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Lincoln Electric NA-5NF manuel d'utilisation

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Table des matières du manuel d’utilisation

  • Page 1

    NA-5 A UTOMA TIC WELDING S Y S TEMS SER VICE MANU AL Sales and Ser vice through Subsidiaries and Distr ibutors Worldwide 22801 St. Clair A ve. Cle veland, Ohio 44117-1199 U .S.A. T el. (216) 481-8100 W orld's Leader in W elding and Cutting Products Premier Manuf acturer of Industr ial Motors SVM131-A July , 1997 Safety Depends on Y ou Lincoln [...]

  • Page 2

    SAFETY i i FOR ENGINE powered equipment. 1.a. T urn the engine off before troub leshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b . Operate engines in open, well-v entilated areas or vent the engine e xhaust fumes outdoors. ________________________________[...]

  • Page 3

    SAFETY ii ii ARC RA YS can b urn. 4.a. Use a shield with the proper filter and cover plates to protect your e yes from sparks and the ra ys of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards. 4.b . Use suitable clothing made from durab le flame-resistant material to protect your[...]

  • Page 4

    SAFETY iii iii FOR ELECTRICALL Y powered equipment. 8.a. T urn off input power using the disconnect switch at the fuse bo x before working on the equipment. 8.b . Install equipment in accordance with the U.S . National Electrical Code, all local codes and the manuf acturer’ s recommendations. 8.c. Ground the equipment in accordance with the U.S. [...]

  • Page 5

    SAFETY iv iv PRÉCA UTIONS DE SÛRETÉ P our v otre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté P our Soudage A L ’Ar c 1. Protegez-vous contre la secousse électrique: a. Les circ[...]

  • Page 6

    v v NA-5 MASTER T ABLE OF CONTENTS FOR ALL SECTIONS Pag e Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-iv Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A T echnical Specifications . . . . . . . . . . . . . . . . .[...]

  • Page 7

    NO TES vi vi NA-5 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 8

    TABLE OF CONTENTS - INSTALLATION SECTION - NA-5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2 Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-[...]

  • Page 9

    A-2 INSTALLATION A-2 NA-5 TECHNICAL SPECIFICATIONS – NA-5 MINIMUM ELECTRICAL INPUT REQUIREMENTS 115 VAC @ 3 amps 50/60 Hz power REQUIRED WELDING POWER SOURCE NA-5 DC Constant Voltage WIRE FEED SPEED and GEAR RATIOS FEED SPEED RANGE MAX. WIRE SIZE in. (mm) GEAR RATIO in./min (m/min) CORED WIRE SOLID WIRE 21:1 100 - 2070 (2.54 - 52.6) 0.052 (1.3) 0[...]

  • Page 10

    INSTALLATION A-3 A-3 NA-5 FIGURE A.1 – BASIC CONTROL AND WIRE DRIVE SYSTEM. CONTROL BOX HEAD MOUNTING PARTS (WITH INSULATION AND HARDWARE) WIRE STRAIGHTENER CROSS SEAM ADJUSTER 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 ASSEMBL[...]

  • Page 11

    MECHANICAL INSTALLATION ELECTRIC SHOCK can kill. • Turn off input power to the welding power source using the disconnect switch before working on this equipment. INTRODUCTION This section covers the basic requirements to install the control box and welding head shown in Figure A.1. This section will give you mounting hole alignments, component mo[...]

  • Page 12

    To install the control box on a fixture, perform the following steps and refer to Figure A.3. 1. Align the mounting holes on the back and/or bottom of the control box with the holes you put in the fixture according to the measurements provided in Figure A.3. 2. Secure the control box to the fixture using lock washers and hex head screws at each of [...]

  • Page 13

    INSTALLATION A-6 A-6 NA-5 When mounting the welding head to the standard travel carriage, (see 305-B sec. T2.2.4) mount it so only a minimum of overhang weight exists. Mount the head so it stays within the dimension shown in Figure A.5. ELECTRICAL INSTALLATION ELECTRIC SHOCK can kill. • Do not touch electrically live parts such as output terminal[...]

  • Page 14

    The “F” models do not include the 4 ft (1.2 m) lengths of electrode cable as standard. If you are not using a K335 or K338 exten- sion cable for the NA-5NF or NA-5SF, order an appropriate length of the needed elec- trode cable. Connect it between the wire contact assembly and the control cable assembly as described above. POWER SUPPLY TO CONTRO[...]

  • Page 15

    INSTALLATION A-8 A-8 NA-5 ELECTRODE POLARITY ELECTRIC SHOCK can kill. • Turn off input power to the welding power source using the disconnect switch before working on this equipment. Polarity is changed at the power source. The polarity of the NA-5 control circuit is shipped connected for electrode positive. If electrode negative is required, two[...]

  • Page 16

    INSTALLATION A-9 A-9 NA-5 FIGURE A.8 – CONNECTION OF NA-5 (ALL) TO A DC-600. N.A. ON EARLIER DC-600'S, #67 TERMINAL WAS ALSO ON THE TERMINAL STRIP. N.B. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS. N.C. EXTEND LEAD #21 USING #14 OR LARGER INSULATED WIRE PHYSICAL[...]

  • Page 17

    INSTALLATION A-10 A-10 NA-5 FIGURE A.9 – CONNECTION OF NA-5 (ALL) TO A DC-650 PRO NOTE: ABOVE DIAGRAMS SHOW ELECTRODE CONNECTED POSITIVE. TO CHANGE POLARITY, TURN POWER OFF, REVERSE THE ELECTRODE   AND WORK CABLES AT THE POWER SOURCE AND POSITION THE SWITCH ON THE POWER SOURCE TO PROPER POLARITY. REFER TO   NA-5 OPERATING MANUAL FOR R[...]

  • Page 18

    INSTALLATION A-11 A-11 NA-5 FIGURE A.10 – CONNECTION OF NA-5 (ALL) TO A R3S-400, -600, OR -800 WITH NO LINE VOLTAGE COMPENSATOR (OBSOLETE). R3S POWER SOURCE SETTINGS TURN POWER SOURCE OFF.  FOR ALL PROCESSES: 1. CONNECT ELECTRODE CABLE TO TERMINAL OF DESIRED POLARITY. 2. SET THE POLARITY SWITCH TO THE SAME POLARITY AS THE ELECTR[...]

  • Page 19

    INSTALLATION A-12 A-12 NA-5 FIGURE A.11 – CONNECTION OF NA-5 (ALL) TO A SAM-400 MOTOR GENERATOR OR ENGINE WELDER. NOTE: TO CHANGE POLARITY, TURN POWER OFF, AND POSITION THE SWITCH ON POWER SOURCE TO PROPER POLARITY. REFER TO NA-5 OPERATING MANUAL FOR  REQUIRED NA-5 CONTROL BOX POLARITY CONNECTIONS.  N.A. REMOVE SAM PORTABLE FIEL[...]

  • Page 20

    INSTALLATION A-13 A-13 NA-5 FIGURE A.12 – CONNECTION OF NA-5 (ALL) TO A SAM-650 ENGINE WELDER. NOTE: TO CHANGE POLARITY, TURN POWER OFF, AND  POSITION THE SWITCH ON POWER SOURCE TO   PROPER POLARITY. REFER TO NA-5   OPERATING MANUAL FOR REQUIRED   NA-5 CONTROL BOX POLARITY CONNECTIONS.  FOR ADDITIONAL INSTALLATION[...]

  • Page 21

    INSTALLATION A-14 A-14 NA-5 FIGURE A.13 – CONNECTION OF NA-5 TO DC-1000 OR DC-1500. THE DIAGRAM SHOWS ELECTRODE CONNECTED POSITIVE. TO CHANGE POLARITY, TURN POWER OFF, REVERSE THE ELECTRODE AND WORK LEADS AT THE POWER SOURCE, POSITION THE POSITIVE-NEGATIVE SWITCH ON THE POWER SOURCE TO CORRESPOND TO THE POLARITY OF THE ELECTRODE CABLE CONNECTI[...]

  • Page 22

    INSTALLATION A-15 A-15 NA-5 FIGURE A.14 – CONNECTION OF NA-5 TO DC-400 OR CV-400. THE DIAGRAM SHOWS ELECTRODE CONNECTED POSITIVE. TO CHANGE POLARITY, TURN POWER OFF, REVERSE THE ELECTRODE AND WORK LEADS AT THE POWER SOURCE AND POSITION THE SWITCH ON POWER SOURCE (IF EQUIPPED), TO PROPER POLARITY. REFER TO NA-5 OPERATING MANUAL FOR REQUIRED [...]

  • 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

    TABLE OF CONTENTS - OPERATING INSTRUCTIONS SECTION - NA-5 Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section B Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2 Operator’s Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 25

    OPERATOR’S INSTRUCTIONS Once the system is properly set up, the operator can make production welds without readjusting the controls using the following simple instructions: 1. Be sure there is enough electrode in the machine to complete the weld. 2 . If submerged arc welding, fill flux hopper with new or freshly screened flux. All reused flux mus[...]

  • Page 26

    OPERATING INSTRUCTIONS B-3 B-3 NA-5 CONTROLS AND THEIR FUNCTIONS The operator controls for the NA-5 are illustrated in Figure B.1. Refer to the figure and the following explanations of the controls. EXPOSED CONTROLS (WITH LOCKABLE COVER DOWN) 1. CIRCUIT BREAKER. Protects the circuit from severe wire feed motor overloads and short circuits. Press to[...]

  • Page 27

    OPERATING INSTRUCTIONS B-4 B-4 NA-5 SETUP INSTRUCTIONS Use the following steps to set up the NA-5 welding system prior to welding: 1. If using a multi-process power source (SAM, DC-400, DC-600, DC-1000, OR DC-1500 type), make con- nections and settings per the power source connection diagram (Figures A.8 to A.14) for the process being used. AUTO TA[...]

  • Page 28

    OPERATING INSTRUCTIONS B-5 B-5 NA-5 11. Set the travel speed as specified by the procedures. With the wire feeder travel switch set to “Hand Travel”, the travel runs without welding, permitting accurate measurement of travel speed. When using a Lincoln travel carriage, adjust the speed with the rheostat and the direction with the toggle switch [...]

  • Page 29

    OPERATING INSTRUCTIONS B-6 B-6 NA-5 The starting sequence is as described above except that when the arc strikes, the machine welds at the wire speed and voltage set by the “Start Controls” panel until the time set on the thumbwheel switch elapses. The circuit then automatically switches to the “Welding Controls” wire speed and voltage. Act[...]

  • Page 30

    OPERATING INSTRUCTIONS B-7 B-7 NA-5 Travel Starts Travel Stops Older Models Newer Models* With “Start” With “Stop” Lead #691 to Pin 6 Button Button Lead #692 to Pin 5 With Arc Striking With Arc Stopping Lead #691 to Pin 6 Lead #692 to Pin 7 With Arc Striking With Stop Button Lead #691 to Pin 5 Lead #692 to Pin 7 With “Start” With End Cr[...]

  • Page 31

    OPERATING INSTRUCTIONS B-8 B-8 Wire Feed Motor Acceleration ELECTRIC SHOCK can kill. • Turn off input power to the welding power source using the disconnect switch before working on this equipment. The NA-5 has two different speeds of controlled wire feed motor acceleration. As shipped, the unit is connected for fast acceleration which is best fo[...]

  • Page 32

    TABLE B.2 – STOPPING SEQUENCE SETTINGS. When “Stop” Button is Pressed Older Models Newer Models* Feed motor stops and Lead #693 to Pin 3 electrode burns back with Lead #690 to Pin 4 contactor delay (standard) Feed motor inches up and Lead #693 to Pin 1 electrode burns back with Lead #690 to Pin 4 contactor delay Feed motor inches up and Lead [...]

  • Page 33

    AUTOMATIC SHUTDOWN If the NA-5 voltage control is unable to supply the “Set” value of the arc voltage while welding, the automatic shutdown circuit will activate. This protection circuit immediately returns the NA-5 control to idle state within a few seconds after the arc voltage discrepancy occurs. Typical causes that activate this protective [...]

  • Page 34

    OPERATING INSTRUCTIONS B-11 B-11 NA-5 In some cases, it is also possible to hold the “Actual” button pressed while starting the arc. Before the NA-5 shuts down, the actual arc voltage can be read on the digital meter. Comparing this reading to the “Set” reading will tell what change in the range controls of the power source are required so [...]

  • Page 35

    OPERATING INSTRUCTIONS B-12 B-12 NA-5 SECURITY OF WELD PROCEDURE SETTINGS There are two means provided to prevent or limit unauthorized readjustment of the NA-5 voltage and wire feed speed controls once set to the desired procedure. 1. The security panel of the NA-5 can be locked to prevent access to the control knobs. 2. The control range of the p[...]

  • Page 36

    TABLE OF CONTENTS - ACCESSORIES SECTION - NA-5 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section C General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2 Listing of Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 37

    C-2 ACCESSORIES C-2 NA-5 Product Number Product Name K29 VERTICAL LIFT ADJUSTER K58 MAGNETIC SEPARATOR K96 HORIZONTAL ADJUSTER K129 SUBMERGED ARC SMALL WIRE TWINARC K148 CONTACT NOZZLE K149 LINC-FILL LONG STICKOUT EXTENSION K218 HORIZONTAL FILLET/LAP ATTACHMENT K219 FLUX HOPPER KIT K223 SOLENOID KIT K225 SUBMERGED ARC TWINARC KIT K238 HIGH FREQUENC[...]

  • Page 38

    ACCESSORIES C-3 C-3 NA-5 LISTING OF ACCESSORIES K29 VERTICAL LIFT ADJUSTER When mounted in the NA-5 head mounting system, the K29 Vertical Lift Adjuster provides quick hand crank adjustment of the vertical head position. It also has some horizontal adjustability as described in Sec. T3.2.3 of operator’s manual IM305. Installation instructions are[...]

  • Page 39

    ACCESSORIES C-4 C-4 K225 SUBMERGED ARC TWINARC KIT The Twinarc kit provides for the feeding of two 5/64, 3/32, or 1/8 in. (1.98, 2.38, or 3.18 mm) solid wires through a single wire feeder. The electrode wire must be the same size. The assembly includes a wire reel, insulated reel mounting bracket, wire straightener, dual wire guides, nozzle, and co[...]

  • Page 40

    ACCESSORIES C-5 C-5 NA-5 K334 START AND CRATER CONTROLS Easily installed procedure and timer boards to permit adjustment of wire speed and voltage. Can be installed to function at either the start of the weld or at the end for crater filling. Installation, operating, and maintenance instructions are shipped with each kit and can be ordered as Sec. [...]

  • 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

    TABLE OF CONTENTS - MAINTENANCE SECTION - NA-5 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section D Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D[...]

  • Page 43

    D-2 MAINTENANCE D-2 NA-5 CONTROL BOX GENERAL Inspect the control box every 3 months. If needed, blow dirt out using low pressure air. No further maintenance should be required. CIRCUIT PROTECTION The circuit breaker mounted on the left side of the control box protects the control circuit from short circuit conditions and from severe wire feed overl[...]

  • Page 44

    MAINTENANCE D-3 D-3 NA-5 The 1/8 amp fast-blow fuse, shown in Figure D.3, on a voltage PC board built since 1983, protects the NA-5 circuitry from damage which may result from a ground or case faulted control lead. If the fuse blows, the NA-5 voltage sensing lead circuit will be opened (Refer to Automatic Shutdown in Section B, Operating Procedures[...]

  • Page 45

    MAINTENANCE D-4 D-4 NA-5 WIRE DRIVE MOTOR Periodically inspect the wire drive motor brushes, Figure D.4. Replace the brushes as needed. CHANGING WIRE FEED GEAR RATIOS Four wire size conversion kits are available to modify the wire feeder for different size or type electrodes. The kits include drive rolls and guide tubes for the wire specified, as s[...]

  • Page 46

    MAINTENANCE D-5 D-5 NA-5 3. Pull the gear from the shaft using the screws as a pulling device. 4. Be certain woodruff key (8) is properly located on the shaft. Screw the adapter plate and motor assembly mounting screws into the new fiber input helical gear from the stenciled side and place the gear on the shaft. Replace plain washer (9), tighten th[...]

  • Page 47

    MAINTENANCE D-6 D-6 NA-5 OPTIONAL FEATURES CONTACT ASSEMBLIES A dirty or rusty electrode and excessively high currents cause rapid wear of the contact tips. The nozzle contact tip must be replaced when it no longer provides accurate wire location or good electrical contact. See Sec. T2.2.6, Sec. T2.2.7, or Sec. T2.5.3 of the IM305 manual for specif[...]

  • Page 48

    E-1 THEOR Y OF OPERA TION E-1 NA-5 T ABLE OF CONTENTS -THEOR Y OF OPERA TION SECTION- Theory of Operation ..................................................................................................................Section E General Description.....................................................................................................[...]

  • Page 49

    E-2 THEOR Y OF OPERA TION E-2 INPUT PO WER CIRCUITS The NA-5 control unit is supplied with 115VAC power usually from the welding power source. The 115VAC power is connected to the control box circuitry through the control cable receptacle, the input power switch and a 5 amp cir- cuit breaker. The 115VAC is applied through a 2 ohm resistor to the po[...]

  • Page 50

    E-3 THEOR Y OF OPERA TION E-3 PO WER AND V OL T A GE BO ARDS The AC voltages that are received by the power board are rectified and regu- lated. These DC voltages are supplied to the motor, voltage board and control board. The two SCR-controlled 115VDC supplies power the motor armature and field circuits. The actual arc voltage is sensed at leads #[...]

  • Page 51

    E-4 THEOR Y OF OPERA TION E-4 CONTROL, LOGIC AND PROCEDURE BO ARDS The logic board interprets and processes the signals it receives from the various PC boards, switches and con- trols. The logic board also houses a DC power supply (+5 -10) which is derived from the 22VAC received from the T2 transformer. This DC voltage is also used on the procedur[...]

  • Page 52

    E-5 THEOR Y OF OPERA TION E-5 OPTIONAL ST ART , CRA TER FILL AND WELD TIMER BO ARDS When installed, the optional start board dictates to the procedure board the starting wire feed speed and arc volt- age. This condition can be operator set for a predetermined period of time. These parameters can be set either higher or lower than those of the weld-[...]

  • Page 53

    E-6 THEOR Y OF OPERA TION E-6 NA-5 SCR OPERA TION A silicon controlled rectifier (SCR) is a three terminal device used to control rather large currents to a load. An SCR acts very much like a switch. When a gate signal is applied to the SCR it is turned ON and there is current flow from anode to cathode. In the ON state the SCR acts like a closed s[...]

  • Page 54

    NA-5 SECTION F-1 TR OUBLESHOO TING & REP AIR SECTION F-1 T ABLE OF CONTENTS -TR OUBLESHOO TING AND REP AIR SECTION- Troubleshooting and Repair ......................................................................................................Section F How to Use Troubleshooting Guide...........................................................[...]

  • Page 55

    W ARNING NA-5 F-2 TR OUBLESHOO TING & REP AIR F-2 This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three-step procedure listed below. Step 1. LOCATE PROBLEM (SYMPTOM). Look under the column labeled “PROBLEM (SYMPTOMS)”. This column describes possible symptoms that the mach[...]

  • Page 56

    NA-5 F-3 TR OUBLESHOO TING & REP AIR F-3 _______________________________ CAUTION: Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor electrical connections. To avoid problems when troubleshooting and replacing PC boards, please use the following procedure: 1 . Determine to the best o[...]

  • Page 57

    F-4 TR OUBLESHOO TING & REP AIR F-4 NA-5 Observe all Safety Guidelines 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 1-[...]

  • Page 58

    F-5 TR OUBLESHOO TING & REP AIR F-5 NA-5 Observe all Safety Guidelines 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 1-[...]

  • Page 59

    F-6 TR OUBLESHOO TING & REP AIR F-6 NA-5 Observe all Safety Guidelines 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 1-[...]

  • Page 60

    F-7 TR OUBLESHOO TING & REP AIR F-7 NA-5 Observe all Safety Guidelines 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 1-[...]

  • Page 61

    F-8 TR OUBLESHOO TING & REP AIR F-8 NA-5 Observe all Safety Guidelines 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 1-[...]

  • Page 62

    F-9 TR OUBLESHOO TING & REP AIR F-9 NA-5 Observe all Safety Guidelines 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 1-[...]

  • Page 63

    F-10 TR OUBLESHOO TING & REP AIR F-10 NA-5 Observe all Safety Guidelines 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 64

    F-11 TR OUBLESHOO TING & REP AIR F-11 NA-5 Observe all Safety Guidelines 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 65

    F-12 TR OUBLESHOO TING & REP AIR F-12 NA-5 Observe all Safety Guidelines 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 66

    F-13 TR OUBLESHOO TING & REP AIR F-13 NA-5 Observe all Safety Guidelines 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 67

    F-14 TR OUBLESHOO TING & REP AIR F-14 NA-5 Observe all Safety Guidelines 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 68

    F-15 TR OUBLESHOO TING & REP AIR F-15 NA-5 Observe all Safety Guidelines 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 69

    F-16 TR OUBLESHOO TING & REP AIR F-16 NA-5 Observe all Safety Guidelines 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 70

    F-17 TR OUBLESHOO TING & REP AIR F-17 NA-5 Observe all Safety Guidelines 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 71

    F-18 TR OUBLESHOO TING & REP AIR F-18 NA-5 Observe all Safety Guidelines 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 72

    F-19 TR OUBLESHOO TING & REP AIR F-19 NA-5 Observe all Safety Guidelines 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 73

    F-20 TR OUBLESHOO TING & REP AIR F-20 NA-5 Observe all Safety Guidelines 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 74

    F-21 TR OUBLESHOO TING & REP AIR F-21 NA-5 Observe all Safety Guidelines 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 75

    F-22 TR OUBLESHOO TING & REP AIR F-22 NA-5 Observe all Safety Guidelines 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 76

    F-23 TR OUBLESHOO TING & REP AIR F-23 NA-5 Observe all Safety Guidelines 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 77

    F-24 TR OUBLESHOO TING & REP AIR F-24 NA-5 Observe all Safety Guidelines 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 78

    F-25 TR OUBLESHOO TING & REP AIR F-25 NA-5 Observe all Safety Guidelines 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 79

    F-26 TR OUBLESHOO TING & REP AIR F-26 NA-5 Observe all Safety Guidelines 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 80

    F-27 TR OUBLESHOO TING & REP AIR F-27 NA-5 Observe all Safety Guidelines 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 81

    F-28 TR OUBLESHOO TING & REP AIR F-28 NA-5 Observe all Safety Guidelines 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 82

    F-29 TR OUBLESHOO TING & REP AIR F-29 NA-5 Observe all Safety Guidelines 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 83

    F-30 TR OUBLESHOO TING & REP AIR F-30 NA-5 Observe all Safety Guidelines 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 84

    F-31 TR OUBLESHOO TING & REP AIR F-31 NA-5 Observe all Safety Guidelines 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 85

    F-32 TR OUBLESHOO TING & REP AIR F-32 NA-5 Observe all Safety Guidelines 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 86

    F-33 TR OUBLESHOO TING & REP AIR F-33 NA-5 Observe all Safety Guidelines 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 87

    F-34 TR OUBLESHOO TING & REP AIR F-34 NA-5 Observe all Safety Guidelines 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 88

    F-35 TR OUBLESHOO TING & REP AIR F-35 NA-5 Observe all Safety Guidelines 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 89

    F-36 TR OUBLESHOO TING & REP AIR F-36 LED Number Functions Indicated By PC Board LEDS 1A +15VDC Analog Supply Present 1B -10VDC Analog Supply Present 1C Down Field Voltage Applied 1D Up Field Voltage Applied 1E Armature Voltage Applied 1F 115VDC Relay Supply Present 7A +15VDC Logic Supply Present 7B "Start" Switch Pressed 7C "Sto[...]

  • Page 90

    F-37 TR OUBLESHOO TING & REP AIR F-37 Light Location Idle "Inch Up" "Inch Down" "Start" "Stop" Burnback Weld Arc No. (PC Board) Mode Switch Switch Switch Switch Mode Establish Pressed Pressed Pressed Pressed 1A Power ON ON ON ON ON ON ON 1B Power ON ON ON ON ON ON ON 1C Power ON ON ON 1D Power ON ON ON ON[...]

  • Page 91

    NA-5 F-38 TR OUBLESHOO TING & REP AIR F-38 TEST DESCRIPTION This will help determine if the power and logic boards are supplying the correct DC voltages to the NA-5 circuitry. MA TERIALS NEEDED 5/16" Nutdriver Volt/Ohmmeter (Multimeter) Wiring diagram DC PO WER SUPPL Y TEST Ser vice and repair should be perf ormed only by Lincoln Electric [...]

  • Page 92

    F-39 TR OUBLESHOO TING & REP AIR F-39 TEST PROCEDURE 1. Remove input power to the NA-5. 2. Using the 5/16" nutdriver open the control box PC board access door. 3 . Locate the power, logic, voltage, control and procedure boards. See Figure F.1 4 . Apply 115VAC to the NA-5 wire feeder at the correct pins. See wiring diagram. 5. Perform the p[...]

  • Page 93

    F-40 TR OUBLESHOO TING & REP AIR F-40 CHECK POINT TEST CONNECTOR LEAD NO. NORMAL LOCATION DESCRIPTION PLUG PIN NO. ACCEPTABLE VOLTAGE READING CONTROL PC CHECK +15VDC PIN 10 + 525 + 14.0 - 16.0 VDC BOARD SUPPLY FROM PIN 9 - 510 - CONNECTOR POWER BOARD PLUG TO CONTROL BOARD VOLTAGE PC CHECK +15VDC PIN 3 + 525 + 14.0 - 16.0 VDC BOARD 12 PIN SUPPLY[...]

  • Page 94

    F-41 TR OUBLESHOO TING & REP AIR F-41 DC PO WER SUPPL Y TEST (continued) NA-5 CHECK POINT TEST CONNECTOR LEAD NO. NORMAL LOCATION DESCRIPTION PLUG PIN NO. ACCEPTABLE VOLTAGE READING PROCEDURE CHECK +15VDC PLUG J19 515 + PC BOARD SUPPLY FROM PIN 5 + J19 CONNECTOR LOGIC BOARD 14.0 - 16.0 VDC PLUG TO PLUG J19 500 - PROCEDURE BOARD PIN 15 - VOLTMET[...]

  • Page 95

    F-42 TR OUBLESHOO TING & REP AIR F-42 NA-5 TEST DESCRIPTION This test will help the technician to determine if the T1 and/or T2 transformers are functioning properly. MA TERIALS NEEDED 115VAC power supply Volt-Ohmmeter (Multimeter) 5/16" Nutdriver Slot head screwdriver T1 and T2 TRANSFORMER TEST Ser vice and repair should be perf ormed onl[...]

  • Page 96

    F-43 TR OUBLESHOO TING & REP AIR F-43 PROCEDURE 1. Remove all input power to the NA-5. 2. Using 5/16" nutdriver open the con- trol box PC board access door. 3. Locate the T1 and T2 transformers. See Figure F.2 4. Locate and remove the two sets of primary leads (#531B and #532) from the upper terminal strip TS2. Label leads for reassembly. [...]

  • Page 97

    F-44 TR OUBLESHOO TING & REP AIR F-44 7. Check for approximately 22VAC at the blue secondary leads. The blue secondary leads are connected to the logic board. See wiring diagram. 8. Check for approximately 18VAC at the white to red leads. The white and red leads are connected to the power board. See wiring diagram. 9. Check for approximately 36[...]

  • Page 98

    F-45 TR OUBLESHOO TING & REP AIR F-45 NA-5 TEST DESCRIPTION This test will aid the technician in determining if the transformer on the voltage board is func- tioning properly. MA TERIALS NEEDED 5/16" Nutdriver Phillips head screwdriver 115VAC power supply Volt/Ohmmeter V OL T A GE BO ARD TRANSFORMER TEST Ser vice and repair should be perf [...]

  • Page 99

    F-46 TR OUBLESHOO TING & REP AIR F-46 TEST PROCEDURE 1. Remove all input power to the NA-5. 2. Using the 5/16" nutdriver open the control box PC board access door. 3 . Locate the voltage board. See Figure F.3 4. Remove the molex type plugs from the voltage board. 5. Using the phillips head screwdriver remove the voltage board from the cont[...]

  • Page 100

    F-47 TR OUBLESHOO TING & REP AIR F-47 7. Using the 115VAC supply carefully apply 115VAC to pins #8 and #9 in the nine pin molex plug cavity on the voltage board. See Figure F.4 Make sure the board and leads are insulated from each other and any metal conductors. 8 . Using the voltmeter check for approximately 24VAC at the sec- ondary test point[...]

  • Page 101

    F-48 TR OUBLESHOO TING & REP AIR F-48 NA-5 TEST DESCRIPTION This test will determine if the wire drive motor is able to function when supplied with the cor- rect voltages.. MA TERIALS NEEDED Variable DC voltage supply 0 to 90 VDC Isolated DC voltage supply 0 to 120 VDC Volt/Ohmeter WIRE FEED DRIVE MO T OR TEST Ser vice and repair should be perf[...]

  • Page 102

    F-49 TR OUBLESHOO TING & REP AIR F-49 TEST PROCEDURE 1. Remove the wire feed motor connec- tor from the NA-5 control box. 2. Using the ohmmeter, measure the resistances per the table below. Also see Figure F.5. 3. If the motor resistance test is good, proceed to the Motor Applied Voltage Test . MO T OR APPLIED V OL T A GE TEST 1 . Carefully con[...]

  • Page 103

    F-50 TR OUBLESHOO TING & REP AIR F-50 NA-5 TEST DESCRIPTION This test will help the technician to determine if the external voltage sensing leads are con- nected properly and intact. MA TERIALS NEEDED Volt-Ohmmeter (Multimeter) 5/16" Nutdriver 3/4" wrench Wiring diagram EXTERNAL RESIST ANCE TEST (LEADS #21 AND #67) Ser vice and repair[...]

  • Page 104

    F-51 TR OUBLESHOO TING & REP AIR F-51 PROCEDURE 1. Make sure the electrode wire is fed through the wire contact assembly tip but NOT touching the "work" piece. 2. Disconnect input power to the NA-5. 3. Make sure the drive motor cable and power source control cables are properly connected to the NA-5 con- trol box. 4. Using the 5/16&qu[...]

  • Page 105

    F-52 TR OUBLESHOO TING & REP AIR F-52 NA-5 TEST DESCRIPTION This test will help determine if the out-of-voltage range shut down circuitry is functioning prop- erly. MA TERIALS NEEDED 5/16" Nutdriver Jumper wire Lincoln CV Power Source OUT OF V OL T A GE RANGE SHUT DO WN TEST Ser vice and repair should be perf ormed only by Lincoln Electric[...]

  • Page 106

    F-53 TR OUBLESHOO TING & REP AIR F-53 TEST PROCEDURE 1. Remove input power to the NA-5 2. Using the 5/16" nutdriver open the control box PC board access door. 3 . Locate the voltage PC board. Jumper together the "BYPASS" and “Common” pins on the NA-5 voltage PC board. See Figure F.6 (On older voltage boards these pins may be [...]

  • Page 107

    F-54 TR OUBLESHOO TING & REP AIR F-54 5 . Start welding and observe the ACTUAL voltage reading on the NA- 5 digital meter. The actual voltage must match the SET voltage within +/- 0.5VDC. If it does NOT, the NA- 5 is designed to shut down. 6. If the NA-5 continues to shut down with the "BYPASS" pins jumpered together, the voltage PC b[...]

  • Page 108

    F-55 TR OUBLESHOO TING & REP AIR F-55 T A CH BO ARD FEEDB A CK TEST NA-5 TEST DESCRIPTION This procedure will aid the technician to determine if the tach board is functioning properly. MA TERIALS NEEDED 5/16" Nutdriver Phillips head screwdriver Analog volt/ohmmeter (Multimeter) Wiring diagram Ser vice and repair should be perf ormed only b[...]

  • Page 109

    F-56 TR OUBLESHOO TING & REP AIR F-56 PROCEDURE 1. Remove input power to the NA-5. 2. Using the 5/16" nutdriver open the control box PC board access door. 3 . Locate leads #510A, #525A and #555 on the control board. 4 . Apply 115VAC to the NA-5 wire feeder at the correct pins. See wiring diagram. 5. Check leads #525A(+) to #510A(-) for the[...]

  • Page 110

    F-57 TR OUBLESHOO TING & REP AIR F-57 NA-5 V OL TMETER A CCURA CY TEST TEST DESCRIPTION This test will help determine if the NA-5 voltmeter is providing accurate readings. MA TERIALS NEEDED Digital volt/ohmmeter with at least 3-1/2 digits and +/-0.5% accuracy Ser vice and repair should be perf ormed only by Lincoln Electric factory trained per-[...]

  • Page 111

    F-58 TR OUBLESHOO TING & REP AIR F-58 TEST PROCEDURE Perform the following checks with the NA-5 connected to a Lincoln CV weld- ing power source according to the prop- er connection diagram. See the Installation Section of this manual. 1 . Connect the test voltmeter (see Materials Needed) between the "work" and the electrode cable con[...]

  • Page 112

    F-59 TR OUBLESHOO TING & REP AIR F-59 4. Remove the jumper wire from leads #2 and #4. 5 . Remove the test voltmeter and, while welding, compare the SET volts and ACTUAL volts meter read- ings. Depending upon the arc volt- age characteristics of the process being welded, the ACTUAL reading may vary somewhat about an aver- age value. The average [...]

  • Page 113

    F-60 TR OUBLESHOO TING & REP AIR F-60 NA-5 WIRE SPEED A CCURA CY TEST TEST DESCRIPTION This test will help determine if the NA-5 is providing the proper wire feed per inches of revolu- tion of the drive roll. MA TERIALS NEEDED Ruler or other linear measuring device 5/16" Nutdriver Ser vice and repair should be perf ormed only by Lincoln El[...]

  • Page 114

    F-61 TR OUBLESHOO TING & REP AIR F-61 TEST PROCEDURE Perform the following checks with the NA-5 connected to a Lincoln CV weld- ing power source according to the prop- er connection diagram. See the Installation Section of this manual. 1. Check to make sure the speedmeter calibration jumper is connected to the proper calibration pin for the hea[...]

  • Page 115

    F-62 TR OUBLESHOO TING & REP AIR F-62 2. Check for the proper wire feed inch- es per revolution of the drive roll. A. Set the Strike speed control to any setting between 50 and 125 IPM. While pressing the INCH DOWN button measure the pre- cise length of wire fed by exactly 10 revolutions of the drive roll. The measured length should be within t[...]

  • Page 116

    F-63 TR OUBLESHOO TING & REP AIR F-63 3. Check for the proper drive roll revo- lutions per minute. (RPM) A. Adjust the STRIKE speed con- trol to obtain the SET speed specified for the speedmeter calibration pin and head ratio specified per Table F.5 While pressing the INCH down button count the drive roll revolutions in 60 seconds. The drive ro[...]

  • Page 117

    F-64 TR OUBLESHOO TING & REP AIR F-64 NA-5 METER CIRCUIT A CCURA CY TEST TEST DESCRIPTION This test will help determine if the NA-5 meter circuit is functioning properly. MA TERIALS NEEDED Digital volt/ohmmeter with at least 3-1/2 digits and +/- 0.5% accuracy 5/16" Nutdriver Ser vice and repair should be perf ormed only by Lincoln Electric[...]

  • Page 118

    F-65 TR OUBLESHOO TING & REP AIR F-65 TEST PROCEDURE 1. Remove input power to the NA-5. 2. Using the 5/16" nutdriver open the control box PC board access door. 3. Locate the voltmeter PC board. See Figure F.9 4. Apply input power to the NA-5. 5. Test for AC supply to the volt- meter PC board . • Check for 8 to 11VAC from lead #601 to #60[...]

  • Page 119

    F-66 TR OUBLESHOO TING & REP AIR F-66 6. Test for DC volts on the voltmeter PC board. • Check for 4.75 to 5.25VDC from TP5 to lead #510C. See Figure F.9 Note: The coating will have to be removed from the test points to ensure accurate voltmeter readings. • If the display is NOT lit and the correct DC voltage is present at TP5 to lead #510C,[...]

  • Page 120

    F-67 TR OUBLESHOO TING & REP AIR F-67 8. Test Voltmeter PC Board Accuracy • Use a test meter with at least 3- 1/2 digits and +/- 0.5% accuracy. • Connect the + probe to lead #517 and the - probe to lead #510C. Do not disconnect plug. Note: The coating will have to be removed from the test points to ensure accurate meter readings. • With t[...]

  • Page 121

    F-68 TR OUBLESHOO TING & REP AIR F-68 9 . Locate the speedmeter PC board. See Figure F.10 10. Apply input power to the NA-5. 11. Test for AC supply to the speed- meter PC board. • Check for 8 to 11VAC from lead #601 ot #602. See Figure F.10 Note: The coating will have to be removed from the test points to ensure accurate voltmeter readings. I[...]

  • Page 122

    F-69 TR OUBLESHOO TING & REP AIR F-69 13. Test Speedmeter Digital Meter Accuracy • Use a test meter with at least 3- 1/2 digits and +/- 0.5% accuracy. • Connect the + probe to TP4 and the - probe to lead 510P. Do NOT disconnect plug. Note: The coating will have to be removed from the test points to ensure accurate meter readings. • With t[...]

  • Page 123

    F-70 TR OUBLESHOO TING & REP AIR F-70 14. Test Speedmeter PC Board Accuracy • Use a test meter with at least 3- 1/2 digits and +/- 0.5% accuracy. • Connect the + probe to lead #519 (Jumper lead) and the - probe to lead #510P. Do not discon- nect plug. Note: The coating will have to be removed from the test points to ensure accurate meter re[...]

  • Page 124

    F-71 TR OUBLESHOO TING & REP AIR F-71 NA-5 PC BO ARD(S) REMO V AL AND REPLA CEMENT DESCRIPTION The following procedure will aid the technician in removing and replacing the printed circuit boards for maintenance or replacement. MA TERIALS NEEDED Phillips head screwdriver 5/16" Nutdriver Ser vice and repair should be perf ormed only by Linc[...]

  • Page 125

    F-72 TR OUBLESHOO TING & REP AIR F-72 PROCEDURE Before starting the following procedure, refer to the PC Board Troubleshooting Procedures at the beginning of this section. 1. Remove the input power to the NA- 5. 2. Using the 5/16" nutdriver open the control box PC board cover. 3 . Carefully remove the molex type plugs (and leads) connected[...]

  • Page 126

    F-73 TR OUBLESHOO TING & REP AIR F-73 NA-5 DIGIT AL METER AND METER PC BO ARD REMO V AL AND REPLA CEMENT DESCRIPTION The following procedure will help the technician remove the digital meters and meter PC boards for repair or replacement. MA TERIALS NEEDED 5/16" Nutdriver Phillips head screwdriver Ser vice and repair should be perf ormed o[...]

  • Page 127

    F-74 TR OUBLESHOO TING & REP AIR F-74 METER PC BO ARD REMO V AL PROCEDURE 1. Remove input power to the NA-5. 2. Using the 5/16" nutdriver open the control box PC board access door. 3 . Locate and unplug the meter PC board that is to be removed. See Figure F.11 4. Using the 5/16" nutdriver remove the four PC board mounting nuts. See Fi[...]

  • Page 128

    F-75 TR OUBLESHOO TING & REP AIR F-75 DIGIT AL METER REMO V AL PROCEDURE 1. Using the phillips head screwdriver remove the four screws from the meter bezel. See Figure F.12 2. Carefully remove the bezel assem- bly. 3 . Carefully remove the meter shield assembly. 4 . Using the 5/16" nutdriver, remove the two nuts, screws and lockwash- ers h[...]

  • Page 129

    F-76 TR OUBLESHOO TING & REP AIR F-76 REPLA CEMENT PROCEDURE 1. With the 5/16" nutdriver, fasten the digital meter to the cover assembly with two screws, nuts and lockwash- ers. 2. Using the phillips head screwdriver, reattach the meter shield and bezel assembly. 3. Position the insulation and plug the PC meter board into the digital meter[...]

  • Page 130

    F-77 TR OUBLESHOO TING & REP AIR F-77 NA-5 T A CH PC BO ARD REMO V AL AND REPLA CEMENT DESCRIPTION The following procedure will help the technician remove the Tach PC board and related com- ponents for repair or replacement. MA TERIALS NEEDED 5/16" Nutdriver Slot head screwdriver Phillips head screwdriver 3/8" Wrench Ser vice and repa[...]

  • Page 131

    F-78 TR OUBLESHOO TING & REP AIR F-78 PROCEDURE 1. Remove input power to the NA-5. 2. With the 5/16" nutdriver locate and remove the four screws holding the tach cover to the wire feed drive motor. See Figure F.13 3. Using the 5/16" nutdriver remove the two screws from the connection box cover. 4 . Locate and disconnect the in-line co[...]

  • Page 132

    F-79 TR OUBLESHOO TING & REP AIR F-79 7 . Carefully remove the rotating disc and tach PC board together. Note spacer washers underneath the disc. 8. If tach PC board is to be removed carefully remove leads from connec- tion box and cover plate. T A CH PC BO ARD REMO V AL AND REPLA CEMENT (Continued) NA-5 FIGURE F.14 PICK-UP ASSEMBLY AND COVER T[...]

  • Page 133

    F-80 TR OUBLESHOO TING & REP AIR F-80 REASSEMBL Y 1. Upon reassembly the spacers must be used to assure that the disc rotates freely and smoothly within the sensor "window" on the printed circuit board. Note the tach PC board must be held in place when aligning the rotating disc in the sen- sor window. Press down on the tach PC board [...]

  • Page 134

    F-81 TR OUBLESHOO TING & REP AIR F-81 NA-5 WIRE DRIVE MO T OR REMO V AL AND REPLA CEMENT DESCRIPTION This procedure will aid the technician in the removal and replacement of the drive motor to the gear box and also associated wiring to the control box. MA TERIALS NEEDED 7/16" Wrench 5/16" Nutdriver Large slot head screwdriver Ser vice[...]

  • Page 135

    F-82 TR OUBLESHOO TING & REP AIR F-82 MO T OR REMO V AL PROCEDURE 1. Remove input power to the NA-5. 2 . Remove the motor and tach cable from the NA-5 control box. 3. Perform the Tach Board Removal Procedure . 4 . Using the slot head screwdriver remove the two screws mounting the tach housing to the drive motor. Remove the tach housing from the[...]

  • Page 136

    F-83 TR OUBLESHOO TING & REP AIR F-83 8 . Remove leads #67, #627, #626, #539 and #541 from the terminal strip in the connector box. 9. Using the 7/16" wrench, remove two 1/4-20 bolts holding the adapter plate and motor assembly to the wire feed gear box. (Older models may have slot head 1/4-20 bolts). See Figure F.17 10. Using the large sl[...]

  • Page 137

    F-84 TR OUBLESHOO TING & REP AIR F-84 MO T OR REPLA CEMENT PROCEDURE 1. Attach the adapter plate to the drive motor using the slot head screwdriv- er. 2 . Carefully install the replacement motor (with correct pinion) and mount the adapter mounting plate using the 1/4-20 bolts and slot head screws previously removed. 3. Attach leads #67, #627, #[...]

  • Page 138

    F-85 TR OUBLESHOO TING & REP AIR 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:.............[...]

  • Page 139

    F-86 NO TES 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

    G-1 ELECTRICAL DIA GRAMS G-1 T ABLE OF CONTENTS -ELECTRICAL DIA GRAMS SECTION- Electrical Diagrams ....................................................................................................................Section G Wiring Diagram ..............................................................................................................[...]

  • Page 141

    NO TES 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

    G-2 ELECTRICAL DIA GRAMS NA-5 Wiring Diagram 1553 8-24-84H 11-14-86L 7-19-91J 7-10-92B 5-19-95D 1-12-96D 7-12-96P NA-5 WIRING DIAGRAM DAD NONE 1553 8-1-80 5-8-92 G1512 t UNLESS OTHERWISE SPECIFIED TOLERANCE ON HOLE SIZES PER E2056 ON 2 PLACE DECIMALS IS .02 WITH PUBLISHED STANDARDS. ON 3 PLACE DECIMALS IS .002 ON ALL ANGLES IS .5 OF A DEGREE MATERI[...]

  • Page 143

    G-3 ELECTRICAL DIA GRAMS NA-5 LOGIC PC BO ARD (L6242-1) SCHEMA TIC R707 R706 581 S801A DISABLE START 500 D9C START S5 581A N.A. C706 DZ702 LED 7C 515 D8C R702 R703 D710 500 D9C S6 582 C704 DZ701 STOP R704 565 PROCEDURE PC BOARD WELD TIME OVER D708 C728 500 D9C R705 C705 500 D9C + 5 4 X707 B 6 1 2 A X707 3 515 D8C R713 LED7D R712 D714 R711 + CR4 CUR[...]

  • Page 144

    G-4 ELECTRICAL DIA GRAMS NA-5 LOGIC PC BO ARD (L6242-2 & above) SCHEMA TIC 3 2 1 3 4 SWITCH #2 4 4 1 4 2 3 4 1 2 3 4 4 4 SWITCH #1 SWITCH #2 2 Inch up with no contactor delay Methods of Burnback 1 1 SWITCH #2 3 SWITCH #2 4 3 1 2 4 4 D30 1.00K R36 X6 7 14 1.50K R38 D33 50V .022 C3 D34 4011 X2 14 7 C17 D35 4011 X4 14 7 4011 X1 14 7 C18 X5 7 14 C1[...]

  • Page 145

    G-5 ELECTRICAL DIA GRAMS NA-5 PO WER PC BO ARD (L6252-1) SCHEMA TIC 6682-1 Ch'ge. Sht. No. 11-20-81G 9-7-84A 5-18-92N 9-11-92J 3-31-94E t UNLESS OTHERWISE SPECIFIED TOLERANCE ON HOLE SIZES PER E2056 ON 2 PLACE DECIMALS IS .02 WITH PUBLISHED STANDARDS. ON 3 PLACE DECIMALS IS .002 ON ALL ANGLES IS .5 OF A DEGREE MATERIAL TOLERANCE (" "[...]

  • Page 146

    G-6 ELECTRICAL DIA GRAMS NA-5 PO WER PC BO ARD (L6252-2 & above) SCHEMA TIC CR1 OFF TRAVEL AUTO HAND S1B CR7 626 666 CR6 S2 FOR THE NA-5R ONLY: BURNBACK KIT IS CONNECTED TO 631 AND 532. 631 AND CR2 ARE REMOVED ON THE NA-5R. MOTOR ARMATURE WIRE FEED 18 115 VAC 531B 532 WIRE FEED 3000 .0047 3000 .0047 BLK 531B RED MOTOR FIELD WHT 500 P1 J3 6 P1 J[...]

  • Page 147

    G-7 ELECTRICAL DIA GRAMS NA-5 V OL T A GE PC BO ARD SCHEMA TIC 6682-3 Ch'ge. Sht. No. 9-27-85E 11-14-86L 3-6-92B 7-10-92A 3-25-94 11-17-95G t UNLESS OTHERWISE SPECIFIED TOLERANCE ON HOLE SIZES PER E2056 ON 2 PLACE DECIMALS IS .02 WITH PUBLISHED STANDARDS. ON 3 PLACE DECIMALS IS .002 ON ALL ANGLES IS .5 OF A DEGREE MATERIAL TOLERANCE (" &q[...]

  • Page 148

    G-8 ELECTRICAL DIA GRAMS NA-5 CONTROL CIRCUIT SCHEMA TIC 6682-2 Ch'ge. Sht. No. 11-9-90D 7-19-91J 3-6-92B 5-15-92N 7-10-92A t UNLESS OTHERWISE SPECIFIED TOLERANCE ON HOLE SIZES PER E2056 ON 2 PLACE DECIMALS IS .02 WITH PUBLISHED STANDARDS. ON 3 PLACE DECIMALS IS .002 ON ALL ANGLES IS .5 OF A DEGREE MATERIAL TOLERANCE (" ") TO AGREE E[...]

  • Page 149

    G-9 ELECTRICAL DIA GRAMS NA-5 PROCEDURE PC BO ARD SCHEMA TIC 563 520 PCB L 565 564 N.E. SPEED WELD N.E. 515 500 500 515 500 520 515 500 J9 4 J10 2 J10 11 J10 9 J10 6 J10 15 J10 12 J10 13 J10 14 J10 8 J9 5 J10 4 J10 1 26.7K R16 C9 J9 6 J10 3 4.75K R17 5.62K R7 X1 1 2 13 10K 2W CW R8 C7 J19 11 X1 10 11 12 C5 J19 10 C4 332 R9 4.7 35V C8 600mA 40V Q2 5[...]

  • Page 150

    G-10 ELECTRICAL DIA GRAMS NA-5 OPTION & TIMER PC BO ARD SCHEMA TICS 6682-5 Ch'ge. Sht. No. 9-7-84A 1-31-86A 7-11-86D 3-6-92B 7-10-92A t UNLESS OTHERWISE SPECIFIED TOLERANCE ON HOLE SIZES PER E2056 ON 2 PLACE DECIMALS IS .02 WITH PUBLISHED STANDARDS. ON 3 PLACE DECIMALS IS .002 ON ALL ANGLES IS .5 OF A DEGREE MATERIAL TOLERANCE (" &quo[...]

  • Page 151

    G-11 ELECTRICAL DIA GRAMS NA-5 METER PC BO ARD SCHEMA TIC & LA Y OUT 515 21143 514 SET S SPEED 512 511 ACTUAL 516 513 VOLTS TO DIGITAL METER 510A 510B 10 VAC 2 +5V 602 WIRE CIRCUIT BOARD B3 J14 2 J14 3 J14 10 J14 5 J14 9 J14 7 J14 4 J14 1 J14 6 J14 8 D3 500 50V C1 C3 OUT IN GND X1 D5 4.7 35V C2 D2 D1 B6 B2 B5 B1 2.8K R3 24.3K R1 2K CW R2 C4 D4 [...]

  • Page 152

    G-12 ELECTRICAL DIA GRAMS NA-5 MISCELLANEOUS PC BO ARDS IDENTIFICATION PART NO. REQ'D ITEM CAPACITORS = MFD/VOLTS RESISTORES = OHMS D3 D2 L6252-2 NA-5 POWER R1 R17 R21 R22 R18 R20 R19 R2 R7 R8 R9 R11 R12 R6 R4 R3 R10 R14 R15 R16 X2 X1 SCR3 SCR4 D1 C24 C22 C20 C11 C12 C10 C9 C6 C5 C8 C19 C7 C16 C17 C3 C4 C2 C13 C21 C18 C1 DZ1 D10 D8 D11 D14 D15[...]