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Lincoln Electric NA-5N, NA-5NF, NA-5S, NA-5SF service manual - page 7

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Contents

Main NA-5 AUTOMATIC WELDING SYSTEMS SERVICE MANUAL SVM131-A SAFETY FOR ENGINE powered equipment. WARNING ELECTRIC AND MAGNETIC FIELDS may be dangerous SAFETY ARC RAYS can burn. ELECTRIC SHOCK can kill. FUMES AND GASES can be dangerous. SAFETY FOR ELECTRICALLY powered equipment. CYLINDER may explode if damaged. WELDING SPARKS can cause fire or explosion. SAFETY PRCAUTIONS DE SRET PRCAUTIONS DE SRET POUR LES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR Mar.93 vv MASTER TABLE OF CONTENTS FOR ALL SECTIONS Page - INSTALLATION SECTION - Section ASection A A-2 INSTALLATION A-2 TECHNICAL SPECIFICATIONS NA-5 INSTALLATION A-3 INSTALLATION MECHANICAL INSTALLATION INTRODUCTION CONTROL BOX INSTALLATION A-4 WELDING HEAD INSTALLATION INSTALLATION ELECTRICAL INSTALLATION INPUT POWER REQUIREMENTS CONTROL BOX TO WELDING HEAD CONNECTIONS INSTALLATION POWER SUPPLY TO CONTROL BOX CONNECTIONS A-7 INSTALLATION ELECTRODE POLARITY POWER SOURCE CONNECTION DIAGRAMS INSTALLATION FIGURE A.8 CONNECTION OF NA-5 (ALL) TO A DC-600. INSTALLATION FIGURE A.9 CONNECTION OF NA-5 (ALL) TO A DC-650 PRO P A R P INSTALLATION B INSTALLATION FIGURE A.11 CONNECTION OF NA-5 (ALL) TO A SAM-400 MOTOR GENERATOR OR ENGINE WELDER. INSTALLATION FIGURE A.12 CONNECTION OF NA-5 (ALL) TO A SAM-650 ENGINE WELDER. INSTALLATION FIGURE A.13 CONNECTION OF NA-5 TO DC-1000 OR DC-1500. POWER SOURCE CONTROL CABLE BOLT TO CABLES FROM NA-5 WIRE CONTACT ASSEMBLY INSTALLATION FIGURE A.14 CONNECTION OF NA-5 TO DC-400 OR CV-400. Page - OPERATING INSTRUCTIONS SECTION - Section BSection B OPERATORS INSTRUCTIONS without readjusting the controls B-2 OPERATING INSTRUCTIONS B-2 SAFETY PRECAUTIONS OPERATING INSTRUCTIONS CONTROLS AND THEIR FUNCTIONS EXPOSED CONTROLS (WITH LOCKABLE COVER DOWN) CONTROLS UNDER THE LOCKABLE SECURITY COVER OPERATING INSTRUCTIONS SETUP INSTRUCTIONS Electrode Polarity Starting and Stopping Sequences Starting and Stopping Sequences OPERATING INSTRUCTIONS Setting Travel Starting and Stopping STARTING AND STOPPING SEQUENCES MEANS OF ARC STRIKING Setting Travel Starting and Stopping OPERATING INSTRUCTIONS must SETTING TRAVEL STARTING AND STOPPING STARTING SEQUENCES STOPPING SEQUENCES Page OPERATING INSTRUCTIONS VOLTAGE CONTROL RESPONSE OPERATING INSTRUCTIONS VOLTAGE NA-5 AUTOMATIC SHUTDOWN Cold Start Circuitry. OPERATING INSTRUCTIONS COLD START CIRCUITRY OPERATING INSTRUCTIONS SECURITY OF WELD PROCEDURE SETTINGS - ACCESSORIES SECTION - Section CSection C C-2 ACCESSORIES C-2 GENERAL ACCESSORIES LISTING OF ACCESSORIES K29 VERTICAL LIFT ADJUSTER K58 MAGNETIC SEPARATOR K96 HORIZONTAL ADJUSTER ACCESSORIES K225 SUBMERGED ARC TWINARC KIT K238 HIGH FREQUENCY UNIT K239 TWINARC KIT FOR INNERSHIELDELECTRODES K278 SPREADARC ACCESSORIES K334 START AND CRATER CONTROLS K336 REMOTE INTERFACE MODULE K337 WELD TIMER MODULE K349 MULTI-PROCEDURE KIT Page - MAINTENANCE SECTION - Section DSection D D-2 MAINTENANCE low D-2 CONTROL BOX GENERAL MAINTENANCE Automatic Shutdown VOLTAGE NA-5 GROUND FAULT FUSE PROTECTION MAINTENANCE WIRE DRIVE MOTOR CHANGING WIRE FEED GEAR RATIOS MAINTENANCE WIRE DRIVE MECHANISM WIRE STRAIGHTENERS MAINTENANCE OPTIONAL FEATURES CONTACT ASSEMBLIES WIRE REEL MOUNTING FOR 50 OR 60 LB (22.7 OR 27.2 KG) COILS TRAVEL CARRIAGE Page E-2 INPUT POWER CIRCUITS FIGURE E.1 Input Circuits GENERAL DESCRIPTION E-3 POWER AND VOLTAGE BOARDS FIGURE E.2 Power and Voltage Boards E-4 CONTROL, LOGIC AND PROCEDURE BOARDS FIGURE E.4 Control Logic and Procedure Boards E-5 STRIKE D OPTIONAL START, CRATER FILL AND WELD TIMER BOARDS FIGURE E.3 Optional Start, Crater Fill and Weld Timer Boards VOLTAGE MOTOR LOGIC SCR OPERATION TABLE OF CONTENTS -TROUBLESHOOTING AND REPAIR SECTION- Step 1. LOCATE PROBLEM (SYMPTOM). Step 2. PERFORM EXTERNAL TESTS. Step 3. RECOMMENDED COURSE OF ACTION HOW TO USE TROUBLESHOOTING GUIDE _______________________________ PC BOARD TROUBLESHOOTING PROCEDURES F-4 F-5 Table F.1. T1 and T2 Transformer Test. Wire Drive Motor Test. F-6 F-7 Voltage Board Transformer #21 - #67 External Resistance Test. F-8 F-9 #21-#67 External resis- tance Test. F-10 #21-#67 External ResistanceTest. Page F-12 T1 and T2 Transformer Test. F-13 F-14 F-15 F-16 F-17 F-18 F-19 F-20 Wire Drive Motor Test. F-21 F-22 TRAVEL FUNCTION PROBLEMS F-23 TRAVEL FUNCTION PROBLEMS F-24 Operation Section. Wire Speed Accuracy Test F-25 Wire Speed Accuracy Test F-26 Tach Board Feedback Test. Tach Board Feedback Test Voltmeter Accuracy F-27 Voltmeter Accuracy Accuraty Test. F-28 Out of Voltage Range Shutdown Test. F-29 F-30 F-31 STARTING/WELDING PROBLEMS Page F-33 F-34 WELDING PROBLEMS Page LED Number Functions Indicated By PC Board LEDS PC BOARD LED (LIGHT) DEFINITIONS NA-5 POWER OILCG NA-5 PC BOARD LED (LIGHT) SEQUENCE TABLE ABOVE CODE 8300 DC POWER SUPPLY TEST Page Page Page T1 and T2 TRANSFORMER TEST Page T1 and T2 TRANSFORMER TEST VOLTAGE BOARD TRANSFORMER TEST VOLT AGE BOARD TRANSFORMER TEST VOLTAGE BOARD VOLT AGE BOARD TRANSFORMER TEST { WIRE FEED DRIVE MOTORTEST Motor Applied Voltage MOTOR APPLIED VOLT AGE TEST WIRE FEED DRIVE MOTORTEST EXTERNAL RESISTANCE TEST (LEADS #21 AND #67) EXTERNAL RESISTANCE TEST (LEADS #21 AND #67) TABLE F.2 EXTERNAL VOLTAGE SENSING LEADS TEST POINTS OUT OF VOLTAGE RANGE SHUT DOWN TEST Installation section OUT OF VOL TAGE RANGE SHUT DOWN TEST External Resistance Test TACH BOARD FEEDBACK TEST TACH BO ARD FEEDBACK TEST Page Installation Section VOLTMETER A CCURACY TEST CR3 RELAY WIRE SPEED ACCURACY TEST Installation Section Troubleshooting Guide (Feeding Problems) Page METER CIRCUIT ACCURACY TEST L6685-[ ] METER Page Page NA5 SPEED METER L6233 Page Page PC BOARD(S) REMOVAL AND REPLACEMENT PC Board Troubleshooting Procedures REPLACEMENT PROCEDURE PC BOARD(S) REMOV AL AND REPLACEMENT Page Page Page REPLACEMENT PROCEDURE TACH PC BOARD REMOVAL AND REPLACEMENT TACH PC BO ARD REMOVAL AND REPLACEMENT Page REASSEMBLY WIRE DRIVE MOTOR REMOVAL AND REPLACEMENT MOTOR REMOVAL Tach Board Removal Procedure WIRE DRIVE MOTOR TACH HOUSING COVER PLATE ADAPTER Page MOTOR REPLACEMENT Tach Board Replacement Procedure RETEST AFTER REPAIR Troubleshooting Section Out of Voltage Range Shut Down Test Wire Speed Accuracy Test Voltmeter Accuracy Test Page G-1 TABLE OF CONTENTS -ELECTRICAL DIAGRAMS SECTION- Page G-2 Wiring Diagram J28 J29 (COMPONENT SIDE OF P.C. BOARD) G-2 G-3 } LOGIC PC BOARD (L6242-1) SCHEMATIC ELECTRICAL SYMBOLS PER E1537 CLEVELAND, OHIO U.S.A. 1-12-96D L6682-4 G-4 LOGIC PC BOARD (L6242-2 & above) SCHEMATIC 1-12-96D (Optional procedure receptacle) G-4 G-5 POWER PC BOARD (L6252-1) SCHEMATIC SCHEMATIC FOR COMPONENT VALUES AND CIRCUIT CONNECTIONS. CLEVELAND, OHIO U.S.A. THE LINCOLN ELECTRIC CO. G-5 G-6 POWER PC BOARD (L6252-2 & above) SCHEMATIC POWER P.C. BOARD SCHEMATIC 5/12/92 NOTES : G-6 G-7 VOLTAGE PC BOARD SCHEMATIC Return to Section TOC Return to Section TOC Return to Section TOC Retur n to Section TOC SHUTDOW CIRCUIT - G-7 G-8 CONTROL CIRCUIT SCHEMATIC ELECTRICAL SYMBOLS PER E1537. ACCELERATION CIRCUIT FEED ENABLE CIRCUIT G-8 G-9 PROCEDURE PC BOARD SCHEMATIC 7-12-96N 7-10-92N 3-6-92B G-9 G-10 OPTION & TIMER PC BOARD SCHEMATICS ELECTRICAL SYMBOLS PER E1537 OPTION BOARD CLEVELAND, OHIO U.S.A. G-10 G-11 METER PC BOARD SCHEMATIC & LAYOUT 510C X1 C1 G-11 IDENTIFICATION PART NO. REQ'D ITEM R2 517 POWER BOARD LOGIC BOARD PROCEDURE BOARD BYPASS BOARD