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Lincoln Electric NA-5NF, NA-5SF service manual Table of Contents, Installation Section a

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

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Section A	TABLE OF CONTENTS	Section A
	- INSTALLATION SECTION -

Installation		Section A
	Technical Specifications	A-2
	Mechanical Installation	A-4
	Introduction	A-4
	Control Box Installation	A-4
	Welding Head Installation	A-5
	Electrical Installation	A-6
	Input Power Requirements	A-6
	Control Box to Welding Head Connections	A-6
	Power Supply to Control Box Connections	A-7
	Electrode Polarity	A-8
	Power Source Connection 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 of NA-5 to DC-1000 or DC-1500 . . . .	A-14
	Figure A.14 — Connection of NA-5 to DC-400 or CV-400	A-15

NA-5

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Lincoln Electric NA-5NF, NA-5SF service manual Table of Contents, Installation Section a

Contents

Safety Depends on You NA-5NF NA-5S NA-5SFISAFETYi Safety Electric Shock can killARC Rays can burn 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 Installation Section a Table of ContentsInstallation Section Installation Technical Specifications NA-5Control Cable Power Source Tachometer FT 1.2 M CableMechanical Installation Control BOX InstallationIntroduction Electric Shock can killWelding Head Installation PlacesHoles Thread Holes View from BottomElectrical Installation Input Power RequirementsControl BOX to Welding Head Connections 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 SectionSafety Precautions Operating InstructionsOPERATOR’S Instructions Welding SparksControls Under the Lockable Security Cover Controls Their FunctionsExposed Controls with Lockable Cover Down See the Starting and Stopping Sequences section Setup InstructionsAuto TAB Starting and Stopping Sequences Means of ARC StrikingTravel Starting and Stopping or Travel Starting and Stopping sectionSetting Travel Starting and Stopping Reconfiguring the Travel SequencesStarting Sequences Stopping SequencesTable B.1 Travel Sequence Lead and Switch Positions Travel Starts Travel Stops Older Models Newer ModelsOptional Crater Controls Wire Feed Motor Acceleration Electric Shock can killBurnback and Electrode Backup Table B.2 Stopping Sequence Settings Voltage Control ResponseAutomatic Shutdown Start CircuitryAuto Stop Electrode BackupCold Start Circuitry Security of Weld Procedure Settings Table of Contents Accessories SectionAccessories Table C.1 NA-5 Automatic Welding System AccessoriesGeneral Product Number Product NameListing of Accessories K281 Solid Wire Straightener for Tiny Twinarc K225 Submerged ARC Twinarc KITK238 High Frequency Unit K239 Twinarc KIT for Innershield ElectrodesK337 Weld Timer Module SPEED-FEED Reel K349 MULTI-PROCEDURE KITK334 Start and Crater Controls Relay ModulesNA-5 Maintenance Section Maintenance Section DMaintenance Control BOXGeneral Circuit ProtectionPipe Plug Ground Fault Fuse ProtectionFAST-BLOW Fuse Wire Drive Motor Changing Wire Feed Gear RatiosWire Drive Mechanism Wire StraightenersSolid Electrode 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 TestPossible Areas Recommended Symptoms Perform the Wire Drive MotorCourse of Action 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 Accuracy Test Problems Possible AreasSection Function Problems Accuracy Test Perform the Meter CircuitFeedback Test If the Tach Board FeedbackPerform the Voltmeter Accuracy 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 Materials Needed DC Power Supply TestTest Description DC Power Supply Test Test ProcedurePlugs for loose or faulty connec 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 DescriptionWire Feed Drive Motor Test Armature Voltage First pinsMotor Applied Voltage Test VDC supply Supply TurnedExternal Resistance Test Leads #21 and #67 Test Points Expected Comments Resistances Conditions External Resistance Test Leads #21 and #67Table F.2 External Voltage Sensing Leads Test Points 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 DescriptionPerform the Tach Board Removal Procedure Wire Drive Motor Removal and ReplacementMotor 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