
AMP
635
1
OPTION BOARD
4
FAST BLOW
FUSE
*
A
532
25
531
GND
ELECTRODE LEAD BOLTED
AND TAPED CONNECTION
4
8
10
3
7
6
2
510P
(CRATER FILL USE)
2
5
1
6
3
1
5
4
6
3
2
1
2
4
532
531A
631
610
585
589
584C
564
583S
500
B
C
D
*
N.R.
*
CR3
*
525
510
500
1
3
OPTION BOARD
(START USE)
WELD TIMER BOARD
(OPTIONAL)
610
531B
500
682
5
6
3
682
610
J29 (C)
P29 (C)
ORANGE
WHITE
S
515
500
681
500
FLUX OR WATER
SOLENOID
87
BLUE BLUE
RED
ORANGE
RED
5
J4
FLUX RECEPTACLE
4
1
11
12
530
667
621
A
87
F
N.E.
J29 (S)
531
B
C
531
GND
B
P29 (S)
6
A
B
C
587
N.H
J3 MOTOR RECEPTACLE
D
A
4
5
3
2
1
A
541
*
B
C
539
626
592
531B
687
688
D
E
F
627
67
N.C.
CONTROL
P.C. BOARD
T1
531B
12
540
525
510
500
628
520
532
8
9
4
3
1
2
7
6
5
531B
532
637
BYPASS
COM
10
9
TIMER BOARD
532
(BURNBACK TIME)
J2
TACH. RECEPTACLE
A
14
13
1
563
*
TS2
B
C
525A
555
AUTO
N.N.
511
511A
8
7
510P
D
510A
*
510P
METER
632
512
511
511A
510P
586
WELD TIME
RECEPT.
500
*
A
2
T2
F
CRATER RECEPT.
START RECEPT.
6
2
3
5
N.B.
5
6
4
3
2
1
*
*
*
B
C
4
CIRCUIT
POLARITY
TERMINALS
TS1
500
655
515
I
VOLTAGE P.C. BOARD
31
32
21
A
S
CONTROL
CABLE
TO
SET-ACTUAL
S7
D
E
F
TS
3
N.D.
*
REMOTE INTERFACE
MODULE (OPTIONAL)
BURNBACK
RECEPT.
4
15
N.J.
510A
POWER
O
525A
555
G
H
B
START
S5
SOURCE
11
PROCEDURE BOARD
ARM.
C
1
581A
500
586
592
TACH.
I
GREEN
631
6
PICK-UP
N.R.
*
5
4
2
3
P.C. BD.
J1 INPUT RECEPTACLE
WHITE
TERMINAL
STRIP JUMPER
581A
WELDING
NOZZLE
582
515
N.K.
592
S4
500
592
ELECTRICAL SYMBOLS PER E1537
N.A. SPEEDMETER BOARD CALIBRATION JUMPER IS TO BE CONNECTED FOR NA-5 HEAD AND DRIVE ROLL
625
531A
R1
531A
531
31
32
R
627
626
INCH
DOWN
UP
WORK CABLE TO
POWER SOURCE
RF BYPASS
P.C. BOARD
25
532
610
682
500
582
500
S3
WORK
532
531
EMPLOYED PER CHART BELOW: (CONNECTED TO PIN "95" OR "21"
WHEN SHIPPED.
621
ELECTRODE
667
87
531
586
5A CIRCUIT
BREAKER
CB1
STOP
"HOT" LIGHT
LT1
RED
RED
TRAVEL SW.
S2
POWER SW.
S1
S6
SPEEDMETER NA-5 HEAD DRIVE ROLL
WIRE SIZE
RATED SPEED
1/8 AMP FUSE
N.G. 531-532 115VAC
531-25 115VAC (SWITCHED)
PIN
57F
57
95
95S
RATIO
PART NUMBER
RANGE
RANGE
250 VAC
SINGLE .035-.052
SINGLE 1/16-3/32
SINGLE 3/32-5/32
SINGLE 1/16-3/32
TWIN .045-.052
40-778 I.P.M.
38-762 I.P.M.
22-428 I.P.M.
23-456 I.P.M.
57/1
57/1
95/1
95/1
S12778
S12515
S12514
S12515
N.H. 531-87 115 VAC (SWITCHED) 1/2 AMP.
PROCEDURE KIT
RECEPTACLE
N.J. CONNECT #67 BLACK (ELECTRODE) LEAD AND #21 WHITE (WORK) LEAD TO APPROPRIATE TERMINAL STRIP
POLARITY CONNECTIONS WHICH MATCH ELECTRODE AND WORK CABLE POLARITY CONNECTIONS TO POWER SOURCE.
S13161-052
S13161-5/64
S14904(OUTER)
S14905(INNER)
S12514
S14904(OUTER)
S14905(INNER)
S12778
TWIN 1/16-5/64
560
564
500
1
N.K. LEAD CONNECTED TO MOTOR FRAME WHICH IS ELECTRICALLY COMMON WITH ELECTRODE DRIVE ROLL AND DRIVEN ELECTRODE.
2
3
TWIN
/
3
32
NOTE: NA-5 MOTORS INSULATED FOR HIGH FREQUENCY STARTING DO NOT HAVE THIS CONNECTION. REFER TO
HI-FREQUENCY INSTALLATION INSTRUCTIONS FOR REQUIRED #67 ELECTRODE VOLTAGE SENSING LEAD CONNECTION.
SINGLE 3/32-7/32
15-289 I.P.M.
15-300 I.P.M.
100-2070 I.P.M.
515500
635
520
142
142T
142/1
142/1
4
5
6
N.L. REMOVE JUMPER PLUG TO INSTALL OPTIONAL KIT. IF KIT IS REMOVED, REPLACE JUMPER PLUG.
TWIN 5/64-1/8
*
N.M. NOT PRESENT ON EARLIER VOLTAGE P.C. BOARDS.
21
SINGLE .035-.052
21/1
632
7
8
510P
W
N.N. BLUE JUMPER LEAD NOT PRESENT ON EARLIER VOLTAGE P.C. BOARDS. THE JUMPER IS TO BE CONNECTED TO THE
=
=
EARLIER SPEEDMETER BOARDS DID NOT HAVE THESE PINS.
SINGLE "21" PIN ON HIGH SPEED BOARD ONLY.
9
"COM" TAB, UNLESS SPECIFIED ON THE POWER SOURCE CONNECTION DIAGRAM TO BE CONNECTED TO THE "AUTO" TAB
TO DISABLE THE "COLD" STARTING FEATURE.
W
10
11
564A
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.
114A 12
N.P. EARLIER RELAYS HAD SAME TERMINAL NUMBERS BUT IN
A
DIFFERENT ORIENTATION.
N.L.
N.R. POTENTIOMETERS AND SWITCHES MOUNTED ON P.C. BOARD ARE CONNECTED TO FRAME, FOR ESD.
(NOT PRESENT ON EARLIER BOARDS)
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
USE OF PIN "S" JUMPER CONNECTION.
N.E. VOLTAGE BOARD RED JUMPER LEAD CONNECTED TO PIN "S" AND WHITE JUMPER LEAD CONNECTED TO
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".
*
CAVITY NUMBERING SEQUENCE
(COMPONENT SIDE OF P.C. BOARD)
N.F. LOGIC BOARD DIP SWITCHES OR JUMPERS TO BE SET TO SUIT DESIRED APPLICATIONS PER CHARTS BELOW:
NA-5 SHIPPED CONNECTED FOR INDICATED METHODS OF TRAVEL
&
BURNBACK.
METHODS OF TRAVEL
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
FOR EARLIER LOGIC P.C.
BOARDS WITH JUMPERS
FOR LOGIC P.C. BOARDS WITH
1
2
3
4
DIP SWITCHES
1
2
3
4
1
2
3
4
CONNECT
SAMPLE SWITCH
LEAD #691 to P6
LEAD #692 to P5
START/STOP WITH SWITCHES
SWITCH POSITION
SWITCH POSITION
1
2
IS UP
SWITCH #1
SWITCH #2
IS DOWN
1
2
3
4
1
2
3
4
CONNECT
SWITCH POSITIONS
3
AND
4
ARE NOT APPLICABLE
LEAD #691 to P6
LEAD #692 to P7
START/STOP WITH WELD CURRENT
METHODS OF BURNBACK
J28
J29
SWITCH #1
SWITCH #2
1
2
3
4
1
2
3
4
FOR LOGIC P.C. BOARDS WITH
DIP SWITCHES
CONNECT
FOR EARLIER LOGIC P.C.
BOARDS WITH JUMPERS
START WITH WELD CURRENT
STOP WITH STOP SWITCH
LEAD #691 to P5
LEAD #692 to P7
USE OF OPTIONAL CRATER MODULE
CRATER BOARD INSTALLED?
1
2
3
4
1
2
3
4
SWITCH #1
SWITCH #2
CONNECT
LEAD #690 TO P4
LEAD #693 TO P3
WIRE FEED STOP WITH
CONTACTOR DELAY
1
2
3
4
1
2
3
4
FOR EARLIER LOGIC P.C.
BOARDS WITH JUMPERS
FOR LOGIC P.C. BOARDS WITH
DIP SWITCHES
CONNECT
START WITH START SWITCH
STOP AFTER CRATER TIME
(OPTIONAL PROCEDURE MODULE
LEAD #691 to P6
LEAD #692 to P9
SWITCH #1
1
SWITCH #2
1
2
3
4
2
3
4
1
2
3
4
1
2
3
4
SWITCH #1
SWITCH #2
CONNECT
CONNECT
LEAD #690 TO P4
LEAD #693 TO P1
YES
NO
INSTALLED IN CRATER RECEPTACLE)
LEAD #694 TO P10
INCH UP WITH CONTACTOR DELAY
UNLESS OTHERWISE SPECIFIED TOLERANCE
ON HOLE SIZES PER E2056
THIS SHEET CONTAINS PROPRIETARY INFORMATION
1-12-96D
7-12-96P
EQUIP.
TYPE
1
2
3
4
1
2
3
4
NA-5
THE LINCOLN ELECTRIC CO.
CLEVELAND, OHIO U.S.A.
CONNECT
SWITCH #1
1
SWITCH #2
1
SWITCH #1
SWITCH #2
OWNED BY
AND IS
8-24-84H
11-14-86L
7-19-91J
START WITH START SWITCH
STOP AFTER BURN-BACK TIME
(OPTIONAL PROCEDURE MODULE
THE LINCOLN ELECTRIC CO.
ON
ON
2
3
PLACE DECIMALS IS .02
PLACE DECIMALS IS .002
NOT TO BE REPRODUCED, DISCLOSED OR USED
WITHOUT THE EXPRESS PERMISSION OF
LEAD #691 to P6
LEAD #692 to P8
2
3
4
2
3
4
1
2
3
4
1
2
3
4
CONNECT
LEAD #690 TO P2
LEAD #693 TO P1
CONNECT
WIRING DIAGRAM
SUBJECT
ON ALL ANGLES IS .5 OF
A
DEGREE
INCH UP WITH NO CONTACTOR
DELAY
SCALE
NONE
LEAD #694 TO P8
SWITCH #1
SWITCH #2
t
SHT.
NO.
MATERIAL TOLERANCE (" ") TO AGREE
WITH PUBLISHED STANDARDS.
7-10-92B
5-19-95D
INSTALLED IN CRATER RECEPTACLE)
THE LINCOLN ELECTRIC CO.
G1512
8-1-80
DAD
5-8-92
REF.
1553
DR
DATE
CHK
SUP'S'D'G
G
SWITCH #1
SWITCH #2
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
NA-5
Download from Www.Somanuals.com. All Manuals Search And Download.
G-3
G-3
ELECTRICAL DIAGRAMS
LOGIC PC BOARD (L6242-1) SCHEMATIC
LED 7B
610
A6G
583S
PROCEDURE
PROCEDURE
PC BOARD
564
D1021
RED
D1023
REMOTE INTERFACE
OPTION
PC BOARD
WELD TIME
OVER
START TIME
OVER
515
D8C
WELD
24
X705
P10
X705
X701
C
PROCEDURE
9
10
B
R741
A7E VAC
R1001
8
9
F
8
ENABLE
D718
START
Q711
D1001
3
4
D712
581A
D1024
D1022
CR2
RED
D1002
DISABLE
LED 7H
TRAVEL
CR
694
R706
C727
P5
1001
N.C.
X705
X707
A
1
2
581
S801A
DZ702
3
6
D1004
C1001
24V SIG.
D722
589
500
D9C
F1001
+
692
N.A.
D1003
SWITCH
CR
C706
X701
D
1001
581A
13
12
R720
E
S5
11 11
10
Q702
START
N.D.
D1005
560
PROCEDURE
PC BOARD
D1A
X705
12
START
C719
D708
565
X701
A
X707
B
4
1
2
PROCEDURE
PC BOARD
PRESET
MONITOR
ENABLE
A
R1002
500
D9C
689
+
3
6
13
D1006
5
500
A7H
D1007
SIGNAL
COMMOM
WELD TIME
OVER
SWITCH
CR
N.B.
CR
515
D8C
1002
COMMON
1002
582
Q709
+
610
A6G
C725
D1009
+
C705
500
D9C
D3A
C1002
D1008
SWITCH
691
X701
B
515
D8C
5
24V SIG.
500
D9C
CR6
4
ELECTRODE
HOT
D1010
.047
MFD
N.D.
LED 7C
STOP
D710
R703
D726
R735
CR
R1003
C728
1003
586
LT1
R
D1011
CR3
500
D9C
582
D1012
CR
DZ701
D725
530
1003
D7J
D720
HOLD-LOW
DISABLE
500
D9C
LED 7K
P6
P8
X705
6
C704
584C
D723
X702
C
PROCEDURE
PC BOARD
C4D
D1014
+
10
9
C
S6
STOP
D1013
SWITCH
C1003
POWER
SOURCE
OUTPUT
X707
13
12
682
5
CRATER
TIME
515
8
R725
D
11
Q708
24V SIG.
Q704
D8C
INITIATE
D1015
C724
INCH UP
500
D9C
C721
R1004
D709
515
D8C
D1016
500
D9C
C711
500
A7H
CR
C708
500
D9C
PROCEDURE
PC BOARD
D1017
SIGNAL
COMMOM
566
1004
592
CR
1004
500
D9C
BURNBACK
TIME OVER
D715
D716
X706
SWITCH
COMMON D1018
SWITCH
D7A
687
X707
C
610
A6G
D1019
10
9
+
C
688
SHUTDOWN
ENABLE
N.E.
SHUT-
DOWN
C1004
6
8
5
LED7D
690
24V SIG.
P4
500
D9C
P1
C5K
C5E
C4M
9
500
D9C
C729
N.D.
D1020
X706
ARC CONTROL
ENABLE
D
F
INCH DOWN
R712
R733
528
CR4
CURRENT
8
+
CURRENT
Q707
D714
P7
C707
X706
12
CR5
588
C723
13
PROCEDURE
PC BOARD
D719
500
D9C
CURRENT
584S
X706
500
D9C
N.A. S801 (SEE PROCEDURE PC BOARD
SCHEMATIC) MUST BE IN "STRIKE"
POSITION TO START WELD CYCLE.
515
X702
A
2
1
E
}
D8C
681
3
6
11
10
START
TIME
R723
PROCEDURE
PCB
561
PROCEDURE
PC BOARD
563
Q703
N.B. COMPONENTS INCLUDED WITH
OPTIONAL LINC-FILL BYPASS KIT
(ALSO SEE SCHEMATIC A).
Q710
INITIATE
STRIKE PROCEDURE
DISABLE
STRIKE
X702
B
DZ706
L701
C720
X706
2
637
PROCEDURE
4
R739
VOLTAGE
PRESENT
A
ENABLE
N.C. LEAD 694 TO BE CONNECTED TO
500
A7H
1
5
C2M
PIN P10 IF OPTIONAL CRATER MODULE
(SEE SCHEMATIC E) IS INSTALLED, OR
X702
D
12
13
C726
11
610
A6G
CRATER
TIME OVER
BURNBACK
TIME
P2
TO PIN P8 IF REMOVED.
500
D9C
515
D8C
N.D. LOGIC BOARD JUMPER LEADS ARE TO
X704
2
Q701
+
X704
4
BE CONNECTED TO SUIT APPLICATION
PER CHARTS BELOW.
N.E. HOLD-LOW DISABLE IS USED WITH
G1556-1 AND EARLIER VOLTAGE BOARDS.
ARC CONTROL ENABLE IS USED WITH
LATER VOLTAGE BOARDS.
P9
B
A
3
6
X706
5
1
PROCEDURE
PC BOARD
P3
INITIATE
B
LED
7E
D717
3
4
583C
X703
4
587
CR1
FEED
FORWARD
C709
X704
D
X704
C
X703
C
9
B
6
13
12
9
10
LED 7G
8
8
D721
11
5
LED 7J
A3K
10
586
B7J
DZ703
FEED
592
C3K
D724
LEAD
NO.
TO PIN
NO.
N.D.
FLUX OR
WATER
2
DZ705
X703
ENABLE
585
Q705
METHODS OF TRAVEL
Q706
693
X705
X703
START-STOP
691
P6
A
3
12
R731
592
R718
D
692
P5
WITH SWITCHES
1
D
11
2
1
S3
INCH
UP
13
START-STOP
691
692
P6
P7
C722
WITH WELD CURRENT
C710
C712
S4
691
P5
500
A7H
START WITH WELD CURRENT
DZ704
INCH
DOWN
692
P7
STOP WITH STOP SWITCH
500
D9C
691
692
WHEN OPTIONAL
START WITH START SWITCH
STOP AFTER CRATER TIME
P6
P9
500
D9C
PROCEDURE MODULE
IS INSTALLED IN
CRATER RECEPTACLE
START WITH START SWITCH
STOP AFTER BURN-BACK TIME
691
P6
692
P8
LEAD
NO.
TO PIN
NO.
METHODS OF BURNBACK
FOR LOGIC P.C. BOARDS L6242-2 OR HIGHER USE G2974 SCHEMATIC FOR
COMPONENT VALUES AND CIRCUIT CONNECTIONS.
P4
WIRE FEED STOP WITH
690
FOR REMOTE INTERFACE PC. BOARDS L6580-1
OR HIGHER USE S21207 SCHEMATIC FOR
CONTACTOR DELAY
693
P3
690
693
INCH UP WITH
P4
P1
COMPONENT VALUES AND CIRCUIT CONNECTIONS.
LOGIC P.C. BOARD
CONTACTOR DELAY
OPTIONAL REMOTE INTERFACE P.C. BOARD
690
INCH UP WITH NO
P2
C701
C702
C703
C704
C705
C706
C707
C708
C709
C710
THRU
C729
D701
THRU
D712
D714
THRU
D717
D718
THRU
D721
D722
THRU
D726
DZ701
DZ702
DZ703
DZ704
DZ705
DZ706
L701
.22/100
500/50
4.7/35
.047/100
10/25
16V, 1W
R704
R705
R706
R707
R708
R709
R710
R711
R712
R713
R714
R715
R716
R717
R718
R720
R721
R722
R723
R724
R725
R726
R727
47K
470
R728
R729
R730
R731
R732
R733
R734
R735
R736
R737
R738
R739
R740
R741
R742
X701
X702
X703
X704
X707
X705
X706
X708
2.7K
1.5K
68K
22K
47K
22K
47K
22K
47K
6.8K
47K
10K
15K
10K
15K
2/50
C1001 THRU C1004
CR1001 THRU CR1004
D1001 THRU D1004
F1001
693
P1
CONTACTOR DELAY
16V, 1W
SPDT, 24VDC
1A, 600V
1/8A FUSE
150
FOR LEAD #694 CONNECTION SEE N.C.
3V, 1/2W
16V, 1W
3V, 1/2W
5.1V, 1/2W
5.6mH, 28mA
100
NA-5 SHIPPED CONNECTED FOR INDICATED
METHODS OF TRAVEL AND BURNBACK.
4.7K
47K
470
470
15K
470
4.7K
4.7K
100K
22K
4.7K
100
2.7K
1.5K
68K
2.7K
1.5K
2.7K
1.5K
68K
R1001 THRU R1004
KEY TO SYMBOLS
POWER SUPPLY SOURCE POINT
.047/100
10/25
COMPONENTS NOT ON P.C. BOARD
10/25
10/25
LED 7A
THRU
CR1
SPST 110 VDC RELAY COIL
(N.O. CONTACTS SHOWN ON
SCHEMATIC A)
SCHEMATIC LOCATION REFERENCE
CR2
CR3
RED
LED 7E
LED 7G
LED 7H
LED 7J
LED 7K
Q701
HORIZONTAL CO-ORDINATE LETTER
VERTICAL CO-ORDINATE NUMBER
SCHEMATIC IDENTIFICATION LETTER
}
}
LIGHT
EMITTING
DIODE
.022/25
REED SWITCH ACTUATED BY
WELDING CURRENT
CR4
CR5
CR6
}
}
}
}
}
}
OPTIONAL 110 VDC RELAY
COIL ACTUATED BY CR4
1A, 400V
1A, 400V
1A, 1000V
1A, 400V
UNLESS OTHERWISE SPECIFIED, COMPONENT VALUES OF:
CAPACITORS MFD/VOLTS
RESISTORS OHMS, 2 /WATT
SINCE COMPONENTS OR CIRCUITRY ON
BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGE-
ABILITY OF COMPLETE BOARD, THIS DIAGRAM MAY NOT
SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS
HAVING COMMON CODE NUMBER.
ELECTRICAL SYMBOLS PER E1537
}
2N 4123
2N 5657
=
=
OPTIONAL LINC-FILL
SOLID-STATE PILOT RELAY
INDICATOR LIGHT
Q702
1
QUAD
INPUT
NAND
GATE
2
THRU
LT1
S3
S4
A
PRINTED CIRCUIT
Q705
}
Q706
THRU
Q711
R701
R702
R703
SPST PUSH BUTTON SWITCH
A
2N 4123
S5
}
HEX
S6
}
4.7K
4.7K
100
INVERTER
A
TIC
22V 600mA SECONDARY
+15
V
VOLTAGE
(PRIMARY SHOWN ON SCHEMATIC A)
1-12-96D
REGULATOR
L6682-4
CLEVELAND, OHIO U.S.A.
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided
for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.
NA-5
Download from Www.Somanuals.com. All Manuals Search And Download.
G-4
G-4
ELECTRICAL DIAGRAMS
LOGIC PC BOARD (L6242-2 & above) SCHEMATIC
2 9 7 G 4
1
610
515
J1
22.1K
515
515
D11
515
583S
22.1K
R52
J4
4
68.1K
PROCEDURE
PC BOARD
J4
CR2
PROCEDURE
LED 7B
2
564
D12
PC BOARD
START TIME
OVER
WELD TIME
OVER
1N4007
1A
D18
WELD
PROCEDURE
ENABLE
1000V
J1
LED 7H
4
9
8
1.00K
D22
10
1
2
X1
A
X5
A
R40
1A
1.50K
589
400V
10.0K
START
Q11
2N4401
TRAVEL
C27
.022
50V
DISABLE
515
15 N.F.
16
1
J2
1N4004
581
1
S2 -1
581A
100K
1
3
4
R6
R4
3
4
X5
B
A
Q2
2N5657
X7
X7
2
100
475
2
R20
N.A.
2.67K
C6
S5
START
500
J3
D13
500
C31
C19
.022
50V
NOTES:
560
PROCEDURE
PC BOARD
8
6
5
2N4403
Q18
100K
R53
500
PRESET
MONITOR
ENABLE
B
N.A. SWITCH (SEE PROCEDURE P.C. BOARD SCHEMATIC)
MUST BE IN "STRIKE" POSITION TO START WELD
CYCLE
500
7.68K
-2
14
S1
3
N.F.
515
500
Q9
2N4401
N.B. COMPONENTS INCLUDED WITH OPTIONAL LINC-FILL
BYPASS KIT (ALSO SEE SCHEMATIC A)
13
12
C32
11
1
4
13
X1
2
B
C25
.022
50V
3
2N4403
Q12
X1
C
D
R41
2
515
N.C. DIP SWITCHES ARE TO BE SET TO SUIT APPLICATION
PER CHARTS BELOW
7.68K
515
100K
515
S1 -1
15
N.F.
N.D. HOLD-LOW DISABLE IS USED WITH G1556-1 AND
EARLIER VOLTAGE BOARDS. ARC CONTROL ENABLE
IS USED WITH LATER VOLTAGE BOARDS.
500
J5
6.81K
6
5
D26
4
16
1
X1
68.1K
LED 7C
6
515
515
D10
689
1.00K
J2
N.E. SINCE COMPONENTS OR CIRCUITRY ON
CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE
INTERCHANGEABILITY OF COMPLETE BOARD, THIS
DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR
CIRCUITRY OF CONTROLS HAVING COMMON CODE NUMBER.
A
PRINTED
ELECTRODE
HOT
D25
J2
22.1K
530
A
584C
9
8
3
1.50K
J4
1
D15
CR3
PROCEDURE
PC BOARD
R
LT1
13
12
10
9
8
HOLD-LOW
ENABLE
X5
D
X2
A
11
X7
C
A
582
D32
Q8
2N4401
CRATER TIME
INITIATE
R42
4
N.F. SCHEMATIC SHOWN WITH DIP SWITCHES IN THE "UP" POSITION.
R17
100
R19
475
J1
6
22.1K
475
C5
CR6
4.7
475
D27
500
C24
.022
50V
LED 7K
POWER
SOURCE
OUTPUT
S6
STOP
D9
35V
100K
D20
1A
1000V
1N4007
D23
1A
C11
.022
50V
C8
10
25V
682
500
400V
J2
5
500
1N4004
N.B.
Methods of Travel
687
515
500
500
500
D8
SHUT DOWN
J3
2
D16
500
1
1
1
1
1
2
3
3
3
3
3
4
4
4
4
4
1
1
1
1
1
2
3
4
4
4
4
4
Start/stop with switches
515
Q4
565
WELD TIME
R25
2.67K
2N5657
22.1K
OVER
PC BOARD
PROCEDURE
C21
.022
50V
SWITCH #1
2
SWITCH #2
C37
515
S2 -4
515
9
8
N.F.
2N4403
Q13
8
9
10
1
2
11
10
100K
J3
3
D
X6
X5
R43
X7
A
E
2
3
566
Start/stop with weld
current
7.68K
1.50K
BURNBACK
TIME OVER
SHUT DOWN
ENABLE
500
7
10
C4
.022
50V
S1 -4
N.D.
11
6
N.F.
N.F.
12
10
7
J2
SWITCH #1
2
SWITCH #2
S1 -3
6
688
15.0K
5
2
3
D28
ARC CONTROL
ENABLE
500
LED 7D
Start with weld current
Stop with stop switch
9
8
SWITCH #1
2
SWITCH #2
Q7
3
4
R12
100
R33
X6
B
2N4401
CR5
D14
22.1K
CURRENT
J5
Start with start switch
Stop after crater time
(Optional procedure
module installed in crater
receptacle)
2
3
C7
10
515
C26
2
25V
100K
J1
1N4007
1A
D19
528
3
C33
500
588
1000V
SWITCH #1
2
SWITCH #2
J3
CURRENT
PROCEDURE
PC BOARD
5
6
1
2
7
X6
C
2N4403
Q14
X8
A
R44
681
CR4
CURRENT
584S
500
Start with start switch
2
3
7.68K
Stop after burn-back time
(Optional procedure
module installed in crater
receptacle)
1
J3
PROCEDURE
PC BOARD
3
9
8
Q3
2N5657
B
4
R23
X2
X6
D
500
2
SWITCH #1
SWITCH #2
2.67K
J3
6
START
TIME
INITIATE
J3
J3
100K
9
5
563
C20
.022
50V
PROCEDURE
PC BOARD
561
STRIKE PROCEDURE
DISABLE
PROCEDURE
PCB
563
DZ1
6
5
STRIKE
Optional Crater Module Installed?
Q10
4
R39
22.1K
X2
C
2N4401
PROCEDURE
ENABLE
11
10
500
R32
475
E
X6
1
2
3
4
1
2
3
4
5.1V
1W
Yes
100K
C23
.022
50V
13
12
11
X2
D
515
515
SWITCH #1
2
SWITCH #2
515
515
1
3
4
1
2
3
4
500
No
515
475
15.0K
D29
1.50K
1
6
3
4
SWITCH #1
SWITCH #2
X4
A
X4
5
B
CRATER
2
C36
TIME OVER
BURNBACK
TIME
221K
R15
3
4
D30
2N4403
Q17
J5
1
X8
B
R48
PROCEDURE
PC BOARD
637
Q1
R35
100
2N4401
INITIATE
7.68K
LED 7E
J3
1
13
12
C35
Methods of Burnback
X6
F
VOLTAGE
PRESENT
583C
C2
.022
50V
C9
Q16
2N4403
CR1
R46
4.7
D31
500
D17
68.1K
1
1
1
2
3
3
3
4
4
4
1
1
1
2
3
4
4
4
6
5
Wire feed stop with
contactor delay
35V
13
4
9
7.68K
X3
B
Q15
11
5
6
10
47.5K
X4
C
X5
C
N.F.
R45
X3
C
2N4401
12
8
J1
11
6
D21
12
S2 -3
5
5
22.1K
SWITCH #1
2
SWITCH #2
1N4007
500
1A
LED 7G
FLUX OR
C34
1000V
D24
2.67K
1
J5
585
2
3
1A
3
WATER
Inch up with contactor
delay
4
X3
A
R49
100
587
400V
1N4004
2
515
515
515
(TO POWER P.C. BOARD)
FEED FORWARD
500
SWITCH #1
2
SWITCH #2
13
12
Q5
2N5657
11
X3
D
D33
LED 7J
2
3
100K
C22
.022
50V
Inch up with no contactor
delay
1.00K
D34
D35
1.50K
SWITCH #1
SWITCH #2
J5
3
FEED
586
J5
592
ENABLE
5
6
500
5
R50
100
X8
C
C3
.022
50V
NA-5 SHIPPED CONNECTED FOR INDICATED
METHODS OF TRAVEL BURNBACK.
Q6
S4
D6
R31
2N4401
&
S3
INCH
22.1K
DOWN
515
INCH
UP
100K
C10
.022
50V
500
500
D5
X9
J4
J2
2
500
628
6
515
IN
OUT
7815
(HS)
J1
GENERAL INFORMATION
ELECTRICAL SYMBOLS PER E1537
LAST NO. USED
D2
500
D1
2
R-
C-
B-
2
DZ1-
1
63
37
Q- 18
LED-
515
GND
1.50K
BLU
J-
5
2
7K
CAPACITORS
RESISTORS
DIODES
=
MFD
(
.022/50V
1/4W
UNLESS OTHERWISE SPECIFIED)
UNLESS OTHERWISE SPECIFIED)
LOGIC
POWER
SUPPLY
500
B1
S-
D- 35
X-
9
LABELS
=
Ohms
(
C12
500
50V
C1
=
1A, 400V
(UNLESS OTHERWISE SPECIFIED)
SUPPLY
VOLTAGE NET
.22
22VAC
C13
14
14
14
14
14
14
14
14
D7
100V
4.7
POWER SUPPLY SOURCE POINT
COMMON CONNECTION
35V
B2
LED 7A
T1C
BLU
X5
X6
X8
C15
C16
C17
C18
C28
C29
C30
X1
X2
X3
X4
X7
FRAME CONNECTION
D4
D3
C14
.022
50V
FILENAME: G2974_2DA
THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY
THE LINCOLN ELECTRIC CO.
4011
4011
4011
4011
4011
J4
3
EARTH GROUND CONNECTION
AND IS NOT TO BE REPRODUCED, DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION OF
THE LINCOLN ELECTRIC CO.
500
500
7
7
7
7
7
7
7
7
EQUIP.
TYPE
Ch'ge.Sht.No.
NA-5
LOGIC CIRCUIT
UNLESS OTHERWISE SPECIFIED TOLERANCE
ON HOLES SIZES PER E-2056
PLACE DECIMALS IS
PLACE DECIMALS IS
ON ALL ANGLES IS
MATERIAL TOLERANCE ("t") TO AGREE
WITH PUBLISHED STANDARDS
THE LINCOLN ELECTRIC CO.
CLEVELAND, OHIO U.S.A.
500
1-12-96D
ON
ON
2
3
+
.O2
.OO2
DEGREE
J4
5
SUBJECT
+
NONE
9-27-94
SCALE
DATE
+
.5 OF
A
SHT.
NO.
500
LOGIC POWER SUPPLY DISTRIBUTION AND BYPASSING
G 2974
MAB
CHK.
SUP'S'D'G.
DR.
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided
for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.
Download from Www.Somanuals.com. All Manuals Search And Download.
NA-5
G-5
G-5
ELECTRICAL DIAGRAMS
POWER PC BOARD (L6252-1) SCHEMATIC
C
G
J
A
B
D
E
F
H
K
L
M
525
CONTROL POWER AND
EMERGENCY STOP
CB1
S1A
A5H
31
531
R1
631
531A
540
PT
1
102B
C104
B2L
500
C119
PT101A
FLUX OR
+
C107
531
WATER SOLENOID
RECEPTACLE
A6H
SCR
102
CR7
666
SCR
101
TRAVEL
RECEPTACLE
87
500
A6H
531
QU101
541
C105
C106
C101
C108
25
GND
C102
115 VAC
INPUT
PT
103B
2
532
C109
C121
AUTO
OFF
PT101C
C1105
PT101B
C1104
C110
F101
WIRE FEED
MOTOR
PT102A
PT103A
SCR
103
BLU
BLK
SCR
104
87
ARMATURE
WIRE FEED
TP101
D103
MOTOR FIELD
S2
TRAVEL
627
WH
587
FEED
FORWARD
CR6
D2G
HAND
C1106
Q102
LED
1C
C112
TO TACH
PICK-UP
P.C. BOARD
D6G
3
4
C103
R102
LED
1E
D101
D102
CR2
D1K
Q101
C122
C1105
LED
1D
CR1
D6K
RED
626
Q103
C120
F102
32
S1B
C111
532
532
539
FIELD SUPPLY
ARMATURE SUPPLY
TP102
500
A6H
GND
FEED DIRECTION CIRCUIT
D108
X101
GND
525
OUT
IN
+15V
D110
D104
D105
ANALOG
ANALOG
RED
BLK
+
+
531B
POWER SUPPLY
18
VAC
2
4
C116
C117
C114
C115
510
115
VAC
WHT
LED 1A
ZERO-VOLT
5
6
18
VAC
D111
DZ101
+
REFERNCE
C113
+
CR3
D3K
532
BLK
RED
T1A
D106
GND
X102
LED 1B
D107
500
-10V
YLW
OUT
IN
601
10
VAC
METER
SUPPLY
D109
602
610
YLW
ORG
RELAY
D112
D113
T1B
BLK
POWER SUPPLY
LED 1F
C118
115
VAC
115
VAC
TP
BLK
103
ORG
BRN
D114
T2A
T2B
D115
500
24
VAC
INTERFACE OPTION
POWER SUPPLY
7
FOR POWER P.C. BOARDS L6252-2 OR HIGHER USE L8956
SCHEMATIC FOR COMPONENT VALUES AND CIRCUIT CONNECTIONS.
BRN
POWER P.C. BOARD
R.F. BYPASS P.C. BOARD
KEY TO SYMBOLS
COMPONENTS NOT ON P.C. BOARD
5A. CIRCUIT BREAKER
FOR R.F. BYPASS P.C. BOARDS M14133-1 OR
HIGHER USE S20995 SCHEMATIC FOR
COMPONENT VALUES AND CIRCUIT CONNECTIONS.
C101
C102
C103
C104
C105
C106
C107
C108
C109
C110
C111
C112
C113
C114
C115
C116
C117
C118
C119
C120
C121
C122
D101
D102
D103
D104
THRU
D111
D112
THRU
D115
Q101
Q102
Q103
QU101
2N4123
2N5816
2N5816
UJT
SCR 101
CB1
.005/1400
.15/200
50/250
.15/200
.047/100
.047/100
4.7/35
16A, 400
16A, 400
16A, 400
V
V
V
8A, 600V
8A, 600V
INPUT CONTROL CABLE CONNECTION
SCR 102
SCR 103
SCR 104
CR1
CR2
CR3
CR6
SPST, N.O. FLUX OR WATER
SPST, N.O. TRAVEL
16A, 400V
16A, 400V
POWER SUPPLY SOURCE POINT
SPST, N.O. POWER SOURCE OUTPUT
SPST, N.O. SOLID STATE, OPTIONAL
LINC-FILL PILOT RELAY
1A, 400
V
C1101
COMMON CONNECTION TO ANALOG POWER
ARC VOLTAGE BY-PASS
.0047/3000
.0047/3000
.0047/3000
R101
R102
R103
R104
R105
R106
R107
R108
R109
R110
R111
R112
R113
R114
R115
R116
TP101
TP102
TP103
40, 12W
68K
C1102
C1103
C1104
C1105
C1106
(SEE SCHEMATIC "C")
SUPPLY; 510
A5H
150V, 10J
FLUX SOLENOID BY-PASS
CR7
R1
OPTIONAL LINC-FILL BY-PASS CONTACTOR
.047/100
.022/25
.022/25
.022/25
.022/25
.22/100
500/50
1A, 1000
V
100
100
SCHEMATIC LOCATION REFERENCE
MOTOR FIELD BY-PASS
10K, 2W
100
X101
X102
+15V VOLTAGE
REGULATOR
-5V VOLTAGE
REGULATOR
2, 50W
HORIZONTAL CO-ORDINATE LETTER
VERTICAL CO-ORDINATE NUMBER
SCHEMATIC IDENTIFICATION LETTER
DZ101
F101
5.1 V.,
1
2
/
W
10K
47K
S1
DPST, CONTROL POWER AND
EMERGENCY STOP
SPDT, TRAVEL
1
/
2A SLOW BLOW,
4.7K
6.8K
680
S2
POWER SUPPLIES FUSE
UNLESS OTHERWISE SPECIFIED, COMPONENT VALUES OF:
F102
1
/
2A SLOW BLOW,
500/50
CAPACITORS
=
=
MFD/VOLTS
T1A
T1B
T1C
T2A
T2B
36 VCT, 300mA SECONDARY
10 VAC, 600mA SECONDARY
SEE LOGIC SCHEMATIC "D"
115VAC, 80mA SECONDARY
24VAC, 30mA SECONDARY
4.7/35
FIELD FUSE
RESISTORS
OHMS, 2 /WATT
1
18/15
47K
680
LED 1A
THRU
LED 1F
RED LIGHT
EMITTING
DIODE
SINCE COMPONENTS OR CIRCUITRY ON
CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE
INTERCHANGEABILITY OF COMPLETE BOARD, THIS
DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS
A
PRINTED
.02/600
.047/100
.022/25
.02/600
.022/25
4.7K
3.3K
68K
A
PT101
PT102
PT103
1:1:1
PULSE
TRANSFORMER
OR CIRCUITRY OF CONTROLS HAVING
CODE NUMBER.
A
COMMON
A.N.S.I. ELECTRICAL SYMBOLS PER E1537
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not avail-
able from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in
NA-5
danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.
Download from Www.Somanuals.com. All Manuals Search And Download.
G-6
G-6
ELECTRICAL DIAGRAMS
POWER PC BOARD (L6252-2 & above) SCHEMATIC
525
J3
P1
540
3
5
6
C19
.047
100V
PT1
CONTROL POWER AND
EMERGENCY STOP
0.2mH
CB1
S1A
31
531
531A
631
R1
2
OHMS
C24
2
50 WATTS
C7
4.7
35V
FLUX OR WATER
SOLENOID RECEPTACLE
500
TRAVEL
RECEPTACLE
531
87
PT2
0.2mH
C4
.15
200V
3
2
1
531
QU1
1
2N6027
C6
.047
100V
C5
.047
100V
2
1
4
3
5
1
GND
J2
531A
J2
J1
.0047
3000
25
3
631
GND
SCR2
2N6398
SCR1
2N6398
.0047
3000
532
BLUE
P1
0.2mH
PT1
0.2mH
PT1
Q9
600mA
40V
WIRE FEED
MOTOR ARMATURE
TP1
150V
45J
PT3
0.2mH
1
M
C2
SCR3
SCR4
.15
CR7
200V
0.5A
125V
2N6403
2N6403
C1
.0047
1400V
C21
.02
600V
CR1
P1
666
BLACK
J1
2
115VAC
INPUT
3
4
3
4
C8
.047
100V
6
PT2
0.2mH
D3
PT3
0.2mH
FEED FORWARD
16A
P1
400V
AUTO
J1
2
J3
WHT
4
CR6
587
.0047
3000
627
C3
50
250V
OFF
Q2
CR2
600mA
40V
R2
S2
TRAVEL
.0047
3000
HAND
133K
J1
P1
Q1
600mA
40V
Q3
600mA
40V
1
R18
RED
626
133K
D1
16A
400V
D2
0.5A
125V
16A
400V
ARMATURE SUPPLY
D8
J2
32
532
2
525
S1B
+15V
ANALOG
FIELD SUPPLY
FIELD DIRECTION
CIRCUIT
X1
J2
GND
TP2
150V
45J
IN
OUT
7815
(HS)
3
500
J3
P1
P1
525
4
FOR THE NA-5R ONLY:
THE TRAVEL RECEPTACLE,THE TRAVEL SWITCH,
AND CR2 ARE REMOVED ON THE NA-5R.
GND
J3
7
C14
500
50V
525
B1
531B
BLK
RED
CR3 IS SHOWN IN THE OPTIONAL BURNBACK KIT
C16
4.7
510
RECEPTACLE WHICH IS DRAWN BELOW.THE
18
VAC
35V
ANALOG
POWER SUPPLY
BURNBACK KIT IS CONNECTED TO 631 AND 532.
631
ZERO VOLT
REFERENCE
115 VAC
B2
WHT
4
J3
8
C13
532
T1A
18
P1
.22
510
5
DZ1
5.1V
1W
100V
VAC
2
C17
18
15V
1
J3
9
C15
500
50V
P1
402
6
510
RED
532
B3
BLK
CR3
404
3
YLW
601
500
4
-10V
GND
2
METER
SUPPLY
10 VAC
T1B
IN
OUT
X2
NA-5R OPTIONAL BURNBACK
KIT RECEPTACLE
J3
5
P1
P1
P1
500
500
500
602
610
SHOWN WITH JUMPER
PLUG INSTALLED
YLW
J3
6
D9
2
J2
J3
1
6
CR3
4
610
D12
D13
1N4007
1N4007
531B
ORG
BLK
B4
RELAY
C18
.02
600V
115
VAC
TP3
150V
45J
POWER SUPPLY
115 VAC
T2A
B5
ORG
BLK
532
D14
D15
1N4007
1N4007
J2
BRN
BRN
500
500
4
24
VAC
INTERFACE OPTION
POWER SUPPLY
T2B
F R A N C E
C A N A D A
A U S T R A L I A
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not avail-
able from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in
NA-5
danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.
Download from Www.Somanuals.com. All Manuals Search And Download.
G-7
G-7
ELECTRICAL DIAGRAMS
VOLTAGE PC BOARD SCHEMATIC
E
F
D
G
C
J
B
H
K
L
M
A
525
A5H
525
A5H
A
L501
R533
R534
C507
N.A.
667
C524
WELD
C520
+
B
1
525
A5H
RESPONSE
JUMPER
(RED)
PIN
F
R510
500
A6H
R509
TP
501
C1102
D519
T501
D520
5
+
R527
D515
1
2
OCI501
4
12
ARC
531B
A5D
+
-
C508
C518
VOLTAGE
PIN
S
DZ
507
14
4
-
D
POLARITY
24
13
+
115
VAC
DZ
506
13
12
C509
2
3
CW
14
6
10
9
A
TERMINALS
R535
C506
VAC
R507
-
+
+
-
532
A5D
X502
C519
ACTUAL VOLTAGE
BUFFER
A
8
+
B
C1101
DZ
637
D5A
11
1
504
-
Q508
+
C
C526
X502
Q501
D517
D506
C501
F501
L502
X502
C521
D522
D521
621
2
POWER SOURCE
CONTROL INTERFACE
CONTROL
AMP
D502
CW
510P
B3C
525
A5H
GAIN
START
D516
-
6
500
A6H
7
510
D
Q507
CW
5
C525
D505
510P
B3C
+
Q506
X501
DZ
6
1
2
4
5
503
9
X501
-
C527
D503
D501
+
8
D504
B
525
A5H
R547
D513
AUTO-STOP
CIRCUIT
0CI502
500
D9C
+
3
4
510P
B3C
C505
10
D512
C523
D514
592
D7A
C504
COM
AUTO-STOP AND
SHUTDOWN BYPASS
TAB JUMPER (BLUE)
510P
B3C
AUTO
R511
C512
R519
ACTUAL VOLTAGE
METER FILTER
C517
+
BYPASS
D514
+
+
HOLD - LOW CIRCUIT
525
A5H
SHUTDOWN
687
C511
FROM
OPTION
AND
PROCEDURE
P.C. BOARD
PIN
A
PIN
B
PIN
516
500
A6H
D508
D
2
3
X501
-
D4B
514
1
VOLTAGE
SETTING
R546
C
635
SBS
501
688A
+
START
D518
Q503
D510
D511
RESPONSE
+
D507
R525
4
5
JUMPER
E2E
SET
S7B
ACTUAL
C510
C516
N.C.
+
7
X502
525
A5H
(WHITE)
DZ502
688
D4J
C
R530
510P
B3C
S7B
VOLTS
SET-ACTUAL
-
6
ARC CONTROL
ENABLE
517
11
4
2
3
1
SET VOLTAGE
BUFFER
C522
C528
5
6
D509
+
688
D4J
500
A6H
C513
CW
CAL
VOLTAGE P.C. BOARD RECEPTACLE FOR
OPTIONAL PULSED POWER FILTER P. C.
BOARD (SHOWN WITH JUMPER PLUG
TP5
+5V
500
A6H
C604
SHUTDOWN
ENABLE
1
X601
GND
2
TP4
4
INSTALLED.)
DM601
OUT
IN
SHUTDOW CIRCUIT
D602
D601
A6E
A6E
601
602
E
C
C603
A
518
+
+
C602
C601
D603 D604
510P
B3C
510
B7G
VOLTMETER
VOLTMETER
POWER SUPPLY
7
VOLTAGE P.C. BOARD
1A, 400V
VOLTMETER P.C. BOARD
COMPONENTS NOT ON P.C. BOARD
KEY TO SYMBOLS
C501
C504
C505
C506
C507
C508
C509
C510
C511
C512
C513
C514
C516
C517
C518
C519
C520
C521
C522
C523
C524
C525
C526
C527
C528
R501
R502
R503
R504
R505
R506
R507
R508
R509
R510
R511
R512
R513
R514
R515
R516
R517
R518
R519
R520
R521
R522
R523
R524
R525
44.2K, 1/4W, 1%
R526
R527
R528
R529
R530
R531
R532
R533
R534
R535
R536
R537
R538
R539
R540
R541
R542
R543
R544
R545
R546
R547
R548
R549
.1/100
4.0/50
.47/50
.022/25
.022/25
39/20
.022/25
1.8/20
.022/25
4.7/35
27/35
4.7/35
.022/25
.47/50
39/20
.0047-.005/1400
.022/25
.022/25
.022/25
.022/25
4.7/35
D501
47K
F501
1
8
AMP FAST
C601
DIGITAL METER
/
500/50
DM601
S7B
INPUT CONTROL CABLE CONNECTION
500 TRIMMER
THRU
D522
47K
22K
22K
27K
100K
27K
10K
100
1K
C602
C603
C604
D601
D602
D603
D604
4.7/35
BLOW FUSE
.022/25
4.75K, 1/4W, 1%
100K
27K
SBS501 SILICON BILATERAL
SWITCH
SPDT, VOLTS SET-ACTUAL
COMMON CONNECTION TO ANALOG POWER
.022/25
6.8V,
1
2W
DZ502
DZ503
DZ504
DZ505
DZ506
DZ507
L501
/
SUPPLY 510
A5H
5.1V, 1/2W
20V, 1W
T501
24 VAC, 185 mf
SECONDARY
150V, 10J
15K
SCHEMATIC LOCATION REFERENCE
1A, 400V
6.2V, 1/2W
15V, 1W
10K
TP501
NOTES:
2.2K
HORIZONTAL CO-ORDINATE LETTER
VERTICAL CO-ORDINATE NUMBER
SCHEMATIC IDENTIFICATION LETTER
6.8V, 1/2W
33uH, 110mA
33uH, 110mA
2.7K
N.A. THESE CAPACITORS ARE LOCATED
ON THE R.F. BYPASS BOARD.
(SEE SCHEMATIC A).
4.7K
L502
100K
1K
10K
33K
56K
27K
R601
R602
R603
24.3K, 1/4W, 1%
2K TRIMMER
OCI501
OCI502
Q501
Q503
Q505
Q506
Q507
Q508
X501
OPTO-ISOLATOR
2.7K
2.80K, 1/4W, 1%
N.B. SEE L6682-3A SCHEMATIC FOR
SUPERSEDED G1556-1 VOLAGE
BOARD.
2N4123
2K TRIMMER
5.6K
UNLESS OTHERWISE SPECIFIED, COMPONENT VALUES OF:
2N5816
X601
5K TRIMMER
1K, 12W
470
+5V VOLTAGE REGULATOR
CAPACITORS
=
MFD/VOLTS
2N4123
100K
1K
RESISTORS
=
OHMS, 2 /WATT
1
2N4857
N.C. EARLIER VOLTAGE BOARDS DO
FOR VOLTMETER P.C. BOARDS
L6685-1 OR HIGHER USE S21143
SCHEMATIC FOR COMPONENT
VALUES AND CIRCUIT CONNECTIONS.
2N5816
100K
39K
SINCE COMPONENTS OR CIRCUITRY ON
CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE
INTERCHANGEABILITY OF COMPLETE BOARD, THIS
DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS
A
PRINTED
68K
NOT HAVE THIS RECEPTACLE, AND
LEAD 688A WAS 688.
2N5816
15K
QUAD OP-AMP
QUAD OP-AMP
15K
15K
A
X502
56K
270
.022/25
.47/50
.01/200
.022/25
330K
22K
270
OR CIRCUITRY OF CONTROLS HAVING
CODE NUMBER.
A
COMMON
100
27K
270
3.3K
A.N.S.I. ELECTRICAL SYMBOLS PER E1537
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not avail-
able from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in
NA-5
danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.
Download from Www.Somanuals.com. All Manuals Search And Download.
G-8
G-8
ELECTRICAL DIAGRAMS
CONTROL CIRCUIT SCHEMATIC
C
G
J
A
B
D
E
F
H
K
L
M
525
A5H
520
+10.00V
C217
C219
Q207
R243
11 12 10
1
C209
C221
6
2
3
525
A5H
512
CW
LO
R221
D206
B4E
B4J
4
X203
8
-
9
C208
C224
X201
2
3
10
5
+
C204
4
A
R211
R217
-
-
X204
6
5
2
3
1
D
A
+
5
11
1
+
11
X202
7
1
+
4
C202
Q204
C229
+
+
C218
11
X203
C212
CW
HI
C203
C210
R231
3
+
4
CW
12
2
CONTROL
AMP
13
+10.00 V
Q203
628
D8A
C216
500
A6H
7
DZ203
Q205
2
3
CAL
C205
C201
QU201
C220
REFERENCE
SUPPLY
ACTUAL SPEED BUFFER
C206
Q206
510
A5H
C225
C223
D205
TACH SIGNAL CONVERTER
D208
540
A1H
511
510P
C211
C227
B4E
511
X203
C119
-
FROM OPTION
511A
C214
525
A5H
B5J
+
13
12
SPEED
SETTING
AND
B
R242
R218
PT
632
525A
PROCEDURE
PC BOARD
101A
14
+
C213
+
C228
L201
500
A6H
E2D
500
A6H
N.B
N.A.
C215
510P
B3C
TO TACH
PICK-UP
555
ARMATURE FIRING CIRCUIT
SET SPEED BUFFER
P.C. BOARD
512
B1G
511
B3G
SET
L202
ACTUAL
4
5
S7A
SPEED
SET-ACTUAL
R214
510A
R212
SPEEDMETER
CALIBRATION
JUMPER
512
B1G
519
FAST-SLOW
ACCELER
JUMPER
R240
-
-
9
D204
8
142T
CW
95S
CW
142
95
57
57F
9
8
B
C
10
10
+
+
X204
X203
PIN
F
PIN
S
525
A5H
511
R241
CW
CW
CW
CW
525
A5H
CW
CAL
CAL
CAL
CAL
CAL
CAL
TP5
+5V
B3G
1
ACC
Q201
X401
OUT
GND
C409
C408
C407
C406
C405
C404
2
4
D202
DM401
E
IN
DZ201
TP4
+
D402
D401
Q202
A6E
601
602
6
7
C403
C207
C
+
A6E
+
C222
C226
C402
C401
D203
D403
D404
D201
R410
500
A6H
510
C7E
510P
B3C
586
FEED
ENABLE
SPEEDMETER
POWER SUPPLY
SPEEDMETER
D7J
ACCELERATION CIRCUIT
FEED ENABLE CIRCUIT
CONTROL P.C. BOARD
SPEEDMETER P.C. BOARD
TACHOMETER P.C. BOARD
COMPONENTS NOT ON P.C. BOARD
KEY TO SYMBOLS
C201
DZ201
DZ202
DZ203
6.8 V.,
16.0 V.,
3.0 V.,
1
2
W.
R201
1K
500 TRIMMER
R227
R228
OCI301
Q301
OPTO-INTERRUPTER
2N4123
.022/25
.022/25
18/15
/
6.8K
C401
DIGITAL METER
500/50
4.7/35
DM401
S7A
POWER SUPPLY SOURCE POINT
C202
C203
C204
C205
C206
C207
C208
C209
C210
C211
C212
C213
C214
C215
C216
C217
THRU
C229
1
W.
R203
R204
R205
R206
R207
R208
R209
R210
R211
R212
R213
R214
R215
R216
R217
R218
R219
R220
R221
R222
R223
R224
R225
R226
10K
C402
C403
THRU
C409
D401
D402
D403
D404
X401
R401
R402
R403
R404
R405
R406
R407
R408
R409
R410
R411
R412
R413
R414
1
W.
1.00K, 1/4W, 1% R229
20K TRIMMER
27K
SPDT SPEED SET-ACTUAL
COMMON CONNECTION TO ANALOG POWER
SUPPLY; 510 A5H
.022/25
4.7/35
2.94K, 1.4W, 1%
R230
R231
R232
R233
R234
R235
R236
R237
R238
R239
R240
R241
R242
R243
L201
L202
15K
10K
R301
R302
R304
1K
15K
1.3K
.0033/200
.47/50
15
100
330 uH, 110mA
SCHEMATIC LOCATION REFERENCE
18/15
4/50
100K TRIMMER
6.8K
2.7K
10K
1A, 400V
Q201
Q202
Q203
Q204
Q205
Q206
Q207
2N4123
2N4123
2N4123
2N4125
BS170
2N4123
2N5816
33K
HORIZONTAL CO-ORDINATE LETTER
VERTICAL CO-ORDINATE NUMBER
SCHEMATIC IDENTIFICATION LETTER
.047/100
4.7/35
10K
+5V VOLTAGE REGULATOR
270
15K
.15/200
.022/25
.022/25
4.7/35
15K
10K
2K TRIMMER
17.8K, 1/4W, 1%
2.80K, 1/4W, 1%
2K TRIMMER
18.2K, 1/4W, 1%
5K TRIMMER
33.2K, 1/4W, 1%
5K TRIMMER
52.3K 1/4W, 1%
10
5K TRIMMER
31.6K, 1/4W, 1%
5K TRIMMER
51.1K, 1/4W, 1%
47K
1M
15K
15K
NOTES:
100K
5.6K
15K
UNLESS OTHERWISE SPECIFIED, COMPONENT VALUES OF:
N.A. 511 IS CONNECTED TO 511A
BY CONNECTION TO
18/15
100pf/100
1K
CAPACITORS
RESISTORS
=
=
MFD/VOLTS
QU201
2N6027
1K
270
OHMS, 2 /WATT
1
VOLTAGE P.C. BOARD.
1K
10
.022/25
33K
SINCE COMPONENTS OR CIRCUITRY ON
CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE
INTERCHANGEABILITY OF COMPLETE BOARD, THIS
DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS
A
PRINTED
N.B. THESE COMPONENTS ARE
LOCATED ON POWER P.C.
X201
X202
X203
X204
VOLTAGE REGULATOR
F- TO -V CONVERTER
QUAD OP-AMP
50K TRIMMER
15K
A
D201
THRU
D206
D208
10K TRIMMER
BOARD (SEE SCHEMATIC A).
QUAD OP-AMP
33K
100K
1K
1A, 400
V
OR CIRCUITRY OF CONTROLS HAVING
CODE NUMBER.
A
COMMON
10K
ELECTRICAL SYMBOLS PER E1537.
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not avail-
able from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in
NA-5
danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.
Download from Www.Somanuals.com. All Manuals Search And Download.
G-9
G-9
ELECTRICAL DIAGRAMS
PROCEDURE PC BOARD SCHEMATIC
OPTIONAL
OPTIONAL
OPTIONAL
START MODULE
WELD TIMER MODULE
CRATER MODULE
BURNBACK TIMER
J19
515
5
515
500
520
+5V
FROM LOGIC
POWER
TIMER BOARD
TIMER BOARD
SUPPLIES
J19
J19
500
-10V
ON LOGIC PCB
500
655
515
I
O
500
655
515
I
O
15
3
520
+10V
FROM REF
VOLTAGE ON
CONTROL PCB
C1
18
OPTION BOARD
OPTION BOARD
15V
TIMER BOARD
TIMER BOARD
J19
2
510P
510P
520
515
562
635
11
562
12
500
13
655
14
632
15
515
655
500
510P
520
515
562
635
11
562
12
500
13
655
14
632
15
515
655
500
584
583
588A
588
O
1
I
584
583
588A
588
O
1
I
N.B.
N.C.
7
1
2
3
4
6
8
9
2
3
4
5
6
7
1
2
3
4
6
8
9
2
3
4
5
6
J9
J11
J11
J11
J11
J11
J11
J11
J11
J11
J11
J11
J11
J11
J9
J9
J9
J9
J9
J10
J10
J10
J10
J10
J10
J10
J10
J10
J10
J10
J10
J10
J8
J8
J8
J8
J8
J8
J19
J18
START TIME INITIATE
WELD TIME OVER
520
+10V
515
+5V
500
-10V
515
+5V
500
-10V
520
+10V
515
+5V
500
-10V
515
+5V
500
-10V
8
584S
565
2
J19
J19
CRATER TIME INITIATE
CURRENT
7
9
584C
588
LOGIC
PCB
J19
START TIME OVER/WELD TIME INITIATE
1
583S
J19
J18
CRATER TIME OVER/BURNBACK TIME INITIATE
BURNBACK TIME OVER
6
3
583C
566
100 Hz
TIME BASE
OUTPUT
1.6384 MHz
TEST POINT
16
1
Q12
Q13
Q14
Q6
Vdd
OUT2
Q8
2
3
4
5
6
7
9
14
13
15
10
11
Q9
X2
Q10
Q5
TO SET
SPEED BUFFER
ON CONTROL PCB
Q7
OUT1
CLK
RES
J19
J19
632
635
10
11
Q4
R20
8
12
Vss
10M
TO SET
VOLTAGE BUFFER
ON VOLTAGE PCB
MC14060
7.68K
1/2W
TIME BASE
FOR
DIGITAL TIMERS
Y1
C9
515
+5V
C2
22p
100V
C3
47p
100V
1.6384MHz
520
+10V
2.21K
500
-10V
N.E.
FRAME
C6
C7
5.62K
5.62K
4.75K
5.62K
5.62K
LED1
LED2
LED3
LED4
4.75K
D2
D3
D4
D1
Q1
600mA
40V
Q2
600mA
40V
STRIKE
START
D6
WELD
CRATER
D8
CW
CW
CW
10K
2W
CW
WELD
VOLTS
STRIKE
VOLTS
10K
2W
10K
2W
10K
2W
8
9
3
4
11
10
2
1
X1
A
X1
B
5
X1
C
D
X1
N.E.
N.E.
N.E.
N.E.
STRIKE
SPEED
WELD
SPEED
D5
D7
6
12
13
STRIKE PROCEDURE
DISABLE
D9
J18
1
561
D10
D11
47.5K
267
1.82K
47.5K
26.7K
332
26.7K
1.82K
STRIKE PROCEDURE
ENABLE
LOGIC
PCB
J19
13
563
STRIKE MODE SETTINGS
WELD MODE SETTINGS
J19
WELD PROCEDURE ENABLE
14
564
515
+5V
PROCEDURE KIT
N.D.
520
RECEPTACLE
J19
J18
WELD PROCEDURE ENABLE
START DISABLE
+10V
4
4
564A
NOTES
:
WELD
START
2
16
N.A. SINCE COMPONENTS OR CIRCUITRY ON
A
PRINTED CIRCUIT BOARD MAY CHANGE
581
WITHOUT AFFECTING THE INTERCHANGEABILITY OF COMPLETE BOARD, THIS DIAGRAM MAY
A
8
9
10
11
3
4
5
CRATER
14
STRIKE
STRIKE
NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING
NUMBER.
A
COMMON CODE
X2
S1
A
S1
B
C4
C8
4.7
35V
N.B.
N.C.
A
JUMPER PLUG CONNECTS 584S TO 583S WHEN THE OPTIONAL START MODULE IS
C5
X1
LOGIC
PCB
MC14060
8
NOT INSTALLED.
PRESET MODE
SELECTOR
A
JUMPER PLUG CONNECTS 584C TO 583C WHEN THE OPTIONAL START MODULE IS
NOT INSTALLED. ALSO, LOGIC CIRCUIT 694 LEAD MUST BE MOVED FROM PIN P10
TO PIN P8.
4066B
C2
C1
START DISABLE
J18
J18
5
6
581A
560
N.E.
7
N.D. 564 IS CONNECTED TO 564A BY
A
LEAD RECEPTACLE JUMPER PLUG, WHICH IS
D12
PRESET MONITOR ENABLE
REMOVED WHEN THE OPTIONAL MULTI-PROCEDURE KIT IS INSTALLED.
N.E. R2, R5, R8, R11 AND S1 ARE CONNECTED TO FRAME BY PCB TRACES AND MOUNTING
SCREW, FOR ESD.
POWER SUPPLY DISTRIBUTION
AND BYPASSING
500
-10V
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not avail-
able from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in
NA-5
danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.
Download from Www.Somanuals.com. All Manuals Search And Download.
G-10
G-10
ELECTRICAL DIAGRAMS
OPTION & TIMER PC BOARD SCHEMATICS
F
G
L
M
E
H
J
K
A
B
C
D
515
D8C
515
D8C
515
0
D001
D002
583
TIME
OVER
D8C
R016
TIMER BOARD
6
5
X002
A
R017
I
OVER
4
3
X901
A
D901
R901
8
9
515
D8C
1
5
6
R015
10
O
515
D8C
INITIATE
500
D9C
X901
B
R916
C004
500
D9C
4
OVER
D902
500
D9C
D003
588A
1
1
1
15
9
15
9
15
9
7
Q1
7
Q1
7
Q1
N.C.
584
TIME
INITIATE
X002
B
1
R018
515
D8C
6
6
6
3
3
3
R014
Q4
Q3
Q4
Q3
Q4
Q3
Q2
Q2
Q2
C
0
C
0
C
0
PE
CF
PE
CF
PE
CF
2
D004
13
520
B1C
13
12
12
12
13
500
D9C
1
15
9
7
X902
X903
X904
4
4
4
INH
INH
INH
6
3
Q4
Q1
Q3
Q2
C002
C
632
B3F
635
C4A
10
10
10
MR
MR
MR
DP1
12
4
13
DP4
2
DP4
2
DP4
2
0
DP3
14
DP2
11
DP1
DP3
14
DP2
11
DP1
DP3
14
DP2
11
X002
D
X002
C
588
CURRENT
Q001
SPEED
8
9
13
12
CW
8
CW
X905
2
3
10
5
5
5
R012
11
X001
X001
INH
VOLTS
9
B
A
4
3
10
MR
DP1
5
515
D8C
5
6
DP4
2
DP3
14
DP2
11
515
D8C
515
D8C
515
D8C
Q002
510P
B3C
PROCEDURE
ENABLE
562
FROM
655
500
D9C
500
D9C
500
D9C
PROCEDURE
R914
C907
500
D9C
PC BOARD
100 HZ TIME
S901A
MOST SIGNIFICANT DIGIT
S901B
S901C
LEAST SIGNIFICANT DIGIT
OPTION BOARD
BASE OUTPUT
500
D9C
4
5
6
7
8
KEY TO SYMBOLS
FOR OPTION P.C. BOARD L6246-2
OR HIGHER USE M16795 SCHEMATIC
FOR COMPONENT VALUES AND
CIRCUIT CONNECTIONS.
COMMON CONNECTION TO ANALOG POWER SUPPLY
SCHEMATIC LOCATION REFERENCE
HORIZONTAL CO-ORDINATE LETTER
VERTICAL CO-ORDINATE NUMBER
SCHEMATIC IDENTIFICATION LETTER
TIMER P.C. BOARD
OPTION P.C. BOARD
2N 4125
2N 4123
C902
THRU
C906
C907
C001
Q001
Q002
.022/25
.022/25
5.6K
THRU
C004
520
515
D8C
100pf/100
QUAD ANALOG
SWITCH
X001
X002
N.C. X905 AND C906 ARE USED ONLY ON 100 SECOND
TIMER BOARDS. BOARD JUMPER IS USED ON 10
SECOND TIMER BOARDS.
R001
R002
R003
R004
R005
R006
R007
R008
R009
R010
R011
R012
THRU
R016
R017
R018
1A, 400
1A, 400
10K, 2W MULTI-TURN POT
QUAD
2
INPUT
D901
D902
B1C
14
14
X002
7
330
5.6K
NAND GATE
X001
C003
1213
1
2
10
C001
7
11
10K, 2W MULTI-TURN POT
R901
THRU
R915
R916
D001
THRU
D004
510P
B3C
500
D9C
UNLESS OTHERWISE SPECIFIED, COMPONENT VALUES OF:
22K, 1/4W
1.8K
4.7K
47K
27K
22K
47K
1A, 400V
9
CAPACITORS
=
=
MFD/VOLTS
RESISTORS
OHMS, 2 /WATT
1
1K
515
D6C
N.C.
QUAD 2-INPUT NAND GATE
X901
X902
THRU
X904
X905
SINCE COMPONENTS OR CIRCUITRY ON
BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGE-
ABILITY OF COMPLETE BOARD, THIS DIAGRAM MAY NOT
SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS
HAVING COMMON CODE NUMBER.
ELECTRICAL SYMBOLS PER E1537
A
PRINTED CIRCUIT
16
X902
8
16
X903
8
16
X904
16
X905
8
14
X901
PROGRAMMABLE
DIVIDE-BY-N
COUNTER
A
22K, 1/4W
C904
8
1213
1
2
7
C906
C903
C902
500
D9C
1K
1K
A
3
DIGIT BCD THUMBWHEEL
X906
POWER SUPPLY DISTRIBUTION AND BYPASSING
SWITCH
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not avail-
able from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in
danger to the Machine Operator or Technician. Improper PC board repairs cDoouwldnloraedsfurolmt iWnwdwa.Smoamgaenuatols.tchome.mAllaMcahniunaels. Search And Download.
NA-5
G-11
G-11
ELECTRICAL DIAGRAMS
METER PC BOARD SCHEMATIC & LAYOUT
2 1 1 S 4 3
514 515
511 512
SET
ACTUAL
510A
510B
516
513
WIRE
SPEED
VOLTS
TO DIGITAL METER
10 VAC
562
TP4
4
510C
E
+5V
510
+5V
518
A
B
3
2
1
5
4
C
D
517
B5
518
510
B2
510C
B3
602
B4
601
B1
6
3
10
8
2
1
7
9
5
B6
J14
J14
J14
J14
J14
J14
J14
J14
J14
J14
D1
24.3K
D5
X1
TP5
C4
CW
D2
2K
OUT
IN
C1
C2
500
50V
4.7
35V
GND
D3
C3
2.8K
TP4
D4
NOTES
N.A.
:
FILE: S21143_1CA
LABELS
GENERAL INFORMATION
ELECTRICAL SYMBOLS PER E1537
SINCE COMPONENTS OR CIRCUITRY ON
CIRCUIT BOARD MAY CHANGE
A
PRINTED
FRAME CONNECTION
WITHOUT AFFECTING
COMPLETE BOARD.
SHOW THE EXACT COMPONENTS
SUPPLY
VOLTAGE NET
CAPACITORS
RESISTORS
DIODES
=
MFD
(
(
.022/50V
1/4W UNLESS OTHERWISE SPECIFIED)
(UNLESS OTHERWISE SPECIFIED)
UNLESS OTHERWISE SPECIFIED)
THE INTERCHANGEABILITY
THIS DIAGRAM MAY NOT
OF
A
POWER SUPPLY SOURCE POINT
COMMON CONNECTION
=
Ohms
EARTH GROUND CONNECTION
OR CIRCUITRY OF
CONTROLS HAVING
A
COMMON
CODE NUMBER.
=
1A, 400V
UNLESS OTHERWISE SPECIFIED TOLERANCE
ON HOLES SIZES PER E-2056
EQUIP.
TYPE
Ch'ge.Sht.No.
LN-9, LN-9F, NA-5
THE LINCOLN ELECTRIC CO.
CLEVELAND, OHIO U.S.A.
3-25-94
ON
ON
2
3
PLACE DECIMALS IS
PLACE DECIMALS IS
+
+
.O2
.OO2
METER BOARD SCHEMATIC
SUBJECT
ON ALL ANGLES IS
+
.5 OF
A
DEGREE
NONE
SCALE
MATERIAL TOLERANCE ("t") TO AGREE
WITH PUBLISHED STANDARDS
SHT.
9-23-93
FM
DR.
DATE
CHK.
SUP'S'D'G.
NO.
S
21143
517
R1
IDENTIFICATION
REQ'D
PART NO.
ITEM
C4
R2
R3
601
C3
510C
602
518
510
J14
C2
D2
D1
D4
D3
D5
L6685-1
METER
X1
C1
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not avail-
able from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in
danger to the Machine Operator or Technician. Improper PC board repairs cDoouwldnloraedsfurolmt iWnwdwa.Smoamgaenuatols.tchome.mAllaMcahniunaels. Search And Download.
NA-5
G-12
G-12
ELECTRICAL DIAGRAMS
MISCELLANEOUS PC BOARDS
LOGIC BOARD
POWER BOARD
REQ'D
IDENTIFICATION
ITEM
PART NO.
ITEM
REQ'D
PART NO.
IDENTIFICATION
R47
C35
C3
R46
NA-5 LOGIC
SCR3
Q15
R49
D33
LED 7E
LED 7D
L6242-2
C34
R13
LED1F
D12
LED 7B
LED 7C
LED 7J
D13
D15
D14
R17
R16
R15
R29
R12
C11
R10
TP1
C1
+
R38
R50
R36
D14
C7
D11
R32
R59
R31
C28
C29
C19
C17
C15
D30
D31
C2
R5
R15
R34
D9
R17
R4
X7
X6
X2
DZ1
SCR4
C16
R5
C17
C18
C14
X1
R6
C6
D7
D6
R40
C27
R54
D16
D27
D15
D8
Q11
X3
X4
C5
X5
R19
R18
R52
C4
J3
R24
R55
C25
Q9
R39
Q8
R33
R42
Q4
C26
R57
R44
Q13
C22
C33
Q2
X8
Q3
Q10
Q1
C1
C20
R9
R8
D4
D5
R7
R11
R23
R61
C20
R1
C30
LED 7A
C31
R53
Q18
Q17
C7
LED1A
Q3
C11
R12
R19
R21
X9
Q2
R28
C22
R60
R27
R30
Q9
Q5
LED 7G
LED 7K
LED 7H
C13
D3
D4
D7
C8
S2
S1
C12
B2
B1
CAPACITORS
RESISTORES
=
MFD/VOLTS
OHMS
=
PROCEDURE BOARD
BYPASS BOARD
6 2 7
ITEM
REQ'D
PART NO.
DESCRIPTION
R11
R8
R5
R2
C6
C5
C4
C3
C2
C1
C5
BURNBACK
C1
C9
START
J8
J9
X1
CRATER
WELD
J10
J11
J19
Q2
C6
C3
C7
Q1
R18
R14
CAPACITORS = MFD/VOLTS
D8
D7
D6
D5
D10
B1
Y1
X2
D12
J18
FRAME
C2
S1
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not avail-
able from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in
NA-5
danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.
Download from Www.Somanuals.com. All Manuals Search And Download.
|