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Lincoln Electric NA-3S Service Manual Download Page 64

THEORY OF OPERATION

E-5

E-5

NA-3 AND NA-4

OPTIONAL START AND
CRATER FILL BOARDS

When installed, the optional start board as
shown in Figure E.4 dictates to the logic
board the starting weld current and arc
voltage. 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 welding 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 (4CR) is closed.

The crater fill board, as shown in Figure E.4,
is used by the operator to adjust the finishing
and voltage either higher or lower than that
of the welding procedure for an adjustable
period of time. This circuit becomes active
when the “Stop” switch is pressed. The
crater fill board then dictates to the logic
board the appropriate signals. This feature
is helpful in controlling bead shape and filling
craters at the end of a weld.

FIGURE E.4 – OPTIONAL START AND CRATER FILL BOARDS.

TRAVEL

RECEPTACLE

TRAVEL
SWITCH

INCH UP
SWITCH

CONTROL

BOARD

LOGIC

BOARD

LOGIC CONTROL

SIGNALS

24 VDC

ARC VOLTAGE

SENSING SIGNALS

OPTIONAL

START

BOARD

OPTIONAL

CRATER

FILL

BOARD

1 CR

2 CR

3 CR

WIRE FEED

SPEED CONTROL

POWER SOURCE

OUTPUT CONTROL

START

SWITCH

STOP

SWITCH

INCH

DOWN

SWITCH

115 VAC

115 VAC

R1

115 VAC

115 VAC

115 VAC

VARIABLE

VOLTAGE

BOARD

ARC
VOLTAGE
METER

VOLTAGE

SENSING

LEADS

ELECTRODE

WORK

115 VAC

115 VAC

115 VAC

115 VAC

FROM

WELDING

POWER

SOURCE

WIRE

DRIVE

MOTOR

WELD CURRENT SENSING

REED SWITCH 4CR

2CR TRAVEL

RELAY CONTACTS

CIRCUIT

BREAKER

Summary of Contents for NA-3S

Page 1: ...rs SVM 121 A June 1997 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 a...

Page 2: ...VIDUALS ARC RAYS can burn 2 a Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding Headshield and filter lens should conform to ANSI Z87 I standards 2 b Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays 2 c Protect other ...

Page 3: ...m 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 4 b Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in...

Page 4: ...haust fumes outdoors ____________________________________________________ 7 c Do not add the fuel near an open flame welding arc or when the engine is run ning Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting Do not spill fuel when filling tank If fuel is spilled wipe it up and do not start engine until fume...

Page 5: ...appropriés et non inflammables 4 Des gouttes de laitier en fusion sont émises de l arc de soudage Se protéger avec des vêtements de protection libres de l huile tels que les gants en cuir chemise épaisse pan talons sans revers et chaussures montantes 5 Toujours porter des lunettes de sécurité dans la zone de soudage Utiliser des lunettes avec écrans lateraux dans les zones où l on pique le laitier...

Page 6: ...NOTES v v NA 3 AND NA 4 ...

Page 7: ...Starting and Stopping Sequences B 14 Accessories Section C General C 2 Listing of Accessories C 3 Maintenance Section D Control Box D 2 Welding Head D 3 Optional Features D 6 Theory of Operation Section E General Description E 2 Input Power Circuits E 2 Control and Logic Boards E 3 Variable Voltage Board E 4 Optional Start and Crater Fill Boards E 5 SCR Operation E 6 Troubleshooting and Repair Sec...

Page 8: ...n of NA 3 All to an SAN A 12 Figure A 10 Connection of NA 3 All to a SAM Motor Generator or Engine Driven Welder A 13 Figure A 11 Connection of NA 3 to R3S 400 600 or 800 with Line Voltage Compensator A 14 Figure A 12 Connection of NA 3 to R3S 400 600 or 800 with No Line Voltage Compensator A 15 Figure A 13 Connection of NA 3 to Idealarc DC 400 and to CV CVI Power Sources A 16 Figure A 14 Connecti...

Page 9: ...PEED RANGE MAX WIRE SIZE in mm GEAR RATIO in min m min CORED WIRE SOLID WIRE 57 1 40 650 12 198 0 120 3 0 3 32 2 4 95 1 25 400 7 5 122 5 32 4 0 1 8 3 2 142 1 17 268 5 2 82 7 32 5 6 PHYSICAL DIMENSIONS LENGTH WIDTH HEIGHT WEIGHT MODEL in mm in mm in mm lbs kg NA 3 Control Box 12 31 313 13 46 342 11 04 280 44 20 NA 4 Control Box 9 70 246 13 46 342 11 04 280 35 16 A 2 INSTALLATION A 2 NA 3 AND NA 4 T...

Page 10: ...ROL AND WIRE DRIVE SYSTEM CONTROL BOX HEAD MOUNTING PARTS WITH INSULATION AND HARDWARE CROSS SEAM ADJUSTER WELDING HEAD CONTACT ASSEMBLY OPTIONAL 4 FT 1 2 M CABLE DRIVE MOTOR TO CONTROL BOX 4 FT 1 2 M ELECTRODE CABLES TWO 4 0 CONTACT ASSEMBLY TO CONTROL BOX ...

Page 11: ... 278 Sec L 2 2 4 2 Install a hex head screw up through the bottom of the adapter plate and the front left mounting hole in the control box 3 Secure the control box to the adapter plate with a flat washer lock washer and hex nut 4 Place the control box adapter plate assembly onto the carriage and secure it in place with a hex head screw through the back right mounting hole of the control box 5 Secu...

Page 12: ...ctrode are electrically hot when welding They must be insulated from ground Standard head mounting hardware and insulation are shipped with the NA 3 and NA 4 welding heads 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 ...

Page 13: ... comply with the applicable U L standard for safety All welding heads include a 4 ft 1 2 m motor cable and when applicable a 4 ft 1 2 m flux hopper cable Insert the plug on this cable into the matching receptacle on the side of the control box If the 4 ft 1 2 m cable is not sufficient install the separate extension cable assembly at the length ordered up to 75 ft 22 8 m The extension cable has plu...

Page 14: ...structions in the power source operating manual 3 Connect the input cable to the power source exactly as specified on the connection diagram in this section Include all jumpers on the terminal strips as shown in the diagrams NOTE Paralleling two power sources of the same model may be practical Request bulletin E1 30 from Lincoln Electric for instructions 4 Connect the work leads of sufficient size...

Page 15: ...e polarized connector of the control cable into the matching receptacle on the side of the control box NA 4 1 Present NA 4s with a potentiometer type current control K248 above code 7560 are designed for use with the AC 1200 power source They may be used with the discontinued AC 1000s or AC 750s but would require an external switch to control transformer output See the diagram in Figure A 15 2 Dis...

Page 16: ...ncy to a minimum disconnect lead 21 on the control cable from the power source terminal strip Extend lead 21 so it can be connected directly to the work piece Remove lead 67 from the NA 4 connection bar Extend and connect lead 67 directly to the electrode contact assembly on the head Use 16 AWG conductors and keep leads 21 and 67 as far as possible from electrode and work leads 115 volt AC power t...

Page 17: ...RGER INSULATED WIRE PHYSICALLY SUITABLE FOR THE INSTALLATION AN S16586 REMOTE VOLTAGE SENSING WORK LEAD IS AVAILABLE FOR THIS PURPOSE CONNECT IT DIRECTLY TO THE WORK PIECE KEEPING IT ELECTRICALLY SEPARATE FROM THE WELDING WORK LEAD CIRCUIT AND CONNECTION FOR CONVENIENCE THIS EXTENDED LEAD 21 SHOULD BE TAPED TO THE WELDING WORK LEAD THIS EXTENDED LEAD 21 CONNECTION REPLACES THE NEED TO EMPLOY THE R...

Page 18: ... CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS N C EXTEND LEAD 21 USING 14 AWG OR LARGER INSULATED WIRE PHYSICALLY SUITABLE FOR THE INSTALLATION AN S16586 REMOTE VOLTAGE SENSING WORK LEAD IS AVAILABLE FOR THIS PURPOSE CONNECT IT DIRECTLY TO THE WORK PIECE KEEPING IT ELECTRICALLY SEPARATE FROM THE WELDING WORK LEAD CIRCUIT AND CONNECTION FOR CONVENIENCE THIS EXTENDED LEAD 21 SHOULD BE...

Page 19: ...MINAL STRIP N A WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS N B EXTEND LEAD 21 USING 14 AWG OR LARGER INSULATED WIRE PHYSICALLY SUITABLE FOR THE INSTALLATION AN S16586 REMOTE VOLTAGE SENSING WORK LEAD IS AVAILABLE FOR THIS PURPOSE CONNECT IT DIRECTLY TO THE WORK PIECE KEEPING IT ELECTRICALLY SEPARATE FROM THE WELDING WORK LEAD CIRCU...

Page 20: ...RMINAL 1 WAS ALSO ON THE TERMINAL STRIP N A EXTEND LEAD 21 USING 14 AWG OR LARGER INSULATED WIRE PHYSICALLY SUITABLE FOR THE INSTALLATION AN S16586 REMOTE VOLTAGE SENSING WORK LEAD IS AVAILABLE FOR THIS PURPOSE CONNECT IT DIRECTLY TO THE WORK PIECE KEEPING IT ELECTRICALLY SEPARATE FROM THE WELDING WORK LEAD CIRCUIT AND CONNECTION FOR CONVENIENCE THIS EXTENDED LEAD 21 SHOULD BE TAPED TO THE WELDING...

Page 21: ... THE POWER SOURCE MUST BE PROPERLY GROUNDED N A ON EARLIER R3S 400 600 AND 800 MACHINES TERMINALS 67 AND 1 WERE ALSO ON THE TERMINAL STRIP N B WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS N C EXTEND LEAD 21 USING 14 AWG OR LARGER INSULATED WIRE PHYSICALLY SUITABLE FOR THE INSTALLATION AN S16586 REMOTE VOLTAGE SENSING WORK LEAD IS AVA...

Page 22: ...RLY GROUNDED N A ON EARLIER R3S 400 600 AND 800 MACHINES TERMINALS 67 AND 1 WERE ALSO ON THE TERMINAL STRIP N B WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS N C EXTEND LEAD 21 USING 14 AWG OR LARGER INSULATED WIRE PHYSICALLY SUITABLE FOR THE INSTALLATION AN S16586 REMOTE VOLTAGE SENSING WORK LEAD IS AVAILABLE FOR THIS PURPOSE CONNECT...

Page 23: ...AD CIRCUIT AND CONNECTION FOR CONVENIENCE THIS EXTENDED LEAD 21 SHOULD BE TAPED TO THE WELDING WORK LEAD IF THE LENGTH OF THE WORK LEAD CIRCUIT IS SHORT AND CONNECTIONS CAN BE EXPECTED TO BE RELIABLE THEN CONTROL CABLE LEAD 21 DOES NOT NEED TO BE EXTENDED AND CAN BE DIRECTLY CONNECTED TO TERMINAL 21 ON THE TERMINAL STRIP NOTE THAT THIS IS NOT THE PREFERRED CONNECTION BECAUSE IT ADDS ERRORS TO THE ...

Page 24: ...ERLY GROUNDED N A WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS N B EXTEND LEAD 21 USING 14 AWG OR LARGER INSULATED WIRE PHYSICALLY SUITABLE FOR THE INSTALLATION AN S16586 REMOTE VOLTAGE SENSING WORK LEAD IS AVAILABLE FOR THIS PURPOSE CONNECT IT DIRECTLY TO THE WORK PIECE KEEPING IT ELECTRICALLY SEPARATE FROM THE WELDING WORK LEAD CIR...

Page 25: ...URCE SHOULD BE 18GA OR LARGER N A WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS N B EXTEND LEAD 21 USING 14 AWG OR LARGER INSULATED WIRE PHYSICALLY SUITABLE FOR THE INSTALLATION AN S16586 REMOTE VOLTAGE SENSING WORK LEAD IS AVAILABLE FOR THIS PURPOSE CONNECT IT DIRECTLY TO THE WORK PIECE KEEPING IT ELECTRICALLY SEPARATE FROM THE WELDI...

Page 26: ...URCE INPUT POWER CONNECTIONS MUST BE PROPERLY CONNECTED TO ELECTRICAL GROUND PER THE POWER SOURCE OPERATING MANUAL N A WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS N B EXTEND LEAD 21 USING 14 AWG OR LARGER INSULATED WIRE PHYSICALLY SUITABLE FOR THE INSTALLATION AN S16586 REMOTE VOLTAGE SENSING WORK LEAD IS AVAILABLE FOR THIS PURPOSE ...

Page 27: ... CONTROL RESPECTIVELY N C WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS N D EXTEND LEAD 21 USING 14 AWG OR LARGER INSULATED WIRE PHYSICALLY SUITABLE FOR THE INSTALLATION AN S16586 REMOTE VOLTAGE SENSING WORK LEAD IS AVAILABLE FOR THIS PURPOSE CONNECT IT DIRECTLY TO THE WORK PIECE KEEPING IT ELECTRICALLY SEPARATE FROM THE WELDING WORK ...

Page 28: ...HE CONTROL CABLE GROUND LEAD TO THE FRAME TERMINAL MARKED NEAR THE POWER SOURCE TERMINAL STRIP OR TO AN UNPAINTED FRAME SCREW THE POWER SOURCE MUST BE PROPERLY GROUNDED N D FOR DC 600 CODES BELOW 8200 CONNECT A JUMPER FROM N TO S THERE IS NO NPS TERMINAL STRIP ON CODES ABOVE 8200 N E EXTEND LEAD 21 USING 14 AWG OR LARGER INSULATED WIRE PHYSICALLY SUITABLE FOR THE INSTALLATION AN S16586 REMOTE VOLT...

Page 29: ...L BE NO OUTPUT CONTROL OF THE POWER SOURCE AT THE NA 3 INTERNALLY POWERED CONTACTOR EXTERNALLY POWERED CONTACTOR OUTPUT CONTACTOR OUTPUT CONTACTOR 115 VAC WORK WORK TO WORK TO WORK ELECTRODE ELECTRODE FOR POWER TO OPERATE CONTACTOR MAX RATING OR NA 3 2 TO 4 CIRCUIT IS 3 AMPS 125 VAC FULL LOAD STEADY STATE MAX RATING OR NA 3 2 TO 4 CIRCUITIS 3 AMPS 125 VAC FULL LOAD STEADY STATE TO 115 VAC 350 VOLT...

Page 30: ...el B 5 Optional Electronic Voltmeter Operation B 6 Setting for CV or CC Power Sources B 6 Welding with DC Constant Voltage CV B 7 Mechanical Setup B 7 Electrical Setup B 7 Control Adjustments and Test Welding B 8 Welding with DC or AC Constant Current CC B 11 Mechanical Setup B 11 Electrical Setup B 11 Control Adjustments and Test Welding B 12 Starting and Stopping Sequences B 14 Available Startin...

Page 31: ... 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 hand wheel 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 electrode up and out of the way Remove the work a...

Page 32: ... CURRENT CONTROL Adjusts wire feed speed to control welding current 5A VOLTMETER STANDARD Indi cates voltage only while welding Also indicates OCV below 60 volts 5B ELECTRONIC VOLTMETER OP TIONAL Replaces the standard voltmeter when precise monitoring of the arc voltage is required See the section on this voltmeter for operating information 6 INCH UP AND INCH DOWN Inches the electrode at the speed...

Page 33: ...controlling power source output VOLTAGE CONTROL Adjusts arc voltage by controlling wire feed speed NA 4 When connected to a constant current output source the NA 4 controls are the same as those for the NA 3S with the exception described below and shown in Figure B 3 Refer to the NA 3N and NA 3S control descriptions and Figures B 1 and B 2 for all other controls Older NA 4s used with AC 1000 power...

Page 34: ... faster or slower than welding feed speeds 2 FUSES Located on the control PC board behind the inner panel door 3 OPEN CIRCUIT VOLTAGE Adjusts OCV of most CV Lincoln power sources to control starting characteristics 4 OPTIONAL CRATER CONTROLS Sets ending current and voltage for an adjustable period of time 5 OPTIONAL START CONTROLS Sets starting current and voltage for an adjustable period of time ...

Page 35: ...oltage SETTING FOR CV OR CC POWER SOURCES The NA 3N welds only with a constant voltage CV power source This machine can be converted for constant current CC welding by installing the proper parts The NA 3S welds with either a CV or CC power source Set the equipment for either CV or CC as appropriate per the following 1 If using a multi process power source set it up per the instructions in the ope...

Page 36: ...e for constant voltage CV welding per the instructions in each of the power source manuals 2 Set the wire feeder for constant voltage CV welding 3 Set the power source for the electrode polarity DC or DC specified by the procedures Interchange the NA 3 voltmeter and ammeter leads if the polarity was changed If using the discontinued solid state remote field control with a motor generator power sou...

Page 37: ... Output Control Remote b Set the Electrode Negative Electrode Positive switch to correspond to the polarity of the electrode cable connection c Set the 3 position toggle switch to CV Innershield or CV Submerged Arc as appropriate for the process and procedure d Set the NA 3 Inch Speed control at 2 e DC 600 Set the OCV Control at approximately the same dial setting as the NA 3 voltage control for t...

Page 38: ...est welds choose a setting from Table B 5 Approximate Voltage Voltage Control Setting 18 22 1 28 32 5 38 42 10 3 Unless previously instructed set the Inch Speed for good arc striking For an inch speed slower than welding feed speed which is usually required for good striking set the Inch Speed control on the inner panel one or two dial numbers below the setting of the Current Control on the front ...

Page 39: ...l carriage adjust the speed with the rheostat and the direction with the toggle switch on the carriage control panel 9 Connect the work lead to the work or a suitable piece of scrap Clip the end of the electrode to a sharp point When using an open arc process it is necessary to use correct eye head and body protection 10 Make a test weld and adjust the wire feeder Voltage Control and Current Contr...

Page 40: ...a multi process power source SAM SAF SA 800 DC 600 DC 1000 or DC 1500 set the power source for constant current CC welding per the instructions in the power source manual 2 Set the wire feeder for constant current CC welding 3 Set the power source for the electrode polarity DC or DC specified by the procedures Reverse the NA 3 or NA 4 voltmeter and ammeter leads if the polarity was changed If usin...

Page 41: ...ower source sub arc stud with the lowest current range that still permits welding at the current specified in the procedures For example if you want 500 Amps welding current use the 300 575 stud and not the 450 Max stud e Make final current adjustments with the NA 3 Current Control This control varies the current over the entire range controlled by the stud connection For initial test welds set th...

Page 42: ...m the work and press the Start button Press the Stop button before the electrode reaches the work 4 If installed set the Start Controls and Crater Controls on the inner panel For initial test welds set both Time in Seconds to 1 and the Current and Voltage controls to the same dial numbers to produce about the same output as the Current Control and Voltage Control on the front panel 5 The setting o...

Page 43: ...the arc strikes and the circuit automatically switches from inching to welding wire feed speed Use either the standard on the fly travel starting or rewire the controls for standstill travel starting as described in the Setting Travel Starting and Stopping section Cold Starting Cold starting is recommended primarily for submerged arc welding with a constant current power source when the weld must ...

Page 44: ... be reconnected so the travel remains at a standstill until the arc starts Standstill travel starting is used when the electrode must be started at a precise location For consistent arc striking with standstill travel starting always clip the end of the electrode to a sharp point before starting Setting Stopping Sequences As shipped travel stops when the Stop button is pressed which produces a sma...

Page 45: ...ting the arc stopping sequence is to prevent the electrode from sticking in the puddle This is easily done with the machine as shipped The standard stopping sequence is as follows 1 Press the Stop button 2 The wire feed motor stops and the Contactor and Electrode Back Up Time Delay starts 3 The arc continues to burn the electrode back from the puddle until the time set on the Contactor and Electro...

Page 46: ...ge set by the Crater Controls until the time set on the Time in Seconds control elapses The circuit then automatically switches to the arc sequence described above With the NA 4 and discontinued AC 1000 or AC 750 combination the current is not adjustable TABLE B 7 STOPPING SEQUENCE SWITCH POSITIONS When Stop Button is Pressed Older Models Newer Models Feed motor stops and Lead 693 to pin 3 electro...

Page 47: ...NOTES B 18 B 18 NA 3 AND NA 4 ...

Page 48: ...per Kit C 3 K221 Start Controls PC Board C 4 K223 Solenoid Kit C 4 K225 Submerged Arc Twinarc Kit C 4 K237 Linc Fill Starting Relay C 4 K238 High Frequency Unit C 4 K239 Twinarc Kit for Innershield Electrodes C 4 K245 Crater Control Board C 4 K263 DC Electronic Voltmeter C 5 K278 SpreadarcTM C 5 K281 Solid Wire Straightener for Tiny Twinarc C 5 K299 Wire Reel Assembly C 5 K310 Flux Screen C 5 K325...

Page 49: ...STARTING RELAY K238 HIGH FREQUENCY UNIT K239 TWINARC KIT FOR INNERSHIELD ELECTRODES K245 CRATER CONTROL BOARD K263 DC ELECTRONIC VOLTMETER K278 SPREADARC K281 SOLID WIRE STRAIGHTENER FOR TINY TWINARC K299 WIRE REEL ASSEMBLY K310 FLUX SCREEN K325 TC 3 TRAVEL CARRIAGE K386 NARROW GAP DEEP GROOVE NOZZLE K391 HIGH CAPACITY SUBMERGED ARC NOZZLE K405 AUTOMATIC INNERSHIELD NOZZLE GENERAL This section con...

Page 50: ... 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 IM278 manual and can be ordered as Sec L2 5 3 K129 K148 CONTACT NOZZLE AND K149 LINC FILLTM LONG STICKOUT EXTENSION This Innershield and submerged arc nozzle is designed for 0 062 through 3 16 in 1 57 through 4...

Page 51: ...g characteristics when using the K149 Linc Fill Long Stickout Nozzle Extension assembly The K221 Start Controls PC Board is required The K237 Linc Fill Starting Relay can be mounted on either the standard travel carriage or in a convenient location near the feeding head in accordance with the instructions shipped with each kit K238 HIGH FREQUENCY UNIT This unit supplies high frequency to the weldi...

Page 52: ...ting and brake assembly Mounting instructions are included with the kit The K299HF is the same as the K299 but has high frequency mounting insulation 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...

Page 53: ...NOTES C 6 C 6 NA 3 AND NA 4 ...

Page 54: ... D 3 Wire Drive Gear Box D 3 Wire Drive Motor D 3 Changing Wire Feed Gear Ratios NA 3 Only 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 lb 22 7 or 27 2 kg Coils D 6 Travel Carriage D 6 Vertical Lift Adjuster D 6 Horizontal Adjuster D 6 Section D Section D ...

Page 55: ...circuit fuse to open FIGURE D 2 CONTROL BOARD FUSE AND LED LOCATIONS 1 Complete or partial wire feed motor field short Normal field resistance is approximately 700 ohms 2 A welding procedure with a lot of electrode to puddle shorting This rapid arc shorting may cause the field voltage polarity to change frequently and blow the fuse Indicator LEDs 1C and 1D will both flicker when welding 3 Too low ...

Page 56: ...ear recoat all gear teeth with a non fluid molydisulfide 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 3 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 outp...

Page 57: ...l 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 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 th...

Page 58: ...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 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 electrode...

Page 59: ... pivot pins 3 Pins and bearings on the mechanism that raise and lower the welding head Every 3 months clean and inspect the control box No further maintenance should be required 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 t...

Page 60: ...N SECTION NA 3 AND NA 4 Theory of Operation Section E General Description E 2 Input Power Circuits E 2 Control and Logic Boards E 3 Variable Voltage Board E 4 Optional Start and Crater Fill Boards E 5 SCR Operation E 6 Section E Section E ...

Page 61: ... variable voltage board and through resistor R1 to the control board The 115 VAC is rectified and regulated by the control board which supplies 24 VDC to the logic board The 115 VAC input power is also coupled to the travel receptacle through the travel relay 2CR and the travel switch See Figure E 1 FIGURE E 1 INPUT POWER CIRCUIT TRAVEL RECEPTACLE TRAVEL SWITCH INCH UP SWITCH CONTROL BOARD LOGIC B...

Page 62: ... board to change the wire drive motor from the preset inch speed to the welding feed speed set by the wire speed control potentiometer Also output control of the power source is transferred from the strike setting to the weld output setting The Inch Down and Stop switches signal the logic board sending the appropriate command to the control board which sets the wire drive motor to the correct mode...

Page 63: ...applied to the electrode during the inch down mode When the electrode makes contact with the work piece this low voltage is loaded down signaling the control circuitry to stop the wire feed motor This feature allows the operator to utilize work touch sensing See Figure E 3 FIGURE E 3 VARIABLE VOLTAGE BOARD TRAVEL RECEPTACLE TRAVEL SWITCH INCH UP SWITCH CONTROL BOARD LOGIC BOARD LOGIC CONTROL SIGNA...

Page 64: ...ng procedure for an adjustable period of time This circuit becomes active when the Stop switch is pressed The crater fill board then dictates to the logic board the appropriate signals This feature is helpful in controlling bead shape and filling craters at the end of a weld FIGURE E 4 OPTIONAL START AND CRATER FILL BOARDS TRAVEL RECEPTACLE TRAVEL SWITCH INCH UP SWITCH CONTROL BOARD LOGIC BOARD LO...

Page 65: ...f the time in the off state The amount of time spent in the on state is controlled by the gate An SCR is fired by a short burst of current into the gate This gate pulse must be more positive than the cathode voltage Since there is a standard pin junction between the gate and cathode the voltage between these terminals must be slightly greater than 0 6 VDC Once the SCR has fired it is not necessary...

Page 66: ...r and Sensor PC Board Removal and Replacement NA 4 Only F 27 Wire Drive Motor Removal and Replacement F 30 PC Board s Removal and Replacement F 32 Retest After Repair F 34 ELECTRIC SHOCK can kill Never work on the inside of the machine without turning off the input power You can receive a life threatening electrical shock if you fail to do this Only qualified technicians should perform installatio...

Page 67: ...d valve function problems Step 2 PERFORM EXTERNAL TESTS The second column labeled POSSIBLE AREAS OF MISADJUSTMENT S lists the obvious external possibilities that may contribute to the machine symptom Perform these tasks checks in the order listed In general these tests can be conducted without removing the case wrap around cover Step 3 PERFORM COMPONENT TESTS The last column labeled RECOMMENDED CO...

Page 68: ...t could have a static charge If the PC board can not be installed immediately put it back in the static shielding bag If the PC board uses protective shorting jumpers do not remove them until installation is complete If you return a PC board to The Lincoln Electric Company for credit it must be in the static shielding bag This will prevent further damage and allow for proper analysis 4 Test the ma...

Page 69: ...d 592 from the Inch Down switch S4 If the problem is resolved the lead or the switch is faulty If light 2J stays on when lead 592 is removed from the Inch Down switch the logic board may be faulty Replace FUNCTION PROBLEMS Observe Safety Guidelines detailed at the beginning of this manual Troubleshooting Guide See the Wiring Diagrams Section for location of specified components and when troublesho...

Page 70: ...n for location of specified components and when troubleshooting specific circuits F 5 F 5 NA 3 AND NA 4 PROBLEMS SYMPTOMS POSSIBLE AREAS OF MISADJUSTMENT S RECOMMENDED COURSE OF ACTION The wire does not feed No inch up or down Wire does NOT feed when Start switch is activated 1 Check lights 1C and 1D on the control board If both lights are lit at the same time replace the control board 2 Press the...

Page 71: ...uit breaker trips when Inch or Start switches are pressed 1 Reset the circuit breaker and observe lights 1C and 1D on the control board with the unit at idle not attempting to feed wire Light 1C should be Off and light 1D should be On If both lights are Off remove power and check field fuse F101 1 2 Amp 2 If both lights are On the control board may be faulty 3 The following conditions may cause fu...

Page 72: ...p properly When the Start switch is pressed the wire feeds down properly NOTE When using DC 400 CV 400 and Pulse Power 500 power sources diode kits must be installed if auto stop circuit is required If auto stop circuit is not required move jumper on variable voltage board to pin L See wiring diagram 1 While pressing the Inch Down switch observe light 2J It should be lit If not the Inch Down switc...

Page 73: ...PTOMS POSSIBLE AREAS OF MISADJUSTMENT S RECOMMENDED COURSE OF ACTION 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 CAUTION 1 Locate lead 21 on the terminal strip and temporarily disconnect it ...

Page 74: ... OF ACTION The wire feeds up with either inch switch 1 While pressing the Inch Down switch observe light 2E on the logic board If light 2E does NOT light the logic board may be faulty If light 2E does light the control board may be faulty 1 Check the wiring to the Inch Down switch See wiring dia gram 2 Check the wiring between the logic board and the control board See wiring diagram The wire feeds...

Page 75: ...ssistance before you proceed Call 216 383 2531 or 1 800 833 9353 CAUTION The wire feeds at full speed in both inch and weld modes 1 If the optional start and crater boards are NOT installed check the NA 3 NA 4 at idle not feeding wire Observe light 2A on the logic board If light 2A is lit the control board may be faulty If light 2A is not lit the logic board may be faulty 2 If the optional start a...

Page 76: ...at the NA 3 NA 4 voltmeter If not check leads 21 and 67 for breaks or faulty connections 1 Check lead 21 for continuity zero ohms to work 2 Check lead 67 for continuity zero ohms to electrode 3 Check lead 690 on the logic board for proper connection See wiring diagram 4 Check leads 2 and 4 for loose or faulty connections between relay 1CR and the control cable receptacle 5 Remove electrode from dr...

Page 77: ...g the printed circuit boards one at a time control logic and variable voltage boards checking to see if the circuit breaker trips when power is reapplied Replace the board that causes the breaker to trip 1 If the circuit breaker continues to trip with all of the circuit boards unplugged the problem is not in a printed circuit board Check the wiring harness for shorted or grounded leads 2 The circu...

Page 78: ...cally hot with lead 2 removed from relay 3CR the problem is in the control cable or the power source 1 While pressing the Stop switch observe light 2C If light 2C is On the logic board may be faulty 2 If installed the crater board may be faulty 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 Departme...

Page 79: ...the jumper plug If the problem is resolved the crater board may be faulty 1 While pressing the Stop switch observe light 2C on the logic board If light 2C is lit the logic board may be faulty 2 If light 2C does not light when the Stop switch is pressed the switch or associated leads may be faulty See wiring diagram The burnback time cannot be set properly 1 The logic board may be faulty 1 Replace ...

Page 80: ... circuit operates properly when the Travel switch is in the Automatic Travel position 1 The Travel switch may be faulty 1 Check the Travel switch and associated wires for loose or faulty connections See wiring diagram The travel circuit runs continuously when the Travel switch is set to the Automatic Travel mode 1 Make sure the jumper leads or DIP switches on the logic board are connected properly...

Page 81: ... coil resistance of relay 2CR Normal coil resistance is 10 000 ohms If the coil resis tance is not correct relay 2CR may be faulty 3 If light 2H is NOT lit and the coil resistance of relay 2CR is normal check wires 589 and 510 between the relay and the logic board If the wiring is good the logic board may be faulty 4 If light 2H on the logic board IS lit remove the input power and also remove lead...

Page 82: ...it check the AC voltage between leads 31 and 87 on the terminal strip Normal voltage is 102 to 130 VAC If the voltage is normal the flux valve solenoid or associated leads may be faulty If the correct AC voltage is not at leads 31 to 87 relay 1CR or associated wiring may be faulty See wiring diagram 3 If light 2G is NOT lit check relay 1CR coil resistance Normal resistance is 10 000 ohms If the co...

Page 83: ...e may be stuck open Check and replace if necessary The flux solenoid valve does not open when the Start switch is pressed The flux solenoid valve works correctly during Inch Down when the electrode touches the work The wire feeds normally 1 Replace the logic board 1 The logic board may be faulty When cold inching the electrode stops feeding but the flux solenoid does not operate when the elec trod...

Page 84: ...lenoid Signal to energize travel circuit Inch Down switch pressed Signal to operate power source contactor Weld Current control and weld Voltage control operative Electrode voltage output from VV board Electrode voltage input to VV board Start Current and Start Voltage controls operative Start cycle ready Crater Current and Crater Voltage controls operative Crater fill cycle ready TROUBLESHOOTING ...

Page 85: ...gic Bd Logic Bd Logic Bd Logic Bd Logic Bd Logic Bd Logic Bd Logic Bd Logic Bd Logic Bd Volt Bd Volt Bd ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON indicates light is dim ON is dependent on code number ON only while switch is pressed FIGURE F 3 VARIABLE VOLTAGE BOARD LED LOCATIONS FIGURE...

Page 86: ...e observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD TEST DESCRIPTION This test will determine if the wire drive motor i...

Page 87: ...e Motor Applied Voltage Test FIGURE F 5 WIRE FEED DRIVE MOTOR CONNECTOR PINS 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 F 1 3 Apply field voltage first pins C and D to the motor Then slowly ap...

Page 88: ...bserve all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD PROCEDURE DESCRIPTION The following procedure will aid the technician ...

Page 89: ... 3 ONLY continued FIGURE F 6 REED SWITCH REMOVAL SHEET METAL SCREW SHUNT BOX COVER REED SWITCH LEADS LOCK WASHER NUT REED SWITCH REED SWITCH BRACKET SLOT HEAD SCREWS BOLT LOCK WASHER NUT HEX NUT FIBER INSULATORS FLAT WASHER LOCK WASHER HEX NUTS NA 3 CONTROL BOX FLAT WASHER LOCK WASHER SHUNT ASSEMBLY 525 AND 539S ...

Page 90: ...lot head screwdriver and 3 8 in wrench remove the two screws lockwashers and nuts mounting the reed switch to the reed switch bracket 8 Carefully remove the reed switch INSTALLATION PROCEDURE 1 Attach the reed switch to the reed switch bracket with two nuts lock washers and screws using the slot head screwdriver and 3 8 in wrench 2 Mount the reed switch bracket to the shunt with two nuts and bolts...

Page 91: ...NOTES F 26 F 26 NA 3 AND NA 4 ...

Page 92: ...se observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD PROCEDURE DESCRIPTION The following procedure will aid the technic...

Page 93: ...CEMENT NA 4 ONLY continued FIGURE F 7 AC CURRENT TRANSFORMER AND PC BOARD REMOVAL SHEET METAL SCREW CURRENT SENSOR BOX COVER CURRENT TRANSFORMER BOLT SCREW TERMINAL LEADS 539 528 CURRENT SENSOR PC BOARD NUT LOCK WASHER INSULATORS COPPER CONDUCTER BAR GLASTIC SPACER NUT WASHERS INSULATING SPACER NA 4 CONTROL BOX ...

Page 94: ... the metal bracket on the other glastic spacer 7 Carefully remove the PC board be careful when pulling leads 539 and 528 free from the grommet in the back of the control box INSTALLATION PROCEDURE 1 Feed leads 539 and 528 through the grommet in the back of the control box 2 Install the current sensor PC board and PC board coil onto the glastic spacer with the insulators lock washer 3 8 in nut and ...

Page 95: ...nd will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 216 383 253...

Page 96: ...e adapter plate and motor assembly with pinion attached 5 With a slot head screwdriver remove the adapter plate from the drive motor MOTOR REPLACEMENT PROCEDURE 1 Attach the adapter plate to the drive motor using the slot head screwdriver 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...

Page 97: ...hock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD PROCEDURE DESCRIPTION The following procedure will aid th...

Page 98: ...w and swing open the outer control panel 3 Using the slot head screwdriver remove the locking screw and swing open the inner control panel 4 Carefully remove the molex type plugs connected to the PC board that is to be removed 5 Using the Phillips head screwdriver remove the PC board mounting screws 6 Carefully remove the PC board FIGURE F 9 CIRCUIT BOARD REMOVAL AND REPLACEMENT PC BOARD S REMOVAL...

Page 99: ...hine must be retested and must meet the following standards Wire Feed Speed per table NA 3 CV only Wire Speed Range Gear Ratio in min m min 57 1 40 650 1 01 16 51 95 1 25 400 0 64 10 16 142 1 17 268 0 43 6 81 Flux or Water Solenoid Must operate when Start switch is pressed LEDS on PC Boards Must operate per table in troubleshooting section Relay 3CR Must operate and close power source contactor Re...

Page 100: ...iring Diagram NA 4 G 3 Operating Schematic NA 3 G 4 Operating Schematic NA 4 G 5 Logic PC Board G1379 2 above Schematic G 6 Variable Voltage PC Board L5394 2 above Schematic G 7 Control PC Board L5224 5 above Schematic G 8 Start PC Board L9917 1 above Schematic G 9 Crater Fill PC Board L5222 2 above Schematic G 10 G 1 G 1 ...

Page 101: ...NOTES NA 3 AND NA 4 ...

Page 102: ...R POWER SOURCES JUMPER TO BE CONNECTED TO PIN H UNITS SHIPPED WITH CONNECTION MADE AT PIN H N H THIS FUSE NOT PRESENT ON EARLIER CONTROL P C BOARD MODELS N B THESE LEADS ARE NOT PRESENT ON LOGIC P C BOARDS WITH DIP SWITCHES Methods of Burnback Methods of Travel Start stop with switches Lead 691 to P6 Lead 692 to P5 Start stop with current Lead 691 to P6 Lead 692 to P7 Start with current Stop with ...

Page 103: ...Boards with jumpers Yes Connect Lead 694 to P10 No Connect Lead 694 to P8 Wire feed stop contactor delay Lead 693 to P3 Lead 690 to P4 Inch up contactor delay Lead 693 to P1 Lead 690 to P4 Inch up no contactor delay Lead 693 to P1 Lead 690 to P2 Crater board installed SWITCH 1 1 2 3 4 SWITCH 2 1 2 3 4 SWITCH 1 1 2 3 4 SWITCH 2 1 2 3 4 For Logic P C Boards with dip switches Remove jumper connector ...

Page 104: ... SWITCH 1CR 2CR 3CR 4CR 5CR ACTUATED BY 4 CR CIRCUIT OPTIONAL LINC FILL STARTING RELAY KIT 6CR SOLID STATE RELAY FOR LINC FILL STARTING RELAY OPERATION 7CR LINC FILL STARTING RELAY A N S I ELECTRICAL SYMBOLS PER E1537 NOTE SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS O...

Page 105: ...USED ONLY ON NA 4 WITH CURRENT CONTROL RHEOSTAT R3 5K OHM 2 W WIRE SPEED CONTROL R4 S1 DPST CONTROL POWER SWITCH S2 SPDT TRAVEL SWITCH S3 SPST INCH UP SWITCH S4 SPST INCH DOWN SWITCH S5 SPST START SWITCH S6 SPST STOP SWITCH S7 SPDT CURRENT CONTROL SWITCH NOT USED ON NA 4 WITH CURRENT CONTROL RHEOSTAT 1CR 2CR 3CR 4CR BY WELDING CURRENT 5CR ACTUATED BY 4 CR CIRCUIT OPTIONAL LINC FILL STARTING RELAY ...

Page 106: ... 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...

Page 107: ...s 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 damag...

Page 108: ...ll 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...

Page 109: ...l 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 ...

Page 110: ... 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...

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