Manuals / Lincoln Electric / Power Tools / Welding System

Lincoln Electric NA-5NF, NA-5SF service manual Maintenance Section D

Models: NA-5S NA-5N NA-5SF NA-5NF

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Section D	TABLE OF CONTENTS	Section D
	- MAINTENANCE SECTION -

Maintenance	Section D
Control Box	D-2
General	D-2
Circuit Protection	D-2
Ground Fault Fuse Protection	D-3
Welding Head	D-3
Wire Drive Gear Box	D-3
Wire Drive Motor	D-4
Changing Wire Feed Gear Ratios	D-4
Wire Drive Mechanism	D-5
Wire Straighteners	D-5
Optional Features	D-6
Contact Assemblies	D-6
Wire Reel Mounting for 50 or 60 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

NA-5

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Lincoln Electric NA-5NF, NA-5SF service manual Maintenance Section D

Contents

Safety Depends on You NA-5NF NA-5S NA-5SFISAFETYi ARC Rays can burn SafetyElectric Shock can kill Fumes and Gases can be dangerousCylinder may explode if damaged Welding Sparks can cause fire or explosionPrécautions DE Sûreté Sûreté Pour Soudage a L’ArcMaster Table of Contents for ALL Sections Return to Master TOC Table of Contents Installation SectionInstallation Section a Installation Technical Specifications NA-5Control Cable Power Source Tachometer FT 1.2 M CableIntroduction Mechanical InstallationControl BOX Installation Electric Shock can killHoles Welding Head InstallationPlaces Thread Holes View from BottomControl BOX to Welding Head Connections Electrical InstallationInput Power Requirements Table A.1Power Supply to Control BOX Connections Power Source Connection Diagrams Electrode PolarityFigure A.8 Connection of NA-5 ALL to a DC-600 Figure A.9 Connection of NA-5 ALL to a DC-650 PRO Figure A.10 Connection of NA-5 ALL to a R3S-400, -600, or With no Line Voltage Compensator ObsoleteSAM Power Source Settings Power Source TAP To NA-5 Input Cable Plug Figure A.13 Connection of NA-5 to DC-1000 or DC-1500 Figure A.14 Connection of NA-5 to DC-400 or CV-400 NA-5 Table of Contents Operating Instructions SectionOPERATOR’S Instructions Safety PrecautionsOperating Instructions Welding SparksControls Their Functions Exposed Controls with Lockable Cover DownControls Under the Lockable Security Cover Setup Instructions Auto TABSee the Starting and Stopping Sequences section Travel Starting and Stopping or Starting and Stopping SequencesMeans of ARC Striking Travel Starting and Stopping sectionStarting Sequences Setting Travel Starting and StoppingReconfiguring the Travel Sequences Stopping SequencesTable B.1 Travel Sequence Lead and Switch Positions Travel Starts Travel Stops Older Models Newer ModelsWire Feed Motor Acceleration Electric Shock can kill Burnback and Electrode BackupOptional Crater Controls Table B.2 Stopping Sequence Settings Voltage Control ResponseAutomatic Shutdown Start CircuitryElectrode Backup Cold Start CircuitryAuto Stop Security of Weld Procedure Settings Table of Contents Accessories SectionGeneral AccessoriesTable C.1 NA-5 Automatic Welding System Accessories Product Number Product NameListing of Accessories K238 High Frequency Unit K281 Solid Wire Straightener for Tiny TwinarcK225 Submerged ARC Twinarc KIT K239 Twinarc KIT for Innershield ElectrodesK334 Start and Crater K337 Weld Timer Module SPEED-FEED ReelK349 MULTI-PROCEDURE KIT Controls Relay ModulesNA-5 Maintenance Section Maintenance Section DGeneral MaintenanceControl BOX Circuit ProtectionGround Fault Fuse Protection FAST-BLOW FusePipe Plug Wire Drive Motor Changing Wire Feed Gear RatiosSolid Electrode Wire Drive MechanismWire Straighteners Flux-Cored ElectrodeOptional Features Table of Contents Theory of Operation Section Theory of OperationInput Power Circuits General DescriptionPower and Voltage BoardsProcedure Boards CONTROL, LogicOptional START, Crater Fill and Weld Timer Boards 5E-5SCR Operation Figure E.4 SCR Operation NA-5Troubleshooting & Repair Table of Contents Troubleshooting and Repair SectionHOW to USE Troubleshooting Guide Recommended Course of ActionPC Board Troubleshooting Procedures Board can be dam- aged by static electricitySymptoms Possible AreasT2 Transformer Test Drive Motor TestCourse of Action Possible Areas Recommended SymptomsPerform the Wire Drive Motor TestTroubleshooting & Repair Problems Possible Areas Recommended Symptoms To Section TOC Perform the #21-#67 External ResistanceTestTroubleshooting & Repair Perform the DC Power Supply Transformer TestProblems Possible Areas Recommended Symptoms Troubleshooting & Repair Mode Function Problems Troubleshooting & Repair Troubleshooting & Repair Troubleshooting & Repair Problems Function Problems Wire Drive Motor TestTOC Travel Function Problems Troubleshooting & Repair Problems Possible Areas SectionAccuracy Test Function Problems Accuracy Test Perform the Meter CircuitPerform the Voltmeter Accuracy Feedback TestIf the Tach Board Feedback Perform the Meter Circuit Accuracy TestProblems Perform the Out of Voltage Range Shutdown Test Circuit breaker trips when Power board may be faulty Circuit breaker trips after Check to make sure there are not STARTING/WELDING Problems Welding Problems Function Problems Welding Problems Welding Problems PC Board LED Light Definitions PC Board LED Light Sequence Table Above Code DC Power Supply Test Test DescriptionMaterials Needed Plugs for loose or faulty connec DC Power Supply TestTest Procedure Also check associated leadsDC Power Supply Test Table F.1 DC Power Supply Checks T1 and T2 Transformer Test Test DescriptionProcedure Figure F.2 T1 and T2 TransformersReturn to Section Return to Section TOC Voltage Board Transformer Test Test DescriptionTest Procedure Voltage Board Transformer Test24VAC Secondary Test Points Wire Feed Drive Motor Test Test DescriptionMotor Applied Voltage Test Wire Feed Drive Motor TestArmature Voltage First pins VDC supply Supply TurnedExternal Resistance Test Leads #21 and #67 External Resistance Test Leads #21 and #67 Table F.2 External Voltage Sensing Leads Test PointsTest Points Expected Comments Resistances Conditions OUT of Voltage Range Shut Down Test OUT of Voltage Range Shut Down Test Figure F.6 Voltage Board and PIN LocationsReturn to Section Return to Section TOC Tach Board Feedback Test Test DescriptionProcedure Tach Board Feedback TestVoltmeter Accuracy Test Voltmeter Accuracy Test Figure F.7 Test Meter Connection PointsCR3 Relay Wire Speed Accuracy Test Test DescriptionWire Speed Accuracy Test Test ProcedureTable F.4 Troubleshooting & Repair Meter Circuit Accuracy Test Test DescriptionMeter Circuit Accuracy Test Test for AC supply to the volt- meter PC boardNA-5 SET Volts Reading Test Voltmeter Reading Test Voltmeter PC Board Accuracy Test for AC supply to the speed- meter PC board Test for DC volts on the speed- meter PC boardTest Speedmeter Digital Meter Accuracy NA-5 SET Speed Reading Test Voltmeter Reading IPMTest Speedmeter PC Board Accuracy PC Boards Removal and Replacement DescriptionPC Boards Removal and Replacement Replacement ProcedureDigital Meter and Meter PC Board Removal and Replacement Meter PC Board Removal Procedure Figure F.11 Meter PC BOARD, Mounting Nuts and PlugDigital Meter Removal Procedure Figure F.12 Meter Bezel and Screw LocationsReplacement Procedure Tach PC Board Removal and Replacement DescriptionTach PC Board Removal and Replacement Pickup Assembly Wire Drive Motor Tach CoverPhillips Screw Disc NUT Tach PC Board Reassembly Wire Drive Motor Removal and Replacement DescriptionWire Drive Motor Removal and Replacement Motor Removal ProcedurePerform the Tach Board Removal Procedure Figure F.17 Drive Motor Motor Replacement Procedure Gear Ratio Wire Speed Range in/min m/min Retest After RepairNA-5 Electrical Diagrams Table of Contents Electrical Diagrams SectionNA-5 Wiring Diagram Logic PC Board L6242-1 Schematic KEY to SymbolsLogic PC Board L6242-2 & above Schematic Power PC Board L6252-1 Schematic C D E F G H JPower PC Board L6252-2 & above Schematic Voltage PC Board Schematic Return toControl Circuit Schematic C D E F G H L MProcedure PC Board Schematic Start Module Weld Timer Crater Module Burnback TimerOption & Timer PC Board Schematics Timer BoardMeter PC Board Schematic & Layout 21143Power Board Logic Board Miscellaneous PC Boards