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Lincoln Electric NA-5N User's Manual

1. 7 60 x 9 55 610 S o o o 55 5 5 o z 5835 E a vc Erg v PROCEDURE LED T8 D 2 gt OCEL 5 PE 8 START TIME WELD TIME 564 PG BOARD way 4 OVER OVER NM ow pe Ci 100v 5
2. DATE 7 2 92 TO TACH PICK UP lt P C BOARD ARMATURE FIRING CIRCUIT SCALE NONE THE LINCOLN ELECTRIC CO CLEVELAND OHIO U S A Return to Section TOC Return to Master TOC L202 SPEEDMETER S7A 2 SPEED N 510A SET ACTUAL CALIBRATION JUMPER FAST SLOW 95 T ACCELER JUMPER PIN PIN E S CW CW j CAL hee C406 ACC GE E 1 Q202 A 0222 C401 510P 510 500 V Cb SPEEDMETER SPEEDMETER POWER SUPPLY ACCELERATION CIRCUIT FEED ENABLE CIRCUIT ON HOLE SIZES PER E2056 ON 2 PLACE DECIMALS IS 02 ON 3 PLACE DECIMALS IS 002 ON ALL ANGLES 15 35 OF A DEGREE MATERIAL TOLERANCE TO AGREE WITH PUBLISHED STANDARDS olo O10 Fle S9 o o G gle Etc 515 2 a CONTROL P C BOARD KEY TO SYMBOLS 022 25 02201 6 8V 12 W K 6 8 001801 OPTO INTERRUPTER C401 500 50 DM401 DIGITAL METER POWER SUPPLY SOURCE POINT 022 25 02202 16 0 V 1 W 500 TRIMMER 0402 4 7 85 18 15 02203 3 00 1 W 00
3. LED2 LED4 An Y WI STRIKE START CRATER p c STRIKE 4 L 40V 1 la ae CT voLTs D5 De STRIKE Ni Y Y Y SPEED STRIKE PROCEDURE DISABLE e UNLESS OTHERWISE SPE olo O10 Fle S9 o o G gle Etc 515 2 a STRIKE PROCEDURE ENABLE STRIKE MODE SETTINGS WELD MODE SETTINGS WELD PROCEDURE ENABLE 564 F PROCEDURE KIT yp RECEPTACLE l 564A WELD PROCEDURE ENABLE SINN NOTES _ START DISABLE 6 SINCE COMPONENTS OR CIRCUITRY PRINTED CIRCUIT BOARD MAY CHANGE STRIKE Te fio fr STRIKE T2 5 CRATER 14 WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE 1A NUMBER AX N B JUMPER PLUG CONNECTS 5845 5835 WHEN THE OPTIONAL START MODULE IS NOT INSTALLED o2 PRESET MODE JUMPER PLUG CONNECTS 5840 TO 5830 WHEN THE OPTIONAL START MODULE IS SELECTOR NOT INSTALLED ALSO LOGIC CIRCUIT 694 LEAD MUST BE MOVED FROM PIN 10 TO PIN P N D 564 IS CONNECTED TO 564A BY A LEAD RECEPTACLE JUMPER PLUG WHICH IS PRESET MONITOR ENABLE REMOVED WH
4. D509 688 500 Fm P C BOARD RECEPTACLE FOR OPTIONAL PULSED POWER FILTER P C SHUTDOWN BOARD SHOWN WITH JUMPER PLUG ENABLE INSTALLED SHUTDOW CIRCUIT D602 ZN D60f 601 h 602 C602 2608 0604 510 VOLTMETER VOLTMETER GO POWER SUPPLY ON 2 PLACE DECIMALS 15 02 ON 3 PLACE DECIMALS IS 002 ON ALL ANGLES IS 45 OF DEGREE MATERIAL TOLERANCE TO AGREE WITH PUBLISHED STANDARDS UNLESS OTHERWISE SPECIFIED Sht 7 956 ON HOLE SIZES PER E2056 olo o Fle cl o G 2 2 5 2 a VOLTAGE P C BOARD VOLTMETER P C BOARD COMPONENTS NOT ON P C BOARD KEY TO SYMBOLS 1 100 D501 44 2K 1 4W 1 F501 18 AMP FAST C601 500 50 DM601 DIGITAL METER 4 0 50 THRU 400V 500 TRIMMER BLOW FUSE C602 47 35 INPUT CONTROL CABLE CONNECTION 47 50 D522 4 75K 1 4W 1 585501 SILICON BILATERAL C608 002 25 578 SPDT VOLTS SET ACTUAL COMMON CONNECTION TO ANALOG POWER 022 25 DZ502 6 8V 12W 00K SWITCH C604 022 25 SUPPLY 510 1022 25 02503 81 1 2W 27k T501 24 VAC 185 mf D60 L 39 20 02504 20V 1 5 SECONDARY D602 022 25 07505 6 21 1 2W TP501 150V 10J D603 1 400V SCHEMATIC LOCATION REFERENCE 1 8 20 02506 15V 1W 2 2K D604 NOTES HORIZONTAL CO ORDINATE LETTER 022 25 02507 6 8V 1 2W
5. e 2 the power source and process being used HI Refer to the appropriate power source RED 515 connection diagram for the proper JUMPER connection of the jumpers located on the PLUG alz NA 5 Voltage P C Board shown in Figure X 3 5 5 To change the voltage control response d 1 all input power to the NA 5 WHITE JUMPER 2 Open the control box PLUG 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 O a appropriate power source connection ES diagram ul olo Ld 5 7 o S m ig 2 2 zz EIE 2 2 NA 5 LINCOLN Return to Section TOC Return to Section TOC Return to Master TOC ojo F e min o o amp 0 12 913 cic 5 45 oO x a Return to Section TOC Return to Master TOC Return to Master TOC OPERATING INSTRUCTIONS B 10 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 powe
6. C 5 5 22022 or S 22182 Current Relay C 5 Speed Feed Drum C 5 Speed Feed Reel C 5 O 2 2 o tc O 9 gt B E E o tc NA 5 LINCOLN 2 ACCESSORIES C 2 GENERAL This section contains a listing and short available with the NA 5 automatic welding description of the accessories that are system TABLE C 1 NA 5 AUTOMATIC WELDING SYSTEM ACCESSORIES Return to Section TOC Return to Master TOC Product Number Product Name K29 VERTICAL LIFT ADJUSTER K58 MAGNETIC SEPARATOR K96 HORIZONTAL ADJUSTER K129 SUBMERGED ARC SMALL WIRE TWINARC K148 CONTACT NOZZLE K149 LINC FILL LONG STICKOUT EXTENSION K218 HORIZONTAL FILLET LAP ATTACHMENT K219 FLUX HOPPER KIT K223 SOLENOID KIT K225 SUBMERGED ARC TWINARC KIT K238 HIGH FREQUENCY UNIT K239 TWINARC KIT FOR INNERSHIELD ELECTRODES K278 SPREADARC K281 SOLID WIRE STRAIGHTENER FOR TINY TWINARC K285 CONCENTRIC FLUX CONE K310 FLUX SCREEN K325 TC 3 TRAVEL CARRIAGE K334 START AND CRATER CONTROLS K336 REMOTE INTERFACE MODULE K337 WELD TIMER MODULE K349 MULTI PROCEDURE KIT 522022 or 522182 CURRENT RELAY SPEED FEED DRUMS SPEED FEED REELS Return to Section TOC Return to Master TOC olo e 515 gt gg G
7. 10 ENABLE a 2 022 z amp 150 D RAO e m START 100K 589 400V 5 oc DISABLE T pi e RAVEL 5 e 1N4004 sa O O mh JD 3 E i i 100 475 2 00 NA 9 EN amp 5 08 267K 1 START z 2409 NOTES in 9 4 100K 500 M Vm 5 gt la T NA SWITCH SEE PROCEDURE P C BOARD SCHEMATIC ENABLE MUST BE N STRKE POSITION TO START WELD L so CYCLE NB COMPONENTS INCLUDED WITH OPTIONAL LINC FL des BYPASS KT ALSO SEE SCHEMATIC A 8 022 7 5 sx 58 NO DIP SWITCHES ARE TO BE SET TO SUIT APPLICATION a PER CHARTS BELOW oO o M DEAE USED BS 80 e ND HOLD LOW DISABLE S USED WITH G1556 1 AND i u EARLIER VOLTAGE BOARDS ARC CONTROL ENABLE LED TC 85 4 59 By SK IS USED WITH LATER VOLTAGE BOARDS I Y ELECTRODE I NE SINCE COMPONENTS OR CIRCUITRY ON A PRINTED ue 025 n Hor CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE B amp 05 9 Qa 595 et em V INTERCHANGEABILITY OF A COMPLETE BOARD THIS Ap q 5 gt poa HOLD LOW H aj 1 DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR ba 582 2 m Bene CIRCUITRY OF CONTROLS HAVING A COMMON CODE NUMBER 0 lt n9 NWE
8. B 6 Starting Sequences B 6 Stopping Sequences B 6 Reconfiguring the Travel Sequences B 6 Voltage Control Response B 9 Automatic Shutdown B 10 Cold Start Circuitry B 11 Security of Weld Procedure Settings B 12 LINCOLN Section B NA 5 Return to Section TOC Return to Section TOC Return to Master TOC olo O o e w ols ois 518 E E 2 2 o a Return to Section TOC Return to Master TOC Return to Master TOC OPERATING INSTRUCTIONS B 2 SAFETY PRECAUTIONS A WARNING ELECTRIC SHOCK V e can kill Do nottouch electrical ly live parts or elec trode with skin or wet clothing Insulate yourself from work or ground Always wear dry insu lating gloves FUMES AND GASES can be dangerous 3 Keep your head out of 0 fumes M Use ventilation or exhaust to remove fumes from breathing zone WELDING SPARKS can cause or explosion e Keep flammable mater ial away Do not weld on con tainers that have held combustibles ARC RAYS can burn A Wear eye ear and body protection Observe additional Safety Guidelines detailed in the beginning of this manual OPERATOR S INSTRUCTIONS Once the system
9. Return to Section TOC Return to Master TOC 6682 3 SHT NO n 312502 ZX 0506 CONTROL 57 POWER SOURCE CONTROL INTERFACE V fn 510 621 SUP S D G_10 5 81 VOLTAGE CIRCUIT NA 5 SCHEMATIC SUBJECT EQUIP AUTO STOP CIRCUIT CHK D514 0504 AUTO STOP AND 151 RST SHUTDOWN BYPASS ACTUAL VOLTAGE C512 JUMPER BLUE METER FILTER HOLD LOW CIRCUIT DATE 7 2 92 SCALE NONE CLEVELAND OHIO U S A THE LINCOLN ELECTRIC CO V SHUTDOWN FROM PINA P 4 MA OPTION V VOLTAGE PROCEDURE 635 SETTING 5 o START 75 P C BOARD 3 RESPONSE n aS ACTUAL AE C510 C5 Sa 525 WHITE vM Ws ni ARC CONTROL i SET ACTUAL SET VOLTAGE ENABLE BUFFER Return to Section TOC Return to Master TOC
10. 2 5 Return to Section TOC Return to Master TOC o 2 E 5 F 44 10 TROUBLESHOOTING amp REPAIR T1 and T2 TRANSFORMER TEST Continued Check for approximately 22VAC at the blue secondary leads The blue secondary leads are connected to the logic board See wiring diagram Check for approximately 18VAC at the white to red leads The white and red leads are connected to the power board See wiring diagram Check for approximately 36VAC at the red to red leads Both red leads are also connected to the power board See wiring diagram If all the secondary voltages are correct the T1 transformer is func tioning properly If any or all of the secondary volt ages are low or not present the T1 transformer may be faulty Using the 115VAC supply carefully apply 115VAC to the T2 primary leads 5318 and 532 NA 5 LINCOLN 5 13 14 15 16 17 18 Check for approximately 115VAC at the orange secondary leads The orange leads are connected to the power board See wiring dia gram Check for approximately 24VAC at the brown secondary leads See wiring diagram If all the secondary voltages are correct the T2 transformer is func tioning properly If any or all of the secondary volt ages are low or not present the T2 transformer may be faulty Reconnect the primary leads 531B and 532
11. a Return to Section TOC Return to Master TOC Return to Master TOC OPERATING INSTRUCTIONS B 11 In some cases it is also possible to hold the Actual button pressed while starting the arc Before the NA 5 shuts down the actual arc voltage can be read on the digital meter Comparing this reading to the Set reading will tell what change in the range controls of the power source are required so it can supply the desired voltage Should the meter read zero check the NA 5 sensing leads 21 and 67 connections Should the meter read negative voltage the polarity connections or settings at the NA 5 or power source are wrong This same general procedure can be used on the other power sources For example if the NA 5 keeps shutting down and the other possible causes have been checked adjust the Set voltage higher and or lower than the desired voltage If the NA 5 continues to weld at one of these voltages it can be determined what change in the range controls of the power source are required so it can supply the desired voltage COLD START CIRCUITRY NA 5 controls above Code 8300 contain circuitry added to the voltage PC board to facilitate the cold starting features of these units This circuitry senses the voltage present between the electrode and work via leads 67 and 21 and permits normal wire feed if this voltage exceeds approximately 6 5 VDC However if this voltage level is not exceeded or
12. SAFETY iv PR CAUTIONS DE S RET 5 Toujours porter des lunettes de s curit dans la zone de Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher metallique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonctionnement Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines souder parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour sou
13. S9 o HE cic Sis ply tc QC Return to Section TOC Return to Master TOC TROUBLESHOOTING amp REPAIR VOLTAGE BOARD TRANSFORMER TEST Continued TEST PROCEDURE 4 Remove the molex type plugs from the voltage board 1 Remove all input power to the NA 5 5 Using the phillips head screwdriver 2 Using the 5 16 nutdriver open the remove the voltage board from the control box PC board access door control box 3 Locate the voltage board See 6 Locate the transformer and test Figure F 3 points on the voltage board See Figure F 4 VOLTAGE DN j BOARD S 2 FIGURE F 3 VOLTAGE BOARD LOCATION NA 5 LINCOLN 5 id TROUBLESHOOTING amp REPAIR VOLTAGE BOARD TRANSFORMER TEST Continued Return to Section TOC Return to Master TOC 24VAC SECONDARY TEST POINTS 1 HE PIN 9 HE PIN 8 NA 5 VOLTAGE G1556 Q 9 8 Return to Master VOLTAGE BOARD TRANSFORMER O FIGURE F 4 TRANSFORMER TEST POINTS Fie 6 5 7 Using the 115VAC supply carefully 10 If the secondary voltage is low or 9 2 apply 115VAC to pins 8 and 9 in not present the transformer may be 2 the nine molex plug cavity on the faulty 22 voltage board See Figure F 4 EJE Make sure the board and leads are 11 Carefully remove the 115VAC sup 5
14. 05 B 12 5 DUM Section C General Ae we Rane whee Ges A ARR C 2 Listing of Accessories 0 C 3 Maintenance isis ence einen tee ee RU UR A RR eee al a Section D Control ance ark Rod A A D 2 Welding Head D 3 Optional Features D 6 Theory of Operation Section E General Description E 2 Input Power Circuits E 2 Power and Voltage E 3 Control Logic and Procedure Boards E 4 Optional start Crater Fill and Weld Timer Boards E 5 SCR Operation sir eis e koe EY ed E 6 Troubleshooting Section F Electrical Diagrams Section Parts Eislihg wien ie ERREUR P 135 NA 5 LINCOLN 5 vi NOTES NA 5 LINCOLN vi NOL uini ti NOL NOL J91Se N 01 uunjeH NOL J91Se N 01 UuunjeH Section A TABLE OF CONTENTS Section A INSTALLATION SECTION O O 5 Installation 2 2 2 1 4 Section A 5 Technical Specificat
15. 5 0 1 Return to Section Return to Master TOC NA 5 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 9 o 3 tc Return to Section TOC Return to Master TOC Q 42 E ACCESSORIES 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 operators manual IM305 Installation instructions are shipped with each K29 Vertical Lift Adjuster kit are contained in the IM305 manual and can be ordered as Sec T2 2 11 K58 MAGNETIC SEPARATOR Useful with any submerged arc equipment The unit removes foreign magnetic particles from reused submerged arc welding flux Operating instructions are included with the kit K96 HORIZONTAL ADJUSTER When mounted in the NA 5 head mounting system the K96 Horizontal Adjuster provides quick hand crank adjustment of the horizontal head position Installation instructions are shipped with each K96 Horizontal Adjuster kit are contained in the IM305 manual and can be ordered as Sec T2 2 12 K129 SUBMERGED ARC SMALL WIRE TWINARC The Twinarc system provides for the feeding of two small
16. O O o 9 E Return to Master LINCOLN P G 1 ELECTRICAL DIAGRAMS G 1 NOTES NA 5 LINCOLN E DOL Je1se A 01 uunjeud DOL Je1Se A 01 uunjeud DOL Je1Se A uunjeu DOL Je1Se A 01 DOL uonoes UNAY DOL 5 uinjeg DOL uon5 s DOL 5 6 2 ELECTRICAL DIAGRAMS 6 2 Wiring Diagram e A OPTIONAL PULSE POWER FILTER P C BOARD LEAD PLUG 581A OPTIONAL PROCEDURE MODULE FLUX RELAY MODULE USED FOR CRATER CONTROL 8 532 eee ELECTRODE CABLE pal T m 9 E OPTIONAL PROCEDURE MODULE TO POWER SOURCE POWER P C BOARD 4 2 626 TIMER BOARD CRATER TIME USE DIGITAL METER DIGITAL METER USED FOINSTARTGONTROL l za HAO f SE CUN 541 344 1 TIMER BOARD TRAVEL p A SES a START TIME USE VOLTMETER BOARD H enw egz 585 0 S Seay s86 H A 5 92 LOGIC P C BOARD 27 528 H 473 587 5 6 gt 689 gt 1 RELAY MODULE 625 REED SWITCH ACTUATED BY 539 64 2 gt 587 J 4 WELDING CURRENT 43525 ne 1 2A SLOW BLOW FIELD FUSE T 9 28 00 15830 7 2 gt 565 324 566 43 5848 1 724 588 H 8 gt 560 6 4 561 L7 Return to Section TOC
17. 004VDC For Hi Speed NA 5 speedmeter IPM X 1000 O10 e S9 o 22 cic Sis a Return to Section TOC Return to Master TOC NA 5 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o e 9 o o E B tc Return to Section TOC Return to Master TOC o E T TROUBLESHOOTING amp REPAIR aia METER CIRCUIT ACCURACY TEST Continued 14 Test Speedmeter PC Board e If the test meter does not match Accuracy 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 discon nect plug Note The coating will have to be removed from the test points to ensure accurate meter readings e 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 NA 5 SET SPEED READING TEST VOLTMETER CALIBRATION PIN IPM READING For Hi Speed NA 5 speedmeter IPM X 1000 NA 5 LINCOLN 5 p TROUBLESHOOTING amp REPAIR nd PC BOARD S REMOVAL AND REPLACEMENT A WARNING
18. 1 2 ELECTRODE CABLES TWO 4 0 CONTACT ASSEMBLY TO CONTROL BOX GEAR BOX 7 ADJUSTER OPTIONAL NA 5 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC E w gls nl g 2 EIE 3 42 Return to Section TOC Return to Master TOC 4 INSTALLATION A 4 MECHANICAL INSTALLATION A WARNING ELECTRIC SHOCK e can kill Turn off input power to the welding power source using the disconnect switch before working on this equipment 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 special instructions or precautions that must be fol lowed when installing the control box and mounting head 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 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 NA 5 LINCOLN 1 Align the mounting holes in adapter plate M 13945 to the holes in the travel carriage 2 Install four hex head screws through the adapter plate and into the travel carriage 3 Secure the
19. 2 July 1997 HE NA 5 5 8 AUTOMATIC WELDING SYSTEMS 5 5 For use with the following models 5 5 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 View Safety Info Return to Master TOC Fg 9 5 2 g o z lo al SERVICE MANUAL View Safety Info Return to Master TOC LINCOLN amp 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 Return to Master TOC Return to Master TOC o ma 7 c E Return to Master TOC i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS A Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and
20. 22 cic 5 5 ply a Return to Section TOC Return to Master TOC NA 5 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o c 9 o o 3 Return to Section TOC Return to Master TOC o 2 E 5 F 65 TROUBLESHOOTING amp REPAIR METER CIRCUIT ACCURACY TEST Continued TEST PROCEDURE 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 voltmeter PC board See Figure F 9 4 Apply input power to the NA 5 L6685 METER 5 Test for AC supply to the volt meter PC board Check for 8 to 11VAC from lead 601 to 602 See Figure F 9 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 FIGURE F 9 VOLTMETER PC BOARD AND TEST POINTS NA 5 LINCOLN 5 F 65 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o c 9 o o 3 Return to Section TOC Return to Master TOC o 2 E 5 TROUBLESHOOTING amp REPAIR METER CIRCUIT ACCURACY TEST
21. BEF G supspi 8107 SWITCH 7 Return to Section TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual NA 5 G 3 ELECTRICAL DIAGRAMS LOGIC PC BOARD L6242 1 SCHEMATIC FE el LED 78 4 PROCED
22. 8182 10 5 500 9 71 2 520 122 632 gt 6 635 4 gt 510P 5 gt 562 11 gt 583 gt 1 Ll A lt 6e B 4 lt 5 592 344 687 2 lt 688 1 H T MOTOR RECEPTACLE i A gt 541 gt B gt 539 gt Co 626 gt D gt 627 EN ENS ost BPH 5 10 525 J2 TACH RECEPTACLE gt 92510 H 14 500 gt B3 525A 13 628 gt C 555 F gt 1 520 gt D gt 510A 8 gt 510P E 7 510p CET z e x 581A 5 4 XH 8 gt 588A 531B 8 4 BYPASS COM 52 lt 9H O amp 637 49 7 5 o AUTO 5 1 500 510 13 500 5 583C gt 584C 5835 gt 5845 1 0 11111 WELD TIME 1 RECEPT 57 CRATER RECEPT 4 500 K 644 T 655 k 4e 4l 515 x 34 BURNBACK 19428 RECEPT 1 se 6 4 gt 6 H 9 gt 588 3 gt 515 P 2 gt 3 gt 520 4 gt 515 2 gt 4 510P o gt gt gt gt 13 gt 500 1 JUMPER PLUGS p p P gt 11 635 115 gt 632 E314
23. Make several test welds readjusting the controls in the following order a Set the Arc Striking Inch Wire Speed and Volts controls for optimum arc striking optimum strike control settings for most processes will be typically 4 to 5 volts higher than the weld mode voltage setting and 4096 to 5096 of the weld mode wire feed speed setting possibly lower if cold starting is used b If striking is still not satisfactor refer to the section on Travel Starting and Stoppinglot IM305 Sec 3 5 2 for information on wire feed motor acceleration c If installed adjust the Start Controls to set the welding procedures for the time set on the timer to provide the bead size penetration or other factor as needed for the application 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 e Set the Burnback Time to provide the stopping char acteristics needed NA 5 LINCOLN B 5 STARTING AND STOPPING SEQUENCES 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 2 The electrically hot electrode inches down as set by the Inch Wire Speed control 3 When the electrode makes contact with the work the
24. ols ois 518 E E ala x Return to Section TOC Return to Master TOC NA 5 LINCOLN Return to Section TOC Return to Section TOC Return to Master TOC ojo FE x e min o ols 0 12 22 cic 5 o a Return to Section TOC Return to Master TOC Return to Master TOC OPERATING INSTRUCTIONS B 8 Wire Feed Motor Acceleration WARNING ELECTRIC SHOCK N e Turn off input power to the welding power source using the disconnect switch before working on this equipment The NA 5 has two different speeds of controlled wire feed motor acceleration As shipped the unit is connected for fast acceleration which is best for most applications To change to the slower acceleration turn off all input power to the NA 5 control box Open the control box Locate the Control PC Board mounted on the back of the box in the lower right hand corner Change the jumper plug from the F pin to the 5 pin as shown in Figure B 2 FIGURE B 2 ACCELERATION JUMPER PLUGS JUMPER PLUG gt o z o o 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 NA 5 LINCOLN The standard stopping sequence when the optional Crater Controls are not us
25. 13161 052 Twin 045 052 513161 5 64 Twin 1 16 5 64 514904 Outer Twin 3 32 514905 Inner 512514 Single 3 32 7 32 514904 Outer Twin 5 64 1 8 514905 Inner o 2 E E o e 2 2 Return to Section TOC Return to Master TOC NA 5 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o c 9 o o o E B tc Return to Section TOC Return to Master TOC o 2 7 E E a TROUBLESHOOTING amp REPAIR WIRE SPEED ACCURACY TEST Continued 3 Check for the proper drive roll revo lutions per minute RPM 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 TABLE F 5 CALIBRATION READING IPM PIN READING IPM 0 27 IPM X 1000 B If the readings do not match the number in Table F 5 refer to the Meter Circuit Accuracy Test DRIVE ROLL ACTUAL RPM SPEEDMETER 0 27 0 01 IPM X 1000 268 268 2 262 262 2 95 249 249 2 95S 265 265 2 142 250 2
26. 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 CONNECT THE NA 5 CONTROL CABLE GROUNDING LEAD TO THE FRAME TERMINAL MARKED 7 7NEAR THE POWER SOURCE TERMINAL STRIP THE POWER SOURCE MUST BE PROPERLY GROUNDED o O S 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 THE TERMINAL STRIP 5 N H FOR PROPER NA 5 OPERATION THE ELECTRODE CABLES MUST SNUGGED UNDER THE CLAMP BAR ON THE LEFT SIDE OF THE NA 5 CONTROL BOX 2 gt 2 EJE LINCOLN jo E z ELECTRIC CLEVELAND U S A dc NA 5 LINCOLN auis INSTALLATION A 14 olo o FIGURE A 13 CONNECTION OF NA 5 TO DC 1000 OR DC 1500 s AAWARNING TURN OFF INPUT POWER olg cc TO THE WELDING POWER 2 2 SOURCE USING THE 0 9 DISCONNECT SWITCH BEFORE WORKING s ON THIS EQUIPMENT ELECTRIC SHOCK CAN KILL POWER SOURCE TO NA 5 INPUT CABLE PLUG C
27. COM 5 VOLTAGE G1556 FIGURE F 6 VOLTAGE BOARD AND PIN LOCATIONS NA 5 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Q e 9 2 5 Return to Section TOC Return to Master TOC o 2 E 5 F 54 TROUBLESHOOTING amp REPAIR 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 If the NA 5 continues to shut down with the BYPASS pins jumpered together the voltage PC board may be faulty If the ACTUAL voltage reading is zero the sensing leads may be faulty Perform the Also check the 1 8 amp fuse on the voltage PC board 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 LINCOLN 5 OUT OF VOLTAGE RANGE SHUT DOWN TEST Continued 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 10 After all tests are complete remove the input power to the wire feeder and remov
28. gt 655 I3 12 gt 5620 gt 6 gt 5620 5 5 10 gt 3 gt 520 4 gt 515 515 59 2 2 gt m fa A gt 9 gt 588 11 4 gt 635 15 632 14 gt 655 gt 12 gt 5625 gt 6 gt 5628 5 10 gt 1 gt 7 4 A 2 x pgs CIRCUIT Ue 3 POLARITY WE tn 2 P T REMOTE INTERFACE Feb 21 510 ra MODULE OPTIONAL A SOURCE G B 555 525A Ce ETC posce LL581A 1 GREEN N 500 6 J1 INPUT RECEPTACLE TERMINAL 1 586 a WELDING STRIP JUMPER 592 lt 4q 582 2 lt NOZZLE 1 WHITE 515 3 lt z d 2 gt ORANGE os BROW 0 RED N BROW Return to Master TOC 12 4 ELECTRODE N J Return to Section TOC 60 624 520 34 635 14 32 1064 5845 86 5835 gt 14 gt 8 gt 588A 561 19 510 lt 2 4 5840 7 je 588 9 563 1364 564 144 564A 4 3 00 1 5 5 NMOG WO9 df o 9015 WOO _LYVIS ELECTRICAL SY
29. oO tc QC Return to Section TOC Return to Master TOC F 6 TROUBLESHOOTING amp REPAIR F 6 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENTS S 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 tion in the wire feeding path down inch up or the start buttons are pressed The wire drive motor Make sure the proper input volt 2 The power board may be faulty does not turn age 115VAC is applied to the SeelTabie F1 NA 5 control unit 3 Check the motor control cable for Check the F102 field fuse on the shorts or grounds power board Replace if faulty Note Frequent motor polarity changes can cause the fuse to fail This can be caused by the following welding procedure with frequent electrode to puddle shorting 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 feed wire in the proper direction down button is pressed the wire when it is installed as shipped feeds up 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 in
30. 0225 SS ITEM REQ D PART NO DESCRIPTION amp D1 D2 D3 D4 D5 D6 D7 12 T12199 1 IN4004 08 09 010 011 012 n B 1 B2 B3 B4 B5 B6 6 13157 19 TERMI NAL Vw d _ Ed J8 J9 J18 3 T13160 65 6 PIN PC BD HEADER Ol c J10 J11 2 T13160 115 HEADER B7 1 1 001185 204 4 96 144 ea 419 1 60 119 HEADER N Ci 22 C3 C5 C6 6 T11577 58 0047 3000V LED 1 LED2 LED3 LED4 4 T13657 2 RED LED C4 o 01 02 2 112704 69 2N4403 NC P R1 R7 810 4 519400 5621 5 62K 1 4W 5 R2 R5 R8 R11 16296 6 10K POT a R5 8 R3 1 519400 2670 267 1 44 CAPACITORS MFD VOLTS amp RG R12 2 19400 1821 1 82K 1 4W TE R9 1 S19400 3320 332 1 4W x R13 R17 2 19400 4751 4 75K Neg R14 R18 2 519400 4752 47 5K 1 4W usc D m R15 R16 2 19400 2672 26 7 1 4W C S _ E R19 1 519400 2211 2 21 1 4W e R20 1 T14231 2 10M 1 2W z o R21 1 519400 7681 7 68K 1 4W 51 1 516670 1 ROTARY SWITCH 1 515018 6 DIG INTEG CIRCUIT 59 X2 1 S15018 17 16 PIN IC YI 1 516665 7 1 6384 MHz 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 LINCOLN P able from Lincoln
31. 05 712704225 2N5657 H 012 013 014 016 017 018 6 12704 69 2N4403 ig q 8 R12 2291340054752 e TAM R1 R3 R11 R13 R38 R47 6 519400 1501 1 5K 1 4W V R9 R14 2 S19400 4751 4 75K R2 R5 R36 3 19400 1001 IK 1 4W 5 R10 1 519400 6811 6 81K 1 4W R4 R9 R 10 R14 R 19 R32 6 519400 4750 475 1 4W ja ei 3 ye Ril 1 19400 6810 681 1 4W R6 R12 R17 R35 R49 R50 6 519400 1000 100 1 4W x 808 R15 1 19400 3321 3 32K 1 4W R15 1 519400 2213 221K 1 4W TE RIS 1 519400 1501 15K 1 4W R16 1 S19400 4752 47 5K 1 4W R20 1 519400 1372 13 7K 174W R18 R24 831 R33 R39 R42 9 19400 2212 22 IK 1 4W 7 21 1 S 19400 3320 332 1 4W R45 R5 1 R52 7 R22 111 161940023222 aa ok 3748 R20 R23 R25 R28 619400 2671 2 67K 1 4W SCR 1 SCR2 2 S15161 14 2N6398 SCR 522 827 R30 3 818400 6512 SCR3 SCR4 2 615161 10 SCR W 514008 7 HS eom T 6 SIK LAV 1 TP2 TP3 113640 11 45J ETT 1 CTS4S400 1062 10K 174W x1 1 515128 5 7815 R4 1 R43 R44 R46 R48 R53 6 519400 7681 7 68K 1 4W x2 1 515128 7 REGULATOR R54 R55 R56 R57 R58 R59 10 519400 1003 100K 1 4W 860 R6 1 862 R63 CAPACITORS MFD VOLTS RESISTORES OHMS ITEM REQ D PART NO IDENTIFICATION B1 1 15128 2 CAPTIVE NUT C1 1 S13490 39 18 15 C2 1 516668 1 22 100 1 S16668 2 47pF 100 C4 C5 C6 C7 C9 5 516668 5 022750 a N wo ps 5 51885
32. ACTUAL START stor swrrcH swircrj METER METER BOARD BOARD INCH uP SWITCH DIGITAI DIGITAI METER 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 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 1 2 VOLTAGE SET VOLTAGE BOARD TRAVEL RECEPTACLE RECEPTACLE TNH DOWN SWITCH ZZOU Cro Oz OPTIONAL START BOARD TIMER STRIKE B EWE oE 5 ENABLE OPTIONAL CRATER GRATER BOARD TIMER OPTIONA WELD TIMER BURNBACK TIMER LOGIC SET SPEED gt mro zm ommm 10 0 REFERENCEVOLTAGE TACH FEEDBACK MOTOR RPM CONTROL BOARD is pressed This optional feature is helpful in controlling bead shape and filling craters at the end of a weld The weld timer permits settin
33. Check light 7B on the logic board power switch is in the ON position Make sure it is not stuck closed It should NOT be on If light 7B is ON remove lead 518A from the 2 Check the Inch Down switch Start switch If the light remains S4 Make sure it is not stuck ON the logic board may be faulty closed If the light goes OFF check the switch and associated leads Check the Inch Up switch 63 See wiring diagram and Figure Make sure it is not stuck closed Check to make sure that jumper Check light 7J on the logic board lead 693 is connected to the It should NOT be on If light 7J is proper pin on the logic board ON remove lead 592 from the See wiring diagram 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 3 Disconnect lead 586 from the Inch Up switch If the problem is resolved check the switch and associated leads See wiring dia gram 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 Disconnect plug A from the logic board If the wire feed stops the logic board may be faulty See 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 doe
34. 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 LINCOLN 8 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O o F F S9 919 ois gje 5 oO tc QC Return to Section TOC Return to Master TOC F 19 TROUBLESHOOTING amp REPAIR F 19 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENTS S COURSE OF ACTION MODE FUNCTION PROBLEMS During the welding sequence the 1 weld light does not go ON While welding the weld mode is omitted in the welding sequence The weld timer is set for a longer time than zero seconds The weld timer does not time out the unit stays in the weld mode 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 If the start module is OK and the weld light does not go ON the logic board may be faulty Replace If a start module is NOT used make sure the jumper plug is installled in the procedure board receptacle The weld timer module may be faulty Replace Set the burnback timer for a value greater than zero sec
35. Return to Master TOC 500 655 515 x x 8 s LJ 688 6 7 TIMER 6 gt 500 QS 687 54 3 RECEPT log lt 2 SLOW BLOW 530 344 J5 TRAVEL RECEPT POWER FUSE 3 gt 540 1 ELECTRODE LEAD BOLTED gt 532 754 525 CONTACTOR l 628 2 24 9 510 RELAY MODULE L 3 582 4 44 i 2 83800 4 N P r581 14 1 500 516 9 514 244 635 441 V8 AMP 510P 8 FAST BLOW 525 344 510 744 500 6 lt 544 530 19 667 114 621 123 gt 6 gt 4 gt 93 9 563 5 563 o m 5 sic 254 564 4 4 583S 1 4 m 682 4 6 lt 5 gt 500 E 3 9 BLUE BLUE gt 6 gt 515 x 2 532 24 610 2 144 AND TAPED CONNECTION B 25 1 I 531 153144 5 585 4 5 631 4 19 L1 589 45 4 amp 4 WELD TIMER BOARD D gt GND H 1 1 gt 610 lt 6 TITI 1111111111 OPTIONAL ORANGE WHITE 15218 lt 3 lt ORANGE RED RED J4 FLUX RECEPTACLE nu 888 Uo rii GDL 7 wp A gt 87 gt B 531 l gt C gt GND 500 lt 244 H 3 24 500 1 dB dit 655 93
36. S CONNECT WHITE JUMPER TO PIN B DER 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 CONNECT THE NA 5 CONTROL CABLE GROUNDING LEAD TO THE FRAME TERMINAL MARKED 7 THE POWER SOURCE TERMINAL STRIP LINCOLN amp ELECTRIC CLEVELAND OHIO U S A NA 5 LINCOLN A INSTALLATION 11 FIGURE A 10 CONNECTION NA 5 ALL TO R3S 400 600 800 WITH NO LINE VOLTAGE COMPENSATOR OBSOLETE A WARNING TURN OFF INPUT POWER o TO THE WELDING POWER SOURCE USING THE DISCONNECT SWITCH BEFORE WORKING ON THIS EQUIPMENT Return to Section TOC Return to Master TOC ELECTRIC SHOCK CAN KILL N H 777 o 76 77 TO AUTOMATIC CONTROL BOX 2 e S 21 2 83 4 olo N E 25 N G CONTROL o CABLE EIE N D N J E N B iic NEGATIVE BOLT TO CABLES FROM NA 5 AL WIRE CONTACT ASSEMBLY N C CONNECT TO WORK POWER SOURCE N B 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 NA 5 SETTINGS TURN POWER SOURCE OFF FOR
37. 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 Return to Section TOC Return to Master TOC 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 Return to Section TOC Return to Master TOC 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 O10 e S9 o 22 cic 5 5 ply a Return to Section TOC Return to Master TOC NA 5 LINCOLN 5 TROUBLESHOOTING amp REPAIR Fe 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 Return to Section TOC Return to Master TOC 1 Remove the input power to
38. TROUBLESHOOTING amp REPAIR ditas WIRE DRIVE MOTOR REMOVAL AND REPLACEMENT Continued Fie 51 MOTOR REMOVAL PROCEDURE gle S S 1 Remove input power to the NA 5 6 Using the 5 16 nutdriver remove the 9 clamp holding the connection box to cc 2 Remove the motor and tach cable the drive motor from the NA 5 control box 7 Carefully remove the connection box 3 Perform the Tach Board Removal being careful not to stretch the leads 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 Return to Section TOC Return to Master TOC TACH HOUSING COVER PLATE ADAPTER O10 e S9 o cic Sis a FIGURE F 16 DRIVE MOTOR AND TACH HOUSING Return to Section TOC Return to Master TOC NA 5 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O10 e S9 o 22 cic Sis a Return to Section TOC Return to Master TOC F 83 TROUBLESHOOTI F 83 NG amp 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 9 Using the 7 16 wrench remove two 1 4 2
39. 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 CIRCUIT BREAKER RESET BUTTON NA 5 LINCOLN 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 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 Shutdown Section B Operating Instructions FIGURE D 2 POWER PC BOARD FUSE LOCATIONS OOO NA 5 POWER FIELD POWER 1 2 AMP 1 2 AMP SLOW BLOW SLOW BLOW FUSE FUSE The power supply for the el
40. inside They can cause an explosion even though they have been cleaned For information purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode Sparks and spatter are thrown from the welding arc Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap over your hair Wear ear plugs when welding out of position or in confined places Always wear safety glasses with side shields when in a welding area Connect the work cable to the work as close to the welding area as practical Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains crane cables or other alternate circuits This can create fire hazards or overheat lifting chains or cables until they fail 6 h Also see item 1 c SAFETY CYLINDER may explode gt if damaged 7 a Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition
41. 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 Perform the Wire Drive Motor 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 LINCOLN 8 F 35 TROUBLESHOOTING amp REPAIR F 35 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENTS S COURSE OF ACTION WELDING PROBLEMS Poor arc striking with sticking or 1 Make sure the welding parame 1 Put the Lincoln power source in blast offs The weld bead is ters voltages and wire feed the machine control mode and has porosity speed and techniques are cor Jumper the BYPASS pins on the rect for the welding procedure NA 5 voltage board Adjust the being used weld voltage at the power source for the process being used If the Check the welding cables for problem is resolved check or loose or faulty connections replace the control cable or the NA 5 voltage board may be faulty Return to Section TOC Return to Master TOC The contact tip may be worn Check or replace The welding power source may be faul
42. 1 4W 1 20 0301 2 4123 C40 S7A SPDT SPEED SET ACTUAL COMMON CONNECTION TO ANALOG POWER 3 47 35 2 94K 1 4W 1 27K Tinu 022 25 0033 200 L201 5K 5 R301 C408 SUPPLY 510 47 50 202 OK 00 R302 15 D401 18 15 OOK TRIMMER 6 8 R304 13 0402 400V SCHEMATIC LOCATIONIREFERENGE 4 50 0201 2N4123 33K 27 D403 HORIZONTAL CO ORDINATE LETTER 047 100 0202 2 4123 OK 0K D404 4 7 85 0203 2 4129 270 X401 TAGE REGULATOR VERTICAL CO ORDINATE NUMBER 15 200 0204 2 4125 5K R401 MER SCHEMATIC IDENTIFICATION LETTER 1022 25 0205 5170 47K R402 BK 1 4W 1 1022 25 0206 2 4123 5K R403 2 1 NOTES 47 35 Q207 2 5816 00K R404 MER NA 51115 CONNECTED TO 511A UNLESS OTHERWISE SPECIFIED COMPONENT VALUES OF 18 15 K R405 2K 1 4W 19 100pf 100 00201 2N6027 K R406 MER S BY CONNECTION TO CAPACITORS MFD VOLTS K R407 1 VOLTAGE BOARD RESISTORS OHMS 1 2 WATT 022 25 33K R408 MER SINCE COMPONENTS OR CIRCUITRY ON A PRINTED X201 VOLTAGE REGULATOR 50K TRIMMER R409 52 3K 1 4W 1 THESE COMP ONTATS ANE CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE X202 F TO V CONVERTER 5K R410 INTERCHANGEABILITY OF A COMPLETE BOARD THIS X203 QUAD OP AMP OK TRIMMER R411 MER BOARD SEE SCHEMATIC 1A 400 V OWNED BY THE LINCOLN ELECTRIC CO AND 15 THE LINCOLN ELECTRIC CO NOT TO BE REPRODUCED DISCLOSED OR USED THIS SHEET CONTAINS PROPRIETARY INFORMATIQN UNLESS OTHERWIS
43. 38 5 56 113724 A Solid or Cored 1 16 3 32 1 59 2 38 T13724 B Solid or Cored 0 035 0 052 0 89 1 32 T13724 C Solid 0 045 0 052 1 14 1 32 T13724 D 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 NOTE Any item numbers in parentheses on Figure D 5 refer to item numbers in the task description breakdown FIGURE D 5 CHANGING THE WIRE FEED GEAR RATIO HEX NUT 11 PLAIN WASHER 9 N SLOT HEAD INPUT SCREWS HELICAL WIRE MOUNTING E GEAR 12 FEED SCREWS E GEARBOX 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 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 TABLE 0 2 WIRE FEED GEAR RATIOS Feed Speed Gear Range Ratio in min m min 100 2070 2 54 52 58 40 778 1 02 19 76 22 456 0 56 11 58 15 300 0 38 7 62 NA 5 LINCOLN in mm Cored Wire S
44. 383 2531 or 1 800 833 9353 Return to Section TOC Return to Master TOC NA 5 LINCOLN 8 F 29 TROUBLESHOOTING amp REPAIR F 29 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENTS S COURSE OF ACTION FUNCTION PROBLEMS The circuit breaker trips when the The power board may be faulty 1 Perform the inch up inch down or start buttons Replace are pressed Return to Section TOC Return to Master TOC 2 Perform the DC Power Supply The circuit breaker trips and or the Contact your Local Lincoln If fuse F101 orthe circuit breaker fuse F101 blows when the NA 5 is Authorized Field Service Facility immediately fails when input turned on input power applied 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 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 Return to Section TOC Return to Master TOC O o F F 5 5 o 919 ois 2 2 oO tc QC CAUTION If for any reaso
45. 77 Wire Drive Motor Removal and F 81 PROTEST After De ax vee n RENE I F 85 o O 0 8 E o tc o O 0 8 o as NA 5 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Q e 2 5 o 2 Return to Section TOC Return to Master TOC o 2 E 5 F 2 TROUBLESHOOTING amp REPAIR F 2 HOW TO USE TROUBLESHOOTING GUIDE A 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 This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions Simply follow the three step procedure listed below 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 cat
46. 8 4 a C7 C16 2 613490 25 4 7 35 C2 1 C22 C23 C24 C25 C26 L9 447 E 11 C9 C 10 C 11 C 12 C20 C22 C24 7 516668 5 022 50 NA 5 LOGIC C27 C28 C29 C30 C31 C32 gt ES C13 1 111577 28 22 100 TE C33 C34 C35 C36 C37 Q 14 015 2 T11577 48 500 50 C5 C9 C 13 3 513490 25 2 7735 Ciz L ST3490 88 18715 C7 C8 2 S13490 12 10725 Su m 25 C12 1 T11577 49 500 50 cp s gee V m 2 prus oe D1 D2 03 D4 05 06 D7 D8 D9 31 12199 1 1N4004 z Be 555 D4 05 D6 07 08 09 010 011 8 T12199 1 144004 emp D12 D13 D14 DIS r12199 2 184007 DIR DIO Dao ae Eos d E UE 011200252 LES D26 D27 D28 D29 D30 D31 m FLFE 2 10728 14 1 2 SLOW BLOW FUSE 032 D33 D34 D35 LED1 LED 1B LED IC LED ID 6 T13657 2 RED LED D18 019 020 021 4 T12188 2 1N4007 Tr LED IE LED IF DZ1 1 112702 52 1N4733A z Ds PT1 PT2 PT3 3 r12737 2 Edi 11 15 2 T13160 65 6 PIN PC BOARD HEADER d 01 02 03 09 T12704 68 2N4401 J2 J4 2 T13160 5 6 PIN RECEPTACLE 001 1 T12707 4 2N6027 J3 1 T13160 3 9 PIN FEMALE RECEPTACLE 2 RI 1 T12300 59 40 OHM 12 WATT RESISTOR LED 7A LED 7B LED 7C 9 113657 2 RED LED g g R2 R16 R17 R18 4 519400 1333 133K 1 4W LED 7D LED 7E LED 76 LED 7H LED 7J LED 7K R3 R4 RE 3 519400 1000 100 1 4W RS BE T i 2 WATT 01 06 07 09 010 O11 015 8 12704 68 2N4401 17 184 102 IOK 177 G2 03 04
47. 8 s wl a d e D 2 Circuit Protection D 2 Ground Fault Fuse Protection D 3 Welding Hedd D 3 Wire Drive Gear Box D 3 Wire Drive Motor D 4 Changing Wire Feed Gear Ratios D 4 Wire Drive Mechanism D 5 Wire Straighteners D 5 Optional Features D 6 Contact Assemblies D 6 Wire Reel Mounting for 50 or 60 Ib 22 7 or 27 2 kg Coils D 6 Travel Carriage D 6 Vertical Lift Adjuster D 6 Horizontal Adjuster D 6 High Frequency Generator D 6 PEU P D 6 NA 5 LINCOLN Section D Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 9 o 3 tc Return to Section TOC Return to Master TOC Q 7 E MAINTENANCE D 2 CONTROL BOX GENERAL Inspect the control box every 3 months If needed blow dirt out using ow pressure air No further maintenance should be required CIRCUIT PROTECTION
48. 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 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 ALTERNATIVE 500 POSITIVE TERMINAL CONNECTION PROVIDED ON DC 1000 MODELS ABOVE CODE 9500 ONLY N L ALTERNATE SUBMERGED ARC 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 O10 O10 Fle w gls nl gie EIE 2 oio Sie jo S gt 2912 LINCOLN ELECTRIC CLEVELAND U S A Ble
49. 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 ELI ECTRODE POLARITY IS CHANGED DOES NOT APPLY TO DC 400 BELOW CODE 9200 WITH POLARITY SWITCH LINCOLN E ELECTRIC CLEVELAND OHIO U S A NA 5 LINCOLN A 16 NOTES NA 5 LINCOLN E A 16 NOL Je1se N 0 NOL Je1se N 0 DOL 4e1se N 0 DOL 4e1se N 0 DOL uonoeg uunjeg DOL uonoeg 0 DOL uonoes uunjeg DOL uonoeg uunjeg Return to Master TOC Return to Master TOC o o o c z 5 tc Return to Master TOC S TABLE OF CONTENTS OPERATING INSTRUCTIONS SECTION Operating Instructions Section B Safety Precautions B 2 Operator s Instructions B 2 Controls and Their Functions B 3 Exposed Controls With Lockable Cover Down 3 Controls Under the Lockable Security Cover B 3 Setup Instructions B 4 Starting and Stopping Sequences B 5 Means of Arc Striking B 5 Setting Travel Starting and Stopping
50. CONNECTED TO PIN M AND BLUE 2 SET MODE SWITCH TO CV INNERSHIELD LEAD IS CONNECTED TO W FOR NR 203 AND NR 302 ELECTRODES FOR OPTIMUM PERFORMANCE WITH NA 5 DC 600 S WITH CODES 8288 AND 1 SET MODE SWITCH TO CV INNERSHIELD ABOVE ARE PREFERRED FOR ADDITIONAL INSTALLATION INSTRUCTIONS 2 WHITE LEAD ON CONTROL PC BOARD IS CONNECTED TO PIN I SEE NA 5 OPERATING MANUAL AND BLUE LEAD IS CONNECTED TO 5 O10 O10 E w gls nl g 2 EIE 2 ON EARLIER DC 600 S 67 TERMINAL WAS ALSO 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 CONNECT THE 5 CONTROL CABLE GROUNDING LEAD TO THE FRAME TERMINAL MARKED 7 7NEAR THE POWER SOURCE TERMINAL STRIP THE POWER SOURCE MUST BE PROPERLY GROUNDED 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 JUMP
51. Continued 6 Test for DC volts on the voltmeter PC board Check for 4 75 to 5 25VDC from TP5 to lead 510C See Figure Note The coating will have to be removed from the test points to ensure accurate voltmeter 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 lf the AC voltage IS present at leads 601 to 602 and the DC voltage is missing the voltmeter PC board may be faulty 7 Test Digital Voltmeter 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 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 test meter matches the settings in the table below e 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 150 004VDC 30 0VDC 300 004VDC 60 0VDC NA 5 LINCOLN 5 600 006 VDC F 66 id TROUBLESHOOTING amp REPAIR dois 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 Return to Section TOC Return to Mast
52. F J NF SCHEMATIC SHOWN WITH DIP SWITCHES IN THE UP POSITION 5 2 d Es p ENERO dT 6 27 ux 6 STOP dus y Tu 500 5 VE 2 2 2 T T Suo Re Methods of Travel 50V 184007 18404 etnoas or ravel lt 5 g y 50 SHUT DOWN D Hi E 42 M Da ee ee c 55 lt 2 lt Tm Start stop with switches WELDTIME OVER 221K IK L PROCEDURE PC BOARD B A 515 5 E T 515 SATOH a 215 4 SD P s e o o 0 o oo d 9 9 Staristop with weld D H3 TIME OVER ok SHUT DOWN curent d v T s NE 84 ENABLE ND 02 u N 2 Y 150K 9 I 51 3 5 688 ARC CONTROL uno V 9 8 ENABLE ES Start with weld curent t x 1 Stop with stop switch o o m le Saha 4 amp w Er Pid m gt CURRENT Start with start switch N Ae Stop after crater ime 2 25 procedure uM 0 Dto module nstaled n crater CURRENT s 588 PROCEDURE 109 a LS Wayaqa d PC BOARD aa 68 CURRENT 768K 500 Start with start switch eee I Stop after bum back PRODUE 4 1 Optional procedure a u m n 500 4 BOARD ROS Q8 er module installed in crater 23 26857 receptacle mr Oo We PR
53. FOR REQUIRED NA 5 CONTROL BOX POLARITY CONNECTIONS SAM POWER SOURCE SETTINGS NA 5 SETTINGS TURN POWER SOURCE OFF FOR SUB ARC FOR SUB ARC 1 RED LEAD ON VOLTAGE PC BOARD IS CONNECTED TO PIN S 1 SET THE ELECTRODE POLARITY SWITCH TO THE VARIABLE VOLTAGE 2 WHITE LEAD ON VOLTAGE PC BOARD IS CONNECTED TO PIN A POSITION OF THE POLARITY DESIRED FOR THE PROCESS BEING USED 2 SET THE TOGGLE SWITCH TO CONSTANT VOLTAGE FOR ALL OPEN ARC PROCESSES 3 SET THE CONSTANT VOLTAGE CONTROL TO NUMBER 7 AND THE 1 RED LEAD ON VOLTAGE PC BOARD IS CONNECTED TO PIN F CURRENT CONTROL TO 500 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 _ 8 SET THE CONSTANT VOLTAGE CONTROL TO NUMBER 5 FOR ADDITIONAL INSTALLATION INSTRUCTIONS SEE NA 5 OPERATING MANUAL O10 Fle w gls nl gie EIE 2 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 EXTEND LEAD 21 USING 14 OR LARGER INSULATED WIRE PHYSICALLY SUITABLE FOR THE INSTALLATION AN 5 16586 REMOTE VOLTAGE SENSING WORK LEAD IS AVAILABLE FOR THIS PURPOSE CONNECT IT DIRECTLY TO THE WORK PIECE KEEPING
54. 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 O o F F 5 5 91 5 ois 2 2 oO tc QC 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 Return to Section TOC Return to Master TOC NA 5 LINCOLN 8 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O o F F 5 5 o 919 ois 2 2 oO tc QC Return to Section TOC Return to Master TOC F 31 TROUBLESHOOTING amp REPAIR F 31 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENTS S 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 slowly The wire stubs or blasts off voltage settings Replace at the start of the weld sequence 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 pr
55. LED Delfinlllone a o nto exeo a F 36 PG Board LED Sequence Table t teet ERE HER ER reed ay kasa F 37 MOST 38 DG Power S pply Test u ukuy EEE 38 Tirano T2 Transtormer rre u ear s F 42 Voltage Board Transformer 5 hetero to fee reper ba Ex ERR e ub RR F 45 E Wire Feed Drive Motor Test 48 External Resistance Test Leads 21 and 67 sse nennen F 50 5 of Voltage Range Shut Sown Test nnne tentent nnns F 52 9 Board Feedback E F 55 z VoltmeterAccuracy 444440 S F 57 2 Wire Speed Accuracy Test axons ape tt pd eevu F 60 S Meter Cireult AG6 racy Test F 64 Replacement ProCedures o ere ea eec F 71 PC Board s Removal and n F 71 Digital Meter and Meter PC Board Removal and F 73 Tach PC Board Removal and F
56. OTHERWISE SPECIFIED TOLERANCE EQUIP 5 8 ON HOLES SIZES PER 2056 THE LINCOLN ELECTRIC CO TYPE LN 9 LN 9F NA 5 519 CLEVELAND OHIO U S A METER BOARD SCHEMATIC 9 2 ON ALL ANGLES IS 5 OF A DEGREE NONE MATERIAL TOLERANCE t TO AGREE LE SHT 9 9 WITH PUBLISHED STANDARDS DR FM DATE 9 23 93 CHK SUP S D G 0 S 21143 Etc 53 a k 517 ITEM REQ D PART NO IDENTIFICATION 9 R2 C1 1 T11577 49 500 50 E o gt 816668 8 022 50 0 518 A 5100 pum s Q D 1 02 03 04 05 5 12199 1 14004 KON 500 600 s PUE Ne i J14 1 516626 BD RECEPTACLE Q jo R1 S 19400 2432 24 3K 1 4W O10 Y 102 C Fie R2 1 108 12 73 2K 1 2W TRI MMER 515 et 1 1 519400 2801 2 8K 1 4W 1 _ ol X 5 15 128 5 L E CO PART NO z 1 6685 1 i 918 RES C n pias 5 5 np ucc oc 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 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
57. REPAIR diis VOLTMETER ACCURACY TEST Continued TEST PROCEDURE Perform the following checks with the 3 Place a jumper wire between leads NA 5 connected to a Lincoln CV weld 2 and 4 located on CR3 relay ing power source according to the prop See Figure F 8 This this should er connection diagram See the energize the output terminals of the Installation Section ot this manual Lincoln CV welding power source An open circuit voltage should be 1 Connect the test voltmeter see present at the welding output termi Materials Needed between the nals The test voltmeter reading work and the electrode cable con should match the ACTUAL volts nection at the welding head See meter reading on the NA 5 within Figure F 7 0 5VDC typically 0 2VDC does not check the integrity and 2 Using the 5 16 nutdriver open the placement of the voltage control box PC board access door sensing leads 21 and 67 and associated wiring Perform the Meter Circuit Accuracy Test 9 lt gt A e PIN T ELECTRODE CABLES DSA g CONNECT VOLTMETER TO ELECTRODE CONNECTION POINT FIGURE F 7 TEST METER CONNECTION POINTS NA 5 LINCOLN 5 iui TROUBLESHOOTING amp REPAIR diis VOLTMETER ACCURACY TEST Continued Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC CR3 RELAY FIGURE F 8 CR3 RELAY 4 Remove the jumper
58. 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 WELD DC650 PRO POWER SOURCE SETTINGS TURN OFF INPUT POWER CONNECT ELECTRODE CABLES TO TERMINALS OF DESIRED POLARITY SETTOGGLE SWITCH TO SAME POLARITY AS ELECTRODE CABLE CONNECTION SETTOGGLE SWITCH TO REMOTE SET MODE SWITCH TO DESIRED POSITION FOR THE PROCESS TO BE USED CONNECT NEGATIVE OUTPUT CABLES TO MATCH MODE SWITCH SETTING NG CABLES MUST BE SIZED EXTEND LEAD 21A BY REMOVING THE INSTALLATION CONVENIENCE TAPE UP CONNECTION FORP EXTEND LEAD 21 USING A 14 OR CONNECT EXTENDED LEAD DIRECTLY TO THE WORK PIECE KEEPING IT SEPARATE FROM THE WELDING WORK CABLE CONNECTION TO THE WORK PIECE FOR THIS EXTENDED LEAD SHOULD BE TAPED ALONG THE WELDING WORK CABLE ROPER NA 5 OPERATION TH N J IF USING AN OL FOR CURRENT AND DUTY CYCLE OF APPLICATION LEAD 21A FROM THE TERMINAL STRIP AND CONNECTING IT TO A 14 OR LARGER INSULATED WIRE PHYSICALLY SUITABLE FOR LARGER INSULATED WIRE PHYSICALLY SUITABLE FOR INSTALLATION E ELECTRODE CABLES MUST BE SNUGGED UNDER THE CLAMP BAR ON THE LEFT SIDE OF THE NA 5 CONTROL BOX CONNECT NEGATIVE OUTPUT CABLES TO STUDS TO MATCH DC650 PRO MODE SWITCH SETTING THE JUMPERS ON THE NA 5 VOLTAGE BOARD MUST BE CONNECTED AS FOLLOWS CONNECT RED JUMPER TO PIN
59. SUB ARC FOR ALL PROCESSES 1 RED LEAD ON VOLTAGE PC BOARD IS CONNECTED TO PIN 8 1 CONNECT ELECTRODE CABLE TO TERMINAL OF DESIRED POLARITY 2 WHITE LEAD ON VOLTAGE PC BOARD IS CONNECTED TO PIN A 2 SET THE POLARITY SWITCH TO THE SAME POLARITY AS THE ELECTRODE ESGRAPCSEENABGRBOSESSES CABLE CONNECTION 1 RED LEAD ON VOLTAGE PC BOARD IS CONNECTED TO PIN F 3 SET TOGGLE SWITCH TO REMOTE A 4 INSTALL VOLTAGE TRIANGLE IN A POSITION AS CLOSE AS POSSIBLE TO 2 WHITE LEADON VOLTAGE PC 15 CONNESTED TO PIN TA THE DESIRED ARC VOLTAGE O10 O10 F E w gls nl g 2 EIE 2 FOR ADDITIONAL INSTALLATION INSTRUCTIONS SEE NA 5 OPERATING MANUAL 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 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 NEAR THE POWER SOURCE TERMINAL STRIP THE POWER SOURCE 5 S MUST BE PROPERLY GRO
60. SUPPLY SOURCE POINT 77 FRAME CONNECTION A J19 520 520 3 022 H 40V VOLTAGE ON CONTROL 15 OPTION BOARD OPTION BOARD TIMER BOARD TIMER BOARD SUBJECT 583 510P 520 5 5 5 518 562 588A 588 635 5 655 500 4 6 8 D 2 H 5 3 4 5 6 8 J10 10 J10 J8 Ti i Y Y START TIME INITIATE 5 15 515 5 500 1 5V E 10V UNLESS OTHERWISE SPECIFIED 50V 1 4W UNLESS OTHERWISE SPECIFIED UNLESS OTHERWISE SPECIFIED NONE 022 MFD SCALE WELD TIME OVER CRATER TIME INITIATE CURRENT CLEVELAND OHIO U S A GENERAL INFORMATION ELECTRICAL SYMBOLS PER E1537 FILE 18754 3DB THE LINCOLN ELECTRIC CO CAPACITORS START TIME OVER WELD TIME INITIATE CRATER TIME OVER BURNBACK TIME INITIATE BURNBACK TIME OVER Return to Section TOC Return to Master TOC 100 Hz TIME BASE 1 6384 MHz OUTPUT TEST POINT Vdd 09 5 oun 0 TO SET SPEED BUFFER EK ON CONTROL PCB RES 12 14060 TO SET E VOLTAGE BUFFER TIME BASE ON VOLTAGE PCB FOR DIGITAL TIMERS 22 1 6884MHz d 100v Y 500 E REE PUBLISHED STANDARDS IED TOLERAN OF A DEGREE AGI
61. Section TOC Return to Master TOC 2 o 2 Return to Section o O o 9 5 tc Return to Master TOC 2 INSTALLATION ne 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 MAX WIRE SIZE in mm GEAR RATIO in min m min CORED WIRE SOLID WIRE 100 2070 2 54 52 6 0 052 1 3 0 052 1 3 38 7 78 0 96 19 8 22 456 0 56 11 6 5 32 4 0 15 300 0 38 7 62 5 32 4 0 7 32 5 6 PHYSICAL DIMENSIONS LENGTH WIDTH HEIGHT WEIGHT MODEL in mm in mm in mm Ibs kg NA 5 Control Box 9 02 229 17 87 454 15 05 382 30 13 NA 5 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC olo e olo gls 0 12 2 2 42 Return to Section TOC Return to Master TOC Return to Master TOC A3 INSTALLATION ids FIGURE A 1 BASIC CONTROL AND WIRE DRIVE SYSTEM CONTROL BOX HEAD MOUNTING PARTS WITH INSULATION AND HARDWARE 2 CONTROL CABLE ER POWER 411 SOURCE lt gt MN TACHOMETER L2 ALISTRAIGHTENER 4 1 2 CABLE DRIVE MOTOR TO CONTROL BOX CABLE 9 4
62. Shut Down Test O10 e S9 o o 22 cic Sis a Return to Section TOC Return to Master TOC NA 5 LINCOLN 5 NOTES F 86 NA 5 LINCOLN E F 86 NOL Je1se A 01 uunjeud DOL Je1Se A 01 uunjeud DOL Je1Se A uunjeu DOL Je1Se A 01 DOL uonoes UNAY DOL 5 uinjeg DOL uon5 s DOL 5 TABLE OF CONTENTS 5 ELECTRICAL DIAGRAMS SECTION 9 gt 8 E Electrical Diagrams cL quce Vau ae mun o LUE Section G Wiring PERI G 2 Logic PC Board L6242 1 5 G 3 Logic PC Board L6242 2 amp above G 4 Power PC Board L6252 1 Schematic sse eene ns G 5 Power PC Board L6252 2 amp above Schematic seen G 6 Voltage PC Board 5 nnns nnne G 7 Control Circuit Schemall vei ke IR epu on Eaa G 8 Procedure Board Schematlic G 9 Option amp Timer Board Schematics nennen nnne nnne nns G 10 Meter PC Board Schematic amp 2 G 11 Miscellaneous PC Board 6 12 Return to Master
63. box 1 Check the lights LEDS locate on the PC boards Some should be If the appropriate lights are lit see Table 1 and the wire does NOT feed perform the Drive Motor Test If only some of the appropriate lights on the power board are lit the power board may be faulty If all of the appropriate lights are lit except light 1D on the power board check resistor R1 Normal resistance is 2 ohms See wiring diagram 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 LINCOLN 8 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Ojo o F F 5 5 o 919 ois 2 2
64. 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 G 5 G 5 POWER PC BOARD L6252 1 SCHEMATIC ELECTRICAL DIAGRAMS B C D CONTROL POWER AND 51 EMERGENCY STOP OBL 531A z FLUX OR WATER SOLENOID RECEPTACLE 531 87 6682 1 o 20 252 SHT NO Return to Section TOC Return to Master TOC TRAVEL RECEPTACLE zh 11m lj PT101B PT101C 2 115 VAC INPUT SUP S D 8 10 3 81 POWER CIRCUIT WIRE FEED SCR SCR MOTOR PT103A 103 104 ARMATURE NA 5 SCHEMATIC WIRE FEED s2 MOTOR FIELD TRAVEL o o FEED 587 FORWARD lt Ls TACH PICK UP P C BOARD o 20 o EQUIP TYPE c122 b R108 ee p ARMATURE SUPPLY y 500 SCALE NONE CLEVELAND OHIO U S A THE LINCOLN ELECTRIC CO FEED DIRECTION CIRCUIT Return to Section TOC Return to Master TOC 525 O ANALOG ANALOG POWER SUPPLY 510 LED 1 ZERO VOLT
65. drops below approximately 3 5 VDC the Auto Stop activates while inching down or electrode backup occurs if the arc start circuit has been initiated Units below Code 8300 can be provided with the 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 NOTE HI FREQ starting cannot be used with converted units below Code 8300 NA 5 LINCOLN A Auto Stop When the Inch Down button is pressed low level DC voltage signal is applied between the electrode and work which permits the wire to inch down normally When the electrode makes electrical contact with the work it shorts out this signal causing the wire feed to automatically stop and the flux solenoid to activate until the Inch Down button is released The Inch Up button is not affected by this circuit B Electrode Backup If while starting or welding the electrode stubs or shorts to work the resulting loss of arc voltage will cause the electrode to momentarily back up until the arc voltage is re established and then change back to the normal feed direction NOTE The cold starting circuitry will cause the NA 5 to feed in the wrong direction when the Start button is pressed if the Actual a
66. in procedure board 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 Return to Section TOC Return to Master TOC NA 5 LINCOLN 8 14 TROUBLESHOOTING amp REPAIR F 14 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENTS S COURSE OF ACTION MODE FUNCTION PROBLEMS Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O o F F 5 5 o 91 5 ois gje 5 oO tc QC Return to Section TOC Return to Master TOC The strike light does not light The strike controls voltage and wire feed speed do function normally The strike light comes on but the strike controls voltage and wire feed speed do not function normally 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 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 The pr
67. oO 5 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O10 E w gls nl g 2 EIE 3 2 Return to Section TOC Return to Master TOC A 15 FIGURE INSTALLATION A 15 A 14 CONNECTION OF NA 5 TO DC 400 OR CV 400 A WARNING TURN OFF INPUT POWER e TO THE WELDING POWER SOURCE USING THE DISCONNECT SWITCH BEFORE WORKING ON THIS EQUIPMENT ELECTRIC SHOCK CAN KILL POWER SOURCE TO NA 5 INPUT CABLE PLUG N E CONTROL CABLE N D AND N H NEGATIVE POSITIVE N B AND N C 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 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 INSTR WELDING CABLES MUST BE OF P UCTIONS SEE NA 5 OPERATING MANUAL ROPER 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 5 16586 LENGTH REMOTE VOLTAGE SENSING WORK LEAD S AVAILABLE FOR THIS PURPOSE CONNECT IT DIRE
68. or gas water solenoid con tinuously remains open FUNCTION PROBLEMS 1 Make sure the switch on the flux hopper is in the ON position 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 1 Check light 7G located on the 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 1 If light 7G located on the logic 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 110VDC is applied to the relay coil terminals 1 and 3 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 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 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 troubleshootin
69. peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants Pour obtenir de plus amples renseignements sur la sdret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 enrouler le c ble lectrode autour de n importe quelle partie PR CAUTIONS DE S RET POUR du corps Un coup d arc peut tre plus s v re qu un coup de soliel LES MACHINES SOUDER donc TRANSFORMATEUR ET a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du ray onnement de l arc et des projections quand on soude ou quand on regarde l arc b Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc c Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes LINCOLN REDRESSEUR 1 Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et
70. result in NA 5 LELECTHIC danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine Return to Section TOC Return to Section TOC Return to Master TOC O o Fle w o G 5 2 x a Return to Section TOC Return to Master TOC Return to Master TOC G 12 ELECTRICAL DIAGRAMS G 12 MISCELLANEOUS PC BOARDS POWER BOARD LOGIC BOARD REQ D IDENTIFICATION Q PART NO ITEM REQ D PART NO IDENTIFICATION e 1 T11577 52 0047 or 005 1400 Bee gt I TAB TERMINAL C2 C4 2 13490 96 15 200 C1 1 11577 28 7227100 2 e c3 1 513490 86 50 MFD 250 V CAPACITOR C2 C4 C6 C10 C11 C14 30 16668 5 022 50 seis C5 C6 C8 C 19 4 513490 102 047 100 C15 C 16 C17 C18 C 19 C20 22
71. 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 NA 5 LINCOLN K148 CONTACT NOZZLE AND K149 LINC FILL LONG STICKOUT EXTENSION This Innershield and submerged arc nozzle is designed for 0 062 through 3 16 in 1 57 through 4 76 mm wire at high currents When long stickout 2 to 5 50 80 to 127 00 mm is required the K149 Linc Fill Long Stickout Extension is recommended along with the K237 Linc Fill Starting Relay Instructions are contained in the IM305 manual and can also be ordered as Sec T2 2 7 K218 HORIZONTAL FILLET LAP ATTACHMENT This special contact assembly automatically guides the electrode when making submerged arc horizontal fillet and lap welds to ensure accurate bead placement without expensive fixtures and clamps Installation operating and maintenance instructions are shipped with each kit are contained in the IM305 manual and can also be ordered as Sec T2 5 4 K219 FLUX HOPPER KIT This flux hopper which has an electric flux valve can be mounted on NA 5N and NA 5NF heads for submerged arc welding Installation instructions are included with each kit The operator and maintenance instructions are contained
72. source 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 The relay may be faulty Check or replace Check the 2 and 4 leads between the CR3 relay and the control cable receptacle 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 LINCOLN 8 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O o F F 5 5 o 919 ois 2 8 tc QC Return to Section TOC Return to Master TOC F 22 TROUBLESHOOTING amp REPAIR F 22 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENTS S COURSE OF ACTION The travel function will not operate regardless of the travel switch posi tion 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 TRAVEL FUNCTION PROBLEMS 1 Check the travel switch for prop
73. strike light is also lit along with the crater light the logic board may be faulty If the weld and or start lights are also lit along with the crater light the procedure board may be faulty O o F F 5 5 o 919 ois 2 2 oO tc QC 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 Return to Section TOC Return to Master TOC NA 5 LINCOLN 8 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O o F F 5 5 o 919 ois gje 5 oO tc QC Return to Section TOC Return to Master TOC F 17 TROUBLESHOOTING amp REPAIR F 17 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENTS S COURSE OF ACTION At the end of the weld the crater light 1 At the end of the weld the crater timer does not time out The unit stays in the crater mode No burnback retract occurs at the end of the weld MODE FUNCTION PROBLEMS Make sure the crater option is installed properly in the NA 5 Make sure the crater timer is set for a time greater than zero sec onds The crater option and or timer board may be faulty Repl
74. sure the logic board jumper 694 is on pin P10 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 Made sure the calibration jumper on the speedmeter board is con nected properly See 2 1 2 3 The contacts terminals 2 and 4 may be stuck closed Check the associated leads for misconnections See wiring dia gram If while pressing the stop button light 7C does NOT go on check the stop button and associated leads Remove the drive motor end cap 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 Perform the Perform the Meter Circuit 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 LINCOLN 8 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Ojo o F F S9 91 5 ois gje 5 oO tc QC Return to Section TOC Return to Master TOC F 25 TROUBLESHOOTING amp REPAIR F 2
75. 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 NOTE Unshaded areas of block logic diagrams are the subject of discussion NA 5 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC olo S F gt 919 0 12 22 a a Return to Section TOC Return to Master TOC Return to Master TOC E 5 THEORY OF OPERATION FIGURE E 3 Optional Start Crater Fill and Weld Timer Boards CONTACTOR CLOSURE 2 AND 4 VOLTS SET amp ACTUAL TACH FEEDBACK MOTOR RPM REMOTE VOLTAGE CONTROL A B C CONTROL CABLE RECEPTACLE 31 WORK SENSING 21 gt lt rvvco INPUT POWER SWITCH CIRCUIT PREAKER R1 2 OHMS FIELD DIRECTION mmzovu VOLT SPEED WIRE FEED SPEED SET amp
76. 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 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 O10 e S9 o 22 cic Sis a Return to Section TOC Return to Master TOC NA 5 LINCOLN 5 7 00 TROUBLESHOOTING amp REPAIR diis WIRE SPEED ACCURACY TEST A 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 Return to Section TOC Return to Master TOC 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 Return to Section TO
77. 0 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 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 11 Carefully remove the adapter plate and motor assembly with pinion attached 12 With a slot head screwdriver remove the adapter plate from the drive motor HEX HEAD 2 BOLT ADAPTER PLATE AND 7 MOTOR ASSEMBLY SLOT HEAD SCREW FIGURE 17 DRIVE MOTOR NA 5 LINCOLN 5 TROUBLESHOOTING 4 REPAIR p 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 Return to Section TOC Return to Master TOC 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 Return to Section TOC Return to Master TOC 5 Using the phillips head screwdriver mount the cover plate adaptor to the drive motor 6 Using the
78. 10 IF MODULE IS REMOVED REPLACE JUMPER PLUG AND LOGIC BOARD LEAD 694 TO PIN 8 N D CONTROL BOARD JUMPER LEAD CONNECTED TO PIN F WHEN SHIPPED SEE OPERATING MANUAL FOR USE OF PIN S JUMPER CONNECTION VOLTAGE BOARD RED JUMPER LEAD CONNECTED TO PIN 8 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 R38 SAM AND SAF OR SA CAVITY NUMBERING SEQUENCE POWER SOURCES WITH K224 EARLIER VOLTAGE BOARDS DO NOT CONTAIN PIN D COMPONENT SIDE OF P C BOARD N F LOGIC BOARD DIP SWITCHES OR JUMPERS TO BE SET TO SUIT DESIRED APPLICATIONS PER CHARTS BELOW N L olo o Fle cl o G 2 2 5 2 a 5 SHIPPED CONNECTED FOR INDICATED METHODS OF TRAVEL amp BURNBACK METHODS OF TRAVEL FOR EARLIER LOGIC P C FOR LOGIC P C BOARDS WITH BOARDS WITH JUMPERS DIP SWITCHES 8800 8800 SAMPLE SWITCH START STOP WITH SWITCHES LEAD 6 LEAD 692 to P5 SWITCH POSITION 1 IS UP mE SWITCH POSITION 2 IS DOWN CONNECT LETT SWITCH POSITIONS 3 AND 4 ARE NOT APPLICABLE START STOP WITH WELD CURRENT LEAD 691 to P6 uu LEAD 8 METHODS OF BURNBACK IIT FOR EARLIER LOGIC P C FOR LOGIC P C BOARDS W
79. 2 7K N A THESE CAPACITORS ARE LOCATED VERTICAL CO ORDINATE NUMBER 47 35 501 33uH 110mA 4 7K N 27 35 L502 33uH 110mA 00K R601 24 3 1 4W 1 ON THE BYPASS BOARD SCHEMATIC IDENTIFICATION LETTER 4 7 35 0015011 oPTO ISOLATOR K R602 2K TRIMMER SEE SCHEMATIC A 022 25 OCI502 2 7K R603 2 80 1 4W 1 B SEE L6682 3A SCHEMATIC FOR 47 50 0801 2N4123 2K TRIMMER 89 20 0503 2 6816 5 6K TRIMMER X601 5V VOLTAGE REGULATOR SUPERSEDED G1556 1 VOLAGE 0047 005 1400 0505 2 4123 00K 12W BOARD 022 25 Q506 2N4897 K EARLIER VOLTAGE BOARDS DO RESISTORS OHMS 1 2 WATT 022 25 0507 2 5816 00K FOR VOLTMETER P C BOARDS as SINCE COMPONENTS OR CIRCUITRY ON A PRINTED 022 25 0508 28816 39K L6685 1 OR HIGHER USE 521143 NOT HAVE THIS RECEPTACLE AND CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE 5 gaol SCHEMATIC FOR COMPONENT LEAD 688A WAS 688 INTERCHANGEABILITY OF A COMPLETE BOARD THIS 590 95 a ye 380K VALUES AND CIRCUIT CONNECTIONS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS 47 50 22K OR CIRCUITRY OF CONTROLS HAVING A COMMON 01 200 27K CODE NUMBER 022 25 3 3K A N S I ELECTRICAL SYMBOLS PER E1537 THIS SHEET CONTAINS PROPRIETARY INFORMATIG OWNED BY THE LINCOLN ELECTRIC CO AND 15 NOT TO BE REPRODUCED DISCLOSED OR USED THE LINCOLN ELECTRIC CO WITHOUT THE EXPRESS PERMISSION OF FOR NA 5 CONTROL CODES Return to Section TOC Return to Master TOC NOTE Lincoln
80. 28 2 qi PLUG PRONGS 2 912 2 o o G 2 e 0 ae 0 P ad 5 z FIGURE F 11 METER PC BOARD MOUNTING NUTS AND PLUG 1 NA 5 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O10 e S9 o 22 cic Sis a Return to Section TOC Return to Master TOC ds TROUBLESHOOTING amp REPAIR DIGITAL METER AND METER PC BOARD REMOVAL AND REPLACEMENT DIGITAL METER REMOVAL PROCEDURE 1 Using the phillips head screwdriver 4 Using the 5 16 nutdriver remove remove the four screws from the the two nuts screws and lockwash meter bezel See Figure F 12 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 METER SHIELD DIGITAL RT ASSEMBLY METER METER SHIELD METER BEZEL FIGURE F 12 METER BEZEL AND SCREW LOCATIONS NA 5 LINCOLN 5 vie TROUBLESHOOTING amp 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 Return to Section TOC Return to Master TOC 2 Using the phillips head screwdriver reattach the meter shie
81. 3 5 5 2 insulated from each other and ply from the voltage board cc metal conductors 12 Install the voltage board and con 8 Using the voltmeter check for nect the molex plugs 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 Return to Section TOC Return to Master TOC NA 5 LINCOLN 5 diis TROUBLESHOOTING amp REPAIR dno WIRE FEED DRIVE MOTOR TEST A 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 Return to Section TOC Return to Master TOC 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 Return to Section TOC Return t
82. 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 FIGURE A 5 MOUNT TO CARRIAGE OVERHANG DIMENSION 19 IN 483 ELECTRICAL INSTALLATION WARNING ELECTRIC SHOCK can kill Do not touch electrically live parts such as output terminals or internal wiring This section provides information on proper wiring procedures for the NA 5 welding sys tem This section also provides basic con NA 5 LINCOLN N A 6 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 CONTROL BOX TO WELDING HEAD CONNECTIONS 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
83. 5 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENTS S COURSE OF ACTION FUNCTION PROBLEMS The set speed and actual speed 1 Contact your local Lincoln 1 Check the lead and switch conti meter readings do not match within Authorized Field Service Facility nuity of the SET speedmeter cir few IPM One or both readings may cuit See wiring diagram be erratic 2 Check the lead and switch conti nuity of the ACTUAL speedmeter circuit See wiring diagram 3 Perform the Accuracy Test 4 Perform the Meter Circuit 5 The control board may be fault The set speed is adjustable and 1 Contact your local Lincoln 1 While the motor is running care steady The actual speed is uncon Authorized Field Service Facility fully unplug the 15 pin molex from trollable The meter displays the the control board actual speed correctly 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 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 LINCOLN 8 Return to Section TOC Return to Master TOC Return to Section TOC Retu
84. 50 2 142T 260 260 2 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 LINCOLN 5 s TROUBLESHOOTING amp REPAIR dass METER CIRCUIT ACCURACY TEST A 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 Return to Section TOC Return to Master TOC 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 Return to Section TOC Return to Master TOC 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 O10 e S9 o
85. 514 SINGLE 3 32 7 32 15 289 I P M HI FREQUENCY INSTALLATION INSTRUCTIONS FOR REQUIRED 467 ELECTRODE VOLTAGE SENSING LEAD CONNECTION 51865 4 514904 00 TWIN 5 64 1 8 15 300 1 N L REMOVE JUMPER PLUG TO INSTALL OPTIONAL KIT IF KIT IS REMOVED REPLACE JUMPER PLUG n 639542 5 514905 82045 6 214 21 1 812778 SINGLE 035 052 100 2070 I P M NOT PRESENT ON EARLIER VOLTAGE P C BOARDS 63249 7 N N BLUE JUMPER LEAD NOT PRESENT ON EARLIER VOLTAGE P C BOARDS THE JUMPER IS TO BE CONNECTED TO THE 510P 8 W 9 ELECTRODE EARLIER SPEEDMETER BOARDS DID NOT HAVE THESE PINS SINGLE 21 PIN ON HIGH SPEED BOARD ONLY TAB UNLESS SPECIFIED ON THE POWER SOURCE CONNECTION DIAGRAM TO BE CONNECTED TO THE AUTO TAB Washo TO DISABLE THE COLD STARTING FEATURE 564A gt 11 N B REMOVE START RECEPTACLE JUMPER PLUG FROM PROCEDURE BOARD TO INSTALL OPTIONAL PROCEDURE EARLIER RELAYS HAD SAME TERMINAL NUMBERS BUT IN A DIFFERENT ORIENTATION 11412 MODULE AS START PROCEDURE CONTROL IF MODULE IS REMOVED REPLACE JUMPER PLUG UY POTENTIOMETERS AND SWITCHES MOUNTED ON P C BOARD ARE CONNECTED TO FRAME FOR ESD N C REMOVE CRATER RECEPTACLE JUMPER PLUG FROM PROCEDURE BOARD TO INSTALL OPTIONAL PROCEDURE NOT PRESENT ON EARLIER BOARDS JUMPER PLUG MODULE AS CRATER PROCEDURE CONTROL AND CONNECT LOGIC BOARD LEAD 694 TO PIN
86. 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 currents or duty cycles higher than 1000 amps at 8096 duty cycle will be used add additional electrode cable per Table A 1 TABLE 8096 Duty Cycle Below 1000 amps Two 4 0 1000 to 1300 amps Three 4 0 1300 to 1500 amps Four 4 0 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo e olo gls 0 12 2 2 42 Return to Section TOC Return to Master TOC A 7 FROM POWER SOURCE 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 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 assem
87. 8 lt CURRENT NA 5 SCHEMATIC SUP S D G 1025 R008 e4R007 R006 HR005 004 R003 HR002 EQUIP TYPE CHK 562 PROCEDURE d 1 Z 4 A FROM 655 e ENABLE EE lt R914 C907 OPTION BOARD 59014 Su BASE OUTPUT T BASE OUTPUT soo 7 MOST SIGNIFICANT DIGIT LEAST SIGNIFICANT DIGI DATE 7 2 92 SCALE NONE Return to Section TOC Return to Master TOC THE LINCOLN ELECTRIC CO CLEVELAND OHIO U S A MATERIAL TOLERANCE TO AGREE WITH PUBLISHED STANDARDS ON HOLE SIZES PER E2056 olo O10 Fle S9 o o G gle Etc 515 2 a FOR OPTION P C BOARD L6246 2 OR HIGHER USE M16795 SCHEMATIC FOR COMPONENT VALUES AND COMMON CONNECTION TO ANALOG POWER SUPPLY CIRCUIT CONNECTIONS SCHEMATIC LOCATION REFERENCE TIMER BOARD OPTION P C BOARD HORIZONTAL CO ORDINATE LETTER E Boot 0001 2N 4125 VERTICAL CO ORDINATE NUMBER THRU p 022 25 0002 2N4123 SCHEMATIC IDENTIFICATION LETTER OWNED BY THE LINCOLN ELECTRIC CO AND Is THE LINCOLN ELECTRIC CO NOT TO BE REPRODUCED
88. 905 Inner 12514 Single 3 32 7 32 14904 Outer Twin 5 64 1 8 14905 Inner O10 e S9 o o cic 5 5 ply tc QC Present 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 Return to Section TOC Return to Master TOC NA 5 LINCOLN 5 jin TROUBLESHOOTING amp REPAIR EE WIRE SPEED ACCURACY TEST Continued Fie 5 5 8 2 Check for the proper wire feed inch es per revolution of the drive roll 0 2 Set the Strike speed control to B If the measured length is not ale any setting between 50 and 125 within the specified lengths IPM While pressing the INCH there may be a problem with the DOWN button measure the pre wire or wire feeding path See cise length of wire fed by exactly the 10 revolutions of the drive roll in this sec The measured length should be tion of the manual Also check within the range specified in for correct drive roll tension Table F 4 for the drive roll and adjustment wire size employed TABLE F 4 DRIVE ROLL PART WIRE SIZE RANGE INCHES OF WIRE FED PER NUMBER 10 REVOLUTIONS OF DRIVE ROLL 512778 Single 035 052 Solid Return to Section TOC Return to Master TOC 519113 Single 045 052 Cored 512515 Single 1 16 3 32 512514 Single 3 32 5 32
89. 9353 NA 5 LINCOLN 8 F 28 TROUBLESHOOTING amp REPAIR F 28 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENTS S COURSE OF ACTION FUNCTION PROBLEMS The NA 5 repeatedly shutsdown 1 Make sure the power source Out of Voltage while welding polarity switch is set for the cor Range Shutdown Test rect electrode polarity Return to Section TOC Return to Master TOC 2 The voltage board may be faulty Make sure the 67 and 21 leads are connected to the TS1 termi nal strip for the correct electrode polarity See wiring diagram Make certain the voltage control switch on the Lincoln CV power source is set in the Remote position Make sure the 21 lead has con tinuity zero ohms to the work piece Make sure the 67 lead has con tinuity zero ohms to the wire feed head assembly Return to Section TOC Return to Master TOC Check the 1 8 amp fuse on the NA 5 voltage board Replace if faulty The control cable may be faulty Check or replace Be sure the welding power source is compatable with the NA 5 O o F F 5 5 91 5 ois 2 2 oO tc QC 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
90. A PRINTED CIRCUIT BOARD MAY CHANGE NOTES olo O10 Fle S9 o o G gle Etc 515 2 a e e Sg y 500 J3 s gt 5 J3 5 s xP 500 NA 5R OPTIONAL BURNBACK KIT RECEPTACLE SHOWN WITH JUMPER PLUG INSTALLED RELAY 115 VAC K POWER SUPPLY T 014 015 184007 1N4007 e INTERFACE OPTION POWER SUPPLY VOVNYO vrvasnv Return to Section TOC Return to Master TOC 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 LELECTHIC danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine NA 5 G 7 ELECTRICAL DIAGRAMS on VOLTAGE PC BOARD SCHEMATIC A G pun 667 C524 WELD 0507 L RESPONSE PIN F Et TP 500 M Ds 506 lt VOLTAGE PIN S C508 POLARITY C518 TERMINALS R507 12 ACTUAL VOLTAGE BUFFER
91. Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Cylinders should be located Away from areas where they may be struck or subjected to physical damage safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Return to Master TOC Return to Master TOC o 8 7 c E Return to Master TOC
92. BILITY OF A COMPLETE BOARD THIS DIAGRAM MAY NOT 0721 0711 R725 27K X705 SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS D722 R701 4 4 7K R726 1 5K X706 INVERTER 22V 600mA SECONDARY HAVING A COMMON CODE NUMBER lt HRU 1A 400V R702 47K R727 68K X708 15 VOLTAGE 5 5 D726 R703 100 REGULATOR PRIMARY SHOWN ON SCHEMATIC A ELECTRICAL SYMBOLS PER E1537 1 12 96D cc CLEVELAND OHIO U S A L6682 4 LINCOLN 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 G 4 ELECTRICAL DIAGRAMS iiic LOGIC PC BOARD L6242 2 amp above SCHEMATIC
93. C Return to Master TOC 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 O10 e S9 o 22 cic 5 5 ply a Return to Section TOC Return to Master TOC NA 5 LINCOLN 5 ad TROUBLESHOOTING amp REPAIR iod 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 Return to Section TOC Return to Master TOC TABLE F 3 SPEEDMETER HEAD DRIVE ROLL WIRE SIZE RANGE RATED SPEED CALIBRATION RATIO PART NUMBER RANGE IPM 512778 Single 035 052 Solid 100 2070 519113 Single 045 052 Cored Return to Section TOC Return to Master TOC 512778 Single 035 052 40 778 512515 Single 1 16 3 32 38 762 95 512514 Single 3 32 5 32 22 428 95S 12515 Single 1 16 3 32 23 456 19113 Single 045 052 Cored 13161 052 Twin 045 052 13161 5 64 Twin 1 16 5 64 14904 Outer Twin 3 32 514
94. CTLY 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 CONNECT N C TAPE UP BOLTED CONNECTION N D CONNECT THE CONTROL CABLE SOURCE GROUNDING TERMINAL ON BECAUSE IT ADDS ERROR TO THE NA 5 VOLTMETER READING GROUND LEAD TO THE FRAME TERMINAL MARKED NEAR THE POWER SOURCE TERMINAL STRIP THE POWER 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
95. D FOR INDICATED 2 06 80V 06 Fai NCH zi s METHODS OF TRAVEL BURNBACK DOWN Os 221K 515 NCH 9 500 5 m x x 2 5 s s 06 qu gt F I J GENERAL INFORMATION 515 D2 e e gt 500 SE ee ee 1 9 d No ze sx ELECTRICAL SYMBOLS PER E1537 med T LOGIC 500 CAPACITORS MFD o 2 POWER V RESISTORS Ohms LABELS F 30 AN SUPPLY VOLTAGENET 47 7 02 z s T Q POWER SUPPLY SOURCE PONT pp 7j CTION o ji Le x o x x x X c29 x x8 y LED7A 57 COMMON CONNECTION x 2 FILENAME 02974 20 777 FRANE CONNECTION id c m an 401 401 401 am n THELNOOLNELECTRC CO E NOON ELECTA EARTH GROUND CONNECTION c 4 i E 515 Van THE LINCOLN ELECTRIC CO E D CLEVELAND OHIO U S A SUBJECT LOGIC CIRCUIT S Gi NONE 8n LOGIC POWER SUPPLY D SE NA sat oc ISTRIBUTION AND BYPASSING m MB 92754 ae 02074 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
96. DED WITH STRIKE PROCEDURE 4 OPTIONAL LINC FILL BYPASS KIT DISABLE PROCEDURE ALSO SEE SCHEMATIC A ENABLE N C LEAD 694 TO BE CONNECTED TO PIN P10 IF OPTIONAL CRATER MODULE SEE SCHEMATIC E IS INSTALLED OR CRATER TO PIN P8 IF REMOVED E Q701 515 TIME OVER N D LOGIC BOARD JUMPER LEADS ARE TO BURNBACK BE CONNECTED TO SUIT APPLICATIO PROCEDURE PER CHARTS BELOW olo LED N E HOLD LOW DISABLE IS USED WITH O16 PC BOARD 583C 587 G1556 1 AND EARLIER VOLTAGE BOARDS E IER ARD ARC CONTROL ENABLE 15 USED WITH LATER VOLTAGE BOARDS 515 592 LEAD TO PIN i t ETHODS OF TRAVEL NO NO CR START STOP 601 P6 592 q 8718 3 R731 WITH SWITCHES 692 P5 o HE ART STOP 691 P6 olo WITH WELD CURREN 690 P7 84 lo START WITH WELD CURRENT 691 P5 cle INCH STOP WITH STOP SWITCH 692 P7 DOWN WHEN OPTIONAL START WITH START SWITCH 69 P6 5 5 500 PROCEDURE MODULE STOP AFTER CRATER TIME 692 P9 IS INSTALLED ART WITH START SWITCH 69 P6 oc CRATER RECEPTACLE STOP AFTER BURN BACK TIME 692 P8 LEAD TO PIN ETHODS OF BURNBACK NO NO FOR LOGIC P C BOARDS L6242 2 OR HIGHER USE G2974 SCHEMATIC FOR FOR REMOTE INTERFACE PC BOARDS L6580 1 A WIRE FEED STOP WITH 690 4 COMPONENT VALUES AND CIRCUIT CONNECTIONS OR HIGHER USE 521207 SCHEMATIC FOR ACTOR DELAY 693 3 COMPONENT VALUES AND CIRCUIT CONNECTIONS INCH UP WITH _ 690 P4 LOGIC P C OPTIONAL REMOTE INTERFACE P C BOARD CORTA TOR DE
97. DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION OF C906 C907 100pf 100 X001 QUAD ANALOG X905 AND C906 ARE USED ONLY ON 100 SECOND 5 6K TIMER BOARDS BOARD JUMPER IS USED ON 10 Dot 002 GUND 2 INPUT SECOND TIMER BOARDS THIS SHEET CONTAINS PROPRIETARY INFORMATION UNLESS OTHERWISE SPECIFIED TOLERANGE 5 6K 10K 2W MULTI TURN POT 1 8K R901 THRU 22K 1 4W R915 R916 1K RESISTORS OHMS 1 2 WATT Do 1A 400V UNLESS OTHERWISE SPECIFIED COMPONENT VALUES OF D004 CAPACITORS MFD VOLTS X901 QUAD 2 INPUT NAND GATE SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT PROGRAMMABLE BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGE DIVIDE BY N 22K 1 4W ABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY NOT COUNTER K SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE NUMBER POWER SUPPLY DISTRIBUTION AND BYPASSING 5908 5 DIGIT BED ELECTRICAL SYMBOLS PER E1537 FOR NA 5 CONTROL CODES Return to Section TOC Return to Master TOC 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 s
98. 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 4 WIRE DRIVE MOTOR GEAR BOX DRIVE MOTOR BRUSH ACCESS HEX HEAD 7 SCREW ADAPTER PLATE AND 7 MOTOR ASSEMBLY FIRST CHAMBER WIRE DRIVE GEARBOX SECOND _ SLOT HEAD B 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 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 9 o 3 tc Return to Section TOC Return to Master TOC Q 7 E D 4 WIRE DRIVE MOTOR Periodically inspect the wire drive motor brushes Figure D 4 Replace the brushes as needed CHANGING WIRE FEED GEAR RATIOS 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 TABLE D 1 CONVERSION KITS Wire Type in mm Conversion Kit 3 32 7 32 2
99. E Allow the machine to heat up so that all electrical components can reach their oper ating temperature 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 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 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 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o O e 9 o E 2 Return to Section Return to Master TOC o E F 4 TROUBLESHOOTING amp REPAIR F 4 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENTS S COURSE OF ACTION WIRE FEEDING PROBLEMS The wire feeds whenever the input 1 Check the Start switch S5 1
100. E SPECIFIED Sht No WITHOUT THE EXPRESS PERMISSION OF X204 QUAD OP AMP 33K R412 6K 1 4W 1 DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS 00K R413 MER OR CIRCUITRY OF CONTROLS HAVING A COMMON K R414 AK 1 4W 1 CODE NUMBER 0 ELECTRICAL SYMBOLS PER E1537 FOR NA 5 CONTROL CODES Return to Section TOC Return to Master TOC 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 LELECTHIC danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine Ge ELECTRICAL DIAGRAMS G 9 PROCEDURE PC BOARD SCHEMATIC OPTIONAL OPTIONAL OPTIONAL START MODULE WELD TIMER MODULE CRATER MODULE BURNBACK TIMER 9 1 LAST NO USE FROM LOGIC 5 TIMER BOARD TIMER BOARD POWER SUPPLIES ON LOGIC PCB 500 gt 220 500 655 515 500 655 515 Return to Section TOC Return to Master TOC NA 5 PROCEDURE SUPPLY VOLTAGE NET SCHEMATIC L EARTH GROUND CONNECTION V COMMON CONNECTION POWER
101. EN THE OPTIONAL MULTI PROCEDURE KIT IS INSTALLED 82 R5 RB R11 AND St ARE CONNECTED TO FRAME BY PCB TRACES AND MOUNTING N SUPPLY DISTRIBUTION SCREW FOR ESD AND BYPASSING 581 START DISABLE Return to Section TOC Return to Master TOC 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 could result in damage to the machine NA 5 on ELECTRICAL DIAGRAMS 9 10 OPTION amp TIMER PC BOARD SCHEMATICS J TIMER BOARD INITIATE E Ez 584 1 id ol 1 TIME lt 3 Sloe 04 03 Q2 01 3 pg Q4 03 02 01 6 pp 04 Q8 Q2 01 INITIATE CF 0 X902 X903 X904 L 6682 5 Return to Section TOC Return to Master TOC SHT NO R001 DP4 DP3 DP2 P3 58
102. ERS ON THE NA 5 VOLTAGE BOARD MUST BE CONNECTED AS FOLLOWS CONNECT RED JUMPER TO PIN S CONNECT WHITE JUMPER TO PIN B 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 LINCOLN 8 ELECTRIC NA 5 LINCOLN CLEVELAND OHIO U S A Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O10 O10 E w gls nl g 2 EIE Return to Section TOC Return to Master TOC A 10 INSTALLATION A 10 14 PI FIGURE POWER SOURCE N AMHENOL A 9 CONNECTION OF NA 5 ALL TO A DC 650 PRO A WARNING v 0 JA TURN OFF INPUT POWER TO THE WELDING POWER SOURCE USING THE DISCONNECT SWITCH BEFORE WORKING ON THIS EQUIPMENT ELECTRIC SHOCK CAN KILL POWER SOURCE CONTROL CABLE 0979799 7 77 7 42 413433 32 31 2 4 21 TO NA 5 INPUT CABLE PLUG bw e N H N H CONTROL CABLE N B N D N E N E CONNECT TO CABLES FROM NA 5 WIRE CONTACT ASSEMBLY NE CONNECT CONNECT TO CABLES FROM NA 5 WIRE CONTACT ASSEMBLY CONNECT TO WORK NOTE ABOVE DIAGRAMS SHOW ELECTRODE CONNECTED POSITIVE TO CHANGE POLARITY TURN POWER OFF
103. ETERS IN PARENTHESES NA 5 LINCOLN INSTALLATION A 5 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 Accessories for more information regarding the adjustable mounting hardware The welding head and electrode are electrically hot when welding They must be insulated from ground 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 FIGURE A 4 WELDING HEAD MOUNTING HOLES APPROXIMATE IN 0 531 DIA SUL On 13 49 2 88 3 49 445 4 5 114 30 NOTE DIMENSIONS ARE IN INCHES WITH MILLIMETERS IN PARENTHESES Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC E w gls nl g 2 EIE 3 42 Return to Section TOC Return to Master TOC A 6 INSTALLATI When mounting the welding head to the standard travel carriage see 305 B sec T2 2
104. 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
105. 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 ELECTRIC danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine NA 5 Grd ELECTRICAL DIAGRAMS G 8 CONTROL CIRCUIT SCHEMATIC C217 V L 6682 2 SHT Return to Section TOC Return to Master TOC 4 X203 GD mme 2 1 11 c218 C212 208 P 0204 C229 L 6231 3 R205 R203 8204 4 70202 CONTROL 13 500 V WV 57 410 00 V 5 REFERENCE ACTUAL SPEED BUFFER SUPPLY SUP S D G 10 8 A 5 SCHEMATIC CONTROL CIRCUIT TACH SIGNAL CONVERTER SUBJECT EQUIP CHK FROM OPTION AND PROCEDURE oe PC BOARD
106. GURE F 1 P C BOARD LOCATIONS NA 5 LINCOLN 5 pat TROUBLESHOOTING amp REPAIR DC POWER SUPPLY TEST continued TABLE F 1 DC POWER SUPPLY CHECKS Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo o F F c 5 8 9 8 0 12 el cic 5 5 a Return to Section TOC Return to Master TOC CHECK POINT LOCATION TEST DESCRIPTION CHECK 15VDC SUPPLY FROM POWER BOARD TO CONTROL BOARD CHECK 15VDC SUPPLY FROM POWER BOARD TO VOLTAGE BOARD CHECK 10VDC SUPPLY FROM POWER BOARD TO VOLTAGE BOARD CHECK 10VDC SUPPLY FROM POWER BOARD TO CONTROL BOARD CHECK 110VDC SUPPLY FROM POWER BOARD TO LOGIC BOARD CONNECTOR PLUG PIN NO PIN 10 PIN 9 PLUG J1 PIN 1 PLUG J1 2 610 500 9 v O NA 5 LINCOLN 5 NORMAL ACCEPTABLE VOLTAGE READING 14 0 16 0 VDC 14 0 16 0 VDC 9 0 11 0 VDC 9 0 11 0 VDC 90 135 VDC Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O10 e S9 o 22 cic 5 5 a Return to Section TOC Return to Master TOC E TROUBLESHOOTING amp REPAIR dnd DC POWER SUPPLY TEST continued TABLE F 1 DC POWER SUPPLY CHECKS continued TEST CON
107. 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 777 NEAR THE POWER SOURCE TERMINAL STRIP THE POWER SOURCE olo 016 MUST BE PROPERLY GROUNDED Fle 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 cls N G ON EARLIER SAM MACHINES 1 TERMINAL WAS ALSO ON THE TERMINAL STRIP 22 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 915 2 2 2 LINCOLN jo ELECTRIC CLEVELAND U S A o NA 5 LINCOLN A INSTALLATION A 13 FIGURE A 12 CONNECTION OF NA 5 ALL TO A SAM 650 ENGINE WELDER A WARNING TURN OFF INPUT POWER TO THE WELDING POWER SOURCE USING THE DISCONNECT SWITCH BEFORE WORKING ON THIS EQUIPMENT ELECTRIC SHOCK CAN KILL Return to Section TOC Return to Master TOC POWER SOURCE N C AND N D TO NA 5 INPUT CABLE PLUG N G CONTROL CABLE NOTE TO CHANGE POLARITY TURN POWER OFF AND POSITION THE SWITCH ON POWER SOURCE TO MAX MED SLOPE SLOPE N D AND N H e S PROPER POLARITY REFER TO NA 5 Fife OPERATING MANUAL FOR REQUIRED N A
108. ITH START WITH WELD CURRENT 5 nan BOARDS WITH JUMPERS DIP SWITCHES STOP WITH STOP SWITCH CONNECT TIT USE OF OPTIONAL CRATER MODULE START WITH START SWITCH CONNECT TII WIRE FEED STOP LEAD 690 OU U0 crater BOARD INSTALLED FOR EARLIER LOGIC P C FOR LOGIC P C BOARDS WITH STOP AFTER CRATER TIME LEAD 691 to P6 Gua CONTACTOR DELAY LEAD 693 TO P3 BOARDS WITH JUMPERS DIP SWITCHES LEAD 892 to P9 OPTIONAL PROCEDURE MODULE III YES CONNECT INCH UP WITH CONTACTOR DELAY LEAD 690 TO P4 9060 0088 LEAD 4694 0000 8000 THIS SHEET CONTAINS PROPRIETARY INFORMATIQN UNLESS OTHERWISE SPECIFIED TOLERAN Bros Sht No 12 0 EQUIP START WITH START SWITCH LEAD 693 TO P1 SWITCH OWNED BY THE LINCOLN ELECTRIC CO AND 15 ON HOLE SIZES PER E2056 D THE LINCOLN ELECTRIC CO NA 5 STOP AFTER BURN BACK TIME 691 to PB GWA CONNECT NO CONNECT NOT TO BE REPRODUCED DISCLOSED on USED ON 2 PLACE DECIMALS IS an2 CLEVELAND OHIO U S A WIRING DIAGRAM p OPTIONAL PROCEDURE MODULE LEAD 692 to PB INCH UP WITH NO CONTACTOR 690 ror 0088 A LEAD 694 TO 0000 ME EXPRESS PERMHION ON ALL ANGLESIS Or ADEGREE a INSTALLED IN CRATER RECEPTACLE DEA LEAD 4693 ENERO THE LINCOLN ELECTRIC CO WITH PUBLISHED STANDARDS
109. LAY 7227100 TW 2 7K E C702 500 50 02702 16V 1W R705 470 R729 15K PUR LIEN m 24VDC CONTACTOR DELAY 693 Pf C703 47 35 DZ703 1 2W R706 100 R730 68K FOR LEAD 694 CONNECTION SEE C704 47100 02704 16V 1W R707 47K R731 2 T TRAV 0400 NM A 5 SHIPPED CONNECTED FOR INDICATED 6705 10 25 02705 2W R708 47K R732 47K 00 QE METHODS OF TRAVEL AND BURNBACK C706 047 100 02706 5 1V 1 2W R709 470 R733 22K P1001 1880 41002 KEY SYMBOLS C707 10 25 L701 _5 6mH 28mA R710 470 R734 47K COMPONE BOARD SUPPLY SOURCE POINT Um DE RD M m SS DR VDO RELAY COL SCHEMATIC LOCATION REFERENCE C710 RED R713 47K R737 6 8K i CONTACTS SHOWN T OJo HRU V 022 25 LED 7G LIGHT R714 47 R738 47K C HEMATIC A HORIZONTAL CO ORDINATE LETTER O o 0729 LED 7H f EMITTING R715 100K R739 10K Rae aaa VERTICAL ORDINATE NUMBER F D701 LED 7J DIODE mr16 22K R740 15K RELAY SCHEMATIC IDENTIFICATION LETTER cla HRU V 1A 400V LED 7K R717 47 R741 10K COIL ACTUATED UNLESS OTHERWISE SPECIFIED COMPONENT VALUES OF olo D712 Q701 2N 4123 R718 100 R742 15 OPTIONAL LINC FILL CAPACITORS MFD VOLTS 0717 0705 R722 eB8K 703 INDICATOR LIGHT SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT 9 gt D718 0706 R723 27 X704 i epee BUS BUTTON Son BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGE HRU V 1A 1000V THRU V2N 4123 R724 45K X707 8 A
110. LTMETER ACCURACY TEST A 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 Return to Section TOC Return to Master TOC 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 Return to Section TOC Return to Master TOC 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 O10 e S9 o 22 cic 5 5 ply a Return to Section TOC Return to Master TOC NA 5 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Q e 49 2 5 Return to Section TOC Return to Master TOC o 2 E 5 T TROUBLESHOOTING amp
111. MBOLS PER E1537 STVNOIS Ave O O ES ETT Pop 625 visio WORK CABLE RF BYPASS 8271 R1 25 I I P C BOARD WORK N A SPEEDMETER BOARD CALIBRATION JUMPER IS TO BE CONNECTED FOR NA 5 HEAD AND DRIVE ROLL POWER SOURCE 531 5321 1 535 1 EMPLOYED PER CHART BELOW CONNECTED TO PIN 95 OR 21 WHEN SWAPPED 21 667 87 531 626 105 ot 5A CIRCUIT BREAKER TRAVEL SW POWER SW LIGHT RED SPEEDMETER A 5 HEAD DRIVEROLL WIRE BIZE RATED SPEED EE 92 LTI PIN PARTNUMBER RANGE RANGE N G 531 532 115VAC 1 8 AMP FUSE 57F 57 1 812778 SINGLE 035 052 40 778 531 25 115VAC SWITCHED 250 VAC dme nemus 57 571 812515 SINGLE 1 16 3 32 38 762 95 95 1 812514 SINGLE 3 32 5 82 22 428 I P M N H 531 87 115 VAC SWITCHED 1 2 1 6 4 PROCEDURE KIT 9585 e 512515 SINGLE 1 16 3 32 23 456 I P M N J CONNECT 67 BLACK ELECTRODE LEAD AND 21 WHITE WORK LEAD TO APPROPRIATE TERMINAL STRIP RECEPTACLE 513161 052 TWIN 045 052 POLARITY CONNECTIONS WHICH MATCH ELECTRODE AND WORK CABLE POLARITY CONNECTIONS TO POWER SOURCE 13161 5 64 TWIN 1 16 5 64 560 1 14904 OUTER N K LEAD CONNECTED TO MOTOR FRAME WHICH IS ELECTRICALLY COMMON WITH ELECTRODE DRIVE ROLL AND DRIVEN ELECTRODE 21 14905 INNER TWIN 332 NOTE NA 5 MOTORS INSULATED FOR HIGH FREQUENCY STARTING DO NOT HAVE THIS CONNECTION REFER TO 500 49 3 812
112. Master TOC olo o F F S9 o 919 ois 2 2 lt a x Return to Section TOC Return to Master TOC THEORY OF OPERATION FIGURE E 4 Control Logic and Procedure Boards CONTACTOR CLOSURE 2 AND 4 ARC VOLTS SET amp ACTUAL TACH FEEDBACK MOTOR RPM REMOTE VOLTAGE CONTROL A B C WORK SENSING 21 115VAC B e E INPUT POWER IRCUIT SWITCH enu BREAKER R1 2 OHMS CONTROL CABLE RECEPTACLE 36VAC 18 18VAC WIRE FEED SPEED SET amp ACTUAL BOARD IDIGITAI DIGITAI METER METER 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 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 SCR 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 powe
113. NA 5 CONTROL BOX POLARITY CONNECTIONS ziv 5 g BOLT TO CABLES gt FROM 5 o 300 450 AUTO WIRE CONTACT o 575 STICK EQUIP WORK 515 ply tt 1 6 CONNECT TO WORK 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 4 3 SET THE CONSTANT VOLTAGE CONTROL NUMBER 5 FOR ADDITIONAL INSTALLATION INSTRUCTIONS SEE NA 5 OPERATING MANUAL 4 CONNECT THE TAP CABLE TO THE 450 MAX MED SLOPE STUD m NB olo SAM POWER SOURCE SETTINGS NA 5 SETTINGS TURN POWER SOURCE OFF FOR SUB ARC 5 FOR SUB 1 RED LEAD ON VOLTAGE PC BOARD IS CONNECTED TO PIN S 1 SET THE ELECTRODE POLARITY SWITCH TO THE POLARITY DESIRED FOR THE 2 WHITE LEAD ON VOLTAGE PC BOARD IS CONNECTED TO PIN A 9 PROCESS BEING USED E 2 SET THE TOGGLE SWITCH TO CONSTANT VOLTAGE FOR ALL OPEN ARC PROCESSES o 3 SET THE CONSTANT VOLTAGE CONTROL TO NUMBER 7 1 RED LEAD ON VOLTAGE PC BOARD IS CONNECTED TO PIN 2 4 CONNECT THE CABLE THE 300 575 MAX SLOPE STUD 2 WHITE LEAD ON VOLTAGE PC BOARD IS CONNECTED TO PIN A cic 4 21 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
114. NECTOR DESCRIPTION PLUG PIN NO PROCEDURE CHECK 15VDC PLUG J19 PC BOARD SUPPLY FROM PIN 5 J19 CONNECTOR LOGIC BOARD PLUG TO PLUG J19 PROCEDURE BOARD PIN 15 CHECK 5VDC TEST POINT SUPPLY TP5 PRODUCED ON THE VOLTMETER TEST POINT BOARD 510P CHECK 5VDC TEST POINT SUPPLY TP5 PRODUCED ON THE TEST POINT SPEEDMETER 510P BOARD Scrape encapsulation from test points NA 5 LINCOLN 5 LEAD NO NORMAL ACCEPTABLE VOLTAGE READING 14 0 16 0 VDC 4 75 5 25 VDC LEAD 510P 4 75 5 25 VDC LEAD 510P Return to Section TOC Return to Section TOC Return to Master TOC O10 e S9 o cic 5 5 ply a Return to Section TOC Return to Master TOC Return to Master TOC F 42 TROUBLESHOOTING amp 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 proc
115. NG amp REPAIR F 23 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENTS S COURSE OF ACTION TRAVEL FUNCTION PROBLEMS The travel will not function with the 1 Make sure the jumper leads 691 1 If light 7H located on the logic travel switch in the Auto postion and 692 are connected properly board does light when the auto The travel operates correctly with the to the correct pins on the logic matic travel is active check the travel switch in the Hand position board See wiring diagram CR2 relay Normal coil resis tance is 10 000 ohms The con Check the travel switch S2 and tacts terminals 2 and 4 should associated leads for loose or close when 110VDC is applied faulty connections See wiring to the relay coil terminals 1 diagram and 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 Make sure the jumper leads 691 1 The 2CR relay may be faulty the travel switch is in the Auto posi and 4692 are connected properly The contacts terminals 2 and 4 tion to the correct pins on the logic may be stuck closed board See wiring diagram Check the associated leads for Check light 7H on the logic board misconnections See wiring dia If light 7H is always ON the logic gram board may b
116. OCEDURE lt Y SS y 5 10K 0 dd E i E E ca O 58 T 022 STRIKE PROCEDURE 4 PROCEDURE 50V DISABLE ozi 75 5 Sa a SIRKE 7 Optional Crater Module Installed E gt z 49 PROCEDURE d ENABLE 475 E 400K Yes ee ee ee ee TW n olg 55 55 9 Simon Son 475 t 07070 e o o elg i 11811 J o ee e o Ted CRATER 2 X A 4 s 8 cas moin TIME OVER La 5 E P BURNBACK n ____ 637 a PROCEDURE TIME R48 MN _ R35 lt m5 PC BOARD yj 768K wp O E gs E gt Methods of Burnback PRESENT 0 gt 44 ga Ts Wre feed stop with e e e o o o o o EE T contactor delay g Dik 5 500 500 m SWITCH 2 iA up 267K 100v 4 p 5 8 iA FLUX OR CEN ES BANT ENC EA a 39 A p Rag 4 587 ho WATER Inch up with contactor s s a Du guru A A so FEED FORWARD ss SATOH SWITCH Q5 LED7J 2N5657 07 10K 10 022 Inch up with contactor SH g 20 TE 8 cp NT a 72 OO gus 150K T e e o o 8 L 1 2 Suis Emm T 592 5 Ero 5 5 R50 go V 50 TY 5 mx NA 5 SHPPED CONNECTE
117. OF ACTION MODE FUNCTION PROBLEMS When the start button is pressed and 1 Make sure the start option is in the unit is welding the start mode is skipped stalled properly in the NA 5 Make sure the start timer is set for a time greater than zero sec onds 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 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 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 1 Check the lead harness between the start option boards and the procedure board for loose or faulty connections 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 LINCOLN 8 Return to Section TOC Return to Master TOC F 16 TROUBLESHOOTING amp REPAIR F 16 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENTS S COU
118. OLS HAVI CODE NUMBER A N S I ELECTRICAL SYMBO CT COMPONENTS G A COMMON LS PER E1537 FOR NA 5 CONTROL CODES Return to Section TOC Return to Master TOC 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 could result in damage to the machine LINCOLN P NA 5 os ELECTRICAL DIAGRAMS Gs POWER PC BOARD L6252 2 amp above SCHEMATIC ONNECTION CONTROL POWER AND EMERGENCY STOP Return to Section TOC Return to Master TOC A SUPPLY VOLTAGE NET POWER SUPPLY SOURCE POINT NA COMMON CONNECTION L EARTH GROUND CONNECTION 2 FRAME 2 OHMS FLUX OR WATER 50 WATTS SOLENOID RECEPTACLE 531 87 C4 NA 5 NA 5R 15 2007 5 047 2 4 POWER P C BOARD SCHEMATIC EQUIP TYPE aJ SCR T 2N6398 p Y BLUE PTI b 1 Ja wire FEED n MOTOR ARMATURE SCR3
119. ONTROL olo CABLE O NK ols NEGATIVE X POSITIVE 0 12 u e e N C N H Sle 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 EXTEND LEAD 21 USING 14 OR LARGER INSULATED WIRE PHYSICALLY SUITABLE FOR THE INSTALLATION AN 5 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 5 CONTROL CABLE GROUND LEAD TO THE FRAME TERMINAL MARKED 77NEAR THE POWER SOURCE TERMINAL STRIP THE POWER SOURCE MUST BE PROPERLY GROUNDED 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 F CONNECT THE JUMPERS ON THE NA 5 VOLTAGE BOARD
120. OWER THE LINCOLN ELECTRIC CO SPST POWER SOURCE OUTPUT 68K TP102 150V 10J C1103 SEE SCHEMATIC NC FILL PILOT RELAY SUPPLY 510 100 103 61104 0047 8000 FLUX SOLENOID BY PASS PTIONAL LINC FILL BY PASS CONTACTOR 100 crc 2622908 MOTOR FIELD BV PASS SCHEMATIC LOCATION REFERENCE 01106 200 HORIZONTAL CO ORDINATE LETTER VERTICAL CO ORDINATE NUMBER SCHEMATIC IDENTIFICATION LETTER 100 REGULATOR 10K X102 5V VOLTAGE PST CONTROL POWER AND UNLESS OTHERWISE SPECIFIED COMPONENT VALUES OF CAPACITORS MFD VOLTS 47K REGULATOR ERGENCY STOP RESISTORS OHMS 1 2 WATT 4 7K DT TRAVEL 6 8K 680 NA 300mA SECONDARY SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD THIS A 1000 V THIS SHEET CONTAINS PROPRIETARY INFORMATIQN UNLESS OTHERWISE SPECIFIED TOLERAN E n s OWNED BY THE LINCOLN ELECTRIC CO AND Is NOT TO BE REPRODUCED DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION OF 47K AC 600mA SECONDARY 680 LOGIC SCHEMATIC D 4 7K 5 80mA SECONDARY 3 3K 24VAC 30mA SECONDARY 68K 047 100 THRU EMITTING 022 25 LED 1F J DIODE 02 600 202020202020 202020202020 20202020 022 25 PT101 PT102 PT103 144 PULSE TRANSFORMER DIAGRAM MAY NOT SHOW THE EXA OR CIRCUITRY OF CONTR
121. RCE 1 AND POSITON THE SWITCH ON POWER SOURCE TO PROPER POLARITY REFER TO NA 5 OPERATING MANUAL FOR REQUIRED N H E NA 5 CONTROL BOX POLARITY CONNECTIONS NEGATIVE POSITIVE N C AND N D N D AND N J CONNECT TO CABLES FROM NA 5 WIRE CONTACT ASSEMBLY CONNECT TO WORK Return to Section TOC Return to Master TOC ALL CODES DC 600 CODES 8046 8200 TURN OFF INPUT POWER FOR SUB ARC ADJUST THE POWER SOURCE DC 600 1 SET MODE SWITCH TO CV SUB ARC 1 CONNECT ELECTRODE CABLES TO TERMINAL OF DESIRED POLARITY 2 WHITE LEAD ON CONTROL PC BOARD IS CONNECTED TO PIN M 2 SET TOGGLE SWITCH TO SAME POLARITY AS THE ELECTRODE CABLE CONNECTION FOR ALL OPEN ARC PROCESSES EXCEPT MR 203 ELECTRODES 3 SET TOGGLE SWITCH TO REMOTE 1 SET MODE SWITCH TO CV INNERSHIELD 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 00 600 CODES 8000 8045 FOR SUB ARC 1 SET MODE SWITCH TO CV INNERSHIELD 1 SET MODE SWITCH TO CV SUB ARC 2 WHITE LEAD ON CONTROL PC BOARD IS CONNECTED TO PIN I 2 WHITE LEAD ON CONTROL PC BOARD IS CONNECTED TO PIN M AND BLUE DC 600 CODES ABOVE 8200 LEAD IS CONNECTED TO W FOR SUB ARC FOR ALL OPEN ARC PROCESSES EXCEPT NR 302 AND NR 203 ELECTRODES 1 SET MODE SWITCH TO CV SUB ARC 1 SET MODE SWITCH TO CV INNERSHIELD FORALLOPENARC PROCESSES 2 WHITE LEAD ON CONTROL PC BOARD IS
122. REFERNCE 10 METER VAC SUPPLY gOXN 602 RELAY POWER SUPPLY D114 7 0115 INTERFACE OPTION POWER SUPPLY ON HOLE SIZES PER E2056 ON 2 PLACE DECIMALS IS 02 ON 3 PLACE DECIMALS IS 002 ON ALL ANGLES IS 45 OF A DEGREE MATERIAL TOLERANCE TO AGREE WITH PUBLISHED STANDARDS FOR POWER P C BOARDS L6252 2 OR HIGHER USE L8956 SCHEMATIC FOR COMPONENT VALUES AND CIRCUIT CONNECTIONS POWER P C BOARD olo O10 Fle S9 o o G gle Etc 515 2 a R F BYPASS P C BOARD COMPONENTS NOT ON P C BOARD KEY TO SYMBOLS 8A 600V FOR R F BYPASS P C BOARDS 14133 1 OR CB1 5A CIRCUIT BREAKER 005 1400 6A 400 V 8A 600V HIGHER USE 520995 SCHEMATIC FOR INPUT CONTROL CABLE CONNECTION 15 200 6A 400 V 50 250 6A 400 V 15 200 047 100 A 400 V 047 100 4 7 35 047 100 022 25 022 25 022 25 5 1 V 1 2 W 022 25 22 100 2A SLOW BLOW 500 50 POWER SUPPLIES FUSE 500 50 02 2A SLOW BLOW 4 7 35 FIELD FUSE 18 15 02 600 LED 1A RED LIGHT 2N4123 SCR 101 2N5816 SCR 102 2N5816 SCR 103 us SOR IDA 16A 400V COMPONENT VALUES AND CIRCUIT CONNECTIONS CRI SPST N O FLUX OR WATER POWER SUPPLY SOURCE POINT 16A 400V CR2 SPST TRAVEL 40 12W TP101 2110 0047 3000 VOLTAGE BY PASS CR6 SPST SOLID STATE OPTIONAL COMMON CONNECTION TO ANALOG P
123. RSE OF ACTION When welding the start timer does not time out The unit stays in the start mode The crater light does not light The 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 MODE FUNCTION PROBLEMS 1 When the weld is stopped check 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 If the start crater and burnback timers are not working properly the procedure board may be faulty Make sure the crater option boards are installed correctly The procedure board may be faulty Replace 1 Check the lead harness between the start option boards and the procedure board for loose or faulty connections See wiring diagram Check the lead harness between the crater option boards and the procedure board for loose or faulty connections See wiring diagram tion Return to Section TOC Return to Master TOC Check the lead harness between the crater option boards and the procedure board for loose or faulty connections See wiring diagram The crater light is ON but the crater controls voltage and wire feed speed do not function The NA 5 is at idle with the selector switch in the Crater position If no other lights are lit the crater option board may be faulty Replace If the
124. S SECTION o O dot eene E EUR eta Section C General cde EVER PEE REC C 2 Listing Of Accessories C 3 5 K29 Vertical Lift Adjuster oa cerise we C 3 K58 Magnetic Separator C 3 K96 Horizontal C 3 K129 Submerged Arc Small Wire Twinarc C 3 K148 Contact Nozzle and K149 Linc Fill Long Stickout Extension C 3 K218 Horizontal Fillet Lap Attachment C 3 K219 Flux Hopper C 3 K223 Solenoid u gaa nspas us eee ee C 3 K225 Submerged Arc Twinarc Kit C 4 gt K238 High Frequency Unit C 4 K239 Twinarc Kit for Innershield Electrodes C 4 5 K278 SpreadarcM C 4 2 K281 Solid Wire Straightener for Tiny Twinarc C 4 z K285 Concentric Flux C 4 g K310 Flux Screen C 4 K325 TC 3 Travel Carriage C 4 5 K334 Start and Crater Controls 5 x K336 Remote Interface Module C 5 K337 Weld Timer Module C 5 K349 Multi Procedure
125. SCR4 2 6403 2 6403 tT Ld 1 BLACK 6 047 100v NONE 5 12 92 SCALE DATE 115VAC FEED FORWARD GENERAL INFORMATION ELECTRICAL SYMBOLS THE LINCOLN ELECTRIC CO CLEVELAND OHIO U S A P1 9 J3 587 o Return to Master TOC Return to Section TOC WIRE FEED MOTOR FIELD 52 EIS TRAVEL HAND at 600mA 971 i ARMATURE SUPPLY T 08 e 525 15V FIELD SUPPLY 7 C FIELD DIRECTION z CIRCUIT HS pi 500 FOR THE NA 5R ONLY gt 55 THE TRAVEL RECEPTACLE THE TRAVEL SWITCH J3 pi AND CR2 ARE REMOVED ON THE NA 5R 55 CR3 I8 SHOWN IN THE OPTIONAL BURNBACK KIT al RECEPTACLE WHICH IS DRAWN BELOW THE 510 BURNBACK KIT IS CONNECTED TO 631 AND 532 115 VAC zero voir ANALOG REFERENCE POWER SUPPLY 510 y 510 edd 10 e n2 e 1n NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY NUMBER N A SINCE COMPONENTS OR CIRCUITRY ON
126. 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 NOTE Unshaded areas of block logic diagrams are the subject of discussion NA 5 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo S F els 0 12 22 a Return to Section TOC Return to Master TOC THEORY OF OPERATION E 3 FIGURE E 2 Power and Voltage Boards TACH FEEDBACK MOTOR RPM CONTACTOR CLOSURE 2 AND 4 ARC VOLTS SET amp ACTUAL RECEPTACLE REMOTE VOLTAGE CONTROL A B C WORK SENSING 821 1 2 115VAC SET VOLTAGE VOLTAGE BOARD TRAVEL RECEPTACLE LUX C RECEPTACLE OPTIONAL START BOARD INPUT POWER CIRCUIT SWITCH BREAKER R1 2 OHMS OPTIONAL CRATER EN OPTIONAL WELD TIMER BURNBACK TIMER zn CONTROL CABLE FIELD DIRECTION oOr zGo 0md o SET SPEED r gt zo o mrm zm ommm 36VAC 18 18VAC 10VDC REFERENCEVOLTAGE TACH FEEDBACK MOTOR RPM CONTROL WIRE FEED SPEED SET amp ACTUAL BOARD POWER AND VOLTAGE BOARDS The AC voltages that are received by The voltage board also generates a low the power board are recti
127. TOC Switch 1 Switch 2 Return to Section TOC With Arc Striking With Arc Stopping Lead 691 to Pin 6 Lead 4692 to Pin 7 m m Switch 1 Switch 2 With Arc Striking With Stop Button Lead 691 to Pin 5 T 2 3 4 T 2 3 4 Switch 1 Switch 2 With Start With End Crater Lead 691 to Pin 6 Button Fill Time With Lead 692 to Pin 9 1 2 3 Allg 3 4 optional procedure m m m module installed in Switch 4H Switch 2 crater receptacle With Start After Burnback Lead 691 to Pin 6 T 2 3 4 T 2 3 4 Button Time with Lead 692 to Pin 8 optional procedure m m m module installed Switch 1 Switch 2 in crater receptacle Return to Section TOC Return to Master TOC 1 the optional procedure module is installed in the crater receptacle NOTE 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 aal position Indicates switch in down position Indicates switch position does not matter olo O o e w
128. The actual strike voltage is a function of the set strike voltage and the contrtol characteristics of the welding power source NA 5 controls with a G1556 3 or higher voltage board must have the jumper plug connected to the 4 cavity receptacle on the board unless the pulsed power filter board option is connected Make sure the shutdown BYPASS pins are not jumpered together on the NA 5 voltage board 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 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 1 3 If the actual reading is the prob lem check the actual volts switch and associated leads See wiring diagram If the set reading is the problem check the set volts switch and the asociated leads See wiring dia gram Perform the Voltmeter Accurac 4 Perform the Meter Circuit Accuraty Test 5 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
129. UNDED ele 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 cla LEAD 77 TO 76 ON TERMINAL STRIP AND ADD JUMPER PER N A 6 6 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 es NJ FOR PROPER NA 5 OPERATION THE ELECTRODE CABLES MUST SNUGGED UNDER THE CLAMP BAR ON THE LEFT SIDE OF THE NA 5 CONTROL BOX 2 c E LINCOLN E 5 5 ELECTRIC CLEVELAND U S A E NA 5 LINCOLN 12 INSTALLATION 12 FIGURE 11 CONNECTION 5 ALL SAM 400 MOTOR GENERATOR ENGINE WELDER A WARNING TURN OFF INPUT POWER e TO THE WELDING POWER SOURCE USING THE DISCONNECT SWITCH BEFORE WORKING ON THIS EQUIPMENT Return to Section TOC Return to Master TOC ELECTRIC SHOCK CAN KILL POWER SOURCE TO AUTOMATIC CONTROL BOX CONTROL CABLE O x 5 nl AUTO BOLT TO CABLES FROM NA 5 EQUIP STICK WORK WIRE CONTACT ASSEMBLY AND N H ply tt 1 6 CONNECT TO WORK 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
130. URE 5835 PROCEDURE 212 PC BOARD TIME WELD TIME eae ene ERFACE 619 515 OVER OVER WELD 8 705 5 PROCEDURE Ve R1001 2 0712 START g 4 r gt 2 gt ENABLE DISABLE 28 LED 7H RE D1002 olg gt CILIRTOS 581A foai K 581 BERE go P TRAVEL b c G3 GR 85 lo 13 5 581A START N D 12 x 560 _ PROCEDURE 500 PROCEDURE 565 PRESET PC BOARD BOARD Kl MONITOR 1701006 WELD TIME ENABLE swros A OVER Q709 582 1002 COMMON CD sw ELECTRODE HOT T 582 LTI 8 10 HOLD LOW lt gt lt gt XL LED 7K 9 95 lo vee T 1 T ps 584C PROCEDURE SONER 13 R735 o STOP f pica bl CRATER POBOARD E Q708 SOURCE eile 12 2 HME S OUTPUT 500 INITIATE S Tora 5 5 500 079 A C708 500 CR PROCEDURE E 9 BOARD 2966 4 500 V 592 1004 SIGNAL p 42 Ameo sa EM AES 2 LED7D BON 5 5 SHUTDOWN COMMON D10183 C1004 01019 DOWN P 9 690 ENABLE SWITCH 24V SIG Ps Ci 500 lt gt C 4 EJE Y X706 pink me ARC CONTROL 01020 5 5 52g KATH 59 D R733 INCH DOWN A xus CR4 0714 C707 CURREN 588 _ CURRENT PROCEDURE A706 PC BOARD N A 801 SEE PROCEDURE PC BOARD E gt SCHEMATIC MUST BE IN STRIKE 1 10 START NES 6725 POSITION START WELD CYCLE mel BC BOARD 5 563 PROCEDURE N B COMPONENTS INCLU
131. ace The logic board may be faulty Replace the crater option board with the jumper plug Set the burnback timer for any time greater than zero seconds If the unit then stops after the weld and burnback time the crater timer board may be faulty Replace If the unit does not stop the pro cedure board may be faulty Make sure the burnback timer is set for a time greater than zero ohms Be sure the jumper leads or dip switches on the logic board are comfigured correctly for the burn back retract desired See wiring diagram The burnback timer module may be faulty Replace The procedure board may be faulty Check the lead harness between the crater boards and the proce dure board for loose or faulty con nections See wiring diagram Check the lead harness between the crater boards and the proce dure board for loose or faulty con nections See wiring diagram Check the lead harness between the burnback module and the pro cedure board for loose or faulty connections 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 LINCOLN 8 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o O c 9 o
132. ach of the head lift bearings This can be done through the front opening in the carriage 3 Add few drops of oil to the clutch handle bearings 4 Add a few drops of oil into each of the cups at the travel mounting pivot point No change of lubrication is required for cold temperature operation Once a year 1 Check the motor brushes If 0 25 in 6 35 mm or shorter replace with new brushes NA 5 LINCOLN 2 Check the carriage drive gear teeth If the teeth are badly worn replace the drive gear 3 After 5 000 hours of operation the motor and the first reduction gear should be removed from the gear box and all the gear teeth should be recoated with a good grade of graphite grease 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 HORIZONTAL ADJUSTER Twice a year a
133. all knobs including the rotary select switch knob c Remove the felt seal and square spacer tube mounted behind each control knob d Open the control box Disconnect then remove the procedure control PC board assembly and its panel insulation e Install a 1 2 in long pan or round head 4 sheet metal screw into the 0 10 in diameter hole located NA 5 LINCOLN beneath each square so the head is on the back side of the panel inside the control box f Remount the PC board assembly and its panel insulation Reconnect the PC board and close and secure the control box g Remount the rotary select switch knob and replace each square spacer tube and felt seal so the 4 screw protrudes between the tube and the felt seal h Turn on the NA 5 input power and set the desired procedure by rotating the shafts of the controls i Carefully replace each control knob so the 4 screw inserts into the center of the shorter length channel on the back of the knob for about 396 of the total range of control or into the center of the longer length channel for about 1596 of the total range of control j With finger pressure on the knob against the felt seal carefully retighten the set screw of each knob NOTE Steps h thru j will have to be repeated if it is desired to change the procedure settings to values outside the selected 3 or 15 control range limit Section C TABLE OF CONTENTS Section C ACCESSORIE
134. and the adapter plate locating bead is in its cavity Replace and tighten the four screws removed in step 1 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 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 NA 5 LINCOLN FIGURE D 6 DRIVE MOTOR PINION GEAR REMOVAL SHAFT ADAPTOR PLATE L r s ROLL PIN MOUNTING SCREW X3 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 WIRE STRAIGHTENERS Solid Electrode Periodically inspect the slide bushing at the top of the straightener and the ingoing wire guide at the bottom of the straightener for signs of wire milling If necessary rotate the guide to present an unworn surface To reverse the slide bushing for a fresh wear surface remove the cross adjustment scre
135. arc strikes and the circuit automatically switches from Strike settings to Weld or Start if used settings NA 5 models above Code 8300 offer both hot start arc striking as described above or Cold Start arc striking which operates as follows 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 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 Use either the standard on the fly travel starting or rewire the controls for standstill travel starting as described in the Travel Starting and Stopping section Optional Start Controls Recommended for applications where penetration bead size and other characteristics must be carefully controlled at the start Return to Section TOC Return to Section TOC Return to Master TOC olo O o e w ols ois 518 EIE 2 2 o a Return to Section TOC Return to Master TOC Return to Master TOC OPERATING INSTRUCTIONS B 6 The starting sequence is as described above excep
136. ard It current is present connect a mode and does not progress through should be ON when welding cur jumper wire from terminal 528 to the welding sequence rent is present If light 7D is ON 500 on terminal strip TS1 See the logic board may be faulty wiring diagram If light 7D does light check the CR4 reed switch If light 7D is NOT lit when weld and associated leads and connec current is present make sure the tions See wiring diagram weld cables have been properly routed through the cable clamp 2 If 7D does NOT light with the on the left side of the control box jumper wire in place check the 528 lead and the 500 lead between the TS1 terminal strip and the logic board See wiring diagram Return to Section TOC Return to Master TOC The logic board may be faulty Replace The strike light is OFF and neither Check light 7D on the logic board 1 If light 7D is ON check the CR4 strike control functions The other If it is off the logic board may be reed switch and associated leads mode lights work The unit will not faulty Replace See wiring diagram feed wire when the start button is pressed 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 912 min 91 5 0 12 HE ply cc QC If the crater light is on all the time the crater board if used may be faulty Replace or install jumper plug
137. bly 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 lf 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 FIGURE A 6 CONTROL BOX ELECTRICAL CONNECTIONS TO WELDING HEAD NA 5 LINCOLN A 7 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 o A 14 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 us
138. cally switches to the arc stopping sequence described above NOTE Setting crater time to 0 00 seconds will give zero crater time however the crater settings will be active during burnback time until the arc goes out Wire will retract at weld mode speed or crater mode speed if installed until the arc goes out and then retract at strike mode speed for the remainder of burnback time B 9 OPERATING INSTRUCTIONS B 9 ojo o TABLE B 2 STOPPING SEQUENCE SETTINGS 5 5 9 When Stop Button 2 is Pressed Older Models Newer Models oje EIE Feed motor stops and Lead 693 to Pin 3 1 2 3 4 electrode burns back with Lead 690 to Pin 4 mH m contactor delay standard Switch 42 Feed motor inches up and Lead 693 to Pin 1 1 2 3 4 electrode burns back with Lead 4690 to Pin 4 x contactor delay Switch 42 Feed motor inches up and Lead 693 to Pin 1 1 2 3 4 contactor opens Lead 690 to Pin 2 gt 9 no burnback SES Fie s 5 NOTE aK nl oe E indicates switch in isl position EIE 5 ndicates switch in x Indicates switch position does not matter VOLTAGE CONTROL FIGURE B 3 VOLTAGE CONTROL RESPONSE JUMPER PLUG RESPONSE LOCATIONS The NA 5 is provided with selectable voltage control response Proper setting depends on
139. ceed Call 216 383 2531 or 1 800 833 9353 NA 5 LINCOLN 8 F 9 TROUBLESHOOTING amp REPAIR F 9 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENTS S COURSE OF ACTION WIRE FEEDING PROBLEMS NA 5 units above code 8300 with 1 Make sure the electrode wire 1 Jumper the 2 and 4 leads at cold starting fed into the welding tip the Lincoln CV power source The wire feeds up instead of down Open circuit voltage should be when the start button is pressed 2 Check the 1 8 amp fuse on the present at both the power source The wire inches up and down prop voltage board Replace if faulty and at the ACTUAL voltmeter erly reading on the NA 5 If open cir 3 Make sure electrode polarity is cuit voltage is present at the correct and the same as the 67 power source but NOT at the NA and 21 leads at terminal strip 5 ACTUAL voltmeter reading per TS1 See wiring diagram form the 21 67 External resis Make sure the welding power source is producing welding arc With the start button pressed light voltage 7K should be lit If it is not the logic board may be faulty Return to Section TOC Return to Master TOC Check contactor relay 3CR Leads 2 and 4 are closed by relay 3CR Make sure the relay is functiioning properly Return to Section TOC Return to Master TOC Check the control cable between the power source and the NA 5 control un
140. cesses 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 CONTACTOR CLOSURE 2 AND 4 ARC VOLTS SET amp ACTUAL REMOTE VOLTAGE CONTROL C CONTROL CABLE RECEPTACLE WORK SENSING 21 115VAC lt rvuco oo INPUT POWER CIRCUIT SWITCH BREAKER A DC VOLTAGE WIRE FEED SPEED SET amp ACTUAL INCH UP SWITCH INPUT POWER CIRCUITS 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 1 2 TACH FEEDBACK MOTOR RPM SET VOLTAGE VOLTAGE BOARD TRAVEL RECEPTACLE RECEPTACLE P OPTIONAL START DC SUPPLY VOLTAGE R BOARD STRIKE B OPTIONAL IRKEMWEIIEROCEDUS E GT MONA ENABLE BOASDI OPTIONA WELD TIMER BURNBACK TIMER SET SPEED 10VDC REFERENCEVOLTAGE TACH FEEDBACK MOTOR RPM CONTROL BOARD motor The voltage board receives 115VAC and transforms and rectifies it to 24VDC for the work touch sensing circuit The
141. control box to the adapter plate with four lock washers and four bolts two from the bottom and two from the back Before mounting the control box onto a fixture you must provide mounting holes in the fixture per the measurements provided 3 or dimension print S16717 When placing the mounting holes ensure the controls and meters are convenient to the operator FIGURE A 2 CONTROL BOX CARRIAGE MOUNTING gt J 8 ADAPTER PLATE TRAVEL CARRIAGE CONTROL BOX Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC E w gls nl g 2 EIE 3 42 Return to Section TOC Return to Master TOC To install the control box on a fixture perform the following steps and refer to Figure A 3 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 FIGURE CONTROL BOX FIXTURE MOUNTING VIEW FROM BACK 0 41 0 28 7 11 SLOTS 10 41 4 PLACES 8 0 562 DIA 14 27 2 HOLES 12 75 323 85 13 77 349 76 12 00 0 43 10 92 27 68 1 4 20 THREAD HOLES VIEW FROM BOTTOM 1 4 20 THREAD HOLES FRONT NOTE DIMENSIONS ARE IN INCHES WITH MILLIM
142. d voltage Can be installed to function at either the start of the weld or at the end for crater filling Installation operating and maintenance instructions are shipped with each kit and can be ordered as Sec T2 5 13 K334 K336 REMOTE INTERFACE MODULE Permits connection of customer furnished remote start stop and inch momentary contact closure or momentary 24 volt signals Also used when a single remote signal is desired to start or stop multiple heads This module replaces the earlier K336 Remote Pushbutton Interface Module Installation and application instructions are shipped with each kit and can be ordered as T2 5 11 K336 K337 WELD TIMER MODULE Permits setting of weld time for an adjustable period Eliminates need to press the Stop button Instructions are included in the kit K349 MULTI PROCEDURE KIT The K349 Multi Procedure Kit provides three additional weld mode procedure settings of wire feed speed and voltage allowing the choice of four NA 5 weld mode procedures Installation operating and maintenance instructions are shipped with each kit are contained in the IM305 manual and can be ordered as Sec 2 5 19 K349 NA 5 LINCOLN 522022 522182 CURRENT RELAY MODULES The current relay is useful to fixture builders and others who need a signal indicating that welding current is flowing Installation operating and maintenance instructions are shipped with each kit The 522022 relay m
143. dage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se prot ger contre les chutes dans le cas ou on recoit un choc Ne jamais soudage Utiliser des lunettes avec crans lateraux dans les zones l on pique le laitier Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de le faire Si on place la masse sur la charpente de la construction ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de levage c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent 9 Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques 10 Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc
144. e Check lights 1A and 1B located 1 on the power board They should both be ON If lights 1A and or 1B are OFF perform the DC Power Suppl 2 Perform the T1 and T2 Transformer Test 3 The power board may be faulty Replace the control board may be faulty Replace The control board may be faulty Replace The voltage board may be faulty Replace Return to Section TOC Return to Master TOC properly olo S F 912 min els 0 12 HE ply tc QC 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 Return to Section TOC Return to Master TOC NA 5 LINCOLN 8 F 13 TROUBLESHOOTING amp REPAIR F 13 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENTS S 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 Replace selector switch position Return to Section TOC Return to Master TOC 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 welding The unit stays in the strike light 7D on the logic bo
145. e NA 5 controls are set for 29 volts and the input voltage to the R3S goes up it may not be possible for the NA 5 control circuit to hold the 29 volts so the welding will shut down By changing to the 27 volt triangle setting the range will be approximately 23 5 to 30 5 volts and at high input voltage there will be sufficient control to hold the Set arc voltage On these machines if the NA 5 stops welding follow this procedure 1 Move the NA 5 voltage set point 2 volts lower than the desired procedure and make a test weld a If the NA 5 still shuts down go to step 2 below b If the NA 5 keeps welding change the 235 triangle setting to the next higher voltage and reset the NA 5 set point to the desired procedure The R3S is now set properly unless there is a significant change in input voltage Skip the following step 2 Move the NA 5 voltage setting set point 2 volts higher than the desired procedure and make a test weld a If the NA 5 keeps welding change the 235 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 Return to Section TOC Return to Section TOC Return to Master TOC ojo F F x Geg min o ols 0 12 22 cic 5 o
146. e 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 LINCOLN 5 F 38 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O10 e S9 o HE cic Sis ply tc QC Return to Section TOC Return to Master TOC F 39 TROUBLESHOOTING amp REPAIR F 39 DC POWER SUPPLY TEST continued TEST PROCEDURE 1 2 Remove input power to the NA 5 Using the 5 16 nutdriver open the control box PC board access door Locate the power logic voltage control and procedure boards See Figure F 1 Apply 115VAC to the NA 5 wire feeder at the correct pins See wiring diagram POWER PROCEDURE BOARD 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 Also check associated leads and plugs for loose or faulty connec tions VOLTAGE BOARD FI
147. e 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 LINCOLN 8 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo o EE w 912 8 ois 5 oO tc QC Return to Section TOC Return to Master TOC F 24 TROUBLESHOOTING amp REPAIR F 24 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENTS S COURSE OF ACTION FUNCTION PROBLEMS After pressing the stop button the 1 Carefully disconnect the 42 lead 1 The SCR relay may be faulty electrode Hot light goes OFF but the electrode wire remains electrical ly hot The welding voltage is always present The wire stops feeding After pressing the stop button the weld light remains on and the wire continues to feed The set and actual speed meter readings match within a few IPM but both are in error 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 Check or replace the control cable between the power source and the NA 5 unit If a crater option module is used check to make
148. e test points to ensure TP5 to lead 510P the digital accurate voltmeter readings If the cor meter may be faulty Replace the rect AC voltage is not present check for meter loose or faulty connects with the associ lf the AC voltage IS present at ated leads See wiring diagram leads 601 to 602 and the DC voltage is missing the speedme ter PC board may be faulty Return to Section TOC Return to Master TOC O10 e S9 o 22 cic Sis a NA5 SPEED METER 16233 FIGURE F 10 SPEEDMETER PC BOARD AND TEST POINTS Return to Section TOC Return to Master TOC NA 5 LINCOLN 7 99 TROUBLESHOOTING amp REPAIR duis 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 Return to Section TOC Return to Master TOC 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 f the NA 5 digital speedmeter does not match the readings the digital meter may befaulty Return to Section TOC Return to Master TOC NA 5 SET SPEED READING IPM 150 004VDC 300
149. e the jumper wire you placed on the BYPASS pins on the voltage PC board and secure the access door F 54 Return to Section TOC Return to Section TOC Return to Master TOC O10 e S9 o 22 cic 5 5 ply a Return to Section TOC Return to Master TOC Return to Master TOC F 55 TROUBLESHOOTING amp REPAIR TACH BOARD FEEDBACK TEST A 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 LINCOLN 5 F 55 Return to Section TOC Return to Master TOC Return to Section TOC Re
150. e wire feeds down when either 1 Wth the unit at idle no buttons 1 Check the inch up and inch down inch button is pressed pressed observe light 7E on the switches buttons for proper oper logic board It should be OFF ation and wiring See wiring dia gram Return to Section TOC Return to Master TOC If light 7E is ON the logic board may be faulty Replace If light 7E is OFF the power board may be faulty Replace Return to Section TOC Return to Master TOC O o EE w 2 2 5 8 ois gje 5 tc QC 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 Return to Section TOC Return to Master TOC NA 5 LINCOLN 8 Return to Section TOC Return to Master TOC TROUBLESHOOTING amp REPAIR Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENTS S COURSE OF ACTION MODE FUNCTION PROBLEMS The speed and voltage controls 1 not function All of the mode lights function properly If both lights and 1B are ON All the mode lights function properly 1 None of the speed controls operate properly All the mode lights function properly 1 None of the voltage controls operat
151. ectronic 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 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 9 o 3 tc Return to Section TOC Return to Master TOC Q 42 E MAINTENANCE D 3 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 FIGURE D 3 VOLTAGE BOARD FUSE LOCATION 1 8 AMP FAST BLOW FUSE OO 9 lt lt O 2 gt GROUND FAULT FUSE PROTECTION 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 LINCOLN NA 5 circuit common 510 Such a condition typically exists when the NA 5 polarity connections are set for electrode negative WELDING HEAD WIRE
152. ed 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 4 Connect work leads of sufficient size and length per Table A 1 between the Work stud on the power source and the work Be sure the connection to the work makes a tight and clean metal to metal contact The K597 cable assembly has a 14 pin MS type connector for use with later model Lincoln CV power Sources Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC E w gls nl g 2 EIE 3 42 Return to Section TOC Return to Master TOC INSTALLATION 8 ELECTRODE POLARITY WARNING ELECTRIC SHOCK e can kill Turn off input power to the welding power source using the disconnect switch before working on this equipment 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 1 Turn off the input power to the NA 5 control box by turning off the welding power source 2 Open the control box door and locate the terminal strips on the back of the control box in t
153. ed is as follows 1 Press the Stop button 2 The wire feed motor stops and the Burnback Time Delay starts 3 The arc continues to burn the electrode back from the puddle until the arc goes out or the time set on the thumbwheel switch elapses This control should be set for just enough burnback time to prevent crater sticking There are two other ways this circuit can be connected One will cause the wire to retract with a contactor drop out delay at the end of the weld The second will cause the wire to retract during burnback time and there will be no contactor drop out delay at the end of the weld If either one of these alternate methods of stopping the weld is desired the connections on the logic board can be easily changed To change the stopping sequence turn the input AC power off at the power source remove the screw holding the inner panel and swing the panel open Change the connections older models or switch positions newer models on the logic board as shown in Table B 2 Optional Crater Controls This option is recommended for applications where the ending bead size must be controlled applications when the crater must be filled roundabouts and any other welds where the end overlaps the start When the Stop button is pressed the machine welds at the wire speed and voltage set by the Crater Controls until the time set on the thumbwheel switch elapses The circuit then automati
154. ed when the inch up button is pressed 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 LINCOLN 8 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o O e 9 o E 2 Return to Section Return to Master TOC o E F 21 TROUBLESHOOTING amp REPAIR F 21 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENTS S COURSE OF ACTION The start button initiates the wire feed but does not activiate the power source output FUNCTION PROBLEMS Make sure that lead 690 is con nected to the proper pin on the logic board On newer logic boards the dip switches must be 2 in the proper position See wiring diagram 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 Check or replace the control cable between the NA 5 and the power
155. eed 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 LINCOLN 5 F 42 diis TROUBLESHOOTING amp REPAIR diis 2 Using 5 16 nutdriver open the con 6 Check for approximately 10VAC at trol box PC board access door the yellow secondary leads 601 and 4602 See wiring diagram 9 o T1 and T2 TRANSFORMER TEST Continued FE JE E PROCEDURE 5 Using the 115VAC supply carefully amp 5 apply 115VAC to the T1 primary 8 8 1 Remove all input power to the NA 5 leads 531B and 532 E 515 dc 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 Return to Section TOC Return to Master TOC UPPER TERMINAL STRIP O10 e S9 gt 22 cic Sis a T2 TRANSFORMER FIGURE F 2 T1 AND T2 TRANSFORMERS Return to Section TOC Return to Master TOC NA 5 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Q e 9
156. egories wire feeding problems mode function problems function problems and welding problems 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 out removing the case wrap around cover 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 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 CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs sa
157. eld voltage first pins C and D to the motor Then slowly apply the armature voltage to pins A and B See Table 1 4 The motor should run and the speed should vary with changes to the armature voltage 5 1 the motor does NOT run and change speed correctly the motor or gear box may be faulty 6 To stop the motor REMOVE THE ARMATURE VOLTAGE FIRST pins A and B TEST POINTS RESISTANCE DC VOLTAGE Lead 539 to lead 541 armature 4 to 5 ohms 0 to 90 VDC Lead 626 to lead 627 field winding 750 to 850 ohms 90 to 120 VDC All leads 500 000 ohms NONE to min motor shell Except lead 67 Lead 67 to motor shell NA 5 LINCOLN 5 zero ohms Not Applicable Return to Section TOC Return to Section TOC Return to Master TOC O10 e S9 o 22 cic 5 5 ply a Return to Section TOC Return to Master TOC Return to Master TOC F 50 TROUBLESHOOTING amp 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 unders
158. er 1 With the travel switch S2 in the operation Also check associat ed leads for loose or faulty con nections Check the travel receptacle and associated leads for loose or faulty connections Make sure the travel unit is oper ational 1 Check the travel switch and asso 1 ciated leads for loose or faulty connectioins 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 If the above voltages are correct the problem is in the travel unit or connecting cable The travel switch 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 LINCOLN 8 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o O e 9 o E 2 Return to Section Return to Master TOC o E F 23 TROUBLESHOOTI
159. er TOC 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 lf the test meter does not match the readings the voltmeter PC board may be faulty Return to Section TOC Return to Master TOC NA 5 SET VOLTS READING TEST VOLTMETER READING 15 0VDC 1 50VDC 04 30 0VDC 3 00VDC 04 60 0VDC 6 00VDC 06 O10 e S9 o 22 cic Sis a Return to Section TOC Return to Master TOC NA 5 LINCOLN 5 TROUBLESHOOTING amp REPAIR Eee METER CIRCUIT ACCURACY TEST Continued F S5 ED E 9 Locate the speedmeter PC board 12 Test for DC volts on the speed iz See Figure F 10 meter PC board 0 2 10 Apply input power to the NA 5 e Check for 4 75 to 5 25VDC from ala TP5 to lead 510P See Figure eic 11 Test for AC supply to the speed F 10 meter PC board Note The coating will have to be Check for 8 to 11VAC from lead removed from the test points to ensure 601 ot 602 See Figure F 10 accurate meter readings e If the display is NOT lit and the Note The coating will have to be correct DC voltage is present at removed from th
160. ere is a high risk of unavoidable or accidental contact with the workpiece or ground use the following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot Always be sure the work cable makes a good electrical connection with the metal being welded The connection should be as close as possible to the area being welded Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 Also see item 1 b ARC RAYS can burn 4 a Use a shield with the proper filter and cover 2 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 standards Use su
161. fely 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 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo o F F c 5 8 l 0 12 cic 5 5 a Return to Section TOC Return to Master TOC TROUBLESHOOTING amp REPAIR F 3 PC BOARD TROUBLESHOOTING PROCEDURES A 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 parts e 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 1 Determine to the best of your technical ability that the PC board is the most likely component causing the failure symptom 2 Check for loose connections at the PC board to assure that the PC board is prop erly connected 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 P C Board can be dam aged by static electricity Remove your b
162. fied and regu DC voltage that is applied to the elec lated These DC voltages are supplied trode during the inch down mode to the motor voltage board and control When the electrode makes contact with board The two SCR controlled the work piece this low voltage is 115VDC supplies power the motor loaded down signaling the control cir armature and field circuits cuitry to stop the wire feed motor This feature allows the operator to utilize the The actual arc voltage is sensed at leads work touch sensing feature 67 electrode and 221 work which are coupled to the voltage board The pre If for any reason the actual welding arc set voltage requirements are also sent to voltage does not match the set weld the voltage board This information is voltage compared and processed on the voltage 0 5Volts the NA 5 will shutdown board and the resultant correction signal This feature insures that the actual is sent to the Lincoln CV power source welding voltage is the same as the pre via the remote voltage leads A B C set voltage during the welding cycle The preset and actual arc voltage infor This circuitry is incorporated on the volt mation is also sent to the voltage meter age board board where it is processed and dis played on the digital meter NOTE Unshaded areas of block logic diagrams are the subject of discussion NA 5 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to
163. g assistance before you proceed Call 216 383 2531 or 1 800 833 9353 NA 5 LINCOLN 8 F 34 TROUBLESHOOTING amp REPAIR F 34 Observe all Safety Guidelines detailed throughout this manual Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O o F F 5 5 91 5 ois 2 2 oO tc QC Return to Section TOC Return to Master TOC PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENTS S COURSE OF ACTION WELDING PROBLEMS Check the welding cables for loose or faulty connections The arc is unstable or oscillating Make sure the electrode and gas if used is correct for the process being used Put the Lincoln power source 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 ing ters are correct for the welding procedure being used Check the welding cables for loose or faulty connections Check the wire feeding path for restrictions The contact tip may be worn Check or replace The welding power source may be faulty Check or replace 1 The NA 5 voltage board may be faulty Replace 1 Put the Lincoln power source in the machine control mode Jumper the BYPASS
164. g of weld time for an adjustable period of time This feature eliminates the need to press the stop switch NOTE Unshaded areas of block logic diagrams are the subject of discussion NA 5 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O10 e S9 o 22 cic 5 5 ply a Return to Section TOC Return to Master TOC E 6 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 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 t
165. han the cathode voltage Since there is a standard PN junc tion between gate and cathode the voltage between THEORY OF OPERATION E 6 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 CATHODE OUTPUT _ NOTE AS THE GATE ANODE PULSE IS APPLIED GATE lg O LATER IN THE CYCLE THE SCR OUTPUT IS DECREASED FIGURE E 4 SCR Operation NA 5 LINCOLN SECTION F 1 TROUBLESHOOTING amp REPAIR SECTION F 1 9 TABLE OF CONTENTS E TROUBLESHOOTING AND REPAIR SECTION 8 8 E E Troubleshooting and Repair essere essen Section F How to Use Troubleshooting irit amatis rx dii eee exo cn d F 2 PC Board Troubleshooting Procedures sse ener enne nnns nens F 3 Troubleshooting 4 PC Board
166. he lower left hand corner as shown in Figure A 7 3 On the right end of the lower terminal strip interchange the black and white leads going to the terminals marked 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 NA 5 LINCOLN FIGURE A 7 TERMINAL STRIP LOCATION TERMINAL STRIPS POWER SOURCE CONNECTION DIAGRAMS 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 WARNING ELECTRIC SHOCK Y o can kill Turn off input power to the welding power source using the disconnect switch before working on this equipment mo INSTALLATION A9 FIGURE A 8 CONNECTION OF 5 ALL TO DC 600 A WARNING TURN OFF INPUT POWER o TO THE WELDING POWER SOURCE USING THE DISCONNECT SWITCH BEFORE WORKING ON THIS EQUIPMENT ELECTRIC SHOCK CAN KILL Return to Section TOC Return to Master TOC POWER SOURCE NA 5 INPUT 75 76 77 80 81 CABLE PLUG N G NA CONTROL CONTA NOTE DIAGRAM SHOWS ELECTRODE CONNECTED POSITIVE TO CHANGE POLARITY TURN POWER OFF REVERSE THE ELECTRODE AND WORK CABLES AT THE POWER SOU
167. ician 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 LINCOLN 5 F 77 pics TROUBLESHOOTING amp REPAIR Eag TACH PC BOARD REMOVAL AND REPLACEMENT Continued Hr p E PROCEDURE 5 Using the phillips head screwdriver remove the two screws from the 9 2 1 Remove input power to the NA 5 pick up assembly cover See ele xd Remove the cover 2 3 2 With the 5 16 nutdriver locate and ao remove the four screws holding the 6 Hold the nut in place with the 3 8 tach cover to the wire feed drive wrench With the phillips head motor See Figure F 13 screwdriver remove the locking screw from the rotating disc See 3 Using the 5 16 nutdriver remove the two screws from the connection box cover 4 Locate and disconnect the in line S connectors from leads 510A RA cs 525A and 555 912 o o ala 2 TACH COVER MOUNTING SCREWS x4 PICKUP di O10 e 5 8 o o 22 cic Sis a FIGURE 13 DRIVE MOTOR TACH COVER AND CONNECTION BOX Return to Section TOC Return to Master TOC NA 5 LINCOLN 5 Jia TROUBLESHOOTING amp REPAIR PN TACH PC BOARD REMOVAL AND REPLACEMENT Continued SCREWS TACHASSEMBLY Return to Section TOC Return to Mas
168. ilation especially in confined areas to insure breathing air is safe Read and understand the manufacturer s instructions for this equipment and the consumables to be used including the material safety data sheet MSDS and follow your employer s safety practices MSDS forms are available from your welding distributor or from the manufacturer Mar 95 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC WELDING SPARKS gt cause fire or explosion 6 a Remove fire hazards from the welding area If this is not possible cover them to prevent the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Welding and Cutting ANSI Standard Z49 1 and the operating information for the equipment being used When not welding make certain no part of the electrode circuit is touching the work or ground Accidental contact can cause overheating and create a fire hazard Do not heat cut or weld tanks drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances
169. in the IM305 manual and can also be ordered as Sec T2 5 9 K223 SOLENOID KIT The solenoid kit includes a valve to control water flow when using the cooling attachment on the K148 or K239 contact nozzle assembly It opens when the start button is pressed and can be wired to close either when the stop button is pressed or when the arc goes out Installation instructions are shipped with each kit Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 9 o 3 tc Return to Section TOC Return to Master TOC Q 42 E ACCESSORIES ca K225 SUBMERGED ARC TWINARC KIT The Twinarc kit provides for the feeding of two 5 64 3 32 or 1 8 in 1 98 2 38 or 3 18 mm solid wires through a single wire feeder The electrode wire must be the same size The assembly includes a wire reel insulated reel mounting bracket wire straightener dual wire guides nozzle and contact block Installation operating and maintenance instructions are shipped with each kit are contained in the IM305 manual and can be ordered as Sec T2 5 3 K225 K238 HIGH FREQUENCY UNIT This unit supplies high frequency to the welding leads for more positive starts which may be required for certain difficult starting applications Factory installed insulation is required Instructions are shipped with each unit Installation i
170. ince it may compromise the quality of the design and may result in ELECTRIC danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine 5 6 11 ELECTRICAL DIAGRAMS METER PC BOARD SCHEMATIC amp LAYOUT 512 ACTUAL 510A 5108 TO DIGITAL METER Return to Section TOC Return to Master TOC 518 562 4 5106 510 45V 5V MRM E RR 6 3 4 10 8 2 Zx J14 1 J14 J14 J14 J14 J14 9 5 o o o 3 tc Return to Master TOC NOTES LABELS FILE 821148 1CA SINCE COMPONENTS OR CIRCUITRY ON A PRINTED A CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING ELECTRICAL SYMBOLS PER E1587 SUPPLY VOLTAGE NET f FRAME CONNECTION THE INTERCHANGEABILITY OF A COMPLETE BOARD CAPACITORS MFD 022 50 UNLESS OTHERWISE SPECIFIED a olo THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS RESISTORS Ohms 1 4W UNLESS OTHERWISE SPECIFIED Power SUPPLY SOURCE POINT EArt AROUND ONNETON e OR CIRCUITRY CONTROLS HAVING A COMMON CODE NUMBER DIODES 1A 400V UNLESS OTHERWISE SPECIFIED V COMMON CONNECTION E UNLESS
171. ions A 2 Mechanical Installation A 4 5 INEROGUCUON uu duo Eee ol ee bay Sh k Pe ea A 4 o Control Box Installation A 4 Welding Head Installation A 5 Electrical Installation A 6 Input Power Requirements A 6 Control Box to Welding Head Connections A 6 Power Supply to Control Box Connections A 7 Electrode Polarity A 8 Power Source Connection Diagrams A 8 Figure A 8 Connection of NA 5 All toa DC 600 A 9 Figure A 9 Connection of NA 5 to DC 650 Pro A 10 Figure A 10 Connection of NA 5 All to a R3S 400 600 5 800 with no Line Voltage Compensator Obsolete A 11 Figure A 11 Connection of NA 5 to a SAM 400 Motor Generator or Engine Welder A 12 9 Figure A 12 Connection of NA 5 All to SAM 650 E Engine Welder A 13 Figure A 13 Connection of 5 to DC 1000 DC 1500 A 14 Figure A 14 Connection of NA 5 to DC 400 CV 400 A 15 o O 5 c o O 5 LINCOLN Return to Section TOC Return to Master TOC Return to
172. is properly set up the operator can make production welds without readjusting the controls using the following simple instructions NA 5 LINCOLN 1 Be sure there is enough electrode in the machine to complete the weld 2 If submerged arc welding fill flux hopper with new or freshly screened flux reused flux must be screened 10096 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 3 Start the power source 4 Turn the Power Control switch on the wire feeder control to On 5 Position the welding head at the start of the weld Be sure the travel carriage or other travel mechanism is set to move in the proper direction 6 Set the travel switch to Automatic Travel When set to Hand Travel the travel system operates without welding 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 a For most applications when hot starting leave the electrode 1 4 in 6 4 mm or more away from the work b When cold starting some submerged arc welding inch the electrode down until it touches the work and the flux valve opens 9 Press the Start button 10 While welding turn the cross seam adjuster handwheel as needed to keep the arc in the joint 11 At the end of the weld press the Stop button 12 If needed press the Inch Up button to get the e
173. isconnected reconnect the 421 lead to the codes above 8300 terminal strip and read the Jumper the AUTO tabs on ACTUAL volts with the inch the voltage board and press down button pressed lf the Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC inch down button If the voltage is less than 8 volts per wire does NOT feed down form the 21 67 Externall the logic board may be If the resis faulty tance test is OK the voltage board may be faulty Replace O o F F 5 5 91 5 ois 2 2 oO tc QC 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 Return to Section TOC Return to Master TOC NA 5 LINCOLN 8 F 8 TROUBLESHOOTING amp REPAIR F 8 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENTS S COURSE OF ACTION WIRE FEEDING PROBLEMS The wire will not inch down but does 1 Check to make sure that light 7J inch up properly The wire does not on the logic board is lit when the feed in either direction when the start inch down button is pressed If 1 The logic board may be faulty Replace Return to Section TOC Return to Master TOC Return
174. it See wiring diagram O o F F 5 5 91 5 ois 2 2 oO tc QC 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 Return to Section TOC Return to Master TOC NA 5 LINCOLN 8 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o O c 9 o o 2 E 3 tc Return to Section TOC Return to Master TOC o E F 10 TROUBLESHOOTING amp REPAIR F 10 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENTS S COURSE OF ACTION WIRE FEEDING PROBLEMS NA 5 units above code 8300 with 1 Check the 1 8 amp fuse on the 1 Rertorn 221 462 External cold starting voltage board Replace if faulty 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 667 and 621 to the voltage work piece observe light 7G on board See wiring diagram the logic board If the light goes on but the wire does NOT stop The logic board may be faulty feeding the logic board may be fau
175. itable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal FUMES AND GASES can be dangerous 5 Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and 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 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 Shielding gases used for arc welding can displace air and cause injury or death Always use enough vent
176. k up Perform the Tach Board Feedback Test If the Tach Board Feedback is OK the control board may be faulty Replace Check the voltage sensing leads for continuity zero ohms 21 should have continuity to the work piece and 67 should have continuity to the wire feed head assembly See wiring diagram Perform the Voltmeter Accurac Perform the Meter Circuit Accuracy Test 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 LINCOLN 8 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Ojo o F F S9 91 5 ois gje 5 oO tc QC Return to Section TOC Return to Master TOC F 27 TROUBLESHOOTING amp REPAIR F 27 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENTS S COURSE OF ACTION The actual volts reading does NOT match the set volts reading within a few tenths of a volt One reading may be erratic The 5 does not shut off FUNCTION PROBLEMS NA 5 units with a G1556 2 or higher voltage board do not con trol the actual strike voltage to match the set strike voltage
177. l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place Mar 93 RETURN TO MAIN INDEX MASTER TABLE OF CONTENTS FOR ALL SECTIONS Page ea Oe et eee ean ee eek we a i iv I stallati MP UT PP Section A Technical Specifications A 2 Mechanical Installation A 4 Electrical Installation A 6 Electrode Polarity 2 RR Eb Rer aa a sau baad A 8 Power Source Connection Diagrams 8 Operating Instructions Section B Safety Precautions B 2 Operator s Instructions B 2 Controls and Their Functions B 3 Setup Instructions B 4 Starting and Stopping Sequences B 5 Setting Travel Starting and Stopping B 6 Voltage Control Response B 9 Automatic Shutdown B 10 Cold Start Circuitry B 11 Security of Weld Procedure
178. ld 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 Return to Section TOC Return to Master TOC O10 e S9 o cic Sis a Return to Section TOC Return to Master TOC NA 5 LINCOLN 5 Return to Section TOC Return to Section TOC Return to Master TOC O10 e S9 o o cic 5 5 ply a Return to Section TOC Return to Master TOC Return to Master TOC F 77 TROUBLESHOOTING amp REPAIR TACH PC BOARD REMOVAL AND REPLACEMENT A 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 techn
179. lectrode up and out of the way Remove the work and reload the fixture NOTE When the contact tip in the end of the nozzle wears during repetitive welding it must be replaced Check the contact tip for wear if weld quality seems to be deteriorating Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC ojo F F x Geg min o ols 0 12 22 cic 5 o a Return to Section TOC Return to Master TOC CONTROLS AND THEIR FUNCTIONS 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 1 CIRCUIT BREAKER Protects the circuit from severe wire feed motor overloads and short circuits Press to reset 2 CONTROL POWER Turns input control power On and Off Also used as an emergency Off in case of malfunction 3 ELECTRODE HOT LIGHT Comes on when the Start button is pressed and the electrode circuit becomes electrically hot FIGURE B 1 NA 5 CONTROLS QOO O 9 LINCOLN amp eN Sd 9 9 NA 5 LINCOLN 4 B 3 OPERATING INSTRUCTIONS B 3 INCH UP AND INCH DOWN Press to inch electrode up or down MODE SELECTOR SWITCH AND LIGHTS Used to preset the voltage and wire feed speed for
180. lty The voltage board may be faulty The wire will NOT inch up but does With the unit at idle no buttons Check the inch up switch button inch down and weld properly pressed observe lights 1D on for proper operation Also check the power board and light 7E on associated leads for loose or the logic board 1D should be faulty connections See wiring ON 7E should be OFF diagram I 4D is OFF replace the power board 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 switches buttons for proper oper board It should be ON ation and wiring See wiring dia gram If light 7E is ON while the inch down button is pressed the power board may be faulty Replace 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 LINCOLN 8 F 11 TROUBLESHOOTING amp REPAIR F 11 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENTS S COURSE OF ACTION WIRE FEEDING PROBLEMS Th
181. n 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 Return to Section TOC Return to Master TOC NA 5 LINCOLN 8 F 30 TROUBLESHOOTING amp REPAIR F 30 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENTS S COURSE OF ACTION FUNCTION PROBLEMS The circuit breaker trips after the Check to make sure there not 1 Perform the DC Power Supply wire has been feeding for a period off any mechanical restrictions in the time Welding is normal wire feeding path which could cause excessive loading on the 2 Perform the Wire Drive Motor wire drive motor Test Return to Section TOC Return to Master TOC The power board may be faulty The 1 8 amp fuse on the voltage Check to make sure the PC Remove the input power to the board repeatedly fails boards are NOT grounded to the NA 5 and replace the 1 8 amp case of the NA 5 This can hap fuse Locate and remove the 21 pen due to metallic dust build up and 67 leads from the TS1 ter minal strip A Make a resistance check from the following leads to the 5 case ground ing screw Lead 510A 510P 500 515 and 525 Return to Section TOC Return to Master TOC The resistances should be above 1000 ohms
182. nstructions are contained in the IM305 manual and can be ordered as Sec T2 5 8 K239 TWINARC KIT FOR INNERSHIELD ELECTRODES This kit provides for welding with two Innershield electrodes Two 3 32 in 2 38 mm flux cored electrodes are fed through a single wire feeder Both wires must be the same size The K239 kit includes the nozzle equipped for water cooling drive rolls drive roll locating collar idle roll assembly ingoing and outgoing guide tubes wire straightener wire reel and wire reel mounting shaft and insulation Instructions are included in the kit are contained in the IM305 manual and can also be ordered as Sec T2 5 3 K239 278 SPREADARC 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 NA 5 LINCOLN 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 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 o
183. o 2 E 3 tc Return to Section TOC Return to Master TOC o gt E F 18 TROUBLESHOOTING amp REPAIR F 18 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENTS S COURSE OF ACTION The burnback timer does not time out properly 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 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 Test if the other timers start MODE FUNCTION PROBLEMS 1 Check the lead harness between the burnback module and the pro cedure board for loose or faulty connections weld crater function properly If they time out correctly the burn back module may be faulty Replace If the other timers start weld crater do NOT function correctly the procedure board may be faulty The procedure board may be faulty Replace If the option boards start and crater are not installed make sure the jumper plugs are installed in the procedure board If the strike light is also lit along with the weld light the logic board may be faulty The procedure board may be faulty Replace CAUTION
184. o Master TOC 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 O to 90 VDC Isolated DC voltage supply 0 to 120 VDC Volt Ohmeter O10 e S9 o 22 cic 5 5 ply a Return to Section TOC Return to Master TOC NA 5 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Q e 49 2 Return to Section TOC Return to Master TOC o 2 E 5 TROUBLESHOOTING amp REPAIR F 49 WIRE FEED DRIVE MOTOR TEST Continued TEST PROCEDURE 1 Remove the wire feed motor connec tor from the NA 5 control box 2 Using the ohmmeter measure the resistances per the table below Also see Figure F 5 3 If the motor resistance test is good proceed to the Motor Applied Voltage Test FIGURE F 5 WIRE FEED DRIVE MOTOR CONNECTOR PINS MOTOR CONNECTOR 67 MOTOR APPLIED VOLTAGE TEST 1 Carefully connect the isolated 120 VDC supply SUPPLY TURNED OFF to pins C and D on the motor connector 2 Carefully connect the variable 0 to 90 VDC supply SUPPLY TURNED OFF to pins A and B on the motor connector See Table 1 3 Apply fi
185. o Master TOC ojo F i Geg 0 12 2 2 cic s x Return to Section TOC Return to Master TOC Return to Master TOC OPERATING INSTRUCTIONS SETUP INSTRUCTIONS Use the following steps to set up the NA 5 welding system prior to welding 1 2 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 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 Set the power source and NA 5 circuit polarity per information on Electrode Polarity in Section Installation Depending on the procedures and applications decide a The means of arc striking and whether to start the travel with the Start button or the arc b Whether the initial bead size or penetration requires use of the optional Start Controls See the Starting and Stopping Sequences section Depending upon the procedures and applications a Select the arc and travel sto
186. oblem is NOT remedied the power source may be at fault If the problem is solved the NA 5 may be at fault If the start response jumper on the voltage board is in the 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 voltage settings Replace sequence Once the arc is estab lished the welding is OK 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 LINCOLN 8 F 32 TROUBLESHOOTING amp REPAIR F 32 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENTS S COURSE OF ACTION WELDING PROBLEMS The arc is unstable or oscillating 1 Check the welding cables for 1 The NA 5 voltage board may be loose o
187. ocedure board may be faulty Replace The procedure board may be faulty Replace Make sure the start option board is installed correctly The procedure board may be faulty Replace If no other mode lights are lit the start option board may be faulty Replace If the strike light is also lit along with the start light the logic board may be faulty If the weld and or crater lights are also lit along with the start light the procedure board may be faulty Check the lead harness between the start option board and the procedure board for loose or faulty connections See wiring diagram Check the lead harness between the start option board and the procedure board for loose or faulty connections 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 LINCOLN 8 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O o F F 5 5 o 919 ois 2 2 oO tc QC Return to Section TOC Return to Master TOC F 15 TROUBLESHOOTING amp REPAIR F 15 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENTS S COURSE
188. ode cable is on your right Do not put your hands near the engine fan Do not attempt to side the work cable should also be on your right side override the governor or idler by pushing on the throttle con trol rods while the engine is running 2 d 4 Connect the work cable to the workpiece as close as possible to the area being welded To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance 2 d 5 Do not work next to welding power source work disconnect the spark plug wires distributor cap or magneto wire as appropriate LINCOLN P Return to Master TOC Return to Master TOC o 8 7 c E Return to Master TOC SAFETY ii ELECTRIC SHOCK can kill 3 a The electrode and work or ground circuits are electrically hot when the welder is on Do not touch these hot parts with your bare skin or wet clothing Wear dry hole free gloves to insulate hands 3 b Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground In addition to the normal safety precautions if welding must be performed under electrically hazardous conditions in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying if th
189. odule is suitable for dry circuit applications and it is rated at 2 Amps 115 VAC or 28 VDC This relay has both normally open and normally closed contacts The S22182 relay module is suitable for applications requiring at least 10 mA current and it is rated at 3 Amps 115 VAC or 28 VDC This relay only has normally open contacts SPEED FEED DRUM These drums must be set on a turntable which permits them to freely turn in a clockwise direction Installation operating and maintenance instructions are contained in the IM305 manual and can be ordered as Sec 2 5 7 SPEED FEED REEL These reels require dereeling equipment that permits the reel to rotate freely as the electrode is used Installation operating and maintenance instructions are contained in the IM305 manual and can be ordered as Sec T2 5 7 B C 6 o Lu o E lt 3 DOL DOL DOL Je1Se N 0 DOL 0 uunjeH DOL uonoes oj DOL uonoes DOL uonoes DOL uonoes Return to Master TOC o 7 E 5 2 Return to Master TOC Return to Master TOC Section D TABLE OF CONTENTS MAINTENANCE SECTION Maintenance Section D Control 2522 25 LEER Ee AERE Re RETE D 2 General diea cia wie heel ex d as
190. ody 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 Reusable f Container If you don t have a wrist Do Not Destroy 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 Tools which come in contact with the P C Board must be either conductive anti static or static dissipative NA 5 LINCOLN 5 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 f the P C Board uses protective shorting jumpers don t remove them until installation is complete 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 NOTE It is desirable to have a spare known good PC board available for PC board trou bleshooting NOT
191. olid Wire 0 052 1 3 3 32 3 0 5 32 4 5 32 4 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 9 o o 3 tc Return to Section TOC Return to Master TOC Q 42 E D 5 MAINTENANCE D 5 3 Pull the gear from the shaft using the screws as a pulling device 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 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 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 7 Reassemble the motor on the gear box make sure the gears mesh properly
192. onds Start the weld sequence and then stop Check the lead harness between the weld timer and the procedure board for loose or faulty connec tions Check the lead harness between the weld timer and the procedure board for loose or faulty connec it with the stop button Check to tions see if the unit returns to the nor mal idle state Strike light ON and Hot Electrode light OFF If the weld mode ends the unit returns to the nor mal idle state the weld 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 LINCOLN 8 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o O e 9 o E 2 Return to Section Return to Master TOC o E 20 TROUBLESHOOTING amp REPAIR F 20 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENTS S COURSE OF ACTION The start button does not initiate the 1 power source output or the wire feed The mode selec
193. other reproductive harm cancer birth defects or other reproductive harm The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you pur chase a copy of Safety in Welding amp Cutting ANSI Standard Z49 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is available from the Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS FOR ENGINE x ag 1 h bros scalding do powered equipment 8 pressure cap when the engine is 1 a Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running X 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors ELECTRIC AND MAGNETIC FIELDS 1 c Do not add the fuel near an open flame weld S may be dangerous ing arc or when the engine is running Stop the engine and allow it to cool before refuel 2 a Electric cu
194. pping 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 LINCOLN 5 10 B 4 Set the head position relative to the work as required for the fixture application and procedures See IM305 Sec 3 2 3 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 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 The mount for standard 50 and 60 Ib 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 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 Straighten the first 6 in 152 4 mm of electrode and push it through the wire straightener to the drive roll
195. pply a thin coat of grease to all sliding surfaces Every year replace the grease in the gear cavity with a medium grease HIGH FREQUENCY GENERATOR Inspect the spark gaps monthly and maintain the setting specified on the spark gap cover plate SPREADARC Refer to the maintenance information provided in IM305 Sec T2 5 6 Return to Master TOC Return to Master TOC O O o 9 E Return to Master E 1 THEORY OF OPERATION TABLE OF CONTENTS THEORY OF OPERATION SECTION T Section E General Description nenne E 2 Input POWer eU TL cL E 2 Power and Voltage Boards senes E 3 Control Logic and Procedure E 4 Optional start Crater Fill and Weld Timer E 5 SCR Operations ET E 6 NA 5 LINCOLN 5 E 1 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O o F F ci o 9 gt 22 a Return to Section TOC Return to Master TOC THEORY OF OPERATION E 2 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 pro
196. r 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 gt lt rvuco oo FIELD DIRECTION ope SENSING 7 VOLTAGE INCH UP SWITCH 1 2 F501 SET VOLTAGE TRAVEL RECEPTACLE FLUX C RECEPTACLE OPTIONAL START BOARD START TIMER CRATER TIMER OPTIONAL TIMER OPTIONAL CRATER BOARD BURNBACK TIMER SET SPEED gt mro gt zm ommm Or zOo 0md o 10VDC REFERENCEVOLTAGE TACH FEEDBACK MOTOR RPM CONTROL BOARD board to proceed from the strike settings to the optional start board if used or to the welding wire speed and arc voltage parameters 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
197. r faulty connections faulty Replace Return to Section TOC Return to Master TOC Make sure the electrode and gas if used is correct for the process being used 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 Return to Section TOC Return to Master TOC olo o EE 912 min 8 0 12 HE ply tc QC 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 Return to Section TOC Return to Master TOC NA 5 LINCOLN 8 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o O e 9 o E 2 Return to Section Return to Master TOC o E F 33 TROUBLESHOOTING amp REPAIR F 33 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENTS S COURSE OF ACTION The flux or gas water solenoid does not function open The flux
198. r source range 2 Power source voltage control not set for Remote 3 Misconnection of NA 5 control cable leads to the power source 4 Incorrect weld polarity connections or settings at NA 5 or power source 5 Lost connection of NA 5 voltage sensing leads 67 and 21 between arc and voltage control or a blown 1 8 amp fuse on voltage PC boards built since 1983 With NA 5 units above Code 8300 the conditions of causes 4 and 5 above would result in the wrong wire feed direction when the weld is started See the section on Cold Start Circuitry In the case of full range control power sources such as the DC 600 this protective shutdown circuit could prevent welding under the conditions of causes 3 4 and 5 above by holding the power output at minimum possibly providing too low of a power source output to even establish an arc or causing the field fuse to blow because of rapid field reversals with NA 5 controls above Code 8300 See the section on Cold Start Circuitry Although out of range shutdown can occur with all power sources when working with very low or very high arc voltages it is most NA 5 LINCOLN 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 th
199. rc voltage as read on the NA 5 voltmeter does not exceed typically about 6 5 volts Usual causes for the situation are 1 No wire loaded through the NA 5 head and nozzle assembly except when using the K148 Contact Nozzle 2 No power source weld cable connection to the NA 5 head or work 3 Incorrect electrode polarity connections at the NA 5 or power source 4 Little or no output voltage from the power source 5 An open voltage sensing lead 67 or 21 to the NA 5 control box or a blown 1 8 amp fuse on a voltage PC board built since 1983 Return to Section TOC Return to Section TOC Return to Master TOC ojo E e min o ols 0 12 9 2 cic 5 o a Return to Section TOC Return to Master TOC Return to Master TOC OPERATING INSTRUCTIONS B 12 SECURITY OF WELD PROCEDURE SETTINGS There are two means provided to prevent or limit unauthorized readjustment of the NA 5 voltage and wire feed speed controls once set to the desired procedure 1 The security panel of the NA 5 can be locked to prevent access to the control knobs The control range of the procedure control knobs can be limited to either about 396 or about 1596 of the full range control by installing a knob rotation stop screw to any or all of the control knobs This stop screw is installed in the following manner a Turn off the input power to the NA 5 b Loosen each knob set screw and remove
200. rdered as Sec T2 5 5 K285 CONCENTRIC FLUX CONE The concentric flux cone was designed to fit on the K148 Contact Nozzle alone the K148 Contact Nozzle with a K149 Linc Fill Long Stickout Extension the 129 Submerged Arc Small Wire Twinarc and the K391 nozzles The maximum electrical stickout when using the K149 Linc Fill Long Stickout Extension will be 4 101 6 Use of this attachment results in the flux being fed concentrically around the electrodes Installation operating and maintenance instructions are shipped with each kit are contained in the IM305 manual and can be ordered as Sec T2 2 8 K285 K310 FLUX SCREEN Useful for any submerged arc equipment It removes foreign magnetic particles from reused submerged arc welding flux Operating instructions are included in the kit K325 TC 3 TRAVEL CARRIAGE The K325 Travel Carriage carries the control box and wire drive head in either direction on a beam of suitable length and mechanical specifications Two models are available Standard and High Capacity Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 9 o 3 tc Return to Section TOC Return to Master TOC Q 42 E ACCESSORIES 5 K334 START CRATER CONTROLS Easily installed procedure and timer boards to permit adjustment of wire speed an
201. 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 For consistent arc striking with Standstill travel starting always clip the end of the electrode to a sharp point before starting STOPPING SEQUENCES As shipped the travel stops when the Stop button is pressed producing a small crater area 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 RECONFIGURING THE TRAVEL SEQUENCES WARNING ELECTRIC SHOCK o can kill Turn off input power to the welding power source using the disconnect Switch before working on this equipment 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 rx shows information on reconfiguring the travel sequences B 7 OPERATING INSTRUCTIONS B 7 TABLE B 1 TRAVEL SEQUENCE LEAD AND SWITCH POSITIONS Travel Starts Travel Stops Older Models Newer Models With Start With Stop Lead 691 to Pin 6 Button Button Lead 692 to Pin 5 a Return to Master
202. rive motor O10 e S9 o 22 cic Sis a Return to Section TOC Return to Master TOC NA 5 LINCOLN 5 rel TROUBLESHOOTING amp REPAIR Fal 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 Return to Section TOC Return to Master TOC 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 Return to Section TOC Return to Master TOC 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 O10 e S9 o cic 5 5 ply a Return to Section TOC Return to Master TOC NA 5 LINCOLN 5
203. rn to Master TOC O o F F 5 5 els ois gje 5 oO tc QC Return to Section TOC Return to Master TOC F 26 TROUBLESHOOTING amp REPAIR F 26 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENTS S COURSE OF ACTION The set speed is adjustable and steady The actual speed reading is incorrect and or erratic The set volts and actual volts read ings match within a few tenths of a volt while welding However both readings are inaccurate FUNCTION PROBLEMS Check that the jumper plug is installed securely in the harness receptacle near the voltage board Codes below 8300 only Check for loose or faulty connec tions on leads 510A 525A and 555 between the tach receptacle and the control board Check the tach cable from the tach board to the tach receptacle The shield in the cable should NOT be grounded to the case Put the Lincoln power source in 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 The control cable may be faulty Check or replace 2 3 Remove the drive motor end cap 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 pic
204. rrent flowing through any conductor causes ing to prevent spilled fuel from vaporizing on localized Electric and Magnetic Fields EMF Welding contact with hot engine parts and igniting Do current creates EMF fields around welding cables and not spill fuel when filling tank If fuel is spilled welding machines wipe it up and do not start engine until fumes have been eliminated EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician Keep all equipment safety guards covers and before welding devices in position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing equip ment Exposure to EMF fields in welding may have other health effects which are now not known All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit 1 6 In some cases it may be necessary to remove safety 2 d 1 Route the electrode and Work cables together Secure guards to perform required maintenance Remove them with tape when possible guards only when necessary and replace them when the maintenance requiring their removal is complete 2 d 2 Never coil the electrode lead around your body Always use the greatest care when working near moving parts 2 d 3 Do not place your body between the electrode and work cables If the electr
205. s 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 Return to Section TOC Return to Section TOC Return to Master TOC ojo Ojo F i Gg 9 s 0 12 2 2 cic 5 5 o o x a Return to Section TOC Return to Master TOC Return to Master TOC OPERATING INSTRUCTIONS 11 Set the travel speed as specified by 12 13 14 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 Connect the work lead to the work or a suitable piece of scrap Clip the end of the electrode to a sharp point Preset the Start if used Weld and Crater if used controls to the wire speed and voltage specified in the procedure
206. s 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 LINCOLN 8 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o O e 9 o E 2 Return to Section Return to Master TOC o E F 5 TROUBLESHOOTING amp REPAIR F 5 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENTS S COURSE OF ACTION The wire does not feed Pressing any of the switches buttons will NOT feed the wire The motor does NOT run WIRE FEEDING PROBLEMS Make sure input power switch is ON Check the circuit breaker CB1 Reset if tripped Make sure 115VAC is being applied to the control box through the control cable receptacle Leads 31 and 32 Check the two fuses on the power board Replace if blown If fuse F101 immediately fails when replaced contact your local Lincoln Authorized Field Service 4 Facility Make sure the motor cable is con nected to the motor receptacle on the NA 5 control
207. side 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 LINCOLN 8 F 7 TROUBLESHOOTING amp REPAIR F 7 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENTS S 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 CV400 power source is used a from the NA 5 polarity terminal does inch up OK and feeds down Diode Kit must be installed in the strip 751 See wiring diagram when the start button is pressed power source With the inch down button pressed read the ACTUAL volts Check to see if light 7J on the on the NA 5 digital voltmeter logic board is ON while the inch The digital meter should read down button is pressed If it does over 19 volts and the wire should NOT light check the inch down inch down button and associated leads See wiring diagram i For codes below 8300 If board may be faulty Replace light 7J DOES light when the inch down button is If the voltage is over 19 volts pressed the logic board and the wire DOES inch down may be faulty with the 21 lead d
208. 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 O10 e 5 8 o o cic Sis a Return to Section TOC Return to Master TOC NA 5 LINCOLN 5 dius TROUBLESHOOTING amp REPAIR dis 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 Return to Section TOC Return to Master TOC 100 2070 2 54 52 58 38 778 97 19 76 22 456 56 11 58 15 300 38 7 62 515 eee Must operate PC Board LED Definitions table in 5 E Troubleshooting Section gt 0919 Flux or Water Solenoid Must operate when Start switch is pressed E Relay Must operate and close power source contactor a Relay 22 Must operate and activate external travel circuit if used Voltmeter ses RE RR Refer to Voltmeter Accuracy Test Wire Speed Meter Refer to Wire Speed Accuracy Test Voltage control and shutdown Refer to Out of Voltage Range
209. ssembly 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 Close and secure the control box access door TABLE F 2 EXTERNAL VOLTAGE SENSING LEADS TEST POINTS TEST POINTS EXPECTED COMMENTS AND RESISTANCES CONDITIONS Lead 667 to 1 ohm Electrode wire Zero or less than Electrode wire must be in contact assembly tip Lead 621 to work piece 1 ohm Zero or less than Polarity switches must be in the correct positions Lead 667 to 621 ohms NA 5 LINCOLN 5 Greater than 15K Using the 3 4 wrench disconnect the welding cable s from the contact assembly F 51 Return to Section TOC Return to Section TOC Return to Master TOC O10 e S9 o 22 cic 5 5 ply a Return to Section TOC Return to Master TOC Return to Master TOC F 52 TROUBLESHOOTING amp REPAIR OUT OF VOLTAGE RANGE SHUT DOWN TEST A 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 tes
210. stance before you proceed Call 216 383 2531 or 800 833 9353 WELD Return to Section TOC Return to Master TOC 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 O10 e S9 o cic 5 5 ply a Return to Section TOC Return to Master TOC NA 5 LINCOLN 5 I TROUBLESHOOTING amp REPAIR ds board DIGITAL METER AND METER PC BOARD REMOVAL AND REPLACEMENT FE 8 METER PC BOARD REMOVAL 2 gt PROCEDURE els 1 Remove input power to the NA 5 5 Carefully remove the meter PC 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 3 Locate and unplug the meter PC back of the PC board plugs into the board that is to be removed See prongs on the meter when you Figure F 11 reassemble 4 Using the 5 16 nutdriver remove the four PC board mounting nuts See o Figure F 11 S8 lo 3 0 2 2 2 gi METER BOARD SPEED METER BOARD 915 E ol 5 x 2m ele aa
211. t 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 LINCOLN 5 F 52 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Q e 2 5 2 Return to Section TOC Return to Master TOC o 2 E 5 F 53 TROUBLESHOOTING amp REPAIR F 53 OUT OF VOLTAGE RANGE SHUT DOWN TEST Continued TEST PROCEDURE 1 Remove input power to the NA 5 4 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 Connect to a Lincoln Electric CV power source per connection dia gram See the Installation section of this manual JUMPER TOGETHER 2 BYPASS AUTO i 8H 1 8 AMP FUSE
212. t 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 Available options for applications with particularly difficult starting 1 K238 High Frequency Generator See IM305 Sec T2 5 8 SETTING TRAVEL STARTING AND STOPPING Standard machines can be connected for a variety of starting and stopping sequences STARTING SEQUENCES On the Fly Travel Starting When shipped all models are connected for On the Fly travel starting The starting sequence is as follows 1 With the electrode NOT touching the work press the Start button This starts both the wire feed and travel motors 2 When the electrically 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 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 LINCOLN 3 Any application for improved arc striking Standstill Travel Starting All models can be
213. tand 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 LINCOLN 5 F 50 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Q e 9 2 Return to Section TOC Return to Master TOC o 2 E 5 F 51 TROUBLESHOOTING amp 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 2 Disconnect input power to the NA 5 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 5 Locate the TS1 terminal strip See wiring diagram Using the ohmmeter check the resis tances per the following table F 2 Reconnect the welding cable leads to the contact a
214. ter TOC Return to Section TOC Return to Master TOC 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 OO e S9 o 22 cic Sis a PC BOARD FIGURE F 15 ROTATING DISC NUT AND TACH BOARD Return to Section TOC Return to Master TOC NA 5 LINCOLN 5 nan TROUBLESHOOTING amp REPAIR din 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 Return to Section TOC Return to Master TOC 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 Return to Section TOC Return to Master TOC 4 Replace the connection box cover 5 Replace the pick up assembly cover 6 Reattach the tach cover to the wire feed d
215. 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 Return to Section TOC Return to Master TOC 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 Ojo O10 e S9 o cic Sis a Return to Section TOC Return to Master TOC NA 5 LINCOLN 5 me TROUBLESHOOTING amp REPAIR DIGITAL METER AND METER PC BOARD REMOVAL AND REPLACEMENT A 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 Return to Section TOC Return to Master TOC 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 assi
216. the various modes of operation Strike Start Weld and Crater 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 7 START Begins welding cycle 10 11 STOP Initiates the stopping cycle at the end of the weld TRAVEL Turn to Off for no travel Hand Travel for travel without welding and Automatic Welding for welding operations VOLTS METER Displays the set or actual voltage for each mode Strike Start Weld Crater WIRE SPEED METER Displays the set or actual wire speed for each mode Strike Start Weld Crater CONTROLS UNDER THE LOCKABLE SECURITY COVER 12 13 14 15 16 17 ARC STRIKING CONTROLS Sets the wire speed until the welding current begins to flow and controls the power source voltage during arc striking BURNBACK AND ELECTRODE BACKUP TIME Controls the length of burnback delay time after the stop circuit is energized WELD CONTROLS Controls the voltage and wire speed during the welding mode CRATER CONTROLS OPTIONAL Sets the ending current and voltage for an adjustable period of time START CONTROLS OPTIONAL Sets the starting current and voltage for an adjustable period of time WELD TIME OPTIONAL Controls the time of the weld mode Return to Section TOC Return to Section TOC Return t
217. tion TOC Return to Master TOC O10 e S9 o 22 cic 5 5 ply a Return to Section TOC Return to Master TOC TUE TROUBLESHOOTING amp REPAIR did PC BOARD LED LIGHT SEQUENCE TABLE ABOVE CODE 8300 INDICATOR LIGHTS CONDITIONS FOR LIGHT ON Light Location Idle Inch Up Inch Down Start Stop Burnback Weld Arc No PC Board Mode Switch Switch Switch Switch Mode Establish Pressed Pressed Pressed Pressed 1A ON ON ON ON ON ON ON ON only while switch is pressed ON dependent on travel mode NA 5 LINCOLN 5 Return to Section TOC Return to Section TOC Return to Master TOC O10 e S9 o 22 cic 5 5 ply a Return to Section TOC Return to Master TOC Return to Master TOC F 38 TROUBLESHOOTING amp REPAIR DC POWER SUPPLY TEST A 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 servic
218. to Section TOC Return to Master TOC o O e 9 o E 2 Return to Section Return to Master TOC o E button is pressed The wire will not inch down but does 1 inch up properly When the start button is pressed the wire feeds up instead of down not check the inch down switch and associated leads See wiring diagram 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 For codes below 8300 make sure the jumper plug is securely installed in the harness receptacle near the voltage board 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 Check the 1 8 amp fuse on the voltage board Replace if faulty The power board may be faulty Replace Jumper the AUTO tabs on the voltage board Above code 8300 Press the inch down but ton If the wire inches down the voltage board may be faulty Replace If the wire does NOT inch down 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 pro
219. to the 52 termi nal strip Close and secure the access door F 44 Return to Section TOC Return to Section TOC Return to Master TOC O10 e S9 o 22 cic 5 5 ply a Return to Section TOC Return to Master TOC Return to Master TOC F 45 TROUBLESHOOTING amp REPAIR VOLTAGE BOARD TRANSFORMER TEST A 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 LINCOLN 5 F 45 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O10 e
220. tor switch is in the strike position and the mode strike light is lit The start button initiates the power source output but the wire does not feed FUNCTION PROBLEMS If the crater and or start option boards are NOT used the jumper plugs must be installed in the pro cedure board receptacles 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 If the wire inches up properly but 1 does not feed when the start but ton is pressed the logic board may be faulty 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 The power board may be faulty 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 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 Check the lead harness between the logic board and the procedure board for loose or faulty connec tions See wiring diagram If the wire does not fe
221. turn to Master TOC Q e 9 2 5 Return to Section TOC Return to Master TOC o 2 E 5 F 56 TROUBLESHOOTING amp REPAIR TACH BOARD FEEDBACK TEST Continued PROCEDURE Remove input power to the NA 5 Using the 5 16 nutdriver open the control box PC board access door Locate leads 510A 525A and 555 on the control board Apply 115VAC to the NA 5 wire feeder at the correct pins See wiring diagram 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 With the motor running activate either inch switches or the start switch and check leads 555 to 510A for the presence of NA 5 LINCOLN 5 between 4 5 10 5VDC The motor 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 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 After the completion of the tests remove the 115VAC power and close and secure the access door TE TROUBLESHOOTING amp REPAIR did VO
222. ty Check or replace Return to Section TOC Return to Master TOC olo o EE 912 min 8 0 12 HE ply tc QC 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 Return to Section TOC Return to Master TOC NA 5 LINCOLN 8 diss TROUBLESHOOTING amp REPAIR rom PC BOARD LED LIGHT DEFINITIONS LED Number Functions Indicated By PC Board LEDS 15VDC Analog Supply Present 10VDC Analog Supply Present Down Field Voltage Applied Up Field Voltage Applied Armature Voltage Applied 115VDC Relay Supply Present E 9 o o x 2 tc Return to Master TOC 15VDC Logic Supply Present Start Switch Pressed Stop Switch Pressed Welding Current Present Signal to Apply Down Field Voltage ojo Signal to Operate Flux or Water Solenoid e Signal to Operate Travel Circuit Sls Inch Down Switch Pressed T E Signal to Operate Power Source Output Contactor 83 gt 8 2 EIE 3a 2 LED LIGHT LOCATIONS LED LIGHT LOCATIONS ojo elg 5 8 milo o 8 2 22 dc ojo zs 5 8 milo 910 2 8 9 22 2 5 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Sec
223. w and turn the bushing over 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 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 9 o 3 tc Return to Section TOC Return to Master TOC Q 42 E D 6 MAINTENANCE D 6 OPTIONAL FEATURES CONTACT ASSEMBLIES 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 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 2 Add a few drops of machine oil to e

Lincoln Electric NA-5N User's Manual

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