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Lincoln Electric NA-5NF, NA-5SF service manual Welding Problems

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

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	F-32	TROUBLESHOOTING & REPAIR			F-32
	Observe all Safety Guidelines detailed throughout this manual

	PROBLEMS		POSSIBLE AREAS OF	RECOMMENDED
	(SYMPTOMS)		MISADJUSTMENTS(S)	COURSE OF ACTION

WELDING PROBLEMS

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The arc is 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 fault. If the problem is solved the NA-5 may be at fault.

1.The NA-5 voltage board may be faulty. Replace.

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CAUTION

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 1-800-833-9353.

NA-5

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Lincoln Electric NA-5NF, NA-5SF service manual Welding Problems

Contents

NA-5NF NA-5S NA-5SF Safety Depends on YouISAFETYi Electric Shock can kill SafetyARC Rays can burn Fumes and Gases can be dangerousWelding Sparks can cause fire or explosion Cylinder may explode if damagedSûreté Pour Soudage a L’Arc Précautions DE SûretéMaster Table of Contents for ALL Sections Return to Master TOC Installation Section Table of ContentsInstallation Section a Technical Specifications NA-5 InstallationFT 1.2 M Cable Control Cable Power Source TachometerControl BOX Installation Mechanical InstallationIntroduction Electric Shock can killPlaces Welding Head InstallationHoles Thread Holes View from BottomInput Power Requirements Electrical InstallationControl BOX to Welding Head Connections Table A.1Power Supply to Control BOX Connections Electrode Polarity Power Source Connection DiagramsFigure A.8 Connection of NA-5 ALL to a DC-600 Figure A.9 Connection of NA-5 ALL to a DC-650 PRO With no Line Voltage Compensator Obsolete Figure A.10 Connection of NA-5 ALL to a R3S-400, -600, orSAM 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 Operating Instructions Section Table of ContentsOperating Instructions Safety PrecautionsOPERATOR’S Instructions Welding SparksExposed Controls with Lockable Cover Down Controls Their FunctionsControls Under the Lockable Security Cover Auto TAB Setup InstructionsSee the Starting and Stopping Sequences section Means of ARC Striking Starting and Stopping SequencesTravel Starting and Stopping or Travel Starting and Stopping sectionReconfiguring the Travel Sequences Setting Travel Starting and StoppingStarting Sequences Stopping SequencesTravel Starts Travel Stops Older Models Newer Models Table B.1 Travel Sequence Lead and Switch PositionsBurnback and Electrode Backup Wire Feed Motor Acceleration Electric Shock can killOptional Crater Controls Voltage Control Response Table B.2 Stopping Sequence SettingsStart Circuitry Automatic ShutdownCold Start Circuitry Electrode BackupAuto Stop Security of Weld Procedure Settings Accessories Section Table of ContentsTable C.1 NA-5 Automatic Welding System Accessories AccessoriesGeneral Product Number Product NameListing of Accessories K225 Submerged ARC Twinarc KIT K281 Solid Wire Straightener for Tiny TwinarcK238 High Frequency Unit K239 Twinarc KIT for Innershield ElectrodesK349 MULTI-PROCEDURE KIT K337 Weld Timer Module SPEED-FEED ReelK334 Start and Crater Controls Relay ModulesNA-5 Maintenance Section D Maintenance SectionControl BOX MaintenanceGeneral Circuit ProtectionFAST-BLOW Fuse Ground Fault Fuse ProtectionPipe Plug Changing Wire Feed Gear Ratios Wire Drive MotorWire Straighteners Wire Drive MechanismSolid Electrode Flux-Cored ElectrodeOptional Features Theory of Operation Table of Contents Theory of Operation SectionGeneral Description Input Power CircuitsBoards Power and VoltageCONTROL, Logic Procedure Boards5E-5 Optional START, Crater Fill and Weld Timer BoardsFigure E.4 SCR Operation NA-5 SCR OperationTable of Contents Troubleshooting and Repair Section Troubleshooting & RepairRecommended Course of Action HOW to USE Troubleshooting GuideBoard can be dam- aged by static electricity PC Board Troubleshooting ProceduresPossible Areas SymptomsDrive Motor Test T2 Transformer TestPerform the Wire Drive Motor Possible Areas Recommended SymptomsCourse of Action TestTroubleshooting & Repair Problems Possible Areas Recommended Symptoms To Section TOC ResistanceTest Perform the #21-#67 ExternalTroubleshooting & Repair Transformer Test Perform the DC Power SupplyProblems Possible Areas Recommended Symptoms Troubleshooting & Repair Mode Function Problems Troubleshooting & Repair Troubleshooting & Repair Troubleshooting & Repair Problems Wire Drive Motor Test Function ProblemsTOC Travel Function Problems Troubleshooting & Repair Section Problems Possible AreasAccuracy Test Accuracy Test Perform the Meter Circuit Function ProblemsIf the Tach Board Feedback Feedback TestPerform 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 Test Description DC Power Supply TestMaterials Needed Test Procedure DC Power Supply TestPlugs for loose or faulty connec Also check associated leadsDC Power Supply Test Table F.1 DC Power Supply Checks Test Description T1 and T2 Transformer TestFigure F.2 T1 and T2 Transformers ProcedureReturn to Section Return to Section TOC Test Description Voltage Board Transformer TestVoltage Board Transformer Test Test Procedure24VAC Secondary Test Points Test Description Wire Feed Drive Motor TestArmature Voltage First pins Wire Feed Drive Motor TestMotor Applied Voltage Test VDC supply Supply TurnedExternal Resistance Test Leads #21 and #67 Table F.2 External Voltage Sensing Leads Test Points External Resistance Test Leads #21 and #67Test Points Expected Comments Resistances Conditions OUT of Voltage Range Shut Down Test Figure F.6 Voltage Board and PIN Locations OUT of Voltage Range Shut Down TestReturn to Section Return to Section TOC Test Description Tach Board Feedback TestTach Board Feedback Test ProcedureVoltmeter Accuracy Test Figure F.7 Test Meter Connection Points Voltmeter Accuracy TestCR3 Relay Test Description Wire Speed Accuracy TestTest Procedure Wire Speed Accuracy TestTable F.4 Troubleshooting & Repair Test Description Meter Circuit Accuracy TestTest for AC supply to the volt- meter PC board Meter Circuit Accuracy TestNA-5 SET Volts Reading Test Voltmeter Reading Test Voltmeter PC Board Accuracy Test for DC volts on the speed- meter PC board Test for AC supply to the speed- meter PC boardNA-5 SET Speed Reading Test Voltmeter Reading IPM Test Speedmeter Digital Meter AccuracyTest Speedmeter PC Board Accuracy Description PC Boards Removal and ReplacementReplacement Procedure PC Boards Removal and ReplacementDigital Meter and Meter PC Board Removal and Replacement Figure F.11 Meter PC BOARD, Mounting Nuts and Plug Meter PC Board Removal ProcedureFigure F.12 Meter Bezel and Screw Locations Digital Meter Removal ProcedureReplacement Procedure Description Tach PC Board Removal and ReplacementPickup Assembly Wire Drive Motor Tach Cover Tach PC Board Removal and ReplacementPhillips Screw Disc NUT Tach PC Board Reassembly Description Wire Drive Motor Removal and ReplacementMotor Removal Procedure Wire Drive Motor Removal and ReplacementPerform the Tach Board Removal Procedure Figure F.17 Drive Motor Motor Replacement Procedure Retest After Repair Gear Ratio Wire Speed Range in/min m/minNA-5 Table of Contents Electrical Diagrams Section Electrical DiagramsNA-5 Wiring Diagram KEY to Symbols Logic PC Board L6242-1 SchematicLogic PC Board L6242-2 & above Schematic C D E F G H J Power PC Board L6252-1 SchematicPower PC Board L6252-2 & above Schematic Return to Voltage PC Board SchematicC D E F G H L M Control Circuit SchematicStart Module Weld Timer Crater Module Burnback Timer Procedure PC Board SchematicTimer Board Option & Timer PC Board Schematics21143 Meter PC Board Schematic & LayoutMiscellaneous PC Boards Power Board Logic Board