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F-85

TROUBLESHOOTING & REPAIR

F-85

If a failed test indicates that any mechanical part that could affect the machine's electrical characteristics must be
replaced or if any electrical components are repaired or replaced, the machine must be retested and must meet
the following standards.

Wire Feed Speed per following table:..........................

RETEST AFTER REPAIR

NA-5

LEDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Must operate per PC Board LED Definitions table in

Troubleshooting Section.

Flux or Water Solenoid . . . . . . . . . . . . . . . . . . . .Must operate when "Start" switch is pressed.

Relay 3CR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Must operate and "close" power source contactor.

Relay 2CR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Must operate and activate external travel circuit, if used.

Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Refer to

Voltmeter Accuracy Test.

Wire Speed Meter . . . . . . . . . . . . . . . . . . . . . . . .Refer to

Wire Speed Accuracy Test.

Voltage control and shutdown . . . . . . . . . . . . . . .Refer to

Out of Voltage Range Shut Down Test.

Gear Ratio

Wire Speed Range in/min (m/min)

21/1

100-2070 (2.54-52.58)

57/1

38-778 (.97-19.76)

95/1

22-456 (.56-11.58)

142/1

15-300 (.38-7.62)

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Summary of Contents for NA-5

Page 1: ...signed 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 For use with the following models NA 5N NA 5NF NA 5S NA 5SF Return to Mast...

Page 2: ...R 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 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 22...

Page 3: ...ode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation 3 g Never dip the electrode in water for cooling 3 h Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders 3 i When working above floor level use a s...

Page 4: ...ire 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 6 b Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Welding and Cutting ANSI Standard Z49 1 and the ...

Page 5: ...tier 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 6 Eloigner les matériaux inflammables ou les recou...

Page 6: ...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 Settings B 12 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 Power and Voltage Boar...

Page 7: ...NOTES vi vi NA 5 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 8: ...Diagrams A 8 Figure A 8 Connection of NA 5 All to a DC 600 A 9 Figure A 9 Connection of NA 5 All to a DC 650 Pro A 10 Figure A 10 Connection of NA 5 All to a R3S 400 600 or 800 with no Line Voltage Compensator Obsolete A 11 Figure A 11 Connection of NA 5 All to a SAM 400 Motor Generator or Engine Welder A 12 Figure A 12 Connection of NA 5 All to a SAM 650 Engine Welder A 13 Figure A 13 Connection ...

Page 9: ...IRE SOLID WIRE 21 1 100 2070 2 54 52 6 0 052 1 3 0 052 1 3 57 1 38 7 78 0 96 19 8 3 32 2 4 1 16 1 6 95 1 22 456 0 56 11 6 5 32 4 0 1 8 3 2 142 1 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 lbs kg NA 5 Control Box 9 02 229 17 87 454 15 05 382 30 13 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Re...

Page 10: ... CONTACT ASSEMBLY OPTIONAL GEAR BOX 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 MOTOR CONTROL CABLE TO POWER SOURCE TACHOMETER CABLE Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 11: ...e mounting kit T14469 and perform the following steps Also refer to Figure A 2 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 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 c...

Page 12: ...g 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 FRONT VIEW FROM BOTTOM 1 4 20 THREAD HOLES 3 50 88 9 VIEW FROM BACK 1 4 20 THREA...

Page 13: ...l a K335 or K338 control to head extension cable of the length ordered up to 30 ft 9 1 m The K335 for the NA 5S head includes motor tachometer and flux hopper lead extensions with polarized plugs on each end and electrode cables The K338 for the NA 5N NF and SF heads is the same as the K335 without the flux hopper lead extension The NA 5N and NA 5S also include two 4 ft 1 2 m lengths of electrode ...

Page 14: ... 400 DC 600 DC 1000 or DC 1500 types be sure it is properly set for the welding process being used per the connection diagram Figures A 8 to A 14 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 ...

Page 15: ...terchange the black and white leads going to the terminals marked and The black lead 67 must be connected to the same polarity as the electrode welding lead i e if the electrode is positive connect the black lead to the terminal on the terminal strip The white lead 21 is connected to the opposite polarity terminal POWER SOURCE CONNECTION DIAGRAMS The following section contains the wiring diagrams ...

Page 16: ...ROL BOX POLARITY CONNECTIONS ALL CODES TURN OFF INPUT POWER ADJUST THE POWER SOURCE DC 600 1 CONNECT ELECTRODE CABLES TO TERMINAL OF DESIRED POLARITY 2 SET TOGGLE SWITCH TO SAME POLARITY AS THE ELECTRODE CABLE CONNECTION 3 SET TOGGLE SWITCH TO REMOTE 4 SET MODE SWITCH TO THE DESIRED POSITION FOR THE PROCESS TO BE USED DC 600 CODES 8000 8045 FOR SUB ARC 1 SET MODE SWITCH TO CV SUB ARC 2 WHITE LEAD ...

Page 17: ...ION N D CONNECT EXTENDED LEAD DIRECTLY TO THE WORK PIECE KEEPING IT SEPARATE FROM THE WELDING WORK CABLE CONNECTION TO THE WORK PIECE FOR CONVENIENCE THIS EXTENDED LEAD SHOULD BE TAPED ALONG THE WELDING WORK CABLE N E TAPE UP CONNECTION N F FOR PROPER NA 5 OPERATION THE ELECTRODE CABLES MUST BE SNUGGED UNDER THE CLAMP BAR ON THE LEFT SIDE OF THE NA 5 CONTROL BOX N G CONNECT NEGATIVE OUTPUT CABLES ...

Page 18: ... 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 TH...

Page 19: ... TERMINAL STRIP N G ON EARLIER SAM MACHINES 1 TERMINAL WAS ALSO ON THE TERMINAL STRIP N H FOR PROPER NA 5 OPERATION THE ELECTRODE CABLES MUST BE SNUGGED UNDER THE CLAMP BAR ON THE LEFT SIDE OF THE NA 5 CONTROL BOX FOR ADDITIONAL INSTALLATION INSTRUCTIONS SEE NA 5 OPERATING MANUAL NA 5 SETTINGS FOR SUB ARC 1 RED LEAD ON VOLTAGE PC BOARD IS CONNECTED TO PIN S 2 WHITE LEAD ON VOLTAGE PC BOARD IS CONN...

Page 20: ...FF N A REMOVE SAM PORTABLE FIELD CONTROL AND CONNECT NA 5 CONTROL CABLE N B WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS N C EXTEND LEAD 21 USING 14 OR LARGER INSULATED WIRE PHYSICALLY SUITABLE FOR THE INSTALLATION AN S 16586 REMOTE VOLTAGE SENSING WORK LEAD IS AVAILABLE FOR THIS PURPOSE CONNECT IT DIRECTLY TO THE WORK PIECE KEEPING ...

Page 21: ...TRIP CONNECT LEAD 77 TO 73 ON TERMINAL STRIP N F CONNECT THE JUMPERS ON THE NA 5 VOLTAGE BOARD AS FOLLOWS CONNECT RED JUMPER TO PIN S CONNECT WHITE JUMPER TO PIN B N G SET THE DC 1000 OR DC 1500 CONTROLS AS FOLLOWS SET THE CONTROL SWITCH TO OUTPUT CONTROL REMOTE FOR SUBMERGED ARC PROCESSES SET THE MODE SWITCH TO C V SUBMERGED ARC FOR OPEN ARC PROCESSES SET THE MODE SWITCH TO C V INNERSHIELD N H FO...

Page 22: ...NNECTION N D CONNECT THE CONTROL CABLE GROUND LEAD TO THE FRAME TERMINAL MARKED NEAR THE POWER SOURCE TERMINAL STRIP THE POWER SOURCE GROUNDING TERMINAL MARKED AND LOCATED NEAR THE POWER SOURCE INPUT POWER CONNECTIONS MUST BE PROPERLY CONNECTED TO ELECTRICAL GROUND PER THE POWER SOURCE OPERATING MANUAL N E THE JUMPERS ON THE NA 5 VOLTAGE BOARD MUST BE CONNECTED AS FOLLOWS CONNECT RED JUMPER TO PIN...

Page 23: ...NOTES A 16 A 16 NA 5 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 24: ...urity Cover B 3 Setup Instructions B 4 Starting and Stopping Sequences B 5 Means of Arc Striking B 5 Setting Travel Starting and Stopping 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 Section B Section B Return to Master TOC Return to Ma...

Page 25: ...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 electrode 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 duri...

Page 26: ... stopping cycle at the end of the weld 9 TRAVEL Turn to Off for no travel Hand Travel for travel without welding and Automatic Welding for welding operations 10 VOLTS METER Displays the set or actual voltage for each mode Strike Start Weld Crater 11 WIRE SPEED METER Displays the set or actual wire speed for each mode Strike Start Weld Crater CONTROLS UNDER THE LOCKABLE SECURITY COVER 12 ARC STRIKI...

Page 27: ... Rotate the wire straightener if used until the top of the straightener faces the wire reel This is required for smooth feeding of the electrode into the straightener 7 Refer to the instructions for the wire contact assembly being used See IM305 Sec T2 2 6 T2 2 7 T2 5 3 or T2 5 4 8 The mount for standard 50 and 60 lb 22 7 and 27 2 kg electrode coils includes a two position brake assembly Generally...

Page 28: ...r as needed for the application e Set the Burnback Time to provide the stopping char acteristics needed 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 ...

Page 29: ...to control the welding cycle duration can be installed 2 Welds started on a run out tab 3 Any application for improved arc striking Standstill Travel Starting All models can be reconnected so the travel remains at a standstill until the arc starts Standstill travel starting is used when the electrode must be started at a precise location For consistent arc striking with Standstill travel starting ...

Page 30: ... Switch 1 Switch 2 1 2 3 4 1 2 3 4 Switch 1 Switch 2 1 2 3 4 1 2 3 4 Switch 1 Switch 2 TABLE B 1 TRAVEL SEQUENCE LEAD AND SWITCH POSITIONS 1 2 3 4 1 2 3 4 Switch 1 Switch 2 NOTE Indicates switch in up position Indicates switch in down position Indicates switch position does not matter 1If the optional procedure module is installed in the crater receptacle DIP switch position 1 on switch 2 should b...

Page 31: ... 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 ...

Page 32: ...n of the jumpers located on the NA 5 Voltage P C Board shown in Figure B 3 To change the voltage control response 1 Turn off all input power to the NA 5 control 2 Open the control box 3 Locate the Voltage P C Board mounted on the right side of the box Position the jumper plugs on the Voltage P C Board per the appropriate power source connection diagram 1 2 3 4 Switch 2 1 2 3 4 Switch 2 1 2 3 4 Swi...

Page 33: ... R3S models with the somewhat limited voltage ranges of the various taps For instance if the R3S 400 triangle tap setting is for 31 volts the range of control from the remote circuit is approximately 7 volts i e 27 5 to 34 5 volts at nominal input voltage If the NA 5 controls are set for 29 volts and the input voltage to the R3S goes up it may not be possible for the NA 5 control circuit to hold t...

Page 34: ...6 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 A Auto Stop When the Inch Down button is pressed a low level DC voltage signal is applied betwee...

Page 35: ...iameter hole located beneath each square so the head is on the back side of the panel inside the control box f Remount the PC board assembly and its panel insulation Reconnect the PC board and close and secure the control box g Remount the rotary select switch knob and replace each square spacer tube and felt seal so the 4 screw protrudes between the tube and the felt seal h Turn on the NA 5 input...

Page 36: ...oid Kit C 3 K225 Submerged Arc Twinarc Kit C 4 K238 High Frequency Unit C 4 K239 Twinarc Kit for Innershield Electrodes C 4 K278 SpreadarcTM C 4 K281 Solid Wire Straightener for Tiny Twinarc C 4 K285 Concentric Flux Cone C 4 K310 Flux Screen C 4 K325 TC 3 Travel Carriage C 4 K334 Start and Crater Controls C 5 K336 Remote Interface Module C 5 K337 Weld Timer Module C 5 K349 Multi Procedure Kit C 5 ...

Page 37: ...STRAIGHTENER FOR TINY TWINARC K285 CONCENTRIC FLUX CONE K310 FLUX SCREEN K325 TC 3 TRAVEL CARRIAGE K334 START AND CRATER CONTROLS K336 REMOTE INTERFACE MODULE K337 WELD TIMER MODULE K349 MULTI PROCEDURE KIT S22022 or S22182 CURRENT RELAY SPEED FEED DRUMS SPEED FEED REELS GENERAL This section contains a listing and short description of the accessories that are available with the NA 5 automatic weld...

Page 38: ...E 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 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...

Page 39: ...y with smooth beads of minimum admixture with the base metal Flux cored electrode open 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 recommend...

Page 40: ...intenance instructions are shipped with each kit are contained in the IM305 manual and can be ordered as Sec T2 5 19 K349 S22022 OR S22182 CURRENT RELAY MODULES The current relay is useful to fixture builders and others who need a signal indicating that welding current is flowing Installation operating and maintenance instructions are shipped with each kit The S22022 relay module is suitable for d...

Page 41: ...NOTES C 6 C 6 NA 5 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 42: ... 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 lb 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 Spreadarc D 6 Section D Section D Return to Master TOC Return to Master TOC Return to Master TOC Return to M...

Page 43: ...x 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...

Page 44: ...hen the NA 5 polarity connections are set for electrode negative WELDING HEAD WIRE DRIVE GEAR BOX Once a year recoat all gear teeth with a non fluid molydisulfide type grease such as Non Fluid Oil Corporation s A 29 Special MS Lubricant For access to the gears in the first chamber remove the adapter plate and motor assembly as shown in Figure D 4 FIGURE D 4 WIRE DRIVE MOTOR GEAR BOX To lubricate t...

Page 45: ...wn FIGURE D 5 CHANGING THE WIRE FEED GEAR RATIO 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 ...

Page 46: ...E 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 The electrode is driven by gripping between the ...

Page 47: ...ar 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 replac...

Page 48: ...Operation Section E General Description E 2 Input Power Circuits E 2 Power and Voltage Boards E 3 Control Logic and Procedure Boards E 4 Optional start Crater Fill and Weld Timer Boards E 5 SCR Operation E 6 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 49: ...1 CR 2 CR 3 FLUX RECEPTACLE TRAVEL RECEPTACLE CONTACTOR CLOSURE 2 AND 4 REMOTE VOLTAGE CONTROL A B C WORK SENSING 21 TACH FEEDBACK MOTOR RPM DC SUPPLY VOLTAGE 10VDC REFERENCEVOLTAGE DC VOLTAGE S I G N A L INPUT POWER SWITCH CIRCUIT BREAKER R1 2 OHMS MOTOR G A T E S I G N A L S CONTROL CABLE RECEPTACLE TACH FEEDBACK MOTOR RPM 115VAC 36VAC 18 18VAC 22VAC 1 V A C 0 D C S U P P L Y V O L T A G E SIGNA...

Page 50: ... same as the pre set voltage during the welding cycle This circuitry is incorporated on the volt age board FIGURE E 2 Power and Voltage Boards NA 5 F1 A R M A T U R E F I E L D V O L T A G E V O L T A G E T1 T2 OPTIONAL START BOARD OPTIONAL CRATER BOARD OPTIONAL WELD TIMER BURNBACK TIMER VOLTAGE BOARD METER BOARD SPEED VOLT METER BOARD DIGITAL METER DIGITAL METER MOTOR LOGIC BOARD CONTROL BOARD P ...

Page 51: ...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 bo...

Page 52: ...re the subject of discussion F1 A R M A T U R E F I E L D V O L T A G E V O L T A G E T1 T2 OPTIONAL START BOARD OPTIONAL CRATER BOARD OPTIONAL WELD TIMER BURNBACK TIMER VOLTAGE BOARD METER BOARD SPEED VOLT METER BOARD DIGITAL METER DIGITAL METER MOTOR LOGIC BOARD CONTROL BOARD P O W E R B O A R D P R O C E D U R E B O A R D TACH INCH DOWN SWITCH STOP SWITCH START SWITCH WELD CURRENT REED SWITCH C...

Page 53: ... a short burst of current into the gate This gate pulse must be more positive than the cathode voltage Since there is a standard PN junc tion between gate and cathode the voltage between 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 ...

Page 54: ... Board Transformer Test F 45 Wire Feed Drive Motor Test F 48 External Resistance Test Leads 21 and 67 F 50 Out of Voltage Range Shut Sown Test F 52 Tach Board Feedback Test F 55 VoltmeterAccuracy Test F 57 Wire Speed Accuracy Test F 60 Meter Circuit Accuracy Test F 64 Replacement Procedures F 71 PC Board s Removal and Replacement F 71 Digital Meter and Meter PC Board Removal and Replacement F 73 T...

Page 55: ...ou 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...

Page 56: ... 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 If 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 prope...

Page 57: ...ulty If the light goes OFF check the switch and associated leads See wiring diagram and Figure F 1 2 Check light 7J on the logic board It should NOT be on If light 7J is ON remove lead 592 from the Inch Down switch If the light remains ON the logic board may be faulty If the light goes OFF check the switch and associated leads See wiring diagram and Figure F 1 3 Disconnect lead 586 from the Inch U...

Page 58: ...eck the lights LEDS locate on the PC boards Some should be lit See Table F 1 If none of the lights are lit perform the T1 and T2 Transformer Test 2 If the appropriate lights are lit see Table F 1 and the wire does NOT feed perform the Wire Drive Motor Test 3 If only some of the appropriate lights on the power board are lit the power board may be faulty 4 If all of the appropriate lights are lit ex...

Page 59: ...e proper input volt age 115VAC is applied to the NA 5 control unit 3 Check the F102 field fuse on the power board Replace if faulty Note Frequent motor polarity changes can cause the fuse to fail This can be caused by the following A welding procedure with frequent electrode to puddle shorting A power source output too low to establish an arc 1 The welding head is designed to feed wire in the prop...

Page 60: ...ght 7J DOES light when the inch down button is pressed the logic board may be faulty For codes above 8300 Jumper the AUTO tabs on the voltage board and press inch down button If the wire does NOT feed down the logic board may be faulty 1 Disconnect the white 21 lead from the NA 5 polarity terminal strip TS1 See wiring diagram With the inch down button pressed read the ACTUAL volts on the NA 5 digi...

Page 61: ...ck the inch down switch and associated leads See wiring diagram 2 Check to make sure that light 7B on the logic board is lit when the start button is pressed If not check the start button and associ ated leads See wiring diagram 1 For codes below 8300 make sure the jumper plug is securely installed in the harness receptacle near the voltage board 2 Check to make sure light 7E on the logic board is...

Page 62: ... polarity is correct and the same as the 67 and 21 leads at terminal strip TS1 See wiring diagram 4 Make sure the welding power source is producing welding arc voltage 1 Jumper the 2 and 4 leads at the Lincoln CV power source Open circuit voltage should be present at both the power source and at the ACTUAL voltmeter reading on the NA 5 If open cir cuit voltage is present at the power source but NO...

Page 63: ...g the logic board may be faulty 1 With the unit at idle no buttons pressed observe lights 1D on the power board and light 7E on the logic board 1D should be ON 7E should be OFF 2 If 1D is OFF replace the power board 3 If 7E is ON replace the logic board 1 While pressing the inch down but ton observe light 7E on the logic board It should be ON 2 If light 7E is ON while the inch down button is press...

Page 64: ...OSSIBLE AREAS OF MISADJUSTMENTS S RECOMMENDED COURSE OF ACTION The wire feeds down when either inch button is pressed 1 Wth the unit at idle no buttons pressed observe light 7E on the logic board It should be OFF 2 If light 7E is ON the logic board may be faulty Replace 3 If light 7E is OFF the power board may be faulty Replace 1 Check the inch up and inch down switches buttons for proper oper ati...

Page 65: ...s function properly All the mode lights function properly None of the speed controls operate properly All the mode lights function properly None of the voltage controls operate properly 1 Check lights 1A and 1B located on the power board They should both be ON 2 If both lights 1A and 1B are ON the control board may be faulty Replace 1 The control board may be faulty Replace 1 The voltage board may...

Page 66: ... light 7D is NOT lit when weld current is present make sure the weld cables have been properly routed through the cable clamp on the left side of the control box 1 Check light 7D on the logic board If it is off the logic board may be faulty Replace 2 If the start light is on all the time the start board if used may be faulty Replace or install jumper plug in procedure board 3 If the crater light i...

Page 67: ... 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 procedure board may be faulty Replace 1 The procedure board may be faulty Replace 1 Make sure the start option board is installed correctly 2 The procedure board may be faulty Replace 1 If no other mode lights are lit the start option board ...

Page 68: ...t for a time greater than zero sec onds 3 If the weld light goes ON as soon as but not before the arc is struck and the start timer is set for a time greater than zero sec onds the start timer board may be faulty 4 If the weld light goes ON before the arc is struck replace the start option board with the jumper plug If the weld light continues to go ON before the arc is struck the logic board may ...

Page 69: ...functioning properly If the crater and or burn back timer IS functioning properly the start timer may be faulty 2 If the start crater and burnback timers are not working properly the procedure board may be faulty 1 Make sure the crater option boards are installed correctly 2 The procedure board may be faulty Replace 1 If no other lights are lit the crater option board may be faulty Replace 2 If th...

Page 70: ...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 2 If the unit does not stop the pro cedure board may be faulty 1 Make sure the burnback timer is set for a time greater than zero ohms 2 Be sure the jumper leads or dip switches on the logic b...

Page 71: ...voltage and wire feed speed do not function The NA 5 is at idle with the selector switch in the Weld postion 1 Test if the other timers start weld crater function properly If they time out correctly the burn back module may be faulty Replace 2 If the other timers start weld crater do NOT function correctly the procedure board may be faulty 1 The procedure board may be faulty Replace 1 If the optio...

Page 72: ...faulty 2 If the start module is OK and the weld light does not go ON the logic board may be faulty Replace 3 If a start module is NOT used make sure the jumper plug is installled in the procedure board receptacle 1 The weld timer module may be faulty Replace 1 Set the burnback timer for a value greater than zero seconds Start the weld sequence and then stop it with the stop button Check to see if ...

Page 73: ... should go ON If lights 7C and 7B are functioning normally the logic board may be faulty 1 If the wire inches up properly but does not feed when the start but ton is pressed the logic board may be faulty 2 If the wire does NOT feed when the inch up button is pressed check light 1E on the power board It should go ON when the inch up button is pressed If light 1E does not go on when the inch up butt...

Page 74: ...ke sure the power source is capable of producing welding output voltage Jumper 2 and 4 at the power source s terminal strip This should produce open circuit voltage at the output termi nals If open circuit voltage is not present the power source may be faulty 3 Check or replace the control cable between the NA 5 and the power source 4 With the start button pressed check light 7K on the logic board...

Page 75: ... leads for loose or faulty con nections 2 Check the travel receptacle and associated leads for loose or faulty connections 3 Make sure the travel unit is oper ational 1 Check the travel switch and asso ciated leads for loose or faulty connectioins 1 With the travel switch S2 in the hand travel position and the 115VAC input power applied to the NA 5 unit check for 115VAC at the travel receptacle 11...

Page 76: ...ravel switch S2 and associated leads for loose or faulty connections See wiring diagram 3 Check light 7H located on the logic board This light should be ON when the Auto travel is active If light 7H does not light the logic board may be faulty 1 Make sure the jumper leads 691 and 692 are connected properly to the correct pins on the logic board See wiring diagram 2 Check light 7H on the logic boar...

Page 77: ...he control cable between the power source and the NA 5 unit 1 If a crater option module is used check to make sure the logic board jumper 694 is on pin P10 2 While pressing the stop button observe light 7C located on the logic board It should be lit If light 7C is ON and the wire feed ing and welding does not stop the logic board may be faulty 1 Made sure the calibration jumper on the speedmeter b...

Page 78: ...e actual speed correctly 1 Contact your local Lincoln Authorized Field Service Facility 1 Contact your local Lincoln Authorized Field Service Facility 1 Check the lead and switch conti nuity of the SET speedmeter cir cuit See wiring diagram 2 Check the lead and switch conti nuity of the ACTUAL speedmeter circuit See wiring diagram 3 Perform the Wire Speed Accuracy Test 4 Perform the Meter Circuit ...

Page 79: ...ble from the tach board to the tach receptacle The shield in the cable should NOT be grounded to the case 1 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 2 The control cable may be faulty Check or replace 1 Remove the drive motor end cap and the tach cover plate...

Page 80: ...rd must have the jumper plug connected to the 4 cavity receptacle on the board unless the pulsed power filter board option is connected 2 Make sure the shutdown BYPASS pins are not jumpered together on the NA 5 voltage board 3 Check the voltage sensing leads for continuity zero ohms 21 lead should have continuity to the work piece and 67 lead should have continuity to the wire feed head assembly S...

Page 81: ...e the 67 and 21 leads are connected to the TS1 termi nal strip for the correct electrode polarity See wiring diagram 3 Make certain the voltage control switch on the Lincoln CV power source is set in the Remote position 4 Make sure the 21 lead has con tinuity zero ohms to the work piece 5 Make sure the 67 lead has con tinuity zero ohms to the wire feed head assembly 6 Check the 1 8 amp fuse on the...

Page 82: ... 1 Contact your Local Lincoln Authorized Field Service Facility 1 Perform the Wire Drive Motor Test 2 Perform the DC Power Supply Test 1 If fuse F101 or the circuit breaker immediately fails when input power is applied unplug all of the PC boards except the power board If the fuse still fails the power board may be faulty If the fuse does not fail reconnect the PC boards one at a time until the fa...

Page 83: ...ath which could cause excessive loading on the wire drive motor 1 Check to make sure the PC boards are NOT grounded to the case of the NA 5 This can hap pen due to metallic dust build up 1 Perform the DC Power Supply Test 2 Perform the Wire Drive Motor Test 3 The power board may be faulty 1 Remove the input power to the NA 5 and replace the 1 8 amp fuse Locate and remove the 21 and 67 leads from t...

Page 84: ...ch 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 3 If the start response jumper on the voltage board is in the B position change to the A posi tion If the A position cures the starting ...

Page 85: ...unstable or oscillating 1 Check the welding cables for loose or faulty connections 2 Make sure the electrode and gas if used is correct for the process being used 3 Put the output control switch on the power source in the Machine Control position Jumper the BYPASS pins on the NA 5 voltage board Control the arc voltage from the power source If the problem is NOT remedied the power source may be at ...

Page 86: ...G 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 ...

Page 87: ...age 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 1 Make sure the welding parame ters are correct for the welding procedure being used 2 Check the welding cables for loose or faulty connections 3 Check the wire feeding path for restrictions 4 The contact tip may be worn Check or replace 5 The welding power...

Page 88: ... 1 Make sure the welding parame ters voltages and wire feed speed and techniques are cor rect for the welding procedure being used 2 Check the welding cables for loose or faulty connections 3 The contact tip may be worn Check or replace 4 The welding power source may be faulty Check or replace 1 Put the Lincoln power source in the machine control mode Jumper the BYPASS pins on the NA 5 voltage boa...

Page 89: ...ignal to Apply Down Field Voltage 7G Signal to Operate Flux or Water Solenoid 7H Signal to Operate Travel Circuit 7J Inch Down Switch Pressed 7K Signal to Operate Power Source Output Contactor PC BOARD LED LIGHT DEFINITIONS NA 5 LED LIGHT LOCATIONS O I L C G LED 7B LED 7C LED 7D LED7A NA 5 LED 7J LED 7K LED 7G LED 7H LED 7E LED LIGHT LOCATIONS NA 5 POWER LED 1F LED 1B LED 1D LED 1C LED 1E LED 1A R...

Page 90: ...N 1F Power ON ON ON ON ON ON ON 7A Logic ON ON ON ON ON ON ON 7B Logic ON 7C Logic ON 7D Logic ON ON 7E Logic ON ON ON 7G Logic ON ON ON 7H Logic ON ON ON 7J Logic ON 7K Logic ON ON ON PC BOARD LED LIGHT SEQUENCE TABLE ABOVE CODE 8300 NA 5 ON only while switch is pressed ON dependent on travel mode INDICATOR LIGHTS CONDITIONS FOR LIGHT ON Return to Section TOC Return to Section TOC Return to Secti...

Page 91: ...ctory 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 _...

Page 92: ...d 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 DC POWER SUPPLY TEST continued NA 5 FIGURE F 1 P C BOARD LOCATIONS PROCEDURE BOARD POWER BOARD LOGIC BOARD CONTROL BOARD VOLTAGE BOARD Return to Section T...

Page 93: ...11 0 VDC BOARD 12 PIN SUPPLY FROM PIN 7 510 CONNECTOR POWER BOARD PLUG TO VOLTAGE BOARD CONTROL PC CHECK 10VDC PIN 14 500 9 0 11 0 VDC BOARD SUPPLY FROM PIN 9 510 CONNECTOR POWER BOARD PLUG TO CONTROL BOARD LOGIC PC CHECK 110VDC PLUG J1 PIN 1 610 90 135 VDC BOARD J1 SUPPLY FROM PLUG J1 PIN 2 500 CONNECTOR POWER BOARD PLUG TO LOGIC BOARD DC POWER SUPPLY TEST continued NA 5 TABLE F 1 DC POWER SUPPLY...

Page 94: ...VOLTMETER CHECK 5VDC TEST POINT1 TP5 BOARD SUPPLY TP5 PRODUCED 4 75 5 25 VDC ON THE VOLTMETER TEST POINT1 LEAD 510P BOARD 510P SPEEDMETER CHECK 5VDC TEST POINT1 TP5 BOARD SUPPLY TP5 4 75 5 25 VDC PRODUCED ON THE TEST POINT1 LEAD 510P SPEEDMETER 510P BOARD TABLE F 1 DC POWER SUPPLY CHECKS continued 500 515 1 Scrape encapsulation from test points Return to Section TOC Return to Section TOC Return to...

Page 95: ...date 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...

Page 96: ...ring diagram and Figure F 2 5 Using the 115VAC supply carefully apply 115VAC to the T1 primary leads 531B and 532 6 Check for approximately 10VAC at the yellow secondary leads 601 and 602 See wiring diagram T1 and T2 TRANSFORMER TEST Continued NA 5 FIGURE F 2 T1 AND T2 TRANSFORMERS POWER BOARD LOGIC BOARD UPPER TERMINAL STRIP T1 TRANSFORMER T2 TRANSFORMER Return to Section TOC Return to Section TO...

Page 97: ...aulty 12 Using the 115VAC supply carefully apply 115VAC to the T2 primary leads 531B and 532 13 Check for approximately 115VAC at the orange secondary leads The orange leads are connected to the power board See wiring dia gram 14 Check for approximately 24VAC at the brown secondary leads See wiring diagram 15 If all the secondary voltages are correct the T2 transformer is func tioning properly 16 ...

Page 98: ...lidate 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 8...

Page 99: ...ltage board 5 Using the phillips head screwdriver remove the voltage board from the control box 6 Locate the transformer and test points on the voltage board See Figure F 4 VOLTAGE BOARD TRANSFORMER TEST Continued NA 5 FIGURE F 3 VOLTAGE BOARD LOCATION VOLTAGE BOARD Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Ret...

Page 100: ...re that the meter probes make good electrical contact 9 If the secondary voltage is correct the transformer is functioning proper ly 10 If the secondary voltage is low or not present the transformer may be faulty 11 Carefully remove the 115VAC sup ply from the voltage board 12 Install the voltage board and con nect the molex plugs 13 Close and secure the access door VOLTAGE BOARD TRANSFORMER TEST ...

Page 101: ... 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 ...

Page 102: ...and B See Table F 1 4 The motor should run and the speed should vary with changes to the armature voltage 5 If 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 WIRE FEED DRIVE MOTOR TEST Continued NA 5 TEST POINTS RESISTANCE DC VOLTAGE Lead 539 to lead 541 4 to 5 ohms 0 to 90 VDC armature Lead 6...

Page 103: ... 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 ...

Page 104: ... per Table F 2 check the associ ated leads cables and circuits for opens or shorts See wiring dia gram 9 Close and secure the control box access door EXTERNAL RESISTANCE TEST LEADS 21 AND 67 Continued NA 5 TEST POINTS EXPECTED COMMENTS AND RESISTANCES CONDITIONS Lead 667 Zero or less than Electrode wire must be in to 1 ohm contact assembly tip Electrode wire Lead 621 to Zero or less than Polarity ...

Page 105: ...tory 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 __...

Page 106: ...may be labeled B This should disable the shut down circuit 4 Connect to a Lincoln Electric CV power source per connection dia gram See the Installation section of this manual OUT OF VOLTAGE RANGE SHUT DOWN TEST Continued NA 5 FIGURE F 6 VOLTAGE BOARD AND PIN LOCATIONS NA 5 VOLTAGE G1556 BYPASS COM AUTO JUMPER TOGETHER 1 8 AMP FUSE Return to Section TOC Return to Section TOC Return to Section TOC R...

Page 107: ...nd its associ ated leads Set the switches to the same polarity as the electrode See the Wiring Diagram 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 t...

Page 108: ... 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 800 833 935...

Page 109: ...est 6 With the motor running activate either inch switches or the start switch and check leads 555 to 510A for the presence of 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 7 If the feedback voltage is missing or does not vary with motor speed the tach PC board may be faulty Als...

Page 110: ...ranty 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 __________...

Page 111: ...ould energize the output terminals of the Lincoln CV welding power source An open circuit voltage should be present at the welding output termi nals The test voltmeter reading should match the ACTUAL volts meter reading on the NA 5 within 0 5VDC typically 0 2VDC If it does not check the integrity and placement of the voltage sensing leads 21 and 67 and associated wiring Perform the Meter Circuit A...

Page 112: ...what about an aver age value The average ACTUAL reading should match the SET read ing within 0 5 VDC If not refer to the Meter Circuit Accuracy Test 6 If no further tests are required remove all test equipment and close and secure the access door VOLTMETER ACCURACY TEST Continued NA 5 FIGURE F 8 CR3 RELAY CR3 RELAY Return to Section TOC Return to Section TOC Return to Section TOC Return to Section...

Page 113: ...r 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 WE...

Page 114: ...00 2070 S19113 Single 045 052 Cored 57F 57 1 S12778 Single 035 052 40 778 57 57 1 S12515 Single 1 16 3 32 38 762 95 95 1 S12514 Single 3 32 5 32 22 428 95S 95 1 S12515 Single 1 16 3 32 23 456 S19113 Single 045 052 Cored S13161 052 Twin 045 052 S13161 5 64 Twin 1 16 5 64 S14904 Outer Twin 3 32 S14905 Inner 142 142 1 S12514 Single 3 32 7 32 15 289 142T 142 1 S14904 Outer Twin 5 64 1 8 15 300 S14905 ...

Page 115: ...bleshooting Guide Feeding Problems in this sec tion of the manual Also check for correct drive roll tension adjustment WIRE SPEED ACCURACY TEST Continued NA 5 DRIVE ROLL PART WIRE SIZE RANGE INCHES OF WIRE FED PER NUMBER 10 REVOLUTIONS OF DRIVE ROLL S12778 Single 035 052 Solid 53 54 S19113 Single 045 052 Cored 53 55 S12515 Single 1 16 3 32 51 53 S12514 Single 3 32 5 32 49 51 S13161 052 Twin 045 05...

Page 116: ...RE SPEED ACCURACY TEST Continued NA 5 SPEEDMETER HEAD SET SPEEDMETER DRIVE ROLL ACTUAL CALIBRATION RATIO READING IPM RPM SPEEDMETER PIN READING IPM 21 21 1 0 27 IPM X 1000 50 2 0 27 0 01 IPM X 1000 57F 57 1 268 50 1 268 2 57 57 1 262 50 1 262 2 95 95 1 249 50 1 249 2 95S 95 1 265 50 1 265 2 142 142 1 250 50 1 250 2 142T 142 1 260 50 1 260 2 TABLE F 5 Present on HI Speed NA 5 speedmeter board only ...

Page 117: ... 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 ____________________________________________...

Page 118: ...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 METER CIRCUIT ACCURACY TEST Continued NA 5 FIGURE F 9 VOLTMETER PC BOARD AND TEST POINTS L6685 METER TP4 TP5 517 518 510 510C 601 602 Return to Section TOC Return to Section...

Page 119: ... 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 If the NA 5 digital voltmeter does not match t...

Page 120: ...ding SET values of STRIKE voltage adjust the strike voltage control until the NA 5 voltmeter matches the settings in the table below If the test meter does not match the readings the voltmeter PC board may be faulty METER CIRCUIT ACCURACY TEST Continued NA 5 NA 5 SET VOLTS READING TEST VOLTMETER READING 15 0VDC 1 50VDC 04 30 0VDC 3 00VDC 04 60 0VDC 6 00VDC 06 Return to Section TOC Return to Sectio...

Page 121: ...75 to 5 25VDC from TP5 to lead 510P See Figure F 10 Note The coating will have to be removed from the test points to ensure accurate meter readings If the display is NOT lit and the correct DC voltage is present at TP5 to lead 510P the digital meter may be faulty Replace the meter If the AC voltage IS present at leads 601 to 602 and the DC voltage is missing the speedme ter PC board may be faulty ...

Page 122: ...s of STRIKE speed adjust the strike wire speed con trol until the test meter matches the settings in the table below If the NA 5 digital speedmeter does not match the readings the digital meter may befaulty METER CIRCUIT ACCURACY TEST Continued NA 5 For Hi Speed NA 5 speedmeter IPM X 1000 NA 5 SET SPEED READING TEST VOLTMETER READING IPM 150 1 50 150 004VDC 300 3 00 300 004VDC Return to Section TO...

Page 123: ...edmeter matches the settings in the table below If the test meter does not match the readings the speedmeter PC board may be faulty 15 When the testing is complete close and secure the access door METER CIRCUIT ACCURACY TEST Continued NA 5 SPEEDMETER NA 5 SET SPEED READING TEST VOLTMETER CALIBRATION PIN IPM READING 21 2 07 6 00 06 57F 778 6 00 06 57 762 6 00 06 95 428 6 00 06 95S 456 6 00 06 142 2...

Page 124: ...our 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 ...

Page 125: ...ved 4 Using the phillips head screwdriver remove the PC board mounting screws 5 Carefully remove the PC board REPLACEMENT PROCEDURE 1 Using the phillips head screwdriver and mounting screws carefully posi tion and install the new PC board 2 Reconnect the molex type plugs and leads into the new PC board 3 Close and secure the access door PC BOARD S REMOVAL AND REPLACEMENT Continued NA 5 Return to S...

Page 126: ...l 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 ______________________________________________________...

Page 127: ...arefully remove the meter PC board Note insulation placement for reassem bly Also make sure the plug on the back of the PC board plugs into the prongs on the meter when you reassemble DIGITAL METER AND METER PC BOARD REMOVAL AND REPLACEMENT NA 5 FIGURE F 11 METER PC BOARD MOUNTING NUTS AND PLUG MOUNTING NUTS PC BOARD PLUG PRONGS SPEED METER BOARD METER BOARD Return to Section TOC Return to Section...

Page 128: ...e the two nuts screws and lockwash ers holding the digital meter to the cover assembly 5 Carefully remove the digital meter DIGITAL METER AND METER PC BOARD REMOVAL AND REPLACEMENT NA 5 FIGURE F 12 METER BEZEL AND SCREW LOCATIONS METER BEZEL METER SHIELD DIGITAL METER MOUNTING INSULATOR METER SHIELD ASSEMBLY Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Re...

Page 129: ...sembly 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 DIGITAL METER AND METER PC BOARD REMOVAL AND REPLACEMENT NA 5 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master T...

Page 130: ...l 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...

Page 131: ...d screwdriver remove the two screws from the pick up assembly cover See Figure F 14 Remove the cover 6 Hold the nut in place with the 3 8 wrench With the phillips head screwdriver remove the locking screw from the rotating disc See Figure F 15 TACH PC BOARD REMOVAL AND REPLACEMENT Continued NA 5 FIGURE F 13 DRIVE MOTOR TACH COVER AND CONNECTION BOX WIRE DRIVE MOTOR MOUNTING SCREWS x4 TACH COVER PI...

Page 132: ...onnec tion box and cover plate TACH PC BOARD REMOVAL AND REPLACEMENT Continued NA 5 FIGURE F 14 PICK UP ASSEMBLY AND COVER TACHASSEMBLY COVER SCREWS FIGURE F 15 ROTATING DISC NUT AND TACH BOARD DISC NUT TACH PC BOARD PHILLIPS SCREW Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master ...

Page 133: ... 3 8 wrench to hold the nut in place Attach the rotating disc with the phillips head screw 3 Thread leads 510A 525A and 555 through the cover plate and into the connection box Attach to their respective in line connectors 4 Replace the connection box cover 5 Replace the pick up assembly cover 6 Reattach the tach cover to the wire feed drive motor TACH PC BOARD REMOVAL AND REPLACEMENT Continued NA ...

Page 134: ...d 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 25...

Page 135: ...llips head screwdriver remove the cover plate adaptor See Figure F 16 6 Using the 5 16 nutdriver remove the clamp holding the connection box to the drive motor 7 Carefully remove the connection box being careful not to stretch the leads WIRE DRIVE MOTOR REMOVAL AND REPLACEMENT Continued NA 5 FIGURE F 16 DRIVE MOTOR AND TACH HOUSING WIRE DRIVE MOTOR TACH HOUSING COVER PLATE ADAPTER Return to Sectio...

Page 136: ... 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 WIRE DRIVE MOTOR REMOVAL AND REPLACEMENT Continued NA 5 FIGURE F 17 DRIVE MOTOR HEX HEAD BOLT ADAPTER PLATE AND MOTOR ASSEMBLY WIRE DRIVE GEARBOX SLOT HEAD SCREW Return t...

Page 137: ...onnector box and clamp to the drive motor and using the 5 16 nutdriver secure in position Be sure NOT to pinch any leads 5 Using the phillips head screwdriver mount the cover plate adaptor to the drive motor 6 Using the slot head screwdriver attach the tach housing to the drive motor 7 Perform the Tach Board Replacement Procedure 8 Assemble the motor and tach cables to the NA 5 control box WIRE DR...

Page 138: ...olenoid Must operate when Start switch is pressed Relay 3CR Must operate and close power source contactor Relay 2CR Must operate and activate external travel circuit if used Voltmeter Refer to Voltmeter Accuracy Test Wire Speed Meter Refer to Wire Speed Accuracy Test Voltage control and shutdown Refer to Out of Voltage Range Shut Down Test Gear Ratio Wire Speed Range in min m min 21 1 100 2070 2 5...

Page 139: ...F 86 NOTES NA 5 F 86 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 140: ... above Schematic G 4 Power PC Board L6252 1 Schematic G 5 Power PC Board L6252 2 above Schematic G 6 Voltage PC Board Schematic G 7 Control Circuit Schematic G 8 Procedure Board Schematic G 9 Option Timer Board Schematics G 10 Meter PC Board Schematic Layout G 11 Miscellaneous PC Board Layouts G 12 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 141: ...NOTES NA 5 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 142: ... 694 TO PIN P8 N D CONTROL BOARD JUMPER LEAD CONNECTED TO PIN F WHEN SHIPPED SEE OPERATING MANUAL FOR N E VOLTAGE BOARD RED JUMPER LEAD CONNECTED TO PIN S AND WHITE JUMPER LEAD CONNECTED TO N G 531 532 115VAC 531 25 115VAC SWITCHED 250 VAC N J CONNECT 67 BLACK ELECTRODE LEAD AND 21 WHITE WORK LEAD TO APPROPRIATE TERMINAL STRIP N K LEAD CONNECTED TO MOTOR FRAME WHICH IS ELECTRICALLY COMMON WITH ELE...

Page 143: ... 47K 100 R702 R703 R704 R705 R706 R707 R708 R709 R710 R711 R712 R713 R714 R715 R716 R717 R718 R720 R721 R722 R723 R724 470 100 4 7K 47K 470 470 15K 470 4 7K 4 7K 100K 22K 4 7K 100 2 7K 1 5K 68K 2 7K 1 5K R725 2 7K R726 R727 R728 R729 R730 R731 R732 R733 R734 R735 R736 R737 R738 R739 R740 R741 R742 X701 1 5K 68K 2 7K 1 5K 68K 22K 47K 22K 47K 22K 47K 6 8K 47K 10K 15K 10K 15K QUAD 2 X702 X703 X704 IN...

Page 144: ...S USED WITH G1556 1 AND MUST BE IN STRIKE POSITION TO START WELD 500 500 X3 4 5 6 S2 6 12 11 5 X3 12 13 11 D5 J2 2 D6 D2 D1 B1 HS IN 7815 OUT GND X9 J4 6 J4 3 X8 7 14 100V 22 C1 C30 500 T1C BLU X3 8 9 10 515 4 7 35V C13 B2 LED 7A D7 D3 D4 500 50V C12 515 N F B C D 3 C A C SUPPLY POWER LOGIC 628 BLU 22VAC 1 50K R1 4011 X7 14 7 PROCEDURE PC BOARD 515 X7 8 9 10 S1 2 16 15 1 500 S1 4 14 13 3 475 R9 47...

Page 145: ...2W 100 10K 47K 4 7K 6 8K 680 47K 680 4 7K 3 3K 68K SCR 101 8A 600V SCR 102 SCR 103 SCR 104 8A 600V 16A 400V 16A 400V TP101 TP102 TP103 150V 10J X101 15V VOLTAGE REGULATOR X102 5V VOLTAGE REGULATOR 0047 3000 C1101 C1102 C1103 C1104 C1105 C1106 0047 3000 0047 3000 ARC VOLTAGE BY PASS SEE SCHEMATIC C FLUX SOLENOID BY PASS MOTOR FIELD BY PASS R F BYPASS P C BOARD CB1 CR1 CR2 CR3 CR6 CR7 5A CIRCUIT BRE...

Page 146: ...50V C14 500 610 ARMATURE SUPPLY B1 D4 133K R17 18 15V C17 D5 3 32K R15 HS IN 7815 OUT GND X1 1W 5 1V DZ1 100V 22 C13 B2 4 75K R14 D8 BRN 24 VAC T2B 532 10 VAC 531B T2A YLW BLK 602 601 YLW BLK BRN 115 VAC 532 BLK T1B METER VAC CANADA ORG 115 ORG RED AUSTRALIA POWER SUPPLY INTERFACE OPTION FRANCE 87 FLUX OR WATER R1 SOLENOID RECEPTACLE 2 OHMS 50 WATTS 531A CB1 531A 631 0047 3000 VAC CR2 T1A SUPPLY J...

Page 147: ... R536 R537 R538 R539 R540 R541 R542 R543 R544 R545 R546 R547 R548 R549 22K 27K 1K 33K 5K TRIMMER 1K 12W 470 68K 15K 15K 270 270 100 270 F501 1 8 AMP FAST BLOW FUSE SWITCH SBS501 T501 24 VAC 185 mf SECONDARY TP501 150V 10J VOLTMETER P C BOARD C602 C603 C604 D601 022 25 D602 D603 D604 24 3K 1 4W 1 2K TRIMMER 5V VOLTAGE REGULATOR INPUT CONTROL CABLE CONNECTION N A THESE CAPACITORS ARE LOCATED ON THE ...

Page 148: ...MATIC A SPEEDMETER P C BOARD C401 C402 C403 THRU C409 500 50 4 7 35 022 25 D401 D402 D403 D404 1A 400V X401 5V VOLTAGE REGULATOR R401 R402 R403 R404 R405 R406 R407 R408 R409 R410 R411 R412 R413 R414 2K TRIMMER 2K TRIMMER 5K TRIMMER 5K TRIMMER 5K TRIMMER 5K TRIMMER 17 8K 1 4W 1 2 80K 1 4W 1 18 2K 1 4W 1 33 2K 1 4W 1 52 3K 1 4W 1 10 31 6K 1 4W 1 51 1K 1 4W 1 R201 C204 C201 5 6 X201 525 A5H A5H 510 A...

Page 149: ...ART STRIKE B CRATER STRIKE A STRIKE PROCEDURE ENABLE START DISABLE WELD PROCEDURE ENABLE START DISABLE 1 6384MHz Y1 LED2 J19 14 J18 4 J19 4 D1 100V 22p C2 LED1 D5 10K 2W CW R2 600mA 40V Q1 5 62K R1 C6 47 5K R14 26 7K R15 267 R3 4 75K R13 D10 LED4 D6 D8 2 21K R19 D9 N E VOLTS TO SET ON 2 PLACE DECIMALS IS O2 ON CONTROL PCB SPEED BUFFER TO SET VOLTAGE BUFFER 632 635 ON HOLES SIZES PER E 2056 ON VOLT...

Page 150: ...903 8 16 X904 8 16 X905 8 16 C906 C904 X001 13 12 13 12 7 2 1 X901 C902 14 N C X002 7 14 C003 515 500 D8C D9C 14 11 7 10 2 1 C001 520 510P B1C B3C R016 X002 A 6 5 R013 OVER TIME INITIATE CURRENT 588 584 0 515 D8C 2 1 X002 B R014 4 3 R017 R015 C004 500 R018 D9C D003 515 D8C 500 B1C D004 D001 515 D8C 500 D9C D002 TIME OVER 583 R012 12 13 C X002 11 9 8 X002 D 10 R010 R011 Q002 520 C002 R007 R008 R009...

Page 151: ... PUBLISHED STANDARDS FM 21143 S SHT 9 23 93 CHK NONE DATE SCALE NO ON HOLES SIZES PER E 2056 Ch ge Sht No ON 2 PLACE DECIMALS IS O2 UNLESS OTHERWISE SPECIFIED TOLERANCE THE LINCOLN ELECTRIC CO TYPE METER BOARD SCHEMATIC SUBJECT SUP S D G COMMON CONNECTION EQUIP EARTH GROUND CONNECTION OR CIRCUITRY OF 1A 400V FILE S21143_1CA LN 9 LN 9F NA 5 3 25 94 B G 11 NOTE Lincoln Electric assumes no responsibi...

Page 152: ...J3 R6 R3 D9 R5 D11 D19 R24 R27 D20 D23 C21 Q4 LED 7K R30 D21 R25 LED 7G C19 Q2 C22 Q5 R29 D18 R22 D1 D2 X1 X5 X2 X6 X3 X4 X7 R42 R41 R20 Q11 C27 C1 C2 C3 C4 C5 C7 C8 C9 C12 J1 J2 J4 J5 LED 7A LED 7B LED 7C LED 7D LED 7E LED 7H LED 7J S1 S2 C13 D7 D6 R1 D5 D4 D3 D17 R16 R15 R35 D30 D29 D31 R32 Q1 R34 R36 R38 R50 D34 D35 R14 R13 D14 R12 D16 R11 D10 R17 D32 D15 D27 D8 R18 R19 C29 R2 C6 D12 R4 R10 C11...

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