Lincoln Electric Na-5s, Na-5nf, Na-5n, Na-5sf

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July, 1997
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NA-5
AUTOMATIC WELDING SYSTEMS
For use with the following models: NA-5N
NA-5NF
NA-5S
NA-5SF
Safety Depends on You

Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However,
your overall safety can be
increased by proper installation

View Safety Info
... and thoughtful operation on

your part. DO NOT INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT READ-
ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON-
TAINED THROUGHOUT. And,
most importantly, think before
you act and be careful.
View Safety Info
SERVICE MANUAL
View Safety Info
World's Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors
Sales and Service through Subsidiaries and Distributors Worldwide
22801 St. Clair Ave. Cleveland, Ohio 44117-1199 U.S.A. Tel. (216) 481-8100
i SAFETY i
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents The engine exhaust from this product contains
are known to the State of California to cause can- chemicals known to the State of California to cause
cer, birth defects, and other reproductive harm. cancer, birth defects, or other reproductive harm.
The Above For Diesel Engines The Above For Gasoline Engines
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you pur-
chase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040,
Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the
Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
FOR ENGINE 1.h. To avoid scalding, do not remove the

radiator pressure cap when the engine is
powered equipment. hot.
1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
1.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.
ELECTRIC AND
MAGNETIC FIELDS
____________________________________________________
1.c. Do not add the fuel near an open flame weld- may be dangerous
ing arc or when the engine is running. Stop
the engine and allow it to cool before refuel- 2.a. Electric current flowing through any conductor causes
ing to prevent spilled fuel from vaporizing on localized Electric and Magnetic Fields (EMF). Welding
contact with hot engine parts and igniting. Do current creates EMF fields around welding cables and
not spill fuel when filling tank. If fuel is spilled, welding machines
wipe it up and do not start engine until fumes
have been eliminated. 2.b. EMF fields may interfere with some pacemakers, and
____________________________________________________ welders having a pacemaker should consult their physician
1.d. Keep all equipment safety guards, covers and before welding.
devices in position and in good repair.Keep
hands, hair, clothing and tools away from V- 2.c. Exposure to EMF fields in welding may have other health
belts, gears, fans and all other moving parts effects which are now not known.
when starting, operating or repairing equip-
ment. 2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
____________________________________________________
1.e. In some cases it may be necessary to remove safety 2.d.1. Route the electrode and work cables together - Secure
guards to perform required maintenance. Remove them with tape when possible.
guards only when necessary and replace them when the
maintenance requiring their removal is complete. 2.d.2. Never coil the electrode lead around your body.
Always use the greatest care when working near moving
parts. 2.d.3. Do not place your body between the electrode and
___________________________________________________ work cables. If the electrode cable is on your right
1.f. Do not put your hands near the engine fan. Do not attempt to side, the work cable should also be on your right side.
override the governor or idler by pushing on the throttle con-
trol rods while the engine is running. 2.d.4. Connect the work cable to the workpiece as close as
___________________________________________________ possible to the area being welded.
1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance 2.d.5. Do not work next to welding power source.
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
Mar ‘95
Return to Master TOC ii SAFETY ii
ELECTRIC SHOCK can kill. ARC RAYS can burn.

3.a. The electrode and work (or ground) circuits 4.a. Use a shield with the proper filter and cover
are electrically “hot” when the welder is on. plates to protect your eyes from sparks and
Do not touch these “hot” parts with your bare the rays of the arc when welding or observing
skin or wet clothing. Wear dry, hole-free open arc welding. Headshield and filter lens
gloves to insulate hands. should conform to ANSI Z87. I standards.
3.b. Insulate yourself from work and ground using dry insulation. 4.b. Use suitable clothing made from durable flame-resistant
Make certain the insulation is large enough to cover your full material to protect your skin and that of your helpers from
area of physical contact with work and ground. the arc rays.
In addition to the normal safety precautions, if welding 4.c. Protect other nearby personnel with suitable, non-flammable
must be performed under electrically hazardous screening and/or warn them not to watch the arc nor expose
conditions (in damp locations or while wearing wet themselves to the arc rays or to hot spatter or metal.
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or FUMES AND GASES
accidental contact with the workpiece or ground) use
the following equipment: can be dangerous.
• Semiautomatic DC Constant Voltage (Wire) Welder. 5.a. Welding may produce fumes and gases
• DC Manual (Stick) Welder. hazardous to health. Avoid breathing these

• AC Welder with Reduced Voltage Control. fumes and gases.When welding, keep
your head out of the fume. Use enough
3.c. In semiautomatic or automatic wire welding, the electrode, ventilation and/or exhaust at the arc to keep
electrode reel, welding head, nozzle or semiautomatic fumes and gases away from the breathing zone. When
welding gun are also electrically “hot”. welding with electrodes which require special
ventilation such as stainless or hard facing (see
3.d. Always be sure the work cable makes a good electrical instructions on container or MSDS) or on lead or
connection with the metal being welded. The connection cadmium plated steel and other metals or coatings
should be as close as possible to the area being welded. which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
3.e. Ground the work or metal to be welded to a good electrical using local exhaust or mechanical ventilation. In
(earth) ground. confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
3.f. Maintain the electrode holder, work clamp, welding cable and also required when welding on galvanized steel.
welding machine in good, safe operating condition. Replace
5.b. Do not weld in locations near chlorinated hydrocarbon vapors
damaged insulation.
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors to
3.g. Never dip the electrode in water for cooling.
form phosgene, a highly toxic gas, and other irritating
products.
3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
5.c. Shielding gases used for arc welding can displace air and
between the two can be the total of the open circuit voltage
cause injury or death. Always use enough ventilation,
of both welders.
especially in confined areas, to insure breathing air is safe.
3.i. When working above floor level, use a safety belt to protect
5.d. Read and understand the manufacturer’s instructions for this
yourself from a fall should you get a shock.
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
3.j. Also see Items 6.c. and 8.
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.e. Also see item 1.b.

Mar ‘95
Return to Master TOC iii SAFETY iii
WELDING SPARKS can CYLINDER may explode

cause fire or explosion. if damaged.
6.a. Remove fire hazards from the welding area.
If this is not possible, cover them to prevent 7.a. Use only compressed gas cylinders
the welding sparks from starting a fire. containing the correct shielding gas for the
Remember that welding sparks and hot process used and properly operating
materials from welding can easily go through small cracks regulators designed for the gas and
and openings to adjacent areas. Avoid welding near pressure used. All hoses, fittings, etc. should be suitable for
hydraulic lines. Have a fire extinguisher readily available. the application and maintained in good condition.
6.b. Where compressed gases are to be used at the job site, 7.b. Always keep cylinders in an upright position securely
special precautions should be used to prevent hazardous chained to an undercarriage or fixed support.
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the 7.c. Cylinders should be located:
equipment being used. • Away from areas where they may be struck or subjected to
physical damage.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact can • A safe distance from arc welding or cutting operations and
cause overheating and create a fire hazard. any other source of heat, sparks, or flame.
6.d. Do not heat, cut or weld tanks, drums or containers until the 7.d. Never allow the electrode, electrode holder or any other
proper steps have been taken to insure that such procedures electrically “hot” parts to touch a cylinder.
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even though they have 7.e. Keep your head and face away from the cylinder valve outlet
been “cleaned”. For information, purchase “Recommended when opening the cylinder valve.
Safe Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous 7.f. Valve protection caps should always be in place and hand
Substances”, AWS F4.1 from the American Welding Society tight except when the cylinder is in use or connected for
use.
(see address above).
7.g. Read and follow the instructions on compressed gas
6.e. Vent hollow castings or containers before heating, cutting or
cylinders, associated equipment, and CGA publication P-l,
welding. They may explode.
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
1235 Jefferson Davis Highway, Arlington, VA 22202.
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a FOR ELECTRICALLY
welding area. powered equipment.
6.g. Connect the work cable to the work as close to the welding
8.a. Turn off input power using the disconnect

area as practical. Work cables connected to the building
switch at the fuse box before working on
framework or other locations away from the welding area
the equipment.
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate circuits.
8.b. Install equipment in accordance with the U.S. National
This can create fire hazards or overheat lifting chains or
Electrical Code, all local codes and the manufacturer’s
cables until they fail.
recommendations.
6.h. Also see item 1.c.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Mar ‘95
Return to Master TOC iv SAFETY iv
5. Toujours porter des lunettes de sécurité dans la zone de

PRÉCAUTIONS DE SÛRETÉ soudage. Utiliser des lunettes avec écrans lateraux dans les
Pour votre propre protection lire et observer toutes les instructions zones où l’on pique le laitier.
et les précautions de sûreté specifiques qui parraissent dans ce
6. Eloigner les matériaux inflammables ou les recouvrir afin
manuel aussi bien que les précautions de sûreté générales suiv-
de prévenir tout risque d’incendie dû aux étincelles.
antes:
7. Quand on ne soude pas, poser la pince à une endroit isolé

Sûreté Pour Soudage A L’Arc
de la masse. Un court-circuit accidental peut provoquer un
1. Protegez-vous contre la secousse électrique:
échauffement et un risque d’incendie.
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter
8. S’assurer que la masse est connectée le plus prés possible
toujours tout contact entre les parties sous tension et
de la zone de travail qu’il est pratique de le faire. Si on
la peau nue ou les vétements mouillés. Porter des
place la masse sur la charpente de la construction ou
gants secs et sans trous pour isoler les mains.
d’autres endroits éloignés de la zone de travail, on
b. Faire trés attention de bien s’isoler de la masse quand
augmente le risque de voir passer le courant de soudage
on soude dans des endroits humides, ou sur un
par les chaines de levage, câbles de grue, ou autres
plancher metallique ou des grilles metalliques,
circuits. Cela peut provoquer des risques d’incendie ou
principalement dans les positions assis ou couché

d’echauffement des chaines et des câbles jusqu’à ce qu’ils
pour lesquelles une grande partie du corps peut être
se rompent.
en contact avec la masse.
c. Maintenir le por te-électrode, la pince de masse, le
9. Assurer une ventilation suffisante dans la zone de soudage.
câble de soudage et la machine à souder en bon et sûr
Ceci est particuliérement important pour le soudage de
état defonctionnement.
tôles galvanisées plombées, ou cadmiées ou tout autre
d. Ne jamais plonger le porte-électrode dans l’eau pour
métal qui produit des fumeés toxiques.
le refroidir.
e. Ne jamais toucher simultanément les par ties sous
10. Ne pas souder en présence de vapeurs de chlore provenant
tension des por te-électrodes connectés à deux
d’opérations de dégraissage, nettoyage ou pistolage. La
machines à souder parce que la tension entre les deux
chaleur ou les rayons de l’arc peuvent réagir avec les
pinces peut être le total de la tension à vide des deux
vapeurs du solvant pour produire du phosgéne (gas
machines.
fortement toxique) ou autres produits irritants.
f. Si on utilise la machine à souder comme une source
de courant pour soudage semi-automatique, ces
11. Pour obtenir de plus amples renseignements sur la sûreté,
precautions pour le porte-électrode s’applicuent aussi
voir le code “Code for safety in welding and cutting” CSA
au pistolet de soudage.
Standard W 117.2-1974.
2. Dans le cas de travail au dessus du niveau du sol, se protéger

contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie
du corps.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc: TRANSFORMATEUR ET À
a. Utiliser un bon masque avec un verre filtrant approprié REDRESSEUR
ainsi qu’un verre blanc afin de se protéger les yeux du ray-
1. Relier à la terre le chassis du poste conformement au code de
onnement de l’arc et des projections quand on soude ou
l’électricité et aux recommendations du fabricant. Le dispositif
quand on regarde l’arc.
de montage ou la piece à souder doit être branché à une
b. Porter des vêtements convenables afin de protéger la
bonne mise à la terre.
peau de soudeur et des aides contre le rayonnement de
l‘arc.
2. Autant que possible, I’installation et l’entretien du poste seront
c. Protéger l’autre personnel travaillant à proximité au
effectués par un électricien qualifié.
soudage à l’aide d’écrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de l’arc de 3. Avant de faires des travaux à l’interieur de poste, la debranch-
soudage. Se protéger avec des vêtements de protection libres er à l’interrupteur à la boite de fusibles.
de l’huile, tels que les gants en cuir, chemise épaisse, pan-
talons sans revers, et chaussures montantes. 4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
Mar. ‘93
RETURN TO MAIN INDEX
v v
MASTER TABLE OF CONTENTS FOR ALL SECTIONS

Page
Safety ................................................... i-iv
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6
Electrode Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8
Power Source Connection Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . A-8
Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section B

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
Operator’s Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
Controls and Their Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3
Setup Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4
Starting and Stopping Sequences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-5
Setting Travel Starting and Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6
Voltage Control Response . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-9
Automatic Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-10
Cold Start Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-11
Security of Weld Procedure Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . B-12
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section C
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
Listing of Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
Maintenance . . . . . . .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section D

Control Box . . . . .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2
Welding Head . . .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-3
Optional Features ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-6
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section E

General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-2
Input Power Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-2
Power and Voltage Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-3
Control, Logic and Procedure Boards . . . . . . . . . . . . . . . . . . . . . . . . E-4
Optional start, Crater Fill and Weld Timer Boards . . . . . . . . . . . . . . . E-5
SCR Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-6
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section F
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section G
Parts Listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-135
NA-5
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
vi
NA-5
NOTES
vi
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
A-2 INSTALLATION A-2
Return to Section TOC
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) 0.052 (1.3)
57:1 38 - 7.78 (0.96 - 19.8) 3/32 (2.4) 1/16 (1.6)

95:1 22 - 456 (0.56 - 11.6) 5/32 (4.0) 1/8 (3.2)
142:1 15 - 300 (0.38 - 7.62) 5/32 (4.0) 7/32 (5.6)
PHYSICAL DIMENSIONS
LENGTH WIDTH HEIGHT WEIGHT
MODEL in. (mm) in. (mm) in. (mm) lbs (kg)
NA-5 Control Box 9.02 (229) 17.87 (454) 15.05 (382) 30 (13)
NA-5
FIGURE A.1 – BASIC CONTROL AND WIRE DRIVE SYSTEM.
CONTROL BOX
HEAD MOUNTING PARTS

(WITH INSULATION
AND HARDWARE)
CONTROL
CABLE
TO
POWER
SOURCE WIRE
TACHOMETER STRAIGHTENER
CABLE
4 FT (1.2 M) CABLE
(DRIVE MOTOR TO
CONTROL BOX)
MOTOR
4 FT (1.2 M) ELECTRODE CABLES CROSS
[(TWO 4/0) CONTACT ASSEMBLY SEAM

TO CONTROL BOX] GEAR BOX ADJUSTER
CONTACT
ASSEMBLY
(OPTIONAL)
NA-5
MECHANICAL 1. Align the mounting holes in adapter

plate M-13945 to the holes in the
INSTALLATION travel carriage.
2. Install four hex head screws through

WARNING the adapter plate and into the travel
carriage.
ELECTRIC SHOCK
can kill. 3. Secure the control box to the adapter
plate with four lock washers and four
• Turn off input power to bolts, two from the bottom and two
the welding power source from the back.
using the disconnect
switch before working on Before mounting the control box onto a
this equipment. fixture, you must provide mounting holes in
the fixture per the measurements provided
in Figure A.3 or dimension print S16717.
INTRODUCTION
When placing the mounting holes, ensure

the controls and meters are convenient to
This section covers the basic requirements to
the operator.
install the control box and welding head
shown in Figure A.1. This section will give FIGURE A.2 – CONTROL BOX
you mounting hole alignments, component CARRIAGE MOUNTING.
mounting clearances, and any special
instructions or precautions that must be fol-
lowed when installing the control box and
mounting head.
CONTROL BOX INSTALLATION
The control box can be mounted either on

the standard travel carriage or on a separate ADAPTER
fixture. It is electrically grounded by a lead PLATE
in the input cable assembly.
TRAVEL
To install the control box on the standard CARRIAGE
travel carriage, use mounting kit T14469 and CONTROL
perform the following steps. Also refer to BOX
Figure A.2.
NA-5
To install the control box on a fixture, WELDING HEAD INSTALLATION

perform the following steps and refer to
Figure A.3. The welding head can be mounted either
with the standard head mounting hardware
1. Align the mounting holes on the back or with the horizontal head and/or vertical lift
and/or bottom of the control box with adjusters. Design the installation of your
the holes you put in the fixture welding head so it meets the adjustability
according to the measurements requirements of your welding application.
provided in Figure A.3. Refer to Section C, Accessories, for more
information regarding the adjustable
2. Secure the control box to the fixture mounting hardware.
using lock washers and hex head
screws at each of the mounting holes. The welding head and electrode are
electrically “hot” when welding. They must
be insulated from ground.
FIGURE A.3 – CONTROL BOX
FIXTURE MOUNTING. Standard head mounting hardware and
insulation are shipped with the NA-5

VIEW FROM BACK welding head. If you are mounting the
0.41 welding head on a separate fixture, provide
0.28 (7.11) SLOTS (10.41) the mounting holes for the standard head
4 PLACES mount as specified in Figure A.4. For best
arc striking, use a rigid mounting that
0.562 DIA (14.27) prevents the head from moving when the
2 HOLES electrode strikes the work.
12.75
1.34 (323.85) FIGURE A.4 – WELDING HEAD
(34.04) 13.77 MOUNTING HOLES.
(349.76)
1.71 12.00 APPROXIMATE
(43.43) (304.8) INSULATOR
0.531 DIA. SIZE
2.88
(13.49)
(73.15)
1.09 0.43
(27.68) 1/4-20 (10.92)
THREAD HOLES
4.265 2.62
(108.33) (66.55)
VIEW FROM BOTTOM
12.00
(304.8) 4.5
1.71 (114.30)
(43.43) NOTE: DIMENSIONS ARE IN INCHES
WITH MILLIMETERS IN
3.50
PARENTHESES.
(88.9)
1/4-20 THREAD HOLES

FRONT
NOTE: DIMENSIONS ARE IN INCHES
WITH MILLIMETERS IN
PARENTHESES.
NA-5
When mounting the welding head to the nection diagrams for connecting automatic
standard travel carriage, (see 305-B sec. welding systems to various welding power
T2.2.4) mount it so only a minimum of sources.
overhang weight exists. Mount the head so
it stays within the dimension shown in Figure INPUT POWER REQUIREMENTS
A.5.
350 volt-amperes of 115 VAC 50/60 Hz
FIGURE A.5 – MOUNT TO CARRIAGE power is required for the wire feed motor and
OVERHANG DIMENSION. controls. Another 250 volt-amperes may be
required depending on the travel circuit.
CONTROL BOX TO WELDING

HEAD CONNECTIONS
19 IN.
(483 MM)
All welding heads include a 4 ft (1.2 m)
motor cable and motor tachometer cable.
Insert the plugs on these cables into the

matching receptacles on the side of the
control box.
If the 4 ft (1.2 m) cables are not sufficient,

install a K335 or K338 control to head
extension cable of the length ordered [up to
30 ft (9.1 m)]. The K335, for the NA-5S
head, includes motor, tachometer and flux
hopper lead extensions with polarized plugs
on each end, and electrode cables. The
K338 for the NA-5N, NF, and SF heads is
the same as the K335 without the flux
hopper lead extension.
The NA-5N and NA-5S also include two 4 ft

(1.2 m) lengths of electrode cable. Bolt the
terminals at one end of the the cable pair to

the wire contact assembly and the terminals
at the other end to the electrode leads on the
ELECTRICAL power source to control cable assembly.
INSTALLATION Properly insulate the bolted connection.
When the K335 or K338 extension cables are
WARNING used between the controls and heads, the 4 ft
(1.2 m) lengths of electrode cable are not
ELECTRIC SHOCK used. If currents or duty cycles higher than
can kill. 1000 amps at 80% duty cycle will be used,
add additional electrode cable per Table A.1.
• Do not touch electrically
live parts such as output TABLE A.1
terminals or internal
wiring. 80% Duty Cycle
Below 1000 amps Two 4/0
This section provides information on proper

wiring procedures for the NA-5 welding sys- 1000 to 1300 amps Three 4/0
tem. This section also provides basic con- 1300 to 1500 amps Four 4/0
NA-5
The “F” models do not include the 4 ft (1.2 Insert the polarized connector of the K215
m) lengths of electrode cable as standard. or K597* control cable into the matching
If you are not using a K335 or K338 exten- receptacle on the side of the control box.
sion cable for the NA-5NF or NA-5SF, order
an appropriate length of the needed elec- With the power source off, connect the
trode cable. Connect it between the wire control cable assembly to the power
contact assembly and the control cable source as follows:
assembly as described above.
1. If using the multi-process power
source (SAM, SA-800, SAF-600,
POWER SUPPLY TO CONTROL DC-400, DC-600, DC-1000, or DC-
BOX CONNECTIONS 1500 types), be sure it is properly set
for the welding process being used
At the NA-5 control box, in order to activate per the connection diagram (Figures
the NA-5 weld current sensing switch, the A.8 to A.14).
electrode cables of the control cable
assembly must be placed under the clamp 2. Connect the K215 control cable
bar on the left-hand side of the control box, leads to the power source terminal
as shown in Figure A.6. This is required strip exactly as specified on the
for proper operation of the reed switch. connection diagram.* Include all
The nuts holding the clamp bar in place jumpers on the terminal strips as
need only to be pulled up snug. Do not shown on the diagram. Do not put
overtighten. If a carriage is used, the on any other jumpers. If currents or
electrode cables should also be clamped duty cycles higher than 1000 amps
to it with the cable clamp supplied on the at 80% duty cycle will be used, add
carriage. Do not clamp the control cable additional electrode cables to the
under the travel carriage clamp but route it K215 assembly per Table A.1.
over its top. 3 Depending on the power source and
FIGURE A.6 – CONTROL BOX the process to be used, the jumpers
ELECTRICAL CONNECTIONS. on the NA-5 voltage board may have
to be changed. As shipped, the
NA-5 is connected for use with the
DC-400, DC-600, DC-1000, and
DC-1500 type power sources. For

CLAMP
other power sources, refer to the
BAR
appropriate connection diagram and
to IM305 Sec. T3.6.
4. Connect work leads of sufficient size

FROM and length per Table A.1. between
POWER the “To Work” stud on the power
SOURCE source and the work. Be sure the
connection to the work makes a tight
and clean metal-to-metal contact.
*The K597 cable assembly has a 14-pin MS-type
connector for use with later model Lincoln CV power
TO sources.
WELDING
HEAD
NA-5
ELECTRODE POLARITY FIGURE A.7 – TERMINAL STRIP

LOCATION.
WARNING
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. TERMINAL

STRIPS
The polarity of the NA-5 control circuit is
shipped connected for electrode positive. If

electrode negative is required, two leads
inside the NA-5 control must be reversed.
POWER SOURCE
Proceed as follows: CONNECTION DIAGRAMS
1. Turn off the input power to the NA-5 The following section contains the wiring
control box by turning off the welding diagrams necessary to connect the
power source. applicable power source to the control box.
If there is no diagram, refer to power source
2. Open the control box door and locate
manual.
the terminal strips on the back of the
control box in the lower left-hand
corner as shown in Figure A.7. WARNING
3. On the right end of the lower terminal ELECTRIC SHOCK
strip, interchange the black and white can kill.
leads going to the terminals marked
(+) and (-). The black lead (#67)

must be connected to the same the welding power
polarity as the electrode welding lead; source using the
i.e. if the electrode is positive, disconnect switch
connect the black lead to the (+) before working on this
terminal on the terminal strip. The equipment.
white lead (#21) is connected to the
opposite polarity terminal.
NA-5
FIGURE A.8 – CONNECTION OF NA-5 (ALL) TO A DC-600.
TO NA-5 INPUT
CABLE PLUG
.A.
NOTE: DIAGRAM SHOWS ELECTRODE CONNECTED POSITIVE.
A
TO CHANGE POLARITY, TURN POWER OFF, REVERSE THE
ELECTRODE AND WORK CABLES AT THE POWER SOURCE
P AND POSITON THE SWITCH ON POWER SOURCE TO PROPER

POLARITY. REFER TO NA-5 OPERATING MANUAL FOR REQUIRED
NA-5 CONTROL BOX POLARITY CONNECTIONS.
CONNECT TO CABLES FROM NA-5

WIRE CONTACT ASSEMBLY
B
CONNECT
TO WORK
ALL CODES: DC-600 CODES 8046-8200:

TURN OFF INPUT POWER FOR SUB ARC:
ADJUST THE POWER SOURCE: DC-600: 1. SET MODE SWITCH TO CV SUB ARC.
1. CONNECT ELECTRODE CABLES TO TERMINAL OF DESIRED POLARITY. 2. WHITE LEAD ON CONTROL PC BOARD IS CONNECTED TO PIN "M".
2. SET TOGGLE SWITCH TO SAME POLARITY AS THE ELECTRODE CABLE
CONNECTION. FOR ALL OPEN ARC PROCESSES EXCEPT MR-203 ELECTRODES:
3. SET TOGGLE SWITCH TO "REMOTE". 1. SET MODE SWITCH TO CV INNERSHIELD.
4. SET MODE SWITCH TO THE DESIRED POSITION FOR THE PROCESS TO BE USED. 2. WHITE LEAD ON CONTROL PC BOARD IS CONNECTED TO PIN "M".
FOR NR-203 ELECTRODES:

DC-600 CODES 8000-8045:

FOR SUB ARC: 1. SET MODE SWITCH TO CV INNERSHIELD.
1. SET MODE SWITCH TO CV SUB ARC. 2. WHITE LEAD ON CONTROL PC BOARD IS CONNECTED TO PIN "I".
2. WHITE LEAD ON CONTROL PC BOARD IS CONNECTED TO PIN "M" AND BLUE DC-600 CODES ABOVE 8200:
LEAD IS CONNECTED TO "W". FOR SUB ARC:
FOR ALL OPEN ARC PROCESSES EXCEPT NR-302 AND NR-203 ELECTRODES: 1. SET MODE SWITCH TO CV SUB ARC.
1. SET MODE SWITCH TO CV INNERSHIELD. FOR ALL OPEN ARC PROCESSES:
2. WHITE LEAD ON CONTROL PC BOARD IS CONNECTED TO PIN "M" AND BLUE 2. SET MODE SWITCH TO CV INNERSHIELD.
LEAD IS CONNECTED TO "W".
FOR NR-203 AND NR-302 ELECTRODES: FOR OPTIMUM PERFORMANCE WITH NA-5, DC-600'S WITH CODES 8288 AND
1. SET MODE SWITCH TO CV INNERSHIELD. ABOVE ARE PREFERRED. FOR ADDITIONAL INSTALLATION INSTRUCTIONS,
2. WHITE LEAD ON CONTROL PC BOARD IS CONNECTED TO PIN "I" SEE NA-5 OPERATING MANUAL.
AND BLUE LEAD IS CONNECTED TO "S".
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 PHYSICALLY SUITABLE FOR THE INSTALLATION. AN S-16586 - [ ] REMOTE VOLTAGE SENSING WORK
LEAD IS AVAILABLE FOR THIS PURPOSE. CONNECT IT DIRECTLY TO THE WORK PIECE KEEPING IT SEPARATE FROM THE WELDING WORK CABLE CONNECTION
TO THE WORK PIECE. FOR CONVENIENCE, THIS EXTENDED #21 LEAD SHOULD BE TAPED ALONG THE WELDING WORK CABLE.
N.D. TAPE UP BOLTED CONNECTION.
N.E. CONNECT THE NA-5 CONTROL CABLE GROUNDING LEAD TO THE FRAME TERMINAL MARKED NEAR THE POWER SOURCE TERMINAL STRIP. THE POWER
SOURCE MUST BE PROPERLY GROUNDED.

N.F. IF USING AN OLDER K-215 CONTROL CABLE: CONNECT LEAD #75 TO #75 ON TERMINAL STRIP, CONNECT LEAD #76 TO #76 ON TERMINAL STRIP, CONNECT
LEAD #77 TO #77 ON TERMINAL STRIP.
N.G. THE JUMPERS ON THE NA-5 VOLTAGE BOARD MUST BE CONNECTED AS FOLLOWS: CONNECT RED JUMPER TO PIN "S". CONNECT WHITE JUMPER TO PIN "B".
N.H. CONNECT A JUMPER FROM "N" TO "P". THERE IS NO NPS TERMINAL STRIP ON DC-600 CODES ABOVE 8200.
N.J. FOR PROPER NA-5 OPERATION, THE ELECTRODE CABLES MUST BE SNUGGED UNDER THE CLAMP BAR ON THE LEFT SIDE OF THE NA-5 CONTROL BOX.
CLEVELAND, OHIO U.S.A.
NA-5
FIGURE A.9 – CONNECTION OF NA-5 (ALL) TO A DC-650 PRO
P CONTROL P
CABLE
P TO NA-5 INPUT
6 CABLE PLUG
TO NA-5 INPUT
CABLE PLUG
CONNECT TO CABLES FROM

NA-5 WIRE CONTACT ASSEMBLY
A
CONNECT TO CABLES FROM NA-5
R WIRE CONTACT ASSEMBLY
CONNECT
TO WORK
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 REQUIRED NA-5 CONTROL BOX POLARITY CONNECTIONS.
DC650 PRO POWER SOURCE SETTINGS

1. TURN OFF INPUT POWER.
2. CONNECT ELECTRODE CABLES TO TERMINALS OF DESIRED POLARITY.
3. SET TOGGLE SWITCH TO SAME POLARITY AS ELECTRODE CABLE CONNECTION.
4. SET TOGGLE SWITCH TO REMOTE.
5. SET MODE SWITCH TO DESIRED POSITION FOR THE PROCESS TO BE USED.
6. CONNECT NEGATIVE OUTPUT CABLES TO MATCH MODE SWITCH SETTING.
N.A. WELDING CABLES MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION.
N.B. EXTEND LEAD #21A BY REMOVING LEAD #21A FROM THE TERMINAL STRIP AND CONNECTING IT TO A #14 OR LARGER INSULATED WIRE PHYSICALLY SUITABLE FOR
THE INSTALLATION.
N.C. EXTEND LEAD #21 USING A #14 OR LARGER INSULATED WIRE PHYSICALLY SUITABLE FOR INSTALLATION.
N.D. CONNECT EXTENDED LEAD DIRECTLY TO THE WORK PIECE KEEPING IT SEPARATE FROM THE WELDING WORK CABLE CONNECTION TO THE WORK PIECE. FOR
CONVENIENCE, THIS EXTENDED LEAD SHOULD BE TAPED ALONG THE WELDING WORK CABLE.
N.E. TAPE UP CONNECTION.
N.F. FOR PROPER NA-5 OPERATION, THE ELECTRODE CABLES MUST BE SNUGGED UNDER THE CLAMP BAR ON THE LEFT SIDE OF THE NA-5 CONTROL BOX.
N.G. CONNECT NEGATIVE OUTPUT CABLES TO STUDS TO MATCH DC650 PRO MODE SWITCH SETTING.
N.H. THE JUMPERS ON THE NA-5 VOLTAGE BOARD MUST BE CONNECTED AS FOLLOWS: CONNECT RED JUMPER TO PIN "S", CONNECT WHITE JUMPER TO PIN "B".
N.J. IF USING AN OLDER K-215 CONTROL CABLE, CONNECT LEAD #75 TO #75 ON TERMINAL STRIP, CONNECT LEAD #76 TO #76 ON THE TERMINAL STRIP, CONNECT
LEAD #77 TO #77 ON THE TERMINAL STRIP.
N.K. CONNECT THE NA-5 CONTROL CABLE GROUNDING LEAD TO THE FRAME TERMINAL MARKED NEAR THE POWER SOURCE TERMINAL STRIP.
NA-5
FIGURE A.10 – CONNECTION OF NA-5 (ALL) TO A R3S-400, -600, OR -800

WITH NO LINE VOLTAGE COMPENSATOR (OBSOLETE).
B
B
POSITIVE
NOTE: ABOVE DIAGRAM SHOWS ELECTRODE CONNECTED POSITIVE. TO CHANGE POLARITY, TURN POWER OFF, REVERSE THE ELECTRODE AND WORK CABLES AT THE
POWER SOURCE AND POSITION THE SWITCH ON POWER SOURCE TO PROPER POLARITY. REFER TO NA-5 OPERATING MANUAL FOR REQUIRED NA-5 CONTROL
BOX POLARITY CONNECTIONS.
R3S POWER SOURCE SETTINGS NA-5 SETTINGS

TURN POWER SOURCE OFF.
FOR SUB ARC:
FOR ALL PROCESSES: 1. RED LEAD ON VOLTAGE PC BOARD IS CONNECTED TO PIN "S".
1. CONNECT ELECTRODE CABLE TO TERMINAL OF DESIRED POLARITY. 2. WHITE LEAD ON VOLTAGE PC BOARD IS CONNECTED TO PIN "A".
2. SET THE POLARITY SWITCH TO THE SAME POLARITY AS THE ELECTRODE
FOR ALL OPEN ARC PROCESSES:
CABLE CONNECTION.
1. RED LEAD ON VOLTAGE PC BOARD IS CONNECTED TO PIN "F".
3. SET TOGGLE SWITCH TO REMOTE.
2. WHITE LEAD ON VOLTAGE PC BOARD IS CONNECTED TO PIN "A".
4. INSTALL VOLTAGE TRIANGLE IN A POSITION AS CLOSE AS POSSIBLE TO
THE DESIRED ARC VOLTAGE.
FOR ADDITIONAL INSTALLATION INSTRUCTIONS, SEE NA-5 OPERATING MANUAL.

N.A. ADD JUMPER FROM #75 TO #76, USING INSULATED COPPER WIRE.
N.C. EXTEND LEAD #21 USING #14 OR LARGER INSULATED WIRE PHYSICALLY SUITABLE FOR THE INSTALLATION. AN S -16586 [ ] REMOTE VOLTAGE-SENSING WORK LEAD
IS AVAILABLE FOR THIS PURPOSE. CONNECT IT DIRECTLY TO THE WORK PIECE, KEEPING IT SEPARATE FROM THE WELDING WORK CABLE CONNECTION TO THE
WORK PIECE. FOR CONVENIENCE, THIS EXTENDED #21 LEAD SHOULD BE TAPED ALONG THE WELDING WORK CABLE.
N.E. CONNECT THE NA-5 CONTROL CABLE GROUNDING LEAD TO THE FRAME TERMINAL MARKED , NEAR THE POWER SOURCE TERMINAL STRIP. THE POWER SOURCE
MUST BE PROPERLY GROUNDED.

N.F. IF USING AN OLDER K-215 CONTROL CABLE: CONNECT LEAD #75 TO #75 ON TERMINAL STRIP, CONNECT LEAD #76 TO #77 ON TERMINAL STRIP, CONNECT
LEAD #77 TO #76 ON TERMINAL STRIP, AND ADD JUMPER PER N.A.
N.G. ON EARLIER R3S MACHINES, #67 AND #1 TERMINALS WERE ALSO ON THE TERMINAL STRIP.
N.H. THE UPPER TERMINAL STRIP (#75, #76, #77) WAS NOT PRESENT ON EARLY R3S MACHINES. THOSE MACHINES ARE NOT COMPATIBLE WITH THE NA-5 SINCE THERE
CAN BE NO ADJUSTMENT OF VOLTAGE BY THE NA-5.
N.J. FOR PROPER NA-5 OPERATION, THE ELECTRODE CABLES MUST BE SNUGGED UNDER THE CLAMP BAR ON THE LEFT SIDE OF THE NA-5 CONTROL BOX.
NA-5
FIGURE A.11 – CONNECTION OF NA-5 (ALL) TO A SAM-400 MOTOR

GENERATOR OR ENGINE WELDER.
BOLT TO CABLES
P FROM NA-5
WIRE CONTACT
ASSEMBLY
N.B.
N.B.
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.
SAM POWER SOURCE SETTINGS NA-5 SETTINGS

TURN POWER SOURCE OFF. FOR SUB ARC:
FOR SUB ARC: 1. RED LEAD ON VOLTAGE PC BOARD IS CONNECTED TO PIN "S".
1. SET THE ELECTRODE POLARITY SWITCH TO THE VARIABLE VOLTAGE 2. WHITE LEAD ON VOLTAGE PC BOARD IS CONNECTED TO PIN "A".
POSITION OF THE POLARITY DESIRED FOR THE PROCESS BEING USED.
2. SET THE TOGGLE SWITCH TO CONSTANT VOLTAGE. FOR ALL OPEN ARC PROCESSES:
3. SET THE CONSTANT VOLTAGE CONTROL TO NUMBER 7 AND THE 1. RED LEAD ON VOLTAGE PC BOARD IS CONNECTED TO PIN "F".
CURRENT CONTROL TO 500. 2. WHITE LEAD ON VOLTAGE PC BOARD IS CONNECTED TO PIN "A".
1. SET THE ELECTRODE POLARITY SWITCH TO THE CONSTANT VOLTAGE
POSITION OF THE POLARITY DESIRED FOR THE PROCESS BEING USED.
2. SET THE TOGGLE SWITCH TO CONSTANT VOLTAGE.
3. SET THE CONSTANT VOLTAGE CONTROL TO NUMBER 5.
N.A. REMOVE SAM PORTABLE FIELD CONTROL AND CONNECT NA-5 CONTROL CABLE.
N.C. EXTEND LEAD #21 USING #14 OR LARGER INSULATED WIRE PHYSICALLY SUITABLE FOR THE INSTALLATION. AN S-16586-[ ] REMOTE VOLTAGE-SENSING WORK LEAD
IS AVAILABLE FOR THIS PURPOSE. CONNECT IT DIRECTLY TO THE WORK PIECE, KEEPING IT SEPARATE FROM THE WELDING WORK CABLE CONNECTION TO
N.E. CONNECT THE NA-5 CONTROL CABLE GROUNDING LEAD TO THE FRAME TERMINAL MARKED , NEAR THE POWER SOURCE TERMINAL STRIP. THE POWER SOURCE

N.F. IF USING AN OLDER K-215 CONTROL CABLE: CONNECT LEAD #76 TO #75 ON TERMINAL STRIP, CONNECT LEADS #75 AND #77 TO #76 ON TERMINAL STRIP.
N.G. ON EARLIER SAM MACHINES, #1 TERMINAL WAS ALSO ON THE TERMINAL STRIP.
N.H. FOR PROPER NA-5 OPERATION, THE ELECTRODE CABLES MUST BE SNUGGED UNDER THE CLAMP BAR ON THE LEFT SIDE OF THE NA-5 CONTROL BOX.
NA-5
FIGURE A.12 – CONNECTION OF NA-5 (ALL) TO A SAM-650 ENGINE WELDER.
POWER SOURCE
TO NA-5 INPUT
CABLE PLUG
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.
BOLT TO CABLES
"TAP" FROM NA-5
WIRE CONTACT
P ASSEMBLY
P P
..
SAM POWER SOURCE SETTINGS NA-5 SETTINGS

TURN POWER SOURCE OFF. FOR SUB ARC:

FOR SUB ARC: 1. RED LEAD ON VOLTAGE PC BOARD IS CONNECTED TO PIN "S".
1. SET THE ELECTRODE POLARITY SWITCH TO THE POLARITY DESIRED FOR THE 2. WHITE LEAD ON VOLTAGE PC BOARD IS CONNECTED TO PIN "A".
PROCESS BEING USED.
2. SET THE TOGGLE SWITCH TO CONSTANT VOLTAGE. FOR ALL OPEN ARC PROCESSES:
3. SET THE CONSTANT VOLTAGE CONTROL TO NUMBER 7. 1. RED LEAD ON VOLTAGE PC BOARD IS CONNECTED TO PIN "F".
4. CONNECT THE TAP CABLE TO THE "300-575, MAX, SLOPE" STUD. 2. WHITE LEAD ON VOLTAGE PC BOARD IS CONNECTED TO PIN "A".
1. SET THE ELECTRODE POLARITY SWITCH TO THE POLARITY DESIRED FOR THE
PROCESS BEING USED.
2. SET THE TOGGLE SWITCH TO CONSTANT VOLTAGE.
3. SET THE CONSTANT VOLTAGE CONTROL TO NUMBER 5.
4. CONNECT THE TAP CABLE TO THE "450-MAX, MED SLOPE" STUD.
N.A. REMOVE SAM PORTABLE FIELD CONTROL AND CONNECT NA-5 CONTROL CABLE.
N.C. EXTEND LEAD #21 USING #14 OR LARGER INSULATED WIRE PHYSICALLY SUITABLE FOR THE INSTALLATION. AN S-16586- [ ] REMOTE VOLTAGE-SENSING WORK
LEAD IS AVAILABLE FOR THIS PURPOSE. CONNECT IT DIRECTLY TO THE WORK PIECE, KEEPING IT SEPARATE FROM THE WELDING WORK CABLE CONNECTION
TO THE WORK PIECE. FOR CONVENIENCE, THIS EXTENDED #21 LEAD SHOULD BE TAPED ALONG THE WELDING WORK CABLE.
N.E. CONNECT THE NA-5 CONTROL CABLE GROUNDING LEAD TO THE FRAME TERMINAL MARKED NEAR THE POWER SOURCE TERMINAL STRIP. THE POWER
SOURCE MUST BE PROPERLY GROUNDED.
N.F. IF USING AN OLDER K-215 CONTROL CABLE: CONNECT LEAD #76 TO #75 ON TERMINAL STRIP, CONNECT LEADS #75 AND #77 TO #76 ON TERMINAL STRIP.
N.G. ON EARLIER SAM MACHINES, #1 TERMINAL WAS ALSO ON THE TERMINAL STRIP.
N.H. FOR PROPER NA-5 OPERATION, THE ELECTRODE CABLES MUST BE SNUGGED UNDER THE CLAMP BAR ON THE LEFT SIDE OF THE NA-5 CONTROL BOX.
NA-5
FIGURE A.13 – CONNECTION OF NA-5 TO DC-1000 OR DC-1500.
POWER SOURCE INPUT CABLE PLUG
CONTROL
CABLE
BOLT TO CABLES FROM

NA-5 WIRE CONTACT
ASSEMBLY
CONNECT TO WORK
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 CONNECTION.
REFER TO NA-5 OPERATING MANUAL FOR REQUIRED NA-5 CONTROL BOX POLARITY CONNECTIONS.
N.A. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS.
N.B. EXTEND LEAD 21 USING #14 OR LARGER INSULATED WIRE PHYSICALLY SUITABLE FOR THE INSTALLATION. AN S-16586-[ ] REMOTE VOLTAGE-SENSING WORK LEAD
IS AVAILABLE FOR THIS PURPOSE. CONNECT IT DIRECTLY TO THE WORK PIECE KEEPING IT SEPARATE FROM THE WELDING WORK CABLE CONNECTION TO
N.C. TAPE UP BOLTED CONNECTION.
N.D. CONNECT THE NA-5 CONTROL CABLE GROUND LEAD TO THE FRAME TERMINAL MARKED NEAR THE POWER SOURCE TERMINAL STRIP. THE POWER SOURCE
N.E. IF USING AN OLDER AUTOMATIC CONTROL CABLE WITH LEADS 75, 76, 77; CONNECT LEAD 75 TO #75 ON TERMINAL STRIP, CONNECT LEAD #76 TO #74 ON TERMINAL
STRIP, CONNECT LEAD #77 TO #73 ON TERMINAL STRIP.
N.F. CONNECT THE JUMPERS ON THE NA-5 VOLTAGE BOARD AS FOLLOWS: CONNECT RED JUMPER TO PIN "S". CONNECT WHITE JUMPER TO PIN "B".
N.G. SET THE DC-1000 OR DC-1500 CONTROLS AS FOLLOWS: SET THE CONTROL SWITCH TO "OUTPUT CONTROL REMOTE".
FOR SUBMERGED ARC PROCESSES, SET THE MODE SWITCH TO "C.V. SUBMERGED ARC". FOR OPEN ARC PROCESSES, SET THE MODE
SWITCH TO "C.V. INNERSHIELD"
N.H. FOR PROPER OPERATION, THE ELECTRODE CABLE MUST BE SNUGGED UNDER THE CLAMP BAR ON THE LEFT SIDE OF THE NA-5 CONTROL BOX.
N.J. TERMINALS #73 AND #74 WERE NOT PRESENT ON DC-1500 MACHINES BELOW CODE 8294. THESE EARLIER CODE MACHINES ARE NOT SUITABLE FOR
USE WITH THE NA-5.
N.K. ALTERNATIVE 500 AMP POSITIVE TERMINAL CONNECTION PROVIDED ON DC-1000 MODELS ABOVE CODE 9500 ONLY.
N.L. ALTERNATE SUBMERGED ARC MODE AVAILABLE FOR IMPROVED ARC STABILITY IN HIGH CURRENT, LARGE PUDDLE, SLOW TRAVEL PROCEDURES BY MAKING
SPECIAL CONNECTIONS ON BOTH DC-1500 AND NA-5.
ON DC-1500 CONTROL BOARD (G-1530-2 AND SUPERSEDING) REMOVE RED AND BLUE JUMPERS FROM "FR" PINS AND RECONNECT TO CORRESPONDING "SR" PINS.
ON NA-5 VOLTAGE BOARD (G-1556-1 AND SUPERSEDING) WHITE JUMPER MUST BE CONNECTED TO PIN "D".
NA-5 PIN "D" CONNECTION MAY ALSO BE USED FOR SOME PROCEDURES ON DC-1500 WITHOUT CONTROL BOARD JUMPERS, DC-1500 WITH CONTROL BOARD
JUMPERS ON "FR" PINS OR DC-1000.
NA-5
FIGURE A.14 – CONNECTION OF NA-5 TO DC-400 OR CV-400.
POWER SOURCE
TO NA-5 INPUT CABLE PLUG
C
B N.E.
A
CONTROL
N.H. 32
31 CABLE
2
4 N.D. AND N.H.
GND
21
NEGATIVE POSITIVE
N.D.
N.B. AND N.C.
BOLT TO CABLES FROM NA-5

N.A.
WIRE CONTACT ASSEMBLY
CONNECT TO WORK
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
NA-5 CONTROL BOX POLARITY CONNECTIONS. ALSO REFER TO NOTE N.H.
N.A. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS.
N.B. EXTEND LEAD #21 USING #14 AWG OR LARGER INSULATED WIRE PHYSICALLY SUITABLE FOR THE INSTALLATION. AN S-16586- [LENGTH] REMOTE
VOLTAGE-SENSING WORK LEAD IS AVAILABLE FOR THIS PURPOSE. CONNECT IT DIRECTLY TO THE WORK PIECE KEEPING IT ELECTRICALLY SEPARATE
FROM THE WELDING WORK LEAD CIRCUIT AND CONNECTION. FOR CONVENIENCE, THIS EXTENDED #21 LEAD SHOULD BE TAPED TO THE WELDING
WORK LEAD. (IF THE LENGTH OF WORK LEAD CIRCUIT IS SHORT, AND CONNECTIONS CAN BE EXPECTED TO BE RELIABLE, THEN CONTROL CABLE
LEAD #21 DOES NOT NEED TO BE EXTENDED AND CAN BE DIRECTLY CONNECTED TO TERMINAL #21 ON THE TERMINAL STRIP. NOTE THAT THIS IS
NOT THE PREFERRED CONNECTION BECAUSE IT ADDS ERROR TO THE NA-5 VOLTMETER READING.)
N.C. TAPE UP BOLTED CONNECTION.
N.D. CONNECT THE CONTROL CABLE GROUND LEAD TO THE FRAME TERMINAL MARKED NEAR THE POWER SOURCE TERMINAL STRIP. THE POWER
SOURCE GROUNDING TERMINAL (MARKED AND LOCATED NEAR THE POWER SOURCE INPUT POWER CONNECTIONS) MUST BE PROPERLY CONNECTED
TO ELECTRICAL GROUND PER THE POWER SOURCE OPERATING MANUAL. .
N.E. THE JUMPERS ON THE NA-5 VOLTAGE BOARD MUST BE CONNECTED AS FOLLOWS: CONNECT RED JUMPER TO PIN "S". CONNECT WHITE JUMPER TO PIN "B".
WHEN USING NA-5 CONTROLS ABOVE CODE 8300 WITHOUT THE OPTIONAL DC-400 DIODE KIT OR CV-400, CVI-500 DIODE OPTIONS:
THE NA-5 INCH DOWN BUTTON WILL NOT OPERATE UNLESS A JUMPER IS CONNECTED BETWEEN THE TWO TAB TERMINALS, LABELED "AUTO",
LOCATED ABOVE THE TRANSFORMER ON THE NA-5 VOLTAGE PC BOARD. THIS JUMPER, HOWEVER, WILL DISABLE THE COLD STARTING/AUTO STOP
FEATURE OF THE NA-5, PERMITTING ONLY HOT STARTING TECHNIQUES TO BE USED.
N.G. FOR PROPER NA-5 OPERATION, THE ELECTRODE CABLES MUST BE SNUGGED UNDER THE CLAMP BAR ON THE LEFT SIDE OF THE NA-5 CONTROL BOX.
N.H.*IF LEAD #21 IS TO BE CONNECTED TO THE TERMINAL STRIP, CONNECT TO THE #21 TERMINAL THAT MATCHES WORK POLARITY. THIS CONNECTION MUST
BE CHANGED WHENEVERTHE ELECTRODE POLARITY IS CHANGED.
* DOES NOT APPLY TO DC-400 BELOW CODE 9200 WITH POLARITY SWITCH.
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 A-16
NA-5
NOTES
A-16
Section B TABLE OF CONTENTS Section B
- OPERATING INSTRUCTIONS SECTION -
Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section B

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
Operator’s Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
Controls and Their Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3
Exposed Controls (With Lockable Cover Down) . . . . . . . . . . . . . B-3
Controls Under the Lockable Security Cover . . . . . . . . . . . . . . . B-3
Setup Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4
Starting and Stopping Sequences . . . . . . . . . . . . . . . . . . . . . . . . . . B-5
Means of Arc Striking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-5
Setting Travel Starting and Stopping . . . . . . . . . . . . . . . . . . . . . . . . B-6
Starting Sequences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6
Stopping Sequences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6
Reconfiguring the Travel Sequences . . . . . . . . . . . . . . . . . . . . . B-6
Voltage Control Response . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-9

Automatic Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-10
Cold Start Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-11
Security of Weld Procedure Settings . . . . . . . . . . . . . . . . . . . . . . . . B-12
NA-5
B-2 OPERATING INSTRUCTIONS B-2
SAFETY PRECAUTIONS 1. Be sure there is enough electrode in

the machine to complete the weld.
WARNING 2. If submerged arc welding, fill flux

hopper with new or freshly screened
ELECTRIC SHOCK flux. All reused flux must be screened
can kill. 100% through an 8 mesh screen
[0.065 to 0.075 in. (1.6 to 1.9 mm)
• Do not touch electrical- opening]. Turn the switch on the
ly live parts or elec- hopper to “On.”
trode with skin or wet
clothing. 3. Start the power source.
• Insulate yourself from 4. Turn the “Power Control” switch on the

work or ground. wire feeder control to “On.”
• Always wear dry insu- 5. Position the welding head at the start
lating gloves.
of the weld. Be sure the travel carriage

or other travel mechanism is set to
FUMES AND GASES move in the proper direction.
can be dangerous.
6. Set the travel switch to “Automatic
• Keep your head out of Travel.” When set to “Hand Travel”,
fumes. the travel system operates without
welding.
• Use ventilation or
exhaust to remove 7. For best starts, cut the electrode to a
fumes from breathing sharp point.
zone.
8. Press the “Inch Down” button to feed
the electrode out of the nozzle.
WELDING SPARKS
can cause fire or a. For most applications, when hot
explosion. starting, leave the electrode
1/4 in. (6.4 mm) or more away
• Keep flammable mater- from the work.

ial away.
b. When cold starting some
• Do not weld on con- submerged arc welding, inch the
tainers that have held electrode down until it touches the
combustibles. work and the flux valve opens.
ARC RAYS 9. Press the “Start” button.

can burn.
10. While welding, turn the cross seam
• Wear eye, ear, and adjuster handwheel as needed to keep
body protection. the arc in the joint.
11. At the end of the weld, press the

Observe additional Safety Guidelines “Stop” button.
detailed in the beginning of this manual.
12. If needed, press the “Inch Up” button
to get the electrode up and out of the
way. Remove the work and reload the

OPERATOR’S fixture.
INSTRUCTIONS
NOTE: When the contact tip in the end of the
Once the system is properly set up, the nozzle wears during repetitive welding, it
operator can make production welds must be replaced. Check the contact tip for
without readjusting the controls using the wear if weld quality seems to be
following simple instructions: deteriorating.
NA-5
CONTROLS AND 4. INCH UP AND INCH DOWN. Press to

THEIR FUNCTIONS inch electrode up or down.
5. MODE SELECTOR SWITCH AND
The operator controls for the NA-5 are
LIGHTS. Used to preset the voltage
illustrated in Figure B.1. Refer to the figure
and wire feed speed for the various
and the following explanations of the
modes of operation (Strike, Start,
controls.
Weld, and Crater).
EXPOSED CONTROLS (WITH 6. SET-ACTUAL BUTTON. When
LOCKABLE COVER DOWN) pressed, will display the actual wire
speed and voltage in the wire speed
1. CIRCUIT BREAKER. Protects the and volts meters. When the button is
circuit from severe wire feed motor not pressed, the set wire speed and
overloads and short circuits. Press to voltage is displayed.
reset.
7. START. Begins welding cycle.
2. CONTROL POWER. Turns input
control power “On” and “Off.” Also 8. STOP. Initiates the stopping cycle at
used as an emergency “Off” in case the end of the weld.
of malfunction.
9. TRAVEL. Turn to “Off” for no travel,
3. ELECTRODE “HOT” LIGHT. “Hand Travel” for travel without
Comes on when the “Start button” is welding, and “Automatic Welding” for
pressed and the electrode circuit welding operations.
becomes electrically hot.
10. VOLTS METER. Displays the set or
actual voltage for each mode (Strike,
FIGURE B.1 – NA-5 CONTROLS. Start, Weld, Crater).
11. WIRE SPEED METER. Displays the
set or actual wire speed for each
mode (Strike, Start, Weld, Crater).
CONTROLS UNDER THE

LOCKABLE SECURITY COVER

12. ARC STRIKING CONTROLS. Sets

the wire speed until the welding
current begins to flow and controls
the power source voltage during arc
11 striking.
17 10
13. BURNBACK AND ELECTRODE
16 BACKUP TIME. Controls the length
15 of burnback delay time after the stop
circuit is energized.
14. WELD CONTROLS. Controls the
12 13 voltage and wire speed during the
welding mode.
7 15. CRATER CONTROLS (OPTIONAL).
3 Sets the ending current and voltage

for an adjustable period of time.
1 16. START CONTROLS (OPTIONAL).

6
Sets the starting current and voltage
for an adjustable period of time.
9 14 4
2 8 17. WELD TIME (OPTIONAL). Controls
5
the time of the weld mode.
NA-5
SETUP INSTRUCTIONS 5. Set the head position relative to the

work as required for the fixture,
Use the following steps to set up the NA-5
application, and procedures. See
welding system prior to welding:
IM305 Sec. T3.2.3.
1. If using a multi-process power source
(SAM, DC-400, DC-600, DC-1000, 6. Rotate the wire straightener, if used,
OR DC-1500 type), make con- until the top of the straightener faces
nections and settings per the power the wire reel. This is required for
source connection diagram (Figures smooth feeding of the electrode into
A.8 to A.14) for the process being the straightener.
used. 7. Refer to the instructions for the wire
AUTO TAB contact assembly being used. See
IM305 Sec. T2.2.6, T2.2.7, T2.5.3, or
When using the NA-5 with the DC- T2.5.4.
400 or CV-400 power source, the
auto tab jumper on the NA-5 voltage 8. The mount for standard 50 and 60 lb
PC board must be connected in order (22.7 and 27.2 kg) electrode coils
for the inch down circuit to function. includes a two-position brake
When the auto tab jumper is assembly. Generally the brake should
connected, the cold starting feature be at the inner position (nearest to
of the NA-5 is disabled and only the the wire reel shaft) for wire feed
hot starting technique can be used. If speeds below 400 in./min (10 m/min).
the cold start technique is to be used, It should be at the outer position for
the optional Diode must be installed faster wire speeds. To adjust the
on the DC-400 or CV-400. brake position, remove the wire reel.
Pull the cotter pin that holds the
2. Set the power source and NA-5 brake shoe to the arm, move the
circuit polarity per information on shoe, and replace the cotter pin. Do
Electrode Polarity in Section A, not bend the cotter pin — it is held in
Installation. place by a friction fit.
3. Depending on the procedures and 9. Load the wire reel per IM305 Sec.
applications, decide: T3.2.2 or install the Speed-Feed
a. The means of arc striking and drum or reel per Sec. T2.5.7-A or -B.
whether to start the travel with
10. Straighten the first 6 in. (152.4 mm)
the “Start” button or the arc.
of electrode and push it through the
b. Whether the initial bead size or wire straightener to the drive rolls. To
penetration requires use of the use the cored wire straightener,
optional “Start Controls.” remove the knurled nut at the top and
feed the wire through the nut, down
See the Starting and Stopping through the straightener, and into the
Sequences section. drive rolls. Screw the nut back onto
the straightener. Feed the wire
4. Depending upon the procedures and
through the nozzle tip and adjust
applications:
the straightener for optimum
a. Select the arc and travel stopping straightness. With wire contact
sequence. See the Starting and assemblies, except the K231, adjust
Stopping Sequences section. until the electrode is straight as it
comes out of the nozzle. Do not
b. Decide if the control of the ending completely straighten the wire when
bead size or crater fill requires using the K231 contact nozzle
the use of optional “Crater because the nozzle relies on the
Controls”. See the Starting and small curvature of the electode for
Stopping Sequences section. proper electrical contact within the
contact tip.
NA-5
11. Set the travel speed as specified by STARTING AND STOPPING

the procedures. With the wire feeder
travel switch set to “Hand Travel”, the
SEQUENCES
travel runs without welding, permitting
accurate measurement of travel MEANS OF ARC STRIKING
speed. When using a Lincoln travel
carriage, adjust the speed with the The NA-5 Codes utilize “hot start” arc
rheostat and the direction with the striking which operates as follows:
toggle switch on the carriage control
panel. 1. With the electrode not touching the
work, press the “Start” button.
12. Connect the work lead to the work or
a suitable piece of scrap. Clip the 2. The electrically “hot” electrode
end of the electrode to a sharp point. inches down as set by the “Inch Wire
Speed” control.
13. Preset the “Start” (if used), “Weld”,
and “Crater” (if used) controls to the 3. When the electrode makes contact
wire speed and voltage specified in with the work, the arc strikes and the
the procedure. circuit automatically switches from
“Strike” settings to “Weld” (or “Start”,
14. Make several test welds, readjusting if used) settings.
the controls in the following order:
NA-5 models above Code 8300 offer both
a. Set the “Arc Striking”, “Inch Wire “hot start” arc striking, as described
Speed”, and “Volts” controls for above, or “Cold Start” arc striking which
optimum arc striking. The operates as follows:
optimum strike control settings for
most processes will be typically 4 1. Press the “Inch Down” button until the
to 5 volts higher than the weld tip of the electrode touches the work,
mode voltage setting and 40% to automatically stops, and the flux (if
50% of the weld mode wire feed used) is automatically dispensed.
speed setting (possibly lower if
cold starting is used). NOTE: If inch speed is set too high, the
electrode may stop with too much force on
b. If striking is still not satisfactory, its tip, resulting in possible poor starting.
refer to the section on Setting
Travel Starting and Stopping or 2. The arc establishes when the “Start”
IM305 Sec. T3.5.2 for information button is pressed, and the circuit
on wire feed motor acceleration. automatically switches to “Weld” (or
“Start”, is used) settings. Should the
c. If installed, adjust the “Start
arc not start immediately, the wire will
Controls” to set the welding
retract slightly until the arc is
procedures for the time set on the
established and then feed down in the
timer to provide the bead size,
normal manner.
penetration, or other factor as
needed for the application.
Use either the standard “on-the-fly” travel
d. If installed, adjust the “Crater starting or rewire the controls for “standstill”
Controls” to set the welding travel starting as described in the Setting
procedures for the set time after Travel Starting and Stopping section.
the “Stop” button is pressed to
provide the bead size or fill the Optional “Start Controls”

crater as needed for the

application. Recommended for applications where
penetration, bead size, and other
e. Set the “Burnback Time” to characteristics must be carefully controlled
provide the stopping char- at the start.
acteristics needed.
NA-5
The starting sequence is as described above 3. Any application for improved arc
except that when the arc strikes, the striking.
machine welds at the wire speed and
voltage set by the “Start Controls” panel until “Standstill” Travel Starting
the time set on the thumbwheel switch
elapses. The circuit then automatically All models can be reconnected so the travel
switches to the “Welding Controls” wire remains at a standstill until the arc starts.
speed and voltage. Actual settings depend “Standstill” travel starting is used when the
on application requirements. electrode must be started at a precise
location.
Available options for applications with
particularly difficult starting. For consistent arc striking with “Standstill”
travel starting, always clip the end of the
1. K238 High Frequency Generator - electrode to a sharp point before starting.
See IM305 Sec. T2.5.8.
STOPPING SEQUENCES
SETTING TRAVEL
STARTING AND STOPPING As shipped, the travel stops when the “Stop”
button is pressed, producing a small crater
area.
Standard machines can be connected for a
variety of starting and stopping sequences. When the end of the weld overlaps the
beginning, changing the stopping sequence
STARTING SEQUENCES to stop the travel later spreads the crater
over a longer area.
“On-the-Fly” Travel Starting
RECONFIGURING THE TRAVEL
When shipped, all models are connected for SEQUENCES
“On-the-Fly” travel starting. The starting
sequence is as follows:
WARNING
1. With the electrode NOT touching the
work, press the “Start” button. This ELECTRIC SHOCK

starts both the wire feed and travel can kill.
motors.
2. When the electrically “hot” electrode the welding power source
touches the work to start the arc, using the disconnect
there is relative motion between the switch before working on
end of the electrode and the work. this equipment.
This “scratching” type contact helps
assure consistent arc striking.
To change the travel sequence, turn off all
This sequence is recommended for most input power to the NA-5 control box. Open
welding applications including: the control box. The logic board is mounted
on the back of the box in the upper right
1. Roundabouts and any other weld hand corner. To change the travel circuit for
which ends at its starting point. A the various modes of starting and stopping,
K337 Weld Timer Module to control follow the information in the wiring diagram
the welding cycle duration can be for the NA-5 being used. Table B.1 also
installed. shows information on reconfiguring the
travel sequences.
2. Welds started on a run-out tab.
NA-5
TABLE B.1 – TRAVEL SEQUENCE LEAD AND SWITCH POSITIONS.
Travel Starts Travel Stops Older Models Newer Models*
With “Start” With “Stop” Lead #691 to Pin 6 1 2 3 4 1 2 3 4

Button Button Lead #692 to Pin 5
Switch #1 Switch #2
With Arc Striking With Arc Stopping Lead #691 to Pin 6

1 2 3 4 1 2 3 4
Lead #692 to Pin 7
Switch #1 Switch #2
With Arc Striking With Stop Button Lead #691 to Pin 5 1 2 3 4 1 2 3 4

Lead #692 to Pin 7
Switch #1 Switch #2
With “Start” With End Crater Lead #691 to Pin 6

Button Fill Time (With Lead #692 to Pin 9 1 2 3 4 1 2 3 4
optional procedure
module installed in Switch #1 Switch #2
crater receptacle1)
With “Start” After Burnback Lead #691 to Pin 6 1 2 3 4 1 2 3 4

Button Time (with Lead #692 to Pin 8
optional procedure
module installed Switch #1 Switch #2
in crater
receptacle1)
1If the optional procedure module is installed in the crater receptacle, *NOTE:
DIP switch position 1 on switch #2 should be in the UP position as
shown. Additionally, remove 583C to 584C jumper plug from the pro Indicates switch in up position
cedure board. If the procedure module is not installed, the switch
should be in the down position and the 583C to 584C jumper plug Indicates switch in down position
should be reinstalled on the procedure board.
Indicates switch position does not matter
NA-5
Wire Feed Motor Acceleration The standard stopping sequence when the
optional “Crater Controls” are not used is as
WARNING follows:
1. Press the “Stop” button.
ELECTRIC SHOCK 2. The wire feed motor stops and the
can kill. “Burnback Time Delay” starts.
• Turn off input power to 3. The arc continues to burn the
the welding power source electrode back from the puddle until
using the disconnect the arc goes out or the time set on the
switch before working on thumbwheel switch elapses. This
this equipment. control should be set for just enough
burnback time to prevent crater
The NA-5 has two different speeds of sticking.
controlled wire feed motor acceleration. As
shipped, the unit is connected for fast There are two other ways this circuit can be
acceleration which is best for most connected. One will cause the wire to
applications. To change to the slower retract* with a contactor drop out delay at
acceleration, turn off all input power to the the end of the weld. The second will cause
NA-5 control box. Open the control box. the wire to retract* during burnback time,
Locate the Control PC Board mounted on and there will be no contactor drop out delay
the back of the box in the lower right hand at the end of the weld. If either one of these
corner. Change the jumper plug from the “F” alternate methods of stopping the weld is
pin to the “S” pin as shown in Figure B.2. desired, the connections on the logic board
can be easily changed.
FIGURE B.2 – ACCELERATION
JUMPER PLUGS. To change the stopping sequence, turn the
input AC power off at the power source,
JUMPER remove the screw holding the inner panel,
PLUG and swing the panel open. Change the
connections (older models) or switch
positions (newer models) on the logic board
as shown in Table B.2.
Optional “Crater Controls”
This option is recommended for applications

where the ending bead size must be
controlled, applications when the crater must
be filled, roundabouts, and any other welds
where the end overlaps the start.
When the “Stop” button is pressed, the

machine welds at the wire speed and
voltage set by the “Crater Controls” until the
time set on the thumbwheel switch elapses.
The circuit then automatically switches to the
arc stopping sequence described above.
NOTE: Setting crater time to 0.00 seconds

will give zero crater time; however, the
Burnback and Electrode Backup crater settings will be active during
burnback time until the arc goes out.
The primary consideration in setting the arc
*Wire will retract at weld mode speed (or crater mode
stopping sequence is to prevent the speed, if installed) until the arc goes out and then retract
electrode from sticking in the puddle. This at strike mode speed for the remainder of burnback
is easily done with the machine as shipped. time.
NA-5
TABLE B.2 – STOPPING SEQUENCE SETTINGS.
When “Stop” Button

is Pressed Older Models Newer Models*
Feed motor stops and Lead #693 to Pin 3 1 2 3 4

electrode burns back with Lead #690 to Pin 4
contactor delay (standard) Switch #2
Feed motor inches up and Lead #693 to Pin 1 1 2 3 4

electrode burns back with Lead #690 to Pin 4
contactor delay Switch #2
Feed motor inches up and Lead #693 to Pin 1 1 2 3 4

contactor opens Lead #690 to Pin 2
(no burnback)
Switch #2
*NOTE:
Indicates switch in up position
Indicates switch in down position
Indicates switch position does not matter
VOLTAGE CONTROL FIGURE B.3 – VOLTAGE CONTROL

RESPONSE JUMPER PLUG
RESPONSE LOCATIONS.
The NA-5 is provided with selectable voltage

control response. Proper setting depends on
the power source and process being used.

Refer to the appropriate power source RED
connection diagram for the proper JUMPER
connection of the jumpers located on the PLUG
NA-5 Voltage P.C. Board, shown in Figure
B.3.
To change the voltage control response:
1. Turn off all input power to the NA-5

WHITE
control.
JUMPER
2. Open the control box. PLUG
3. Locate the Voltage P.C. Board B

mounted on the right side of the box. D
A
Position the jumper plugs on the
Voltage P.C. Board per the
appropriate power source connection

diagram.
VOLTAGE
NA-5
NA-5
AUTOMATIC SHUTDOWN likely to occur when using the R3S models

with the somewhat limited voltage ranges of
If the NA-5 voltage control is unable to the various taps. For instance, if the R3S-
supply the “Set” value of the arc voltage 400 triangle tap setting is for 31 volts, the
while welding, the automatic shutdown range of control from the remote circuit is
circuit will activate. This protection circuit approximately 7 volts, i.e. 27.5 to 34.5 volts
immediately returns the NA-5 control to idle at nominal input voltage. If the NA-5
state within a few seconds after the arc controls are set for 29 volts, and the input
voltage discrepancy occurs. voltage to the R3S goes up, it may not be
possible for the NA-5 control circuit to hold
Typical causes that activate this protective the 29 volts, so the welding will shut down.
shutdown circuit are as follows: By changing to the 27 volt triangle setting,
the range will be approximately 23.5 to 30.5
1. “Set” value of arc voltage is outside volts, and at high input voltage, there will be
the power source range. sufficient control to hold the “Set” arc
voltage. On these machines, if the NA-5
2. Power source voltage control not set

stops welding, follow this procedure:

for “Remote”.
1. Move the NA-5 voltage set point 2
3. Misconnection of NA-5 control cable
volts lower than the desired
leads to the power source.
procedure and make a test weld.
4. Incorrect weld polarity connections, or
a. If the NA-5 still shuts down, go to
settings, at NA-5 or power source.
step 2 below.
5. Lost connection of NA-5 voltage
b. If the NA-5 keeps welding,
sensing leads (#67 and #21) between
change the R3S triangle setting
arc and voltage control or a blown 1/8
to the next higher voltage and
amp fuse on voltage PC boards built
reset the NA-5 set point to the
since 1983.
desired procedure. The R3S is
With NA-5 units above Code 8300, the now set properly unless there is
conditions of causes 4 and 5 above would a significant change in input
result in the wrong wire feed direction when voltage. Skip the following step.
the weld is started. See the section on Cold 2. Move the NA-5 voltage setting set
Start Circuitry. point 2 volts higher than the desired
procedure and make a test weld.
In the case of full-range control power
sources, such as the DC-600, this protective a. If the NA-5 keeps welding,
shutdown circuit could prevent welding change the R3S triangle setting
under the conditions of causes 3, 4 and 5 to the next lower voltage and
above by holding the power output at reset the NA-5 set point to the
minimum, possibly providing too low of a desired procedure. The R3S is
power source output to even establish an now set properly unless there is
arc, or causing the field fuse to blow a significant change in input
because of rapid field reversals with NA-5 voltage. Skip the following step.
controls above Code 8300. See the section
on Cold Start Circuitry. b. If the NA-5 still shuts down, refer
to the following paragraph and
Although out of range shutdown can occur other causes previously listed.
with all power sources when working with
very low or very high arc voltages, it is most
NA-5
In some cases, it is also possible to hold the A. Auto Stop

“Actual” button pressed while starting the
arc. Before the NA-5 shuts down, the actual When the “Inch Down” button is pressed, a
arc voltage can be read on the digital meter. low-level DC voltage signal is applied
Comparing this reading to the “Set” reading between the electrode and work which
will tell what change in the range controls of permits the wire to inch down normally.
the power source are required so it can When the electrode makes electrical contact
supply the desired voltage. Should the with the work, it shorts out this signal
meter read zero, check the NA-5 sensing causing the wire feed to automatically stop
leads (#21 and #67) connections. Should and the flux solenoid to activate until the
the meter read negative (-) voltage, the “Inch Down” button is released. The “Inch
polarity connections or settings at the NA-5 Up” button is not affected by this circuit.
or power source are wrong.
B. Electrode Backup
This same general procedure can be used
on the other power sources. For example, If while starting or welding the electrode
stubs or shorts to work, the resulting loss of
if the NA-5 keeps shutting down and the

other possible causes have been checked, arc voltage will cause the electrode to
adjust the “Set” voltage higher and/or lower momentarily back up until the arc voltage is
than the desired voltage. If the NA-5 re-established and then change back to the
continues to weld at one of these voltages, normal feed direction.
it can be determined what change in the
NOTE: The “cold starting” circuitry will
range controls of the power source are
cause the NA-5 to feed in the wrong
required so it can supply the desired voltage.
direction when the “Start” button is pressed
if the “Actual” arc voltage, as read on the
COLD START CIRCUITRY NA-5 voltmeter, does not exceed typically
about 6.5 volts. Usual causes for the
NA-5 controls above Code 8300 contain situation are:
circuitry added to the voltage PC board to
facilitate the “cold starting” features of these 1. No wire loaded through the NA-5
units.* This circuitry senses the voltage head and nozzle assembly (except
present between the electrode and work, via when using the K148 Contact
Nozzle).
leads #67 and #21, and permits normal wire

feed if this voltage exceeds approximately 2. No power source weld cable
6.5 VDC. However, if this voltage level is connection to the NA-5 head or work.
not exceeded, or drops below approximately
3.5 VDC, the “Auto Stop” activates while 3. Incorrect electrode polarity
inching down or electrode backup occurs if connections at the NA-5 or power
the arc start circuit has been initiated. source.
*Units below Code 8300 can be provided with the cold 4. Little or no output voltage from the
start circuitry by replacing the old L-6257 voltage board power source.
with the new G-1556 voltage board. This new board
will mount and connect in the same manner as the old 5. An open voltage sensing lead #67 or
board, except the third harness connector (previously
connected to a jumper plug) must be connected to the #21 to the NA-5 control box or a
lower receptacle of the new voltage board. blown 1/8 amp fuse on a voltage PC
board built since 1983.
NOTE: HI-FREQ starting cannot be used
with converted units below Code 8300.
NA-5
SECURITY OF WELD beneath each square so the head

is on the back side of the panel
PROCEDURE SETTINGS (inside the control box).
There are two means provided to prevent or f. Remount the PC board assembly
limit unauthorized readjustment of the NA-5 and its panel insulation.
voltage and wire feed speed controls once Reconnect the PC board and
set to the desired procedure. close and secure the control box.
1. The security panel of the NA-5 can be g. Remount the rotary select switch
locked to prevent access to the knob and replace each square
control knobs. spacer tube and felt seal so the
#4 screw protrudes between the
2. The control range of the procedure tube and the felt seal.
control knobs can be limited to either
about 3% or about 15% of the full h. Turn on the NA-5 input power and
range control by installing a knob set the desired procedure by
rotation stop screw to any or all of the rotating the shafts of the controls.
control knobs. This stop screw is
installed in the following manner: i. Carefully replace each control
knob so the #4 screw inserts into
a. Turn off the input power to the the center of the shorter length
NA-5. channel on the back of the knob
for about 3% of the total range of
b. Loosen each knob set screw and control or into the center of the
remove all knobs, including the longer length channel for about
rotary select switch knob. 15% of the total range of control.
c. Remove the felt seal and square j. With finger pressure on the knob
spacer tube mounted behind against the felt seal, carefully
each control knob. retighten the set screw of each
d. Open the control box. knob.
Disconnect, then remove, the
NOTE: Steps h thru j will have to be
procedure control PC board
repeated if it is desired to change the
assembly and its panel insulation.

procedure settings to values outside the
e. Install a 1/2 in. long, pan or round selected 3% or 15% control range limit.
head, #4 sheet metal screw into
the 0.10 in. diameter hole located
NA-5
Section C TABLE OF CONTENTS Section C
- ACCESSORIES SECTION -
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section C
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
Listing of Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
K29 Vertical Lift Adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
K58 Magnetic Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
K96 Horizontal Adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
K129 Submerged Arc Small Wire Twinarc® . . . . . . . . . . . . . . . . . C-3
K148 Contact Nozzle and K149 Linc-FillTM
Long Stickout Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
K218 Horizontal Fillet/Lap Attachment . . . . . . . . . . . . . . . . . . . . C-3
K219 Flux Hopper Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
K223 Solenoid Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
K225 Submerged Arc Twinarc Kit . . . . . . . . . . . . . . . . . . . . . . . C-4
K238 High Frequency Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4

K239 Twinarc Kit for Innershield® Electrodes . . . . . . . . . . . . . . . C-4
K278 SpreadarcTM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4
K281 Solid Wire Straightener for Tiny Twinarc . . . . . . . . . . . . . . C-4
K285 Concentric Flux Cone . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4
K310 Flux Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4
K325 TC-3 Travel Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4
K334 Start and Crater Controls . . . . . . . . . . . . . . . . . . . . . . . . . C-5
K336 Remote Interface Module . . . . . . . . . . . . . . . . . . . . . . . . . C-5
K337 Weld Timer Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5
K349 Multi-Procedure Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5
S-22022 or S-22182 Current Relay . . . . . . . . . . . . . . . . . . . . . . C-5
Speed-Feed Drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5
Speed-Feed Reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5
NA-5
C-2 ACCESSORIES C-2
GENERAL
This section contains a listing and short available with the NA-5 automatic welding
description of the accessories that are system.
TABLE C.1 – NA-5 AUTOMATIC WELDING SYSTEM ACCESSORIES.
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 FREQUENCY UNIT
K239 TWINARC KIT FOR INNERSHIELD ELECTRODES
K278 SPREADARC
K281 SOLID WIRE STRAIGHTENER FOR TINY TWINARC
K285 CONCENTRIC FLUX CONE
K310 FLUX SCREEN
K325 TC-3 TRAVEL CARRIAGE
K334 START AND CRATER CONTROLS
K336 REMOTE INTERFACE MODULE

K337 WELD TIMER MODULE
K349 MULTI-PROCEDURE KIT
S22022 or S22182 CURRENT RELAY
SPEED-FEED DRUMS
SPEED-FEED REELS
NA-5
C-3 ACCESSORIES C-3
LISTING OF ACCESSORIES K148 CONTACT NOZZLE AND

K149 LINC-FILLTM LONG
K29 VERTICAL LIFT ADJUSTER STICKOUT EXTENSION
When mounted in the NA-5 head mounting This Innershield and submerged arc nozzle
system, the K29 Vertical Lift Adjuster is designed for 0.062 through 3/16 in.
provides quick hand crank adjustment of the (1.57 through 4.76 mm) wire at high
vertical head position. It also has some currents. When long stickout [2 to 5 (50.80
horizontal adjustability as described in Sec. to 127.00 mm)] is required, the K149
T3.2.3 of operator’s manual IM305. Linc-Fill Long Stickout Extension is
Installation instructions are shipped with recommended along with the K237 Linc-Fill
each K29 Vertical Lift Adjuster kit, are Starting Relay. Instructions are contained in
contained in the IM305 manual, and can be the IM305 manual and can also be ordered
ordered as Sec. T2.2.11. as Sec. T2.2.7.
K58 MAGNETIC SEPARATOR K218 HORIZONTAL

Useful with any submerged arc equipment. FILLET/LAP ATTACHMENT

The unit removes foreign magnetic particles
from reused submerged arc welding flux. This special contact assembly automatically
Operating instructions are included with the guides the electrode when making
kit. submerged arc horizontal fillet and lap welds
to ensure accurate bead placement without
expensive fixtures and clamps. Installation,
K96 HORIZONTAL ADJUSTER operating, and maintenance instructions are
shipped with each kit, are contained in the
When mounted in the NA-5 head mounting
IM305 manual, and can also be ordered as
system, the K96 Horizontal Adjuster
Sec. T2.5.4.
provides quick hand crank adjustment of the
horizontal head position. Installation
instructions are shipped with each K96 K219 FLUX HOPPER KIT
Horizontal Adjuster kit, are contained in the
IM305 manual, and can be ordered as Sec. This flux hopper, which has an electric flux
valve, can be mounted on NA-5N and
T2.2.12.
NA-5NF heads for submerged arc welding.

Installation instructions are included with
K129 SUBMERGED ARC SMALL each kit. The operator and maintenance
WIRE TWINARC® instructions are contained in the IM305
manual and can also be ordered as
The Twinarc system provides for the feeding Sec. T2.5.9.
of two small solid wires through a single wire
feeder. The Twinarc assembly includes a
wire reel, reel brake, shaft and mounting
K223 SOLENOID KIT
bracket, drive roll, idle roll assembly, dual The solenoid kit includes a valve to control
wire guides, and nozzle and contact tip or water flow when using the cooling
contact tip holder. Instructions are shipped attachment on the K148 or K239 contact
with each kit, are contained in the IM305 nozzle assembly. It opens when the start
manual, and can be ordered as Sec. T2.5.3 button is pressed and can be wired to close
K129. either when the stop button is pressed or
when the arc goes out. Installation
instructions are shipped with each kit.
NA-5
C-4 ACCESSORIES C-4
K225 SUBMERGED arc, and submerged arc procedures can be

ARC TWINARC KIT used. Instructions are shipped with the kit,
are contained in the IM305 manual, and can
The Twinarc kit provides for the feeding of also be ordered as Sec. T2.5.6.
two 5/64, 3/32, or 1/8 in. (1.98, 2.38, or
3.18 mm) solid wires through a single wire K281 SOLID WIRE
feeder. The electrode wire must be the STRAIGHTENER FOR
same size. The assembly includes a wire TINY TWINARC
reel, insulated reel mounting bracket, wire
straightener, dual wire guides, nozzle, and This wire straightener will straighten 0.045
contact block. Installation, operating, and through 3/32 in. (1.14 through 2.38 mm) wire
maintenance instructions are shipped with diameters. It is recommended for welding
each kit, are contained in the IM305 manual, procedures requiring long stickout and
and can be ordered as Sec. T2.5.3 K225. where wire position accuracy is essential.
Instructions are shipped with the kit, are
K238 HIGH FREQUENCY UNIT
contained in the IM305 manual, and can be
This unit supplies high frequency to the ordered as Sec. T2.5.5.

welding leads for more positive starts, which
may be required for certain difficult starting K285 CONCENTRIC FLUX CONE
applications. Factory-installed insulation is
required. Instructions are shipped with each
The concentric flux cone was designed to
unit. Installation instructions are contained
fit on the K148 Contact Nozzle alone, the
in the IM305 manual and can be ordered as
K148 Contact Nozzle with a K149 Linc-Fill
Sec. T2.5.8.
Long Stickout Extension, the K129
Submerged Arc Small Wire Twinarc, and
K239 TWINARC KIT FOR the K391 nozzles. (The maximum electrical
INNERSHIELD® ELECTRODES stickout when using the K149 Linc-Fill Long
Stickout Extension will be 4 in. [101.6 mm.]).
This kit provides for welding with two Use of this attachment results in the flux
Innershield electrodes. Two 3/32 in. being fed concentrically around the
(2.38 mm) flux-cored electrodes are fed electrodes. Installation, operating, and
through a single wire feeder. Both wires
maintenance instructions are shipped with

must be the same size. The K239 kit each kit, are contained in the IM305 manual,
includes the nozzle equipped for water and can be ordered as Sec. T2.2.8 K285.
cooling, drive rolls, drive roll locating collar,
idle roll assembly, ingoing and outgoing
guide tubes, wire straightener, wire reel, and
K310 FLUX SCREEN
wire reel mounting shaft and insulation.
Useful for any submerged arc equipment. It
Instructions are included in the kit, are
removes foreign magnetic particles from
contained in the IM305 manual, and can
reused submerged arc welding flux.
also be ordered as Sec. T2.5.3 K239.
Operating instructions are included in the kit.
K278 SPREADARC TM
K325 TC-3 TRAVEL CARRIAGE
The primary application for this accessory is
for hardfacing buildup using a Twinarc The K325 Travel Carriage carries the control
nozzle. The combination “Spreadarc- box and wire drive head, in either direction,
Twinarc” covers large areas quickly with on a beam of suitable length and
smooth beads of minimum admixture with mechanical specifications. Two models are
the base metal. Flux cored electrode, open available: Standard and High Capacity.
NA-5
C-5 ACCESSORIES C-5
K334 START AND CRATER S22022 OR S22182 CURRENT

CONTROLS RELAY MODULES
Easily installed procedure and timer boards The current relay is useful to fixture builders
to permit adjustment of wire speed and and others who need a signal indicating that
voltage. Can be installed to function at welding current is flowing. Installation,
either the start of the weld or at the end for operating, and maintenance instructions are
crater filling. Installation, operating, and shipped with each kit. The S22022 relay
maintenance instructions are shipped with module is suitable for dry circuit applications
each kit and can be ordered as Sec. T2.5.13 and it is rated at 2 Amps, 115 VAC or 28
K334. VDC. This relay has both normally open and
normally closed contacts. The S22182 relay
K336 REMOTE INTERFACE module is suitable for applications requiring
MODULE at least 10 mA current and it is rated at 3
Amps, 115 VAC or 28 VDC. This relay only
Permits connection of customer-furnished has normally open contacts.
remote start-stop and inch momentary

contact closure or momentary 24 volt SPEED-FEED DRUM
signals. Also used when a single remote
signal is desired to start or stop multiple These drums must be set on a turntable
heads. This module replaces the earlier which permits them to freely turn in a
K336 Remote Pushbutton Interface Module. clockwise direction. Installation, operating,
Installation and application instructions are and maintenance instructions are contained
shipped with each kit and can be ordered as in the IM305 manual and can be ordered as
Sec. T2.5.11 K336. Sec. T2.5.7-A.
K337 WELD TIMER MODULE SPEED-FEED REEL
Permits setting of weld time for an adjustable These reels require dereeling equipment
period. Eliminates need to press the “Stop” that permits the reel to rotate freely as the
button. Instructions are included in the kit. electrode is used. Installation, operating,
and maintenance instructions are contained
K349 MULTI-PROCEDURE KIT in the IM305 manual and can be ordered as

Sec. T2.5.7-B.
The K349 Multi-Procedure Kit provides three
additional weld mode procedure settings of
wire feed speed and voltage, allowing the
choice of four NA-5 weld mode procedures.
Installation, operating, and maintenance
instructions are shipped with each kit, are
contained in the IM305 manual, and can be
ordered as Sec. T2.5.19 K349.
NA-5
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC C-6
NA-5
NOTES
C-6
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
D-2 MAINTENANCE D-2
CONTROL BOX If a complete or partial short occurs in the

field circuit, or if there is a defect on the PC
board, a 1/2 amp slow-blow type fuse will
GENERAL blow. This field circuit fuse is mounted on the
power PC board, shown in Figure D.2, inside
Inspect the control box every 3 months. If the control box. Before replacing the fuse,
needed, blow dirt out using low pressure air. check the motor field for a short condition.
No further maintenance should be required. Normal resistance is approximately 700
ohms.
CIRCUIT PROTECTION
With NA-5 controls above Code 8300, the
The circuit breaker mounted on the left side field circuit fuse may blow due to frequent
of the control box protects the control circuit motor field reversals from application
from short circuit conditions and from severe problems affecting the “cold” starting circuit,
wire feed overloads. If it is open, determine such as the power source output being too
and correct the cause for the overload. To low to establish an arc or the welding
reset the circuit breaker, push in the red procedure causing frequent electrode-to-
button shown in Figure D.1. puddle shorting. (Refer to Automatic

Shutdown in Section B, Operating
FIGURE D.1 – CIRCUIT BREAKER Instructions.)
RESET BUTTON.
FIGURE D.2 – POWER PC BOARD
FUSE LOCATIONS.
NA-5 POWER
FIELD
POWER 1/2 AMP
1/2 AMP SLOW-BLOW
SLOW-BLOW FUSE
FUSE
The power supply for the electronic circuitry

is protected by a 1/2 amp slow-blow type fuse
shown in Figure D.2. It is located on the

power PC board inside the control box.
CIRCUIT
BREAKER
RESET BUTTON
NA-5
D-3 MAINTENANCE D-3
The 1/8 amp fast-blow fuse, shown in Figure NA-5 circuit common (#510). Such a
D.3, on a voltage PC board built since 1983, condition typically exists when the NA-5
protects the NA-5 circuitry from damage polarity connections are set for electrode
which may result from a ground or case negative.
faulted control lead. If the fuse blows, the
NA-5 voltage sensing lead circuit will be
opened (Refer to Automatic Shutdown in WELDING HEAD
Section B, Operating Procedures) and the
Troubleshooting Guide. WIRE DRIVE GEAR BOX
FIGURE D.3 – VOLTAGE BOARD FUSE Once a year, recoat all gear teeth with a
LOCATION. non-fluid molydisulfide type grease such as
Non-Fluid Oil Corporation’s A-29 Special/MS
1/8 AMP Lubricant. For access to the gears in the first
FAST-BLOW chamber, remove the adapter plate and
FUSE motor assembly as shown in Figure D.4.
FIGURE D.4 – WIRE DRIVE MOTOR

GEAR BOX.
DRIVE MOTOR
BRUSH ACCESS
HEX HEAD
SCREW
ADAPTER
PLATE AND
MOTOR
ASSEMBLY
FIRST
CHAMBER
PIPE
PLUG
WIRE DRIVE
GEARBOX
VOLTAGE
SECOND
CHAMBER
NA-5
GROUND FAULT FUSE SLOT HEAD

PROTECTION SCREW
To lubricate the gears in the second

A 1/8 amp fast-blow fuse, shown in Figure chamber, remove one of the pipe plugs and
D.3, is located on the voltage PC board. feed grease until it comes in contact with the
This fuse will protect the NA-5 circuitry from bevel gear teeth. Then, rotate the output
damage resulting from a ground or case shaft by hand until all teeth are lubricated.
faulted control lead when the arc voltage
potential exists between ground and the
NA-5
D-4 MAINTENANCE D-4
WIRE DRIVE MOTOR FIGURE D.5 – CHANGING THE WIRE

FEED GEAR RATIO
Periodically inspect the wire drive motor HEX NUT (11)
brushes, Figure D.4. Replace the brushes
as needed. PLAIN WASHER (9)
CHANGING WIRE FEED GEAR SLOT HEAD INPUT

RATIOS SCREWS HELICAL
WIRE (MOUNTING GEAR (12)
Four wire size conversion kits are available FEED SCREWS)
to modify the wire feeder for different size or GEARBOX
type electrodes. The kits include drive rolls
and guide tubes for the wire specified, as
shown in Table D.1.
TABLE D.1 - CONVERSION KITS WOODRUFF

KEY (8)
Wire Type in. (mm) Conversion Kit
3/32-7/32 (2.38-5.56) T13724-A
Solid or Cored
1/16-3/32 (1.59-2.38) T13724-B
Solid or Cored
0.035-0.052 (0.89-1.32) T13724-C
Solid
1. Remove the four screws that mount
0.045-0.052 (1.14-1.32) T13724-D the adapter plate and motor assembly
Cored to the gear box. Remove the adapter
plate and motor assembly from the
gear box.
Refer to Table D.2. Four gear ratios are
available: 21:1, 57:1, 95:1, and 142:1. To 2. Take the two long screws removed in
change the gear ratio, replace the motor step 1 and screw one into each of the
tapped holes located on the face of

pinion and the first reduction gear per the

following instructions (Refer to Figures D.4, fiber input helical gear (12). Insert the
D.5 and D.6). screws through the full thickness of
the gear, and using a screwdriver
NOTE: Any item numbers in parentheses wedged between the screws to
on Figure D.5 refer to item numbers in the prevent rotation, remove hex nut (11)
task description breakdown. that holds the gear to the shaft.
Remove plain washer (9).
TABLE D.2 – WIRE FEED GEAR RATIOS.

Feed Speed Max Wire Size
Gear Range in. (mm)
Ratio in/min (m/min) Cored Wire Solid Wire
21:1 100-2070 (2.54-52.58) 0.052 (1.3) 0.052 (1.3)
57:1 40-778 (1.02-19.76) 3/32 (3.0) 1/16 (1.6)
95:1 22-456 (0.56-11.58) 5/32 (4.0) 1/8 (3.2)

142:1 15-300 (0.38-7.62) 5/32 (4.0) 7/32 (5.6)
NA-5
D-5 MAINTENANCE D-5
3. Pull the gear from the shaft using the FIGURE D.6 – DRIVE MOTOR PINION
screws as a pulling device. GEAR REMOVAL.
4. Be certain woodruff key (8) is properly
located on the shaft. Screw the WIRE
adapter plate and motor assembly DRIVE
mounting screws into the new fiber MOTOR
input helical gear from the stenciled
side and place the gear on the shaft.
Replace plain washer (9), tighten the
hex nut (1), and remove the adapter
plate and motor assembly mounting
screws from the gear.
SHAFT
5. After noting the relation of the adapter
plate with the motor leads, remove
the adapter plate from the wire drive
motor. See Figure D.6. Support the

pinion properly and, with the proper ADAPTOR
size punch, drive the roll pin that PLATE
holds the pinion out of the shaft. Pull
the pinion off. Install the new pinion PINION
and replace the roll pin. Replace the
adapter plate in its original location.
6. Cover the teeth of the motor pinion ROLL PIN MOUNTING

and the input gear with a non-fluid SCREW (X3)
molydisulfide type grease such as
The electrode is driven by gripping
Non-Fluid Oil Corporation’s A-29
between the grooved drive rolls and
Special/MS Lubricant. This grease
spring-loaded idle roll. Replace the drive
can be scooped from the cavity of the
rolls when they become worn. The drive rolls
gear case.
for 1/16 in. (1.6 mm) and larger diameter
7. Reassemble the motor on the gear electrodes have two sets of teeth so they
can be reversed once before they must be

box; make sure the gears mesh

properly and the adapter plate replaced.
locating bead is in its cavity. Replace
and tighten the four screws removed WIRE STRAIGHTENERS
in step 1.
Solid Electrode
8. Jumper on wire speed meter PC
board must be properly positioned for Periodically inspect the slide bushing at the
the gear ratio and drive rolls being top of the straightener and the ingoing wire
used (See the wiring diagram for the guide at the bottom of the straightener for
wire speed meter PC board.) signs of wire milling. If necessary, rotate the
guide to present an unworn surface. To
WIRE DRIVE MECHANISM reverse the slide bushing for a fresh wear
surface, remove the cross adjustment screw
Drive mechanisms for three wire size ranges and turn the bushing over.
are available: 0.035 through 0.052 in.
(0.9 through 1.3 mm), 1/16 through 3/32 in. Flux-Cored Electrode
1.6 through 2.4 mm), and 3/32 through

7/32 in. (2.4 through 5.6 mm). If changing to Severe wear at the “V” groove in the curved
wire sizes outside this range, change the arm of the straightener can result in wire
drive rolls and the incoming and outgoing wander at the arc. Periodically check the
guide tubes. Also change the gear ratio as groove and replace the arm when badly
necessary. worn. Also replace the ingoing guide at the
top of the straightener if it shows signs of
wire milling.
NA-5
D-6 MAINTENANCE D-6
OPTIONAL FEATURES 2. Check the carriage drive gear teeth.

If the teeth are badly worn, replace
the drive gear.
CONTACT ASSEMBLIES
3. After 5,000 hours of operation, the
A dirty or rusty electrode and excessively motor and the first reduction gear
high currents cause rapid wear of the should be removed from the gear box,
contact tips. The nozzle contact tip must be and all the gear teeth should be
replaced when it no longer provides accurate recoated with a good grade of
wire location or good electrical contact. See graphite grease.
Sec. T2.2.6, Sec. T2.2.7, or Sec. T2.5.3 of
the IM305 manual for specific instructions to
replace contact tips and to perform VERTICAL LIFT ADJUSTER
maintenance on other various contact
assemblies. Every month, add a few drops of SAE-140
oil or equivalent to the oil cup on the back
WIRE REEL MOUNTING FOR
of the vertical lift housing. Every year,

50 OR 60 LB (22.7 OR replace the grease in the top section gear
27.2 KG) COILS cavity with a medium grease. If the unit is
disassembled for cleaning, apply a layer of
Periodically coat the reel shaft with a thin medium grease to the screw threads of the
layer of grease. No maintenance of the two- head lift tube and head lift screw. Apply a
position adjustable brake is needed except thin layer of grease to the outside diameter
to replace the shoe assembly if it wears of the head lift tube and the inside diameter
through. of the long hole in the head lift body. Slide
the head lift tube into the head lift body and
TRAVEL CARRIAGE screw in the head lift screw. Fill the upper
section gear cavity one-half full of grease.
Be sure the needle bearings are packed in
Periodically: grease.
1. Disengage the release handle and
see that the carriage moves freely HORIZONTAL ADJUSTER
along the beam.

Twice a year, apply a thin coat of grease to
2. Add a few drops of machine oil to all sliding surfaces. Every year, replace the
each of the head lift bearings. This grease in the gear cavity with a medium
can be done through the front grease.
opening in the carriage.
HIGH FREQUENCY GENERATOR
3. Add a few drops of oil to the clutch
handle bearings.
Inspect the spark gaps monthly and maintain
4. Add a few drops of oil into each of the the setting specified on the spark gap cover
cups at the travel mounting pivot plate.
point.
SPREADARC
(No change of lubrication is required
for cold temperature operation.) Refer to the maintenance information
provided in IM305 Sec. T2.5.6.
Once a year:
1. Check the motor brushes. If 0.25 in.

(6.35 mm) or shorter, replace with
new brushes.
NA-5
E-1 E-1
Return to Master TOC THEORY OF OPERATION
TABLE OF CONTENTS
-THEORY OF OPERATION SECTION-
Theory of Operation ..................................................................................................................Section E
General Description..........................................................................................................................E-2
Input Power Circuits .........................................................................................................................E-2
Power and Voltage Boards...............................................................................................................E-3
Control, Logic and Procedure Boards ..............................................................................................E-4
Optional start, Crater Fill and Weld Timer Boards............................................................................E-5
SCR Operation .................................................................................................................................E-6
NA-5
E-2 E-2
THEORY OF OPERATION
GENERAL DESCRIPTION
The NA-5 is a fully automatic wire feed voltage on digital meters. These preset
control unit. It is designed for multiple conditions are internally monitored and
process CV operation and can be used remain constant until changed by the
with a variety of wire feeder heads, con- operator.
tact nozzles and welding processes.
The NA-5 control unit enables the oper-
ator to preset wire feed speed and arc
FIGURE E.1 Input Circuits
CONTACTOR CLOSURE (#2 AND #4) TACH FEEDBACK (MOTOR RPM)
ARC VOLTS (SET & ACTUAL)
REMOTE VOLTAGE CONTROL (A, B, C)

1/2 AMP
WORK SENSING (#21) F501
115VAC
SET VOLTAGE
R
ODE SENSING (#67) VOLTAGE
TACH
T
C BOARD TRAVEL
E
L RECEPTACLE
E D FLUX
C RECEPTACLE
S A 3
MOTOR U R
C A CR
P N
P V D
L O
L S 2
Y T H CR
A START STOP INCH A U
R V V
V DOWN GT
F O SWITCH SWITCH SWITCH E D
M O
A L I L O O
W 1
T T E T L N CR
U A L A T
R G G A
D E OPTIONAL
E E G P VOLTS SPEED
START
BOARD
START
TIMER
INPUT E DC SUPPLY VOLTAGE
R
POWER
SWITCH
CIRCUIT P F2 OB
STRIKE
BREAKER R1(2 OHMS) O OPTIONAL CRATER
#31 W LOGIC STRIKE/WELD PROCEDURE
ENABLE
CO CRATER
BOARD TIMER
CONTROL EA
CABLE 115 E BOARD
VAC DR
RECEPTACLE R UD
OPTIONAL
WELD
TIMER
#32 F1
B R WELD
O FIELD DIRECTION SIGNAL F E VOLTS SPEED
BURNBACK
A E
E
TIMER
R D
D MOTOR ARMATURE
G
E
N WELD
CURRENT
A A
T1 T2 T B REED SWITCH
E L
S E
I
G S
115VAC N I
A G SET SPEED
1 L N
0 36VAC (18+18VAC) S A
L
V 22VAC
A
C
10VDC REFERENCEVOLTAGE
DC VOLTAGE
VOLT
METER
SPEED
METER
WIRE FEED SPEED (SET & ACTUAL) CONTROL TACH FEEDBACK (MOTOR RPM)
BOARD BOARD
BOARD
INCH
UP
SWITCH
DIGITAL DIGITAL
METER METER
INPUT POWER CIRCUITS
The NA-5 control unit is supplied with motor. The voltage board receives
115VAC power usually from the welding 115VAC and transforms and rectifies it
power source. The 115VAC power is to 24VDC for the "work touch sensing"
connected to the control box circuitry circuit. The T1 and T2 transformer pri-
through the control cable receptacle, maries are also supplied with 115VAC
the input power switch and a 5 amp cir- via the F1 (1/2amp) fuse on the power
cuit breaker. board. The T1 and T2 secondary wind-

ings offer a variety of isolated AC sup-
The 115VAC is applied through a 2 ohm ply voltages to the power, logic and
resistor to the power board where is meter boards.
rectified and controlled to supply arma-
ture and field voltage to the wire drive
NOTE: Unshaded areas of block logic diagrams are the subject of discussion.
NA-5
E-3 E-3
THEORY OF OPERATION
FIGURE E.2 Power and Voltage Boards

1/2 AMP
115VAC
SET VOLTAGE
R
TACH
T
C BOARD TRAVEL
E
L RECEPTACLE
E D FLUX
C RECEPTACLE
S A 3
MOTOR U R
C A CR
P N
P V D
L O
L S 2
Y T H CR
R V V
V DOWN GT
M O F O SWITCH SWITCH SWITCH E D
A L I L O O
W 1
T T E T L N CR
U A L A T
R G G A
D E OPTIONAL
E E G P VOLTS SPEED
START
BOARD
START
TIMER
R
POWER
SWITCH
CIRCUIT P F2 OB
STRIKE
CO CRATER
TIMER
BOARD
ENABLE
CONTROL EA
CABLE 115 E BOARD
VAC DR
RECEPTACLE R UD
OPTIONAL
WELD
TIMER
#32 F1
B R WELD
BURNBACK
A E
E
TIMER
R D
D MOTOR ARMATURE
G
E
N WELD
CURRENT
A A
E L
S E
I
G S
115VAC N I
A G SET SPEED
1 L N
0 36VAC (18+18VAC) S A
L
V 22VAC
A
C
DC VOLTAGE
VOLT
METER
SPEED
METER
BOARD BOARD
BOARD
INCH
UP
SWITCH
DIGITAL DIGITAL
METER METER
POWER AND VOLTAGE

BOARDS
The AC voltages that are received by The voltage board also generates a low
the power board are rectified and regu- DC voltage that is applied to the elec-
lated. These DC voltages are supplied trode during the inch down mode.
to the motor, voltage board and control When the electrode makes contact with
board. The two SCR-controlled the work piece, this low voltage is
115VDC supplies power the motor "loaded down", signaling the control cir-
armature and field circuits. cuitry to stop the wire feed motor. This
feature allows the operator to utilize the
The actual arc voltage is sensed at leads "work touch sensing" feature.
#67(electrode) and #21(work) which are
coupled to the voltage board. The pre- If for any reason the actual welding arc
set voltage requirements are also sent to voltage does not match the set weld
the voltage board. This information is voltage
compared and processed on the voltage (+/- 0.5Volts) the NA-5 will shutdown.
board and the resultant correction signal This feature insures that the actual
is sent to the Lincoln CV power source welding voltage is the same as the pre-
via the remote voltage leads (A,B,C). set voltage during the welding cycle.
The preset and actual arc voltage infor- This circuitry is incorporated on the volt-
mation is also sent to the voltage meter age board.
board where it is processed and dis-
played on the digital meter.
NA-5
E-4 E-4
THEORY OF OPERATION
FIGURE E.4 Control Logic and Procedure Boards

1/2 AMP
115VAC
SET VOLTAGE
R
TACH
T
C BOARD TRAVEL
E
L RECEPTACLE
E D FLUX
C RECEPTACLE
S A 3
MOTOR U R
C A CR
P N
P V D
L O
L S 2
Y T H CR
R V V
V DOWN GT
F O SWITCH SWITCH SWITCH E D
M O
A L I L O O
W 1
T T E T L N CR
U A L A T
R G G A
D E OPTIONAL
E E G P VOLTS SPEED
START
BOARD
START
TIMER
R
POWER
SWITCH
CIRCUIT P F2 OB
STRIKE
ENABLE
CO CRATER
BOARD TIMER
CONTROL EA
CABLE 115 E BOARD
VAC DR
R OPTIONAL
RECEPTACLE WELD
#32 F1
UD TIMER
B R WELD
BURNBACK
A E
E
TIMER
R D
D MOTOR ARMATURE
G
E
N WELD
CURRENT
A A
E L
S E
I
G S
115VAC N I
A G SET SPEED
1 L N
0 36VAC (18+18VAC) S A
L
V 22VAC
A
C
DC VOLTAGE
VOLT
METER
SPEED
METER
BOARD BOARD
BOARD
INCH
UP
SWITCH
DIGITAL DIGITAL
METER METER
CONTROL, LOGIC AND board to proceed from the "strike" settings to the optional
start board if used, or to the welding wire speed and arc
PROCEDURE BOARDS
voltage parameters.
The logic board interprets and processes the signals it

The control board receives information from the logic
receives from the various PC boards, switches and con-
board, the procedure board and the tach feedback cir-
trols. The logic board also houses a DC power supply
cuit. The control board then applies the appropriate gate
(+5 -10) which is derived from the 22VAC received from
signal to the SCR power supply on the power board.
the T2 transformer. This DC voltage is also used on the
This variable and regulated DC voltage is applied to the
procedure board.
motor armature thus controlling the speed of the wire
feed motor. The preset and actual wire feed speed infor-
Upon receiving voltage reference level commands from
mation is sent to the speed meter board where it is
the procedure and voltage boards, or the user-operated
processed and displayed on the digital meter.
switches, the logic board sends the appropriate com-
The procedure board incorporates the many options
mand signals to the control and power boards to drive
available with the NA-5. The "strike" and "weld" controls
the wire feed motor to the proper speed and direction.
are part of the procedure board and are not optional.
When the "start" signal is received by the logic board the
The wire feed speed and arc voltage settings for the vari-
power source contact relay (3CR) is energized along
ous modes are "programmed" through the procedure
with the travel relay (2CR) and the flux relay (1CR). The
board and are then sent to the logic, voltage and control
"inch down" and "stop" switches signal the logic board
boards at the appropriate times during the welding cycle.
which then directs the control and power boards to apply
The burnback time is also coupled through the procedure

the appropriate armature and field voltages to the wire
board. This control determines the length of time of
drive motor. The "inch up" switch, which is connected
burnback delay after the stop circuit is energized.
directly to the control board, dictates that the wire drive
Depending on the connections on the logic board, it may
motor reverse direction, backing the electrode wire away
also determine the length of time the wire feed motor
from the work piece. When the welding current closes
reverses after the stop button is pressed.
the reed switch the logic board directs the procedure
NA-5
E-5 E-5
THEORY OF OPERATION
FIGURE E.3 Optional Start, Crater Fill and Weld Timer Boards

1/2 AMP
115VAC
SET VOLTAGE
R
TACH
T
C BOARD TRAVEL
E
L RECEPTACLE
E D FLUX
C RECEPTACLE
S A 3
MOTOR U R
C A CR
P N
P V D
L O
L S 2
Y T H CR
R V V
V DOWN GT
M O F O SWITCH SWITCH SWITCH E D
A L I L O O
W 1
T T E T L N CR
U A L A T
R G G A
D E OPTIONAL
E E G P VOLTS SPEED
START
BOARD
START
TIMER
R
POWER
SWITCH
CIRCUIT P F2 OB
STRIKE
ENABLE
CO CRATER
BOARD TIMER
CONTROL EA
CABLE 115 E BOARD
VAC DR
RECEPTACLE R OPTIONAL
WELD
UD
TIMER
#32 F1
B R WELD
BURNBACK
A E
E
TIMER
R D
D MOTOR ARMATURE
G
E
N WELD
CURRENT
A A
E L
S E
I
G S
115VAC N I
A G SET SPEED
1 L N
0 36VAC (18+18VAC) S A
L
V 22VAC
A
C
DC VOLTAGE
VOLT
METER
SPEED
METER
BOARD BOARD
BOARD
INCH
UP
SWITCH
DIGITAL DIGITAL
METER METER
OPTIONAL START, CRATER

FILL AND WELD TIMER

BOARDS
When installed, the optional start board is pressed. This optional feature is
dictates to the procedure board the helpful in controlling bead shape and
starting wire feed speed and arc volt- filling craters at the end of a weld.
age. This condition can be operator set
for a predetermined period of time. The weld timer permits setting of weld
These parameters can be set either time for an adjustable period of time.
higher or lower than those of the weld- This feature eliminates the need to
ing procedure to control penetration, press the "stop" switch.
bead shape, or other factors at the start
of the weld. The start circuit becomes
active when the weld current sensing
reed switch is closed.
The crater fill board is used by the oper-

ator to adjust the finishing wire feed
speed and voltage either higher or
lower than the welding procedure for an
adjustable period of time. This circuit
becomes active when the "stop" switch
NA-5
E-6 E-6
THEORY OF OPERATION
SCR OPERATION
A silicon controlled rectifier (SCR) is a three terminal these terminals must be slightly greater than 0.6V.
device used to control rather large currents to a load. Once the SCR has fired it is not necessary to continue
An SCR acts very much like a switch. When a gate the flow of gate current. As long as current continues
signal is applied to the SCR it is turned ON and there to flow from anode to cathode the SCR will remain on.
is current flow from anode to cathode. In the ON state When the anode to cathode current drops below a
the SCR acts like a closed switch. When the SCR is minimum value, called holding current, the SCR will
turned OFF there is no current flow from anode to shut off. This normally occurs as the AC supply volt-
cathode thus the device acts like an open switch. As age passes through zero into the negative portion of
the name suggests, the SCR is a rectifier, so it passes the sine wave. If the SCR is turned on early in the
current only during positive half cycles of the AC sup- positive half cycle, the conduction time is longer
ply. The positive half cycle is the portion of the sine resulting in greater SCR output. If the gate firing
wave in which the anode of the SCR is more positive occurs later in the cycle the conduction time is less
than the cathode. resulting in lower SCR output.
When an AC supply voltage is applied to the SCR, the

device spends a certain portion of the AC cycle time in
the on state and the remainder of the time in the off
state. The amount of time spent in the ON state is
controlled by the Gate.
An SCR is fired by a short burst of current into the

gate. This gate pulse must be more positive than the
cathode voltage. Since there is a standard PN junc-
tion between gate and cathode, the voltage between
INPUT
CATHODE
OUTPUT
NOTE: AS THE GATE
ANODE PULSE IS APPLIED
GATE
LATER IN THE CYCLE
THE SCR OUTPUT
IS DECREASED.
GATE
FIGURE E.4 SCR Operation
NA-5
SECTION F-1 SECTION F-1
TROUBLESHOOTING & REPAIR
TABLE OF CONTENTS
-TROUBLESHOOTING AND REPAIR SECTION-
Troubleshooting and Repair ......................................................................................................Section F

How to Use Troubleshooting Guide......................................................................................................F-2
PC Board Troubleshooting Procedures................................................................................................F-3
Troubleshooting Guide .........................................................................................................................F-4
PC Board LED Definitions ..................................................................................................................F-36
PC Board LED Sequence Table.........................................................................................................F-37
Test Procedures .................................................................................................................................F-38
DC Power Supply Test ....................................................................................................................F-38
T1 and T2 Transformer Test ...........................................................................................................F-42
Voltage Board Transformer Test .....................................................................................................F-45
Wire Feed Drive Motor Test ............................................................................................................F-48

External Resistance Test (Leads #21 and #67) ..............................................................................F-50
Out of Voltage Range Shut Sown Test ...........................................................................................F-52
Tach Board Feedback Test .............................................................................................................F-55
VoltmeterAccuracy Test ..................................................................................................................F-57
Wire Speed Accuracy Test..............................................................................................................F-60
Meter Circuit Accuracy Test ............................................................................................................F-64
Replacement Procedures ...................................................................................................................F-71
PC Board(s) Removal and Replacement ........................................................................................F-71
Digital Meter and Meter PC Board Removal and Replacement ......................................................F-73
Tach PC Board Removal and Replacement ...................................................................................F-77
Wire Drive Motor Removal and Replacement .................................................................................F-81
Retest After Repair .............................................................................................................................F-85
NA-5
F-2 F-2
HOW TO USE TROUBLESHOOTING GUIDE

WARNING
Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician and
machine operator and will invalidate your factory warranty. For your safety and to avoid
Electrical Shock, please observe all safety notes and precautions detailed throughout this
manual.
__________________________________________________________________________
This Troubleshooting Guide is provided to out removing the case wrap-around cover.
help you locate and repair possible machine Step 3. RECOMMENDED COURSE OF
malfunctions. Simply follow the three-step ACTION

procedure listed below.
The last column labeled “Recommended
Step 1. LOCATE PROBLEM (SYMPTOM). Course of Action” lists the most likely com-
Look under the column labeled “PROBLEM ponents that may have failed in your
(SYMPTOMS)”. This column describes machine. It also specifies the appropriate
possible symptoms that the machine may test procedure to verify that the subject
exhibit. Find the listing that best describes component is either good or bad. If there
the symptom that the machine is exhibiting. are a number of possible components,
Symptoms are grouped into the following check the components in the order listed to
categories: wire feeding problems, mode eliminate one possibility at a time until you
function problems, function problems and locate the cause of your problem.
welding problems.
All of the referenced test procedures
Step 2. PERFORM EXTERNAL TESTS. referred to in the Troubleshooting Guide are
The second column labeled “POSSIBLE described in detail at the end of this chap-
AREAS OF MISADJUSTMENT(S)” lists the ter. Refer to the Troubleshooting and Repair
obvious external possibilities that may con- Table of Contents to locate each specific
tribute to the machine symptom. Perform Test Procedure. All of the specified test
these tests/checks in the order listed. In points, components, terminal strips, etc. can
general, these tests can be conducted with- be found on the referenced electrical wiring
diagrams and schematics. Refer to the
Electrical Diagrams Section Table of
Contents to locate the appropriate diagram.
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 trou-
bleshooting assistance before you proceed call 216-383-2531 or 1-800-833-9353.
_____________________________________________________________
NA-5
F-3 F-3
PC BOARD TROUBLESHOOTING PROCEDURES
- Remove the P.C. Board from the static-

WARNING shielding bag and place it directly into the
ELECTRIC SHOCK can kill. equipment. Don’t set the P.C. Board on or
Have an electrician install near paper, plastic or cloth which could have
and service this equip- a static charge. If the P.C. Board can’t be
ment. Turn the input power installed immediately, put it back in the static-
OFF at the fuse box before shielding bag.
working on equipment. Do
not touch electrically hot - If the P.C. Board uses protective shorting
parts. jumpers, don’t remove them until installation
_______________________________ is complete.
CAUTION: Sometimes machine failures
appear to be due to PC board failures. These - If you return a P.C. Board to The Lincoln
problems can sometimes be traced to poor Electric Company for credit, it must be in the
electrical connections. To avoid problems static-shielding bag. This will prevent further
when troubleshooting and replacing PC damage and allow proper failure analysis.
boards, please use the following procedure:
4. Test the machine to determine if the fail-
1. Determine to the best of your technical ure symptom has been corrected by the
ability that the PC board is the most likely replacement PC board.
component causing the failure symptom.
NOTE: It is desirable to have a spare (known
2. Check for loose connections at the PC good) PC board available for PC board trou-
board to assure that the PC board is prop- bleshooting.
erly connected.
NOTE: Allow the machine to heat up so that
3. If the problem persists, replace the sus- all electrical components can reach their oper-
pect PC board using standard practices to ating temperature.
avoid static electrical damage and electri-
cal shock. Read the warning inside the 5. Remove the replacement PC board and
static resistant bag and perform the follow- substitute it with the original PC board to
ing procedures: recreate the original problem.
P.C. Board can be dam- a. If the original problem does not reap-
aged by static electricity. pear by substituting the original
board, then the PC board was not the
- Remove your body’s stat- problem. Continue to look for bad
ic charge before opening connections in the control wiring har-
the static-shielding bag. ness, junction blocks, and terminal
ATTENTION Wear an anti-static wrist strips.
Static-Sensitive strap. For safety, use a 1
Devices b. If the original problem is recreated by
Meg ohm resistive cord
Handle only at the substitution of the original board,
connected to a grounded
Static-Safe then the PC board was the problem.
part of the equipment
Workstations Reinstall the replacement PC board
frame.
and test the machine.
Reusable
Container - If you don’t have a wrist 6. Always indicate that this procedure was
Do Not Destroy strap, touch an unpainted, followed when warranty reports are to be
grounded, part of the
submitted.
equipment frame. Keep touching the frame to
prevent static build-up. Be sure not to touch NOTE: Following this procedure and writing
any electrically live parts at the same time. on the warranty report, “INSTALLED AND
SWITCHED PC BOARDS TO VERIFY
- Tools which come in contact with the P.C. PROBLEM,” will help avoid denial of legiti-
Board must be either conductive, anti-static or mate PC board warranty claims.
static-dissipative.
NA-5
F-4 TROUBLESHOOTING & REPAIR F-4
Observe all Safety Guidelines detailed throughout this manual

PROBLEMS POSSIBLE AREAS OF RECOMMENDED

(SYMPTOMS) MISADJUSTMENTS(S) COURSE OF ACTION
WIRE FEEDING PROBLEMS
The wire feeds whenever the input 1. Check the “Start” switch (S5). 1. Check light 7B on the logic board.
power switch is in the “ON” position. Make sure it is not stuck closed. It should NOT be on. If light 7B is
ON remove lead #518A from the
2. Check the “Inch Down” switch “Start” switch. If the light remains
(S4). Make sure it is not stuck ON the logic board may be faulty.
closed. If the light goes OFF check the
switch and associated leads.
3. Check the “Inch Up” switch (S3) See wiring diagram and Figure
Make sure it is not stuck closed. F.1.
4. Check to make sure that jumper 2. Check light 7J on the logic board.
lead #693 is connected to the It should NOT be on. If light 7J is

proper pin on the logic board. ON remove lead #592 from the
See wiring diagram. “Inch Down” switch. If the light
remains ON the logic board may
be faulty. If the light goes OFF
check the switch and associated
leads. See wiring diagram and
Figure F.1.
3. |Disconnect lead #586 from the

“Inch Up” switch. If the problem
is resolved check the switch and
associated leads. See wiring dia-
gram.
4. Check lights 7B, 7J and 7E.

They should all be OFF. If lights
7B and 7J are OFF and light 7E

is ON the logic board may be
faulty. See Figure F.1.
5. Disconnect plug “A” from the logic

board. If the wire feed stops the
logic board may be faulty. See
Figure F.1.
6. If the feed does not stop with plug

“A” disconnected, disconnect plug
“E” from the logic board. If the
wire feed stops with plug “E” dis-
connected the logic board may be
faulty. If the wire feed does NOT
stop with plug “E” disconnected
the power board may be faulty.

Replace. See Figure F.1.
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


The wire does not feed. Pressing 1. Make sure input power switch is 1. Check the lights (LEDS) locate on
any of the switches (buttons) will ON. the PC boards. Some should be
NOT feed the wire. The motor does lit. See Table F.1. If none of the
NOT run. 2. Check the circuit breaker (CB1). lights are lit perform the T1 and
Reset if tripped. T2 Transformer Test.
3. Make sure 115VAC is being 2. If the appropriate lights are lit

applied to the control box through (see Table F.1.) and the wire
the control cable receptacle. does NOT feed perform the Wire
Leads #31 and #32. Drive Motor Test.
4. Check the two fuses on the 3. If only some of the appropriate

power board. Replace if blown. If lights on the power board are lit
fuse F101 immediately fails when the power board may be faulty.
replaced contact your local
Lincoln Authorized Field Service 4. If all of the appropriate lights are
Facility. lit, except light 1D on the power,
board, check resistor R1. Normal
5. Make sure the motor cable is con- resistance is 2 ohms. See wiring
nected to the motor receptacle on diagram.
the NA-5 control box.
5. If fuse F101 immediately fails
when input power is applied,
unplug all of the PC boards
except the power board. If the
fuse still fails the power board
may be faulty. If the fuse does
not fail reconnect the PC boards

one at a time until the faulty
board is located. Also check and
inspect the wiring harness for
“short” or “grounds”. Reconnect
the PC boards in the following
order: control, voltage,logic,pro-
cedure,option,timer, remote inter-
face,speedmeter and voltmeter.
NOTE: Some of the above PC

boards are optional and may not
be used in all NA-5 control units.
CAUTION
NA-5


The wire will not feed and the circuit 1. Check for a mechanical restric- 1. Perform the Wire Drive Motor
breaker (CB1) trips when the inch tion in the wire feeding path. Test.
down, inch up or the start buttons
are pressed. The wire drive motor 2. Make sure the proper input volt- 2. The power board may be faulty.
does not turn. age (115VAC) is applied to the See Table F.1.
NA-5 control unit.
3. Check the motor control cable for
3. Check the F102 field fuse on the “shorts’ or “grounds”.
power board. Replace if faulty.
Note: Frequent motor polarity
changes can cause the fuse to

fail. This can be caused by the
following:
•A welding procedure with
frequent electrode to puddle
shorting.
•A power source output too

low to establish an arc.
When the inch up button is press the 1. The welding head is designed to
wire feeds down. When the inch feed wire in the proper direction
down button is pressed the wire when it is installed as shipped
feeds up. from the factory. If the nozzle
and wire straightener aare rotated

about the axis of the gearbox
outpu shaft, the wire may feed in
the opposite direction.
Interchange leads #626 and #627
at the terminal strip (TS2) inside
the control box. See wiring dia-
gram.
CAUTION
NA-5


The wire will not feed when the inch 1. If a DC400, Pulse Power 500 or a 1. Disconnect the white #21 lead
down button is pressed. The wire CV400 power source is used a from the NA-5 polarity terminal
does inch up OK and feeds down Diode Kit must be installed in the strip (TS1). See wiring diagram.
when the start button is pressed. power source. With the inch down button
pressed read the ACTUAL volts
2. Check to see if light 7J on the on the NA-5 digital voltmeter.
logic board is ON while the inch The digital meter should read
down button is pressed. If it does over 19 volts and the wire should
NOT light check the inch down inch down. If not, perform the
button and associated leads. Voltage Board Transformer
See wiring diagram. Test. If the test is OK the voltage

•(For codes below 8300) If board may be faulty. Replace.
light 7J DOES light when
the inch down button is 2. If the voltage is over 19 volts
pressed the logic board and the wire DOES inch down
may be faulty. with the #21 lead disconnected
reconnect the #21 lead to the
•(For codes above 8300) terminal strip and read the
Jumper the AUTO tabs on ACTUAL volts with the inch
the voltage board and press down button pressed. If the
inch down button. If the voltage is less than 8 volts per-
wire does NOT feed down form the #21 - #67 External
the logic board may be Resistance Test. If the resis-
faulty. tance test is OK the voltage
board may be faulty. Replace.
CAUTION
NA-5


The wire will not inch down but does 1. Check to make sure that light 7J, 1. The logic board may be faulty.
inch up properly. The wire does not on the logic board, is lit when the Replace.
feed in either direction when the start inch down button is pressed. If
button is pressed. not check the inch down switch 2. The power board may be faulty.
and associated leads. See wiring Replace.
diagram.
2. Check to make sure that light 7B,

on the logic board, is lit when the
start button is pressed. If not
check the start button and associ-

ated leads. See wiring diagram.
The wire will not inch down but does 1. For codes below 8300 make sure 1. Jumper the AUTO tabs on the
inch up properly. When the start the jumper plug is securely voltage board. (Above code
button is pressed the wire feeds up installed in the harness receptacle 8300) Press the inch down but-
instead of down. near the voltage board. ton. If the wire inches down the
voltage board may be faulty.
2. Check to make sure light 7E, on Replace.
the logic board, is on when the
inch down button is pressed. If If the wire does NOT inch down
light 7E is ON the power board the logic board may be faulty.
may be faulty. Replace.
3. Check the 1/8 amp fuse on the

voltage board . Replace if faulty.

CAUTION
NA-5


NA-5 units above code 8300 with 1. Make sure the electrode wire is 1. Jumper the #2 and #4 leads at
“cold starting”. fed into the welding tip. the Lincoln CV power source.
The wire feeds up instead of down Open circuit voltage should be
when the start button is pressed. 2. Check the 1/8 amp fuse on the present at both the power source
The wire inches up and down prop- voltage board. Replace if faulty. and at the ACTUAL voltmeter
erly. reading on the NA-5. If open cir-
3. Make sure electrode polarity is cuit voltage is present at the
correct and the same as the #67 power source but NOT at the NA-
and #21 leads at terminal strip 5 ACTUAL voltmeter reading per-
(TS1). See wiring diagram. form the #21-#67 External resis-
tance Test.
4. Make sure the welding power
source is producing welding arc 2. With the start button pressed light
voltage. 7K should be lit. If it is not the
logic board may be faulty.
3. Check contactor relay 3CR.

Leads #2 and #4 are closed by
relay 3CR. Make sure the relay is
functiioning properly.
4. Check the control cable between

the power source and the NA-5
control unit. See wiring diagram.
CAUTION
NA-5


NA-5 units above code 8300 with 1. Check the 1/8 amp fuse on the 1. Perform the #21-#67 External
“cold starting”. voltage board. Replace if faulty. ResistanceTest.
While pressing the inch down button
the wire does not stop when it touch- 2. While pressing the inch down but- 2. Check the continuity of leads
es the work. ton with the wire touching the #667 and #621 to the voltage
work piece, observe light 7G on board. See wiring diagram.
the logic board. If the light goes
on but the wire does NOT stop 3. The logic board may be faulty.
feeding the logic board may be
faulty. 4. The voltage board may be faulty.
The wire will NOT inch up but does 1. With the unit at idle (no buttons 1. Check the inch up switch (button)
inch down and weld properly. pressed) observe lights 1D, on for proper operation. Also check
the power board, and light 7E, on associated leads for loose or
the logic board. 1D should be faulty connections. See wiring
ON. 7E should be OFF. diagram.
2. If 1D is OFF replace the power

board.
3. If 7E is ON replace the logic

board.
The wire feeds UP when either inch 1. While pressing the inch down but- 1. Check the inch up and inch down
button is pressed. ton observe light 7E on the logic switches (buttons) for proper oper-
board. It should be ON. ation and wiring. See wiring dia-
gram.
2. If light 7E is ON, while the inch
down button is pressed, the
power board may be faulty.
Replace.
3. If light 7E remains OFF, while

the inch down button is pressed,
the logic board may be faulty.
Replace.
CAUTION
NA-5


The wire feeds down when either 1. Wth the unit at idle (no buttons 1. Check the inch up and inch down
inch button is pressed. pressed) observe light 7E on the switches (buttons) for proper oper-
logic board. It should be OFF. ation and wiring. See wiring dia-
gram.
2. If light 7E is ON the logic board
3. If light 7E is OFF the power board

CAUTION
NA-5


MODE FUNCTION PROBLEMS
The speed and voltage controls do 1. Check lights 1A and 1B located 1. If lights 1A and /or 1B are OFF
not function. All of the mode lights on the power board. They should perform the DC Power Supply
function properly. both be ON. Test.
2. If both lights 1A and 1B are ON 2. Perform the T1 and T2

the control board may be faulty. Transformer Test.
Replace.
3. The power board may be faulty.
Replace.
All the mode lights function properly. 1. The control board may be faulty.
None of the speed controls operate Replace.
properly.
All the mode lights function properly. 1. The voltage board may be faulty.
None of the voltage controls operate Replace.
properly.
CAUTION
NA-5


Only the strike mode functions, when 1. The logic board may be faulty.
the unit is at idle, regardless of the Replace.
selector switch position.
2. The procedure board may be
faulty.
Only the strike mode functions while 1. While the unit is welding check . If light 7D is NOT lit, when weld
welding. The unit stays in the strike light 7D on the logic board. It current is present, connect a
mode and does not progress through should be ON when welding cur- jumper wire from terminal #528 to
the welding sequence. rent is present. If light 7D is ON #500 on terminal strip TS1. See
the logic board may be faulty. wiring diagram. If light 7D does
light check the CR4 reed switch
3. If light 7D is NOT lit when weld and associated leads and connec-
current is present make sure the tions. See wiring diagram.
weld cables have been properly
routed through the cable clamp 2. If 7D does NOT light, with the
on the left side of the control box. jumper wire in place, check the
#528 lead and the #500 lead
between the TS1 terminal strip
and the logic board. See wiring
diagram.
3. The logic board may be faulty.

Replace.
The strike light is OFF and neither 1. Check light 7D on the logic board. 1. If light 7D is ON check the CR4
strike control functions. The other If it is off the logic board may be reed switch and associated leads.
mode lights work. The unit will not faulty. Replace. See wiring diagram.
feed wire when the start button is
pressed. 2. If the start light is on all the time
the start board (if used) may be
faulty. Replace or install jumper
plug in procedure board.
3. If the crater light is on all the time

the crater board (if used) may be
faulty. Replace or install jumper
plug in procedure board.
4. If the weld light is on all the time


Replace.
CAUTION
NA-5


The strike light does not light. The 1. The procedure board may be
strike controls (voltage and wire feed faulty. Replace.
speed) do function normally.
The strike light comes on but the 1. The procedure board may be
strike controls (voltage and wire feed faulty. Replace.
speed) do not function normally.
The start light does not light. The 1. Make sure the start option board 1. Check the lead harness between
start controls (voltage and wire feed is installed correctly. the start option board and the
speed) may or may not function nor- procedure board for loose or
mally. The NA-5 is at idle with the 2. The procedure board may be faulty connections. See wiring
selector switch in the “Start” position. faulty. Replace. diagram.
The start light is ON but the start 1. If no other mode lights are lit the 1. Check the lead harness between
controls (voltage and wire feed start option board may be faulty. the start option board and the
speed) do not function. The NA-5 is Replace. procedure board for loose or
at idle with the selector switch in the faulty connections. See wiring
“Start” position. 2. If the strike light is also lit (along diagram.
with the start light) the logic board
may be faulty.
3. If the weld and or crater lights are

also lit (along with the start light)
the procedure board may be
faulty.
CAUTION
NA-5


When the start button is pressed and 1. Make sure the start option is in- 1. Check the lead harness between
the unit is welding, the start mode is stalled properly in the NA-5. the start option boards and the
skipped. procedure board for loose or
2. Make sure the start timer is set faulty connections. See wiring
for a time greater than zero sec- diagram.
onds.
3. If the weld light goes ON as soon

as (but not before) the arc is
struck and the start timer is set
for a time greater than zero sec-

onds, the start timer board may
be faulty.
4. If the weld light goes ON before

the arc is struck replace the start
option board with the jumper
plug. If the weld light continues
to go ON before the arc is struck
Replace.
5. With the jumper plug installed: If

the weld light does NOT go ON
until the arc is struck the start
option board may be faulty.
CAUTION
NA-5


When welding the start timer does 1. When the weld is stopped check 1. Check the lead harness between
not time out. The unit stays in the to see if the crater (if used) or the start option boards and the
start mode. burnback timer is functioning procedure board for loose or
properly. If the crater and or burn- faulty connections. See wiring
back timer IS functioning properly diagram.
the start timer may be faulty.
2. If the start, crater and burnback

timers are not working properly
faulty.
The crater light does not light. The 1. Make sure the crater option 1. Check the lead harness between
crater controls (voltage and wire boards are installed correctly. the crater option boards and the
feed speed) may or may not func- procedure board for loose or
tion. The NA-5 is at idle with the 2. The procedure board may be faulty connections. See wiring
selector switch in the ”Crater” pos- faulty. Replace. diagram.
tion.
The crater light is ON but the crater 1. If no other lights are lit the crater 1. Check the lead harness between
controls (voltage and wire feed option board may be faulty. the crater option boards and the
speed) do not function. The NA-5 is Replace. procedure board for loose or faulty
at idle with the selector switch in the connections. See wiring diagram.
“Crater” position. 2. If the strike light is also lit (along
with the crater light) the logic
board may be faulty.
3. If the weld and or start lights are

also lit (along with the crater light)
faulty.
CAUTION
NA-5


At the end of the weld the crater light 1. Make sure the crater option is 1. Check the lead harness between
does NOT light. installed properly in the NA-5. the crater boards and the proce-
dure board for loose or faulty con-
2. Make sure the crater timer is set nections. See wiring diagram.
for a time greater than zero sec-
onds.
3. The crater option and or timer

At the end of the weld the crater 1. Replace the crater option board 1. Check the lead harness between
timer does not time out. The unit with the jumper plug. Set the the crater boards and the proce-
stays in the crater mode. burnback timer for any time dure board for loose or faulty con-
greater than zero seconds. If the nections. See wiring diagram.
unit then stops after the weld and
burnback time, the crater timer
2. If the unit does not stop the pro-

cedure board may be faulty.
No burnback/retract occurs at the 1. Make sure the burnback timer is 1. Check the lead harness between
end of the weld. set for a time greater than zero the burnback module and the pro-
ohms. cedure board for loose or faulty
connections.
2. Be sure the jumper leads or dip
switches on the logic board are
comfigured correctly for the burn-
back/retract desired. See wiring
diagram.
3. The burnback timer module may

be faulty. Replace.

faulty.
CAUTION
NA-5


The burnback timer does not time 1. Test if the other timers (start, 1. Check the lead harness between
out properly. weld, crater) function properly. If the burnback module and the pro-
they time out correctly the burn- cedure board for loose or faulty
back module may be faulty. connections.
Replace.
2. If the other timers (start, weld,

crater) do NOT function correctly
faulty.
The weld light does not light. The 1. The procedure board may be
weld controls (voltage and wire feed faulty. Replace.
speed) may or may not function.
The NA-5 is at idle with the selector
switch in the “Weld” position.
The weld light is ON but the weld 1. If the option boards (start and
controls (voltage and wire feed crater) are not installed make
speed) do not function. The NA-5 is sure the jumper plugs are
at idle with the selector switch in the installed in the procedure board.
“Weld” postion.
2. If the strike light is also lit (along

with the weld light) the logic

faulty. Replace.
CAUTION
NA-5


During the welding sequence the 1. If the optional start timer is

weld light does not go ON. installed determine if the start
mode is timing out. If the
sequence stays in the “start”
mode the start timer may be
faulty.
2. If the start module is OK and the

weld light does not go ON the
logic board may be faulty.
Replace.
3. If a start module is NOT used

make sure the jumper plug is
installled in the procedure board
receptacle.
While welding the weld mode is 1. The weld timer module may be 1. Check the lead harness between
omitted in the welding sequence. faulty. Replace. the weld timer and the procedure
The weld timer is set for a longer board for loose or faulty connec-
time than zero seconds. tions.
The weld timer does not time out. 1. Set the burnback timer for a value 1. Check the lead harness between
the unit stays in the weld mode. greater than zero seconds. Start the weld timer and the procedure
the weld sequence and then stop board for loose or faulty connec-
it with the stop button. Check to tions.
see if the unit returns to the nor-
mal idle state.(Strike light ON and
“Hot Electrode” light OFF).
• If the weld mode ends and
the unit returns to the nor-
mal idle state, the weld
timer module may be
faulty.
• If the unit does NOT return

to the normal idle state the
procedure board may be

faulty.
CAUTION
NA-5


FUNCTION PROBLEMS
The start button does not initiate the 1. If the crater and or start option 1. If light 7C is ON check the stop
power source output or the wire boards are NOT used the jumper button and associated leads for
feed. The mode selector switch is in plugs must be installed in the pro- “shorts” or “grounds”. Light 7C
the strike position and the mode cedure board receptacles. should be on ONLY when the
strike light is lit. stop button is pressed.
2. With the unit at idle check light 7C
on the logic board. It should be 2. If light 7B does NOT go on, when
OFF. Also check light 7B on the the start button is pressed, check
logic board. With the start button the start switch (button) and asso-
pressed light 7B should go ON. If ciated leads for loose or faulty
lights 7C and 7B are functioning connections. See wiring diagram.
normally the logic board may be

faulty. 3. Check the lead harness between
the logic board and the procedure
board for loose or faulty connec-
tions. See wiring diagram.
The start button initiates the power 1. If the wire inches up properly, but 1. If the wire does not feed when the
source output, but the wire does not does not feed when the start but- inch up button is pressed perform
feed. ton is pressed, the logic board the Wire Drive Motor Test.
may be faulty.
2. If the wire does NOT feed, when

the inch up button is pressed,
check light 1E on the power
board. It should go ON when the

inch up button is pressed. If light
1E does not go on when the inch
up button is pressed the control

CAUTION
NA-5


FUNCTION PROBLEMS
The start button initiates the wire 1. Make sure that lead #690 is con- 1. The CR3 relay may be faulty.
feed, but does not activiate the nected to the proper pin on the Check or replace.
power source output. logic board. On newer logic
boards the dip switches must be 2. Check the #2 and #4 leads
in the proper position. See wiring between the CR3 relay and the
diagram. control cable receptacle. See
wiring diagram.
2. Make sure the power source is
capable of producing welding
output voltage. Jumper #2 and
#4 at the power source’s terminal
strip. This should produce open

circuit voltage at the output termi-
nals. If open circuit voltage is not
present the power source may be
faulty.
3. Check or replace the control

cable between the NA-5 and the
power source.
4. With the start button pressed

check light 7K on the logic board
and the “Electrode Hot” light.
Both lights should be on. If the
lights are OFF unplug the burn-
back timer. If the problem is
resolved the burnback timer may
be faulty. Replace.

CAUTION
NA-5


TRAVEL FUNCTION PROBLEMS
The travel function will not operate 1. Check the travel switch for proper 1. With the travel switch (S2) in the
regardless of the travel switch posi- operation. Also check associat- hand travel position, and the
tion. ed leads for loose or faulty con- 115VAC input power applied to
nections. the NA-5 unit, check for 115VAC
at the travel receptacle. 115VAC
2. Check the travel receptacle and should be present at leads #531
associated leads for loose or to #532. 115VAC should also be
faulty connections. present at leads #25 to #531. If
either of these two voltages are
3. Make sure the travel unit is oper- missing or not correct check the
ational. lead harness, switch (S2) and
travel receptacle for loose or

faulty connections. See wiring
diagram.
2. If the above voltages are correct

the problem is in the travel unit or
connecting cable.
The travel will not function with the 1. Check the travel switch and asso- 1. The travel switch may be faulty.
travel switch in the “Hand” travel ciated leads for loose or faulty Check or replace.
position. The unit operates properly connectioins.
with the travel switch in the “Auto”
position.
CAUTION
NA-5


TRAVEL FUNCTION PROBLEMS
The travel will not function with the 1. Make sure the jumper leads #691 1. If light 7H, located on the logic
travel switch in the “Auto” postion. and #692 are connected properly board, does light when the auto-
The travel operates correctly with the to the correct pins on the logic matic travel is active check the
travel switch in the “Hand” position. board. See wiring diagram. CR2 relay. Normal coil resis-
tance is 10,000 ohms. The con-
2. Check the travel switch (S2) and tacts (terminals 2 and 4) should
associated leads for loose or “close” when 110VDC is applied
faulty connections. See wiring to the relay coil (terminals 1 +
diagram. and 3 -).
3. Check light 7H located on the

logic board. This light should be

ON when the “Auto” travel is
active. If light 7H does not light
The travel runs continuously when 1. Make sure the jumper leads #691 1. The 2CR relay may be faulty.
the travel switch is in the “Auto” posi- and #692 are connected properly The contacts (terminals 2 and 4)
tion. to the correct pins on the logic may be stuck closed.
board. See wiring diagram.
2. Check the associated leads for
2. Check light 7H on the logic board. misconnections. See wiring dia-
If light 7H is always ON the logic gram.
CAUTION
NA-5


FUNCTION PROBLEMS
After pressing the stop button, the 1. Carefully disconnect the #2 lead 1. The 3CR relay may be faulty.
electrode “Hot” light goes OFF, but from the power source terminal The contacts (terminals 2 and 4)
the electrode wire remains electrical- strip. The welding voltage should may be stuck closed.
ly hot. (The welding voltage is be disabled. If the welding volt-
always present). The wire stops age is still present the power 2. Check the associated leads for
feeding. source is faulty. misconnections. See wiring dia-
gram.
2. Check or replace the control
cable between the power source
and the NA-5 unit.
After pressing the stop button, the 1. If a crater option module is used, 1. If, while pressing the stop button,
weld light remains on and the wire check to make sure the logic light 7C does NOT go on, check
continues to feed. board jumper (#694) is on pin the stop button and associated
P10. leads.
2. While pressing the stop button

observe light 7C located on the
logic board. It should be lit. If
light 7C is ON and the wire feed-
ing and welding does not stop,
The set and actual speed meter 1. Made sure the calibration jumper 1. Remove the drive motor end cap
readings match within a few IPM, but on the speedmeter board is con- and the tach cover plate from the
both are in error. nected properly. See Operation end of the wire drive motor.
Section. Check to make sure the slotted
disc is secure and aligned and
rotates freely through the center
of the module pick-up.
2. Perform the Wire Speed

Accuracy Test
3. Perform the Meter Circuit

Accuracy Test.
4. The control board may be faulty.

Replace.
CAUTION
NA-5


FUNCTION PROBLEMS
The set speed and actual speed 1. Contact your local Lincoln 1. Check the lead and switch conti-
meter readings do not match within a Authorized Field Service Facility. nuity of the SET speedmeter cir-
few IPM. One or both readings may cuit. See wiring diagram.
be erratic.
2. Check the lead and switch conti-
nuity of the ACTUAL speedmeter
circuit. See wiring diagram.
3. Perform the Wire Speed

Accuracy Test

Accuracy Test.
5. The control board may be fault
The set speed is adjustable and 1. Contact your local Lincoln 1. While the motor is running care-
steady. The actual speed is uncon- Authorized Field Service Facility. fully unplug the 15 pin molex from
trollable. The meter displays the the control board.
actual speed correctly. A. If the motor continues to
run the power board may
be faulty. Replace.
B. If the motor stops the

control board may be
faulty. Replace.
2. Perform the Wire Drive Motor

Test.
CAUTION
NA-5


FUNCTION PROBLEMS
The set speed is adjustable and 1. Check that the jumper plug is 1. Remove the drive motor end cap
steady. The actual speed reading is installed securely in the harness and the tach cover plate from the
incorrect and or erratic. receptacle near the voltage end of the wire drive motor.
board. Codes below 8300 only. Check to make sure the slotted
disc is secure and aligned and
2. Check for loose or faulty connec- rotates freely through the center
tions on leads #510A, #525A and of the module pick-up.
#555 between the tach receptacle
and the control board. 2. Perform the Tach Board
Feedback Test.
3. Check the tach cable from the
tach board to the tach receptacle. 3. If the Tach Board Feedback

The shield in the cable should Test is OK the control board may
NOT be grounded to the case. be faulty. Replace.
1. Check the voltage sensing leads

The set volts and actual volts read- 1. Put the Lincoln power source in for continuity. (zero ohms). #21
ings match within a few tenths of a the machine control mode. should have continuity to the
volt while welding. However both Check to see if the power supply work piece and #67 should have
readings are inaccurate. can be set for the arc voltage continuity to the wire feed head
required for the process. If not, assembly. See wiring diagram.
the power source may be faulty.
2. Perform the Voltmeter Accuracy
2. The control cable may be faulty. Test.
Check or replace.
Accuracy Test.
4. The voltage board may be faulty.

CAUTION
NA-5


FUNCTION PROBLEMS
The actual volts reading does NOT 1. NA-5 units with a G1556-2 (or 1. If the actual reading is the prob-
match the set volts reading within a higher) voltage board do not con- lem check the actual volts switch
few tenths of a volt. One reading trol the actual strike voltage to and associated leads. See wiring
may be erratic. The NA-5 does not match the set strike voltage. The diagram.
shut off. actual strike voltage is a function
of the set strike voltage and the 2. If the set reading is the problem
OCV contrtol characteristics of check the set volts switch and the
the welding power source. asociated leads. See wiring dia-
gram.
NA-5 controls with a G1556-3 (or
higher) voltage board must have 3. Perform the Voltmeter Accuracy
the jumper plug connected to the Test

4-cavity receptacle on the board,
unless the pulsed power filter 4. Perform the Meter Circuit
board option is connected. Accuraty Test.
2. Make sure the shutdown 5. The voltage board may be faulty.

“BYPASS” pins are not jumpered
together on the NA-5 voltage
board.
3. Check the voltage sensing leads

for continuity. (zero ohms). #21
lead should have continuity to the
work piece and #67 lead should
have continuity to the wire feed
head assembly. See wiring dia-
gram.
4. Put the Lincoln welding power

source in the machine control
mode. Check to see if the power
supply can be set for the arc volt-
age required for the process. If
not, the power supply may be
faulty.
CAUTION
NA-5


FUNCTION PROBLEMS
The NA-5 repeatedly shutsdown 1. Make sure the power source 1. Perform the Out of Voltage
while welding. polarity switch is set for the cor- Range Shutdown Test.
rect electrode polarity.
2. The voltage board may be faulty.
2. Make sure the #67 and #21 leads
are connected to the TS1 termi-
nal strip for the correct electrode
polarity. See wiring diagram.
3. Make certain the voltage control

switch on the Lincoln CV power
source is set in the “Remote”

position.
4. Make sure the #21 lead has con-

tinuity (zero ohms) to the work
piece.
5. Make sure the #67 lead has con-

tinuity (zero ohms) to the wire
feed head assembly.
6. Check the 1/8 amp fuse on the

NA-5 voltage board. Replace if
faulty.
7. The control cable may be faulty.

Check or replace.
8. Be sure the welding power

source is compatable with the
NA-5.
CAUTION
NA-5


FUNCTION PROBLEMS
The circuit breaker trips when the 1. The power board may be faulty. 1. Perform the Wire Drive Motor
inch up, inch down, or start buttons Replace. Test.
are pressed.
2. Perform the DC Power Supply
Test.
The circuit breaker trips and or the 1. Contact your Local Lincoln 1. If fuse F101 or the circuit breaker-
fuse (F101) blows when the NA-5 is Authorized Field Service Facility. immediately fails when input
turned on. (input power applied). power is applied, unplug all of

the PC boards except the power
board. If the fuse still fails the
power board may be faulty. If
the fuse does not fail reconnect
the PC boards one at a time until
the faulty board is located. Also
check and inspect the wiring har-
ness for “short” or “grounds”.
Reconnect the PC boards in the
following order: control,
voltage,logic,procedure,option-
timer, remote interface,speedme-
ter and voltmeter.
NOTE: Some of the above PC
boards are optional and may not
be used in all NA-5 control units.
CAUTION
NA-5


FUNCTION PROBLEMS
The circuit breaker trips after the 1. Check to make sure there are not 1. Perform the DC Power Supply
wire has been feeding for a period of any mechanical restrictions in the Test.
time. Welding is normal. wire feeding path which could
cause excessive loading on the 2. Perform the Wire Drive Motor
wire drive motor. Test.

The 1/8 amp fuse on the voltage 1. Check to make sure the PC 1. Remove the input power to the
board repeatedly fails. boards are NOT grounded to the NA-5 and replace the 1/8 amp
case of the NA-5. This can hap- fuse. Locate and remove the #21
pen due to metallic dust build-up. and #67 leads from the TS1 ter-
minal strip.
A. Make a resistance check
from the following leads
to the NA-5 case ground-
ing screw. Lead #510A,
510P, 500, 515 and 525.
B. The resistances should

be above 1000 ohms. If
any tests are below 1000
ohms that circuit has low
resistance to case
ground. Isolate faulty
leads or PC board. See

wiring diagram and
schematic.
CAUTION
NA-5


STARTING/WELDING PROBLEMS
The arc voltage appears to rise too 1. Increase the strike and or start 1. The voltage board may be faulty.
slowly. The wire stubs or blasts off voltage settings. Replace.
at the start of the weld sequence.
Once the arc is established the weld- 2. Put the output control switch (on
ing is OK. 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.
3. If the start response jumper, on

the voltage board, is in the “B”
position, change to the “A” posi-
tion. If the “A” position cures the
starting problem the voltage
The voltage seems too high or flares 1. Decrease the strike and or start 1. The voltage board may be faulty.
excessively at the start of the weld voltage settings. Replace.
sequence. Once the arc is estab-
lished the welding is OK. 2. Put the output control switch (on
the power source) in the
Jumper the “BYPASS” pins on

the voltage board. Control the
arc voltage from the power
CAUTION
NA-5


WELDING PROBLEMS
The arc is unstable or oscillating. 1. Check the welding cables for 1. The NA-5 voltage board may be
loose or faulty connections. faulty. Replace.
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
Jumper the “BYPASS “ pins on
the NA-5 voltage board. Control

the arc voltage from the power
CAUTION
NA-5


FUNCTION PROBLEMS
The flux or gas/water solenoid does 1. Make sure the switch on the flux 1. If light 7G, located on the logic
not function (open). hopper is in the ON position. board, does light when the flux
(gas/water) solenoid is normally
2. Check light 7G located on the active, check the CR1 relay.
logic board. This light should be Normal coil resistance is 10,000
on when the flux valve would nor- ohms. The contacts (terminals 2
mally be active. If light 7G does and 4) should “close” when
not light the logic board may be 110VDC is applied to the relay coil
faulty. (terminals 1 + and 3 -).
2. Check the wiring harness for

loose or faulty connections

between the CR1 relay, the logic
board, the TS2 terminal strip and
the flux receptacle. See wiring
diagram.
The flux or gas/water solenoid con- 1. Check light 7G located on the 1. Check the CR1 relay. The con-
tinuously remains open. logic board. This light should be tacts (terminal 2 and 4) should
lit only when the flux valve would “close” only when 110VDC is
normally be active. If light 7G is applied to the relay coil. (termi-
lit continuously the logic board nals 1+ and 3-). If the contacts
may be faulty. are “closed” continuously replace
the CR1 relay.
2. Check to make sure the solenoid
is not stuck in the open position.
CAUTION
NA-5


WELDING PROBLEMS
The arc is unstable or oscillating. 1. Check the welding cables for 1. The NA-5 voltage board may be
loose or faulty connections. faulty Replace.
2. Make sure the electrode and gas

(if used) is correct for the process
being used.
3. Put the Lincoln power source in

the machine control
mode.Jumper the “BYPASS” pins
on the NA-5 voltage board.
Adjust the weld voltage at the

power source for the process
being used. If the problem is
NOT resolved the power source
may be faulty.
The welding arc is variable or “hunt- 1. Make sure the welding parame- 1. Put the Lincoln power source in
ing”. ters are correct for the welding the machine control mode.
procedure being used. Jumper the “BYPASS” pins on the
NA-5 voltage board. Adjust the
2. Check the welding cables for- weld voltage at the power source
loose or faulty connections. for the process being used. If the
problem is resolved check or
3. Check the wire feeding path for replace the control cable or the
restrictions. NA-5 voltage board may be faulty.
4. The contact tip may be worn. 2. Perform the Wire Drive Motor
Check or replace. Test.
5. The welding power source may

be faulty. Check or replace.
CAUTION
NA-5


WELDING PROBLEMS
Poor arc striking with sticking or 1. Make sure the welding parame- 1. Put the Lincoln power source in
“blast offs”. The weld bead is ropey ters (voltages and wire feed the machine control mode.
and has porosity. speed) and techniques are cor- Jumper the “BYPASS” pins on the
rect for the welding procedure NA-5 voltage board. Adjust the
being used. weld voltage at the power source
for the process being used. If the
2. Check the welding cables for problem is resolved check or
loose or faulty connections. replace the control cable or the
NA-5 voltage board may be faulty.
3. The contact tip may be worn.
Check or replace.
4. The welding power source may

be faulty. Check or replace.
CAUTION
NA-5
F-36 F-36
PC BOARD LED (LIGHT) DEFINITIONS
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 "Stop" Switch Pressed
7D Welding Current Present
7E Signal to Apply Down Field Voltage
7G Signal to Operate Flux or Water Solenoid

7H Signal to Operate Travel Circuit

7J "Inch Down" Switch Pressed
7K Signal to Operate Power Source Output Contactor
LED LIGHT LOCATIONS LED LIGHT LOCATIONS
NA-5 L OGI C
LED 1E
LED 7B LED 7E
LED 7J LED 1C
LED 7C
LED 7D LED 1D
LED 1A
LED 1B
LED7A
LED 1F
LED 7K LED 7G LED 7H
NA-5 POWER
NA-5
F-37 F-37
PC BOARD LED (LIGHT) SEQUENCE TABLE ABOVE CODE 8300
INDICATOR LIGHTS CONDITIONS FOR LIGHT "ON"

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
1E Power ON ON ON ON
1F Power ON ON ON ON ON ON ON
7A Logic ON ON ON ON ON ON ON
7B Logic ON*
7C Logic ON*
7D Logic ON ON
7E Logic ON ON ON
7G Logic ON* ON ON
7H Logic ON** ON** ON
7J Logic ON*
7K Logic ON ON ON
ON* only while switch is pressed ON** dependent on travel mode

NA-5
F-38 F-38
DC POWER SUPPLY TEST
WARNING
Service and repair should be performed only by Lincoln Electric factory trained per-
sonnel. Unauthorized repairs performed on this equipment could result in danger to
the technician or the machine operator and will invalidate your factory warranty. For
your safety and to avoid electrical shock, please observe all safety notes and precau-
tions 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 (800) 833-9353 (WELD).
_____________________________________________________________
TEST DESCRIPTION
This will help determine if the power and logic boards are supplying the correct DC voltages
to the NA-5 circuitry.
This procedure takes approximately 16 minutes to perform.

MATERIALS NEEDED
5/16" Nutdriver
Volt/Ohmmeter (Multimeter)
Wiring diagram
NA-5
F-39 F-39
DC POWER SUPPLY TEST (continued)
TEST PROCEDURE
1. Remove input power to the NA-5. 5. Perform the power supply checks as
described in Table F.1 If any of the
2. Using the 5/16" nutdriver open the readings are incorrect (out of range)
control box PC board access door. or missing the power or logic board
may be faulty. See wiring diagram.
3. Locate the power, logic, voltage, Note: Do not unplug the molex con-
control and procedure boards. See nectors.
Figure F.1
Also check associated leads and
4. Apply 115VAC to the NA-5 wire plugs for loose or faulty connec-
feeder at the correct pins. See tions.
wiring diagram.
POWER
BOARD
VOLTAGE
BOARD
LOGIC
BOARD
PROCEDURE CONTROL
BOARD BOARD
FIGURE F.1 P.C. BOARD LOCATIONS
NA-5
F-40 F-40
TABLE F.1 DC POWER SUPPLY CHECKS
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
510 -
PLUG TO
CONTROL BOARD
525 +
VOLTAGE PC CHECK +15VDC PIN 3 + 525 + 14.0 - 16.0 VDC

BOARD 12 PIN SUPPLY FROM PIN 7 - 510 -
PLUG TO
VOLTAGE BOARD
510 -
525 +
VOLTAGE PC CHECK -10VDC PIN 6 - 500 - 9.0 - 11.0 VDC

BOARD 12 PIN SUPPLY FROM PIN 7+ 510 +
PLUG TO
VOLTAGE BOARD
510 +
500 -
CONTROL PC CHECK -10VDC PIN 14 - 500 - 9.0 - 11.0 VDC

BOARD SUPPLY FROM PIN 9 + 510 +
510 +
PLUG TO
CONTROL BOARD 500 -
LOGIC PC CHECK +110VDC PLUG J1 PIN 1+ 610 + 90 - 135 VDC

BOARD J1 SUPPLY FROM PLUG J1 PIN 2 - 500 -
PLUG TO
LOGIC BOARD 610 +
500 -
NA-5
F-41 F-41
TABLE F.1 DC POWER SUPPLY CHECKS (continued)
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 -
515 +
500 -
VOLTMETER CHECK +5VDC TEST POINT1. TP5 +

BOARD SUPPLY TP5 +
PRODUCED 4.75 - 5.25 VDC
ON THE
VOLTMETER TEST POINT1. LEAD 510P -
BOARD 510P -
SPEEDMETER CHECK +5VDC TEST POINT1. TP5 +

BOARD SUPPLY TP5 + 4.75 - 5.25 VDC

PRODUCED
ON THE TEST POINT1. LEAD 510P -
SPEEDMETER 510P -
BOARD
1.
Scrape encapsulation from test points.
NA-5
F-42 F-42
T1 and T2 TRANSFORMER TEST

WARNING

Call (216) 383-2531 or (800) 833-9353 (WELD).
_____________________________________________________________
TEST DESCRIPTION
This test will help the technician to determine if the T1 and/or T2 transformers are functioning
properly.

MATERIALS NEEDED
115VAC power supply
Volt-Ohmmeter (Multimeter)
5/16" Nutdriver
Slot head screwdriver
NA-5
F-43 F-43
T1 and T2 TRANSFORMER TEST (Continued)
PROCEDURE 5. Using the 115VAC supply carefully

apply 115VAC to the T1 primary
1. Remove all input power to the NA-5. leads #531B and #532.
2. Using 5/16" nutdriver open the con- 6. Check for approximately 10VAC at
trol box PC board access door. the yellow secondary leads (#601
and #602). See wiring diagram.
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. See
wiring diagram and Figure F.2
POWER
BOARD
UPPER
TERMINAL
STRIP
LOGIC
BOARD
T1 TRANSFORMER
T2 TRANSFORMER
FIGURE F.2 T1 AND T2 TRANSFORMERS
NA-5
F-44 F-44
T1 and T2 TRANSFORMER TEST (Continued)
7. Check for approximately 22VAC at 13. Check for approximately 115VAC

the blue secondary leads. The blue at the orange secondary leads.
secondary leads are connected to The orange leads are connected to
the logic board. See wiring diagram. the power board. See wiring dia-
gram.
8. Check for approximately 18VAC at
the white to red leads. The white 14. Check for approximately 24VAC at
and red leads are connected to the the brown secondary leads. See
power board. See wiring diagram. wiring diagram.
9. Check for approximately 36VAC at 15. If all the secondary voltages are
the red to red leads. Both red leads correct the T2 transformer is func-
are also connected to the power tioning properly.
board. See wiring diagram.
16. If any or all of the secondary volt-

10. If all the secondary voltages are ages are low or not present the T2
correct the T1 transformer is func- transformer may be faulty.
tioning properly.
17. Reconnect the primary leads
11. If any or all of the secondary volt- (#531B and #532) to the TS2 termi-
ages are low or not present the T1 nal strip.
transformer may be faulty.
18. Close and secure the access door.
12. Using the 115VAC supply carefully
apply 115VAC to the T2 primary
leads #531B and #532.
NA-5
F-45 F-45
VOLTAGE BOARD TRANSFORMER TEST
WARNING

Call (216) 383-2531 or (800) 833-9353 (WELD).
_____________________________________________________________
TEST DESCRIPTION
This test will aid the technician in determining if the transformer on the voltage board is func-
tioning properly.

MATERIALS NEEDED
5/16" Nutdriver
Phillips head screwdriver
115VAC power supply
Volt/Ohmmeter
NA-5
F-46 F-46
VOLTAGE BOARD TRANSFORMER TEST (Continued)
TEST PROCEDURE 4. Remove the molex type plugs from

the voltage board.
1. Remove all input power to the NA-5.
5. Using the phillips head screwdriver
2. Using the 5/16" nutdriver open the remove the voltage board from the
control box PC board access door. control box.
3. Locate the voltage board. See 6. Locate the transformer and test
Figure F.3 points on the voltage board. See
Figure F.4
VOLTAGE
BOARD
FIGURE F.3 VOLTAGE BOARD LOCATION
NA-5
F-47 F-47
VOLTAGE BOARD TRANSFORMER TEST (Continued)
24VAC
SECONDARY
TEST POINTS
PIN #9 {
PIN #8
VOLTAGE
G1556-[ ]
NA-5
VOLTAGE BOARD
TRANSFORMER
FIGURE F.4 TRANSFORMER TEST POINTS

7. Using the 115VAC supply carefully 10. If the secondary voltage is low or
apply 115VAC to pins #8 and #9 in not present the transformer may be
the nine pin molex plug cavity on the faulty.
voltage board. See Figure F.4
Make sure the board and leads are 11. Carefully remove the 115VAC sup-
insulated from each other and any ply from the voltage board.
metal conductors.
12. Install the voltage board and con-
8. Using the voltmeter check for nect the molex plugs.
approximately 24VAC at the sec-
ondary test points. See Figure F.4 13. Close and secure the access door.
Note: The secondary voltage will vary

with the input primary voltage. The
insulating material will have to be
removed from the secondary test

points to insure that the meter probes
make good electrical contact.
9. If the secondary voltage is correct

the transformer is functioning proper-
ly.
NA-5
F-48 F-48
WIRE FEED DRIVE MOTOR TEST
WARNING

Call (216) 383-2531 or (800) 833-9353 (WELD).
_____________________________________________________________
TEST DESCRIPTION
This test will determine if the wire drive motor is able to function when supplied with the cor-
rect voltages..

MATERIALS NEEDED
Variable DC voltage supply 0 to 90 VDC
Isolated DC voltage supply 0 to 120 VDC
Volt/Ohmeter
NA-5
F-49 F-49
WIRE FEED DRIVE MOTOR TEST (Continued)
TEST PROCEDURE MOTOR APPLIED

VOLTAGE TEST
1. Remove the wire feed motor connec-
tor from the NA-5 control box. 1. Carefully connect the isolated 120
VDC supply (SUPPLY TURNED
2. Using the ohmmeter, measure the OFF) to pins C and D on the motor
resistances per the table below. Also connector.
see Figure F.5.
2. Carefully connect the variable 0 to 90
3. If the motor resistance test is good, VDC supply (SUPPLY TURNED
proceed to the Motor Applied Voltage OFF) to pins A and B on the motor
Test. connector. (See Table F.1.)
3. Apply field voltage first (pins C and

FIGURE F.5 WIRE FEED DRIVE MOTOR D) to the motor. Then, slowly apply
CONNECTOR PINS. the armature voltage to pins A and B.
(See Table F.1).
MOTOR
CONNECTOR
PINS 4. The motor should run, and the speed
should vary with changes to the
#67 #541 armature voltage.
F
E A 5. If the motor does NOT run and
change speed correctly, the motor or
D B
C gear box may be faulty.
#539 6. To stop the motor, REMOVE THE

#627
ARMATURE VOLTAGE FIRST (pins
A and B).
#626
TEST POINTS RESISTANCE DC VOLTAGE
Lead #539 to lead #541 4 to 5 ohms 0 to 90 VDC

armature
Lead #626 to lead #627 750 to 850 ohms 90 to 120 VDC

field winding
All leads 500,000 ohms NONE

to min.
motor shell
(Except lead #67)
Lead #67 to motor zero ohms Not Applicable

shell
NA-5
F-50 F-50
EXTERNAL RESISTANCE TEST (LEADS #21 AND #67)
WARNING

Call (216) 383-2531 or (800) 833-9353 (WELD).
_____________________________________________________________
TEST DESCRIPTION
This test will help the technician to determine if the external voltage sensing leads are con-
nected properly and intact.

MATERIALS NEEDED
Volt-Ohmmeter (Multimeter)
5/16" Nutdriver
3/4" wrench
Wiring diagram
NA-5
F-51 F-51
EXTERNAL RESISTANCE TEST (LEADS #21 AND #67) (Continued)
PROCEDURE
1. Make sure the electrode wire is fed 6. Using the ohmmeter check the resis-
through the wire contact assembly tances per the following table F.2
tip but NOT touching the "work"
piece. 7. Reconnect the welding cable leads
to the contact assembly.
2. Disconnect input power to the NA-5.
8. If any of the resistances are not cor-
3. Make sure the drive motor cable and rect per Table F.2 check the associ-
power source control cables are ated leads, cables and circuits for
properly connected to the NA-5 con- "opens" or "shorts". See wiring dia-
trol box. gram.
4. Using the 5/16" nutdriver open the 9. Close and secure the control box
control box PC board access door. access door.
5. Locate the TS1 terminal strip. See

wiring diagram.
TABLE F.2 EXTERNAL VOLTAGE SENSING LEADS TEST POINTS
TEST POINTS EXPECTED COMMENTS AND

RESISTANCES CONDITIONS
Lead #667 Zero or less than Electrode wire must be in

to 1 ohm contact assembly tip

Electrode wire
Lead #621 to Zero or less than Polarity switches must be

work piece 1 ohm in the correct positions
Lead #667 to Greater than 15K Using the 3/4" wrench

#621 ohms disconnect the welding
cable(s) from the
contact assembly
NA-5
F-52 F-52
OUT OF VOLTAGE RANGE SHUT DOWN TEST
WARNING

Call (216) 383-2531 or (800) 833-9353 (WELD).
_____________________________________________________________
TEST DESCRIPTION
This test will help determine if the out-of-voltage range shut down circuitry is functioning prop-
erly.

MATERIALS NEEDED
5/16" Nutdriver
Jumper wire
Lincoln CV Power Source
NA-5
F-53 F-53
OUT OF VOLTAGE RANGE SHUT DOWN TEST (Continued)
TEST PROCEDURE
1. Remove input power to the NA-5 4. Connect to a Lincoln Electric CV

power source per connection dia-
2. Using the 5/16" nutdriver open the gram. See the Installation section
control box PC board access door. of this manual.
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
labeled "B"). This should disable the
shut down circuit.
1/8 AMP FUSE

JUMPER
TOGETHER
BYPASS
COM
AUTO
VOLTAGE
G1556-[ ]
NA-5
FIGURE F.6 VOLTAGE BOARD AND PIN LOCATIONS
NA-5
F-54 F-54
OUT OF VOLTAGE RANGE SHUT DOWN TEST (Continued)
5. Start welding and observe the 9. If the ACTUAL voltage reading is dif-
ACTUAL voltage reading on the NA- ferent from the SET voltage reading,
5 digital meter. The actual voltage the power source may not be capa-
must match the SET voltage within ble of producing the required arc
+/- 0.5VDC. If it does NOT, the NA- voltage, the control cable may be
5 is designed to shut down. faulty or misconnected, or the NA-5
voltage PC board may be faulty.
6. If the NA-5 continues to shut down
with the "BYPASS" pins jumpered 10. After all tests are complete, remove
together, the voltage PC board may the input power to the wire feeder
be faulty. and remove the jumper wire you
placed on the "BYPASS' pins on
7. If the ACTUAL voltage reading is the voltage PC board. Close and
zero, the sensing leads may be secure the access door.
faulty. Perform the External

Resistance Test. Also check the
1/8 amp fuse on the voltage PC
board.
8. Check the polarity switche in the

Lincoln power source and its associ-
ated leads. Set the switches to the
same polarity as the electrode. See
the Wiring Diagram.
NA-5
F-55 F-55
TACH BOARD FEEDBACK TEST
WARNING

Call (216) 383-2531 or (800) 833-9353 (WELD).
_____________________________________________________________
TEST DESCRIPTION
This procedure will aid the technician to determine if the tach board is functioning properly.

MATERIALS NEEDED
5/16" Nutdriver
Analog volt/ohmmeter (Multimeter)
Wiring diagram
NA-5
F-56 F-56
TACH BOARD FEEDBACK TEST (Continued)
PROCEDURE
1. Remove input power to the NA-5. between 4.5 - 10.5VDC. (The motor
must be running.) This is the feed-
2. Using the 5/16" nutdriver open the back voltage from the tach PC board
control box PC board access door. to the control PC board. This volt-
age is dependent upon motor speed.
3. Locate leads #510A, #525A and
#555 on the control board. 7. If the feedback voltage is missing or
does not vary with motor speed, the
4. Apply 115VAC to the NA-5 wire tach PC board may be faulty. Also
feeder at the correct pins. See check for loose or faulty connec-
wiring diagram. tions.
5. Check leads #525A(+) to #510A(-) 8. After the completion of the tests

for the presence of 15VDC. This is remove the 115VAC power and
the supply voltage from the control close and secure the access door.
PC board to the tach PC board. If
the voltage is present, proceed to
the next step. If the voltage is miss-
ing check the associated wiring and
then perform the DC Power Supply
Test.
6. With the motor running (activate

either inch switches or the start
switch) and check leads #555(+) to
#510A(-) for the presence of
NA-5
F-57 F-57
VOLTMETER ACCURACY TEST
WARNING

Call (216) 383-2531 or (800) 833-9353 (WELD).
_____________________________________________________________
TEST DESCRIPTION
This test will help determine if the NA-5 voltmeter is providing accurate readings.

MATERIALS NEEDED
Digital volt/ohmmeter with at least 3-1/2 digits and +/-0.5% accuracy
NA-5
F-58 F-58
VOLTMETER ACCURACY TEST (Continued)
TEST PROCEDURE
Perform the following checks with the 3. Place a jumper wire between leads
NA-5 connected to a Lincoln CV weld- #2 and #4 located on CR3 relay.
ing power source according to the prop- See Figure F.8 This this should
er connection diagram. See the energize the output terminals of the
Installation Section of this manual. Lincoln CV welding power source.
An open circuit voltage should be
1. Connect the test voltmeter (see present at the welding output termi-
Materials Needed) between the nals. The test voltmeter reading
"work" and the electrode cable con- should match the ACTUAL volts
nection at the welding head. See meter reading on the NA-5 within +/-
Figure F.7 0.5VDC (typically +/- 0.2VDC). If it
does not, check the integrity and
2. Using the 5/16" nutdriver open the placement of the voltage

control box PC board access door. sensing leads #21 and #67 and
associated wiring. Perform the
Meter Circuit Accuracy Test.
ELECTRODE CABLES
CONNECT VOLTMETER
TO ELECTRODE
CONNECTION
POINT
FIGURE F.7 TEST METER CONNECTION POINTS
NA-5
F-59 F-59
VOLTMETER ACCURACY TEST (Continued)
CR3 RELAY
FIGURE F.8 CR3 RELAY
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 ACTUAL
reading should match the SET read-
ing within +/- 0.5 VDC. If not, refer
to the Meter Circuit Accuracy Test.
6. If no further tests are required,

remove all test equipment and close
and secure the access door.
NA-5
F-60 F-60
WIRE SPEED ACCURACY TEST
WARNING

Call (216) 383-2531 or (800) 833-9353 (WELD).
_____________________________________________________________
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.

MATERIALS NEEDED
Ruler or other linear measuring device
5/16" Nutdriver
NA-5
F-61 F-61
WIRE SPEED ACCURACY TEST (Continued)
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
head and drive roll system being
used. See Table F.3
TABLE F.3
SPEEDMETER HEAD DRIVE ROLL WIRE SIZE RANGE RATED SPEED
CALIBRATION RATIO PART NUMBER RANGE (IPM)
21* 21/1 S12778 Single .035 - .052 Solid 100 - 2070

S19113 Single .045 - .052 Cored
57F** 57/1 S12778 Single .035 - .052 40 - 778

57** 57/1 S12515 Single 1/16 - 3/32 38 - 762
95 95/1 S12514 Single 3/32 - 5/32 22 - 428
95S*** 95/1 S12515 Single 1/16 - 3/32 23 - 456

S19113 Single .045 - .052 Cored
S13161-052 Twin .045 -.052
S13161-5/64 Twin 1/16 - 5/64
S14904 (Outer) Twin 3/32

S14905 (Inner)
142 142/1 S12514 Single 3/32 - 7/32 15 - 289
142T*** 142/1 S14904 (Outer) Twin 5/64 - 1/8 15 - 300

S14905 (Inner)
* Present on HI -Speed NA-5 speedmeter board only. ** Early speedmeter pins were labeled 55F and 55,
respectively.
*** Early speedmeter PC boards did not include these calibration pins.
NA-5
F-62 F-62
2. Check for the proper wire feed inch-

es per revolution of the drive roll.
A. Set the Strike speed control to B. If the measured length is not

any setting between 50 and 125 within the specified lengths
IPM. While pressing the INCH there may be a problem with the
DOWN button measure the pre- wire or wire feeding path. See
cise length of wire fed by exactly the Troubleshooting Guide
10 revolutions of the drive roll. (Feeding Problems) in this sec-
The measured length should be tion of the manual. Also check
within the range specified in for correct drive roll tension
Table F.4 for the drive roll and adjustment.
wire size employed.
TABLE F.4
DRIVE ROLL PART WIRE SIZE RANGE INCHES OF WIRE FED PER
NUMBER 10 REVOLUTIONS OF
DRIVE ROLL
S12778 Single .035 - .052 Solid 53 - 54
S19113 Single .045 - .052 Cored 53 - 55
S12515 Single 1/16 - 3/32 51 - 53
S12514 Single 3/32 - 5/32 49 - 51
S13161-052 Twin .045 - .052 53 - 55
S13161-5/64 Twin 1/16 - 5/64 53 - 55

S14904 (Outer) Twin 3/32 51 - 52

S14905 (Inner)
S12514 Single 3/32 - 7/32 49 - 52
S14904 (Outer) Twin 5/64 - 1/8 51 - 53

S14905 (Inner)
NA-5
F-63 F-63
3. Check for the proper drive roll revo- B. If the readings do not match the
lutions per minute. (RPM) number in Table F.5 refer to the
A. Adjust the STRIKE speed con- Meter Circuit Accuracy Test.
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 roll revo-
lutions and actual speed reading
should match Table F.5
TABLE F.5
SPEEDMETER HEAD SET SPEEDMETER DRIVE ROLL ACTUAL

CALIBRATION RATIO READING (IPM) RPM SPEEDMETER
PIN READING (IPM)
21* 21/1 0.27 (IPM X 1000) 50 +/- 2 0.27 +/- 0.01

(IPM X 1000)
57F** 57/1 268 50 +/- 1 268 +/- 2
57** 57/1 262 50 +/- 1 262 +/- 2
95 95/1 249 50 +/- 1 249 +/- 2
95S*** 95/1 265 50 +/- 1 265 +/- 2

142 142/1 250 50 +/- 1 250 +/- 2
142T*** 142/1 260 50 +/- 1 260 +/- 2
* Present on HI -Speed NA-5 speedmeter board only. ** Early speedmeter pins were labeled 55F and 55,
respectively.
*** Early speedmeter PC boards did not include these calibration pins.
NA-5
F-64 F-64
METER CIRCUIT ACCURACY TEST
WARNING

Call (216) 383-2531 or (800) 833-9353 (WELD).
_____________________________________________________________
TEST DESCRIPTION
This test will help determine if the NA-5 meter circuit is functioning properly.
The Speed Meter Circuit tests take approximately 15 minutes to perform.
The Volt Meter Circuit tests take approximately 15 minutes to perform.

MATERIALS NEEDED
Digital volt/ohmmeter with at least 3-1/2 digits and +/- 0.5% accuracy
5/16" Nutdriver
NA-5
F-65 F-65
METER CIRCUIT ACCURACY TEST (Continued)
TEST PROCEDURE 5. Test for AC supply to the volt-

meter PC board.
1. Remove input power to the NA-5.
• Check for 8 to 11VAC from lead
2. Using the 5/16" nutdriver open the #601 to #602. See Figure F.9
control box PC board access door.
Note: The coating will have to be
3. Locate the voltmeter PC board. See removed from the test points to ensure
Figure F.9 accurate voltmeter readings. If the cor-
rect AC voltage is not present check for
4. Apply input power to the NA-5. loose or faulty connects with the associ-
ated leads. See wiring diagram.
517
TP4 518 601

510C
510
602
TP5
L6685-[ ] METER
FIGURE F.9 VOLTMETER PC BOARD AND TEST POINTS
NA-5
F-66 F-66
6. Test for DC volts on the voltmeter 7. Test Digital Voltmeter Accuracy

PC board.
• Use a test meter with at least 3-
• Check for 4.75 to 5.25VDC from 1/2 digits and +/- 0.5% accuracy.
TP5 to lead #510C. See Figure
F.9 • Connect the + probe to TP4 and
the - probe to lead 510C. Do NOT
Note: The coating will have to be disconnect plug.
removed from the test points to ensure
accurate voltmeter readings. Note: The coating will have to be
• If the display is NOT lit and the accurate meter readings.
correct DC voltage is present at
TP5 to lead #510C, the digital • With the NA-5 voltmeter reading
meter may be faulty. Replace the SET values of STRIKE voltage,

meter. adjust the strike voltage control
until the test meter matches the
• If the AC voltage IS present at settings in the table below.
leads #601 to #602 and the DC
voltage is missing, the voltmeter • If the NA-5 digital voltmeter does
PC board may be faulty. not match the readings, the digital
meter may be faulty.
NA-5 SET VOLTS READING TEST VOLTMETER READING
15.0VDC .150 +/- .004VDC

30.0VDC .300 +/- .004VDC
60.0VDC .600 +/- .006 VDC
NA-5
F-67 F-67
8. Test Voltmeter PC Board Accuracy

1/2 digits and +/- 0.5% accuracy.
• Connect the + probe to lead #517

and the - probe to lead #510C.
Do not disconnect plug.

accurate meter readings.
• With the NA-5 voltmeter reading

SET values of STRIKE voltage,

adjust the strike voltage control
until the NA-5 voltmeter matches
the settings in the table below.
• If the test meter does not match

the readings, the voltmeter PC
NA-5 SET VOLTS READING TEST VOLTMETER READING
15.0VDC 1.50VDC +/- .04

30.0VDC 3.00VDC +/- .04
60.0VDC 6.00VDC +/- .06
NA-5
F-68 F-68
9. Locate the speedmeter PC board. 12. Test for DC volts on the speed-
See Figure F.10 meter PC board.
10. Apply input power to the NA-5. • Check for 4.75 to 5.25VDC from
TP5 to lead #510P. See Figure
11. Test for AC supply to the speed- F.10
meter PC board.
• Check for 8 to 11VAC from lead removed from the test points to ensure
#601 ot #602. See Figure F.10 accurate meter readings.
• If the display is NOT lit and the
Note: The coating will have to be correct DC voltage is present at
removed from the test points to ensure TP5 to lead #510P, the digital
accurate voltmeter readings. If the cor- meter may be faulty. Replace the
rect AC voltage is not present check for meter.

loose or faulty connects with the associ- • If the AC voltage IS present at
ated leads. See wiring diagram. leads #601 to #602 and the DC
voltage is missing, the speedme-
ter PC board may be faulty.
TP4
TP5
602 510P
601 510
NA5 SPEED METER L6233

FIGURE F.10 SPEEDMETER PC BOARD AND TEST POINTS
NA-5
F-69 F-69
13. Test Speedmeter Digital Meter

Accuracy

1/2 digits and +/- 0.5% accuracy.
• Connect the + probe to TP4 and

the - probe to lead 510P. Do NOT
disconnect plug.

• With the NA-5 speedmeter read-

ing SET values of STRIKE speed,
adjust the strike wire speed con-
trol until the test meter matches
the settings in the table below.
• If the NA-5 digital speedmeter

does not match the readings, the
digital meter may befaulty.
NA-5 SET SPEED READING TEST VOLTMETER READING

(IPM)
150 (1.50*) .150 +/- .004VDC

300 (3.00*) .300 +/- .004VDC
*For Hi-Speed NA-5 speedmeter (IPM X 1000).

NA-5
F-70 F-70
14. Test Speedmeter PC Board • If the test meter does not match
Accuracy the readings, the speedmeter PC
1/2 digits and +/- 0.5% accuracy. 15. When the testing is complete close
and secure the access door.
• Connect the + probe to lead #519
(Jumper lead) and the - probe to
lead #510P. Do not discon-
nect plug.

• With the NA-5 speedmeter read-

ing SET values of STRIKE speed ,
adjust the strike wire speed con-
trol until the NA-5 speedmeter
matches the settings in the table
below.
SPEEDMETER NA-5 SET SPEED READING TEST VOLTMETER

CALIBRATION PIN (IPM) READING
21* 2.07* 6.00 +/- .06

57F 778 6.00 +/- .06
57 762 6.00 +/- .06

95 428 6.00 +/- .06
95S 456 6.00 +/- .06
142 289 6.00 +/- .06
142T 300 6.00 +/- .06
* For Hi-Speed NA-5 speedmeter (IPM X 1000)
NA-5
F-71 F-71
PC BOARD(S) REMOVAL AND REPLACEMENT
WARNING

Call (216) 383-2531 or (800) 833-9353 (WELD).
_____________________________________________________________
DESCRIPTION
The following procedure will aid the technician in removing and replacing the printed circuit
boards for maintenance or replacement.
MATERIALS NEEDED
5/16" Nutdriver
NA-5
F-72 F-72
PC BOARD(S) REMOVAL AND REPLACEMENT (Continued)
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 to the
PC board that is to be removed.
4. Using the phillips head screwdriver,

remove the PC board mounting
screws.
5. Carefully remove the PC board.
REPLACEMENT PROCEDURE

and mounting screws carefully posi-
tion and install the new PC board.
2. Reconnect the molex type plugs

(and leads) into the new PC board.

NA-5
F-73 F-73
DIGITAL METER AND METER PC BOARD REMOVAL AND REPLACEMENT
WARNING

Call (216) 383-2531 or (800) 833-9353 (WELD).
_____________________________________________________________
DESCRIPTION
The following procedure will help the technician remove the digital meters and meter PC
boards for repair or replacement.
This meter PC Board portion of this procedure takes approximately 8 minutes to perform.
The total Meter PC Board and Meter Replacement procedure takes approximately 15 minutes to perform.
MATERIALS NEEDED
5/16" Nutdriver
NA-5
F-74 F-74
METER PC BOARD REMOVAL

PROCEDURE
1. Remove input power to the NA-5. 5. Carefully remove the meter PC

board.
2. Using the 5/16" nutdriver open the
control box PC board access door. Note insulation placement for reassem-
bly. Also make sure the plug on the
3. Locate and unplug the meter PC back of the PC board plugs into the
board that is to be removed. See prongs on the meter when you
Figure F.11 reassemble.
4. Using the 5/16" nutdriver remove the

four PC board mounting nuts. See
Figure F.11
METER BOARD SPEED METER BOARD

MOUNTING
NUTS
PC BOARD
PLUG PRONGS
FIGURE F.11 METER PC BOARD, MOUNTING NUTS AND PLUG
NA-5
F-75 F-75
DIGITAL METER REMOVAL

PROCEDURE
1. Using the phillips head screwdriver 4. Using the 5/16" nutdriver, remove
remove the four screws from the the two nuts, screws and lockwash-
meter bezel. See Figure F.12 ers holding the digital meter to the
cover assembly.
2. Carefully remove the bezel assem-
bly. 5. Carefully remove the digital meter.
3. Carefully remove the meter shield

assembly.
MOUNTING
INSULATOR METER SHIELD
DIGITAL ASSEMBLY
METER METER SHIELD
METER BEZEL
FIGURE F.12 METER BEZEL AND SCREW LOCATIONS
NA-5
F-76 F-76
REPLACEMENT 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.
4. Mount the meter PC board using the

four nuts previously removed.
5. Reattach the molex plug.

NA-5
F-77 F-77
TACH PC BOARD REMOVAL AND REPLACEMENT
WARNING

Call (216) 383-2531 or (800) 833-9353 (WELD).
_____________________________________________________________
DESCRIPTION
The following procedure will help the technician remove the Tach PC board and related com-
ponents for repair or replacement.
MATERIALS NEEDED
5/16" Nutdriver
Slot head screwdriver
3/8" Wrench
NA-5
F-78 F-78
TACH PC BOARD REMOVAL AND REPLACEMENT (Continued)
PROCEDURE 5. Using the phillips head screwdriver,

remove the two screws from the
1. Remove input power to the NA-5. pick-up assembly cover . See
Figure F.14. Remove the cover.
2. With the 5/16" nutdriver locate and
remove the four screws holding the 6. Hold the nut in place with the 3/8"
tach cover to the wire feed drive wrench. With the phillips head
motor. See Figure F.13 screwdriver, remove the locking
screw from the rotating disc. See
3. Using the 5/16" nutdriver remove the Figure F.15
two screws from the connection box
cover.
4. Locate and disconnect the in-line

connectors from leads #510A,

#525A and #555.
TACH COVER
MOUNTING
SCREWS (x4)
PICKUP
ASSEMBLY
WIRE
DRIVE
MOTOR
FIGURE F.13 DRIVE MOTOR, TACH COVER, AND CONNECTION BOX
NA-5
F-79 F-79
SCREWS TACH ASSEMBLY

COVER
FIGURE F.14 PICK-UP ASSEMBLY AND COVER
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.
PHILLIPS
SCREW DISC NUT
TACH
PC BOARD
FIGURE F.15 ROTATING DISC, NUT AND TACH BOARD
NA-5
F-80 F-80
REASSEMBLY
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 with your finger to simulate
the cover.
2. Use the 3/8" wrench to hold the nut

in place. Attach the rotating disc

with the phillips head screw.
3. Thread leads #510A, #525A and

#555 through the cover plate and
into the connection box. Attach to
their respective in-line connectors.
4. Replace the connection box cover.
5. Replace the pick-up assembly cover.
6. Reattach the tach cover to the wire

feed drive motor.
NA-5
F-81 F-81
WIRE DRIVE MOTOR REMOVAL AND REPLACEMENT
WARNING

Call (216) 383-2531 or (800) 833-9353 (WELD).
_____________________________________________________________
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.

MATERIALS NEEDED
7/16" Wrench
5/16" Nutdriver
Large slot head screwdriver
NA-5
F-82 F-82
WIRE DRIVE MOTOR REMOVAL AND REPLACEMENT (Continued)
MOTOR REMOVAL
PROCEDURE
1. Remove input power to the NA-5. 6. Using the 5/16" nutdriver remove the
clamp holding the connection box to
2. Remove the motor and tach cable the drive motor.
from the NA-5 control box.
7. Carefully remove the connection box
3. Perform the Tach Board Removal being careful not to stretch the leads.
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

drive motor.

remove the cover plate adaptor.
See Figure F.16
TACH HOUSING COVER PLATE

ADAPTER
WIRE
DRIVE
MOTOR
FIGURE F.16 DRIVE MOTOR AND TACH HOUSING
NA-5
F-83 F-83
8. Remove leads #67, #627, #626, 11. Carefully remove the adapter plate
#539 and #541 from the terminal and motor assembly (with pinion
strip in the connector box. attached).
9. Using the 7/16" wrench, remove two 12. With a slot head screwdriver,
1/4-20 bolts holding the adapter remove the adapter plate from the
plate and motor assembly to the wire drive motor.
feed gear box. (Older models may
have slot head 1/4-20 bolts). See
Figure F.17
10. Using the large slot head screwdriv-

er, remove the two slot head screws
that go through the wire feed gear
box and into the adapter plate.
HEX HEAD
BOLT
ADAPTER
PLATE AND
MOTOR
ASSEMBLY
WIRE DRIVE
GEARBOX
SLOT HEAD
SCREW
FIGURE F.17 DRIVE MOTOR
NA-5
F-84 F-84
MOTOR REPLACEMENT
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, #626, #539

and #541 to their respective termi-

nals in the connector box.
4. Carefully position the connector box

and clamp to the drive motor and
using the 5/16' nutdriver secure in
position. Be sure NOT to "pinch"
any leads.

mount the cover plate adaptor to the
drive motor.
6. Using the slot head screwdriver

attach the tach housing to the drive
motor.
7. Perform the Tach Board

Replacement Procedure.
8. Assemble the motor and tach cables

to the NA-5 control box.
NA-5
F-85 F-85
RETEST AFTER REPAIR
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:..........................
Gear Ratio Wire Speed Range in/min (m/min)
21/1 100-2070 (2.54-52.58)

57/1 38-778 (.97-19.76)
95/1 22-456 (.56-11.58)
142/1 15-300 (.38-7.62)
LEDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Must operate per PC Board LED Definitions table in

Troubleshooting Section.
Flux or Water Solenoid . . . . . . . . . . . . . . . . . . . .Must operate when "Start" switch is pressed.
Relay 3CR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Must operate and "close" power source contactor.
Relay 2CR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Must operate and activate external travel circuit, if used.
Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Refer to Voltmeter Accuracy Test.
Wire Speed Meter . . . . . . . . . . . . . . . . . . . . . . . .Refer to Wire Speed Accuracy Test.
Voltage control and shutdown . . . . . . . . . . . . . . .Refer to Out of Voltage Range Shut Down Test.
NA-5
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-86
NA-5
NOTES
F-86
Return to Master TOC G-1 ELECTRICAL DIAGRAMS G-1
TABLE OF CONTENTS
-ELECTRICAL DIAGRAMS SECTION-
Electrical Diagrams ....................................................................................................................Section G

Wiring Diagram ....................................................................................................................................G-2
Logic PC Board (L6242-1) Schematic .................................................................................................G-3
Logic PC Board (L6242-2 & above) Schematic ...................................................................................G-4
Power PC Board (L6252-1) Schematic................................................................................................G-5
Power PC Board (L6252-2 & above) Schematic..................................................................................G-6
Voltage PC Board Schematic ..............................................................................................................G-7
Control Circuit Schematic ....................................................................................................................G-8
Procedure Board Schematic ................................................................................................................G-9
Option & Timer Board Schematics.....................................................................................................G-10
Meter PC Board Schematic & Layout ................................................................................................G-11

Miscellaneous PC Board Layouts ......................................................................................................G-12
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
NA-5
NOTES
G-2 ELECTRICAL DIAGRAMS G-2
Wiring Diagram
G 1553
564A OPTIONAL PULSE POWER
581A FILTER P.C. BOARD
OPTIONAL PROCEDURE MODULE FLUX RELAY MODULE
LEAD PLUG
87
USED FOR CRATER CONTROL
532 N.P.
688A
ELECTRODE CABLE
525
500
688
POWER P. C. BOARD 4 2
N.F.
637
586
528
OPTIONAL PROCEDURE MODULE
592
587
689
TIMER BOARD TO POWER SOURCE 626 1
610 585 LOGIC
(CRATER TIME USE) USED FOR START CONTROL CR1
DIGITAL METER DIGITAL METER 2
1 3 P.C. BOARD
541 3
*
655
515
500
N.L.
O
TIMER BOARD 4 TRAVEL
5
3
4
627
6
I
(START TIME USE) RELAY MODULE 1 583C
5
SPEED- 142 142T 625 *
VOLTMETER BOARD REED SWITCH ACTUATED BY 539 6 2 587 * 2 565 4 2 1 3
655
515
500
METER
95 95S 532 N.P.
O
BOARD WELDING CURRENT 4 525 3 566
I
TIMER 4
510P
57 57F 1/2A SLOW BLOW 2
518
602
601
6 4
517
8 584S
510
510 688 *
RECEPT. N.M.
510P
*
655
515
500
N.A. FIELD FUSE 589
510
519
602
601
6 500 610 CR2 687 5 7 588
O
528
*
I
MAGNETICALLY 1 3 530 3 8
3 540 560
P28 (C) N.R. TIMER CR4
COUPLED 7 525 CONTACTOR 628 2 6 561
4 1 4 1 RECEPT. 500 516 9
655
6 2 6 2
515
500
5 3 5 3 1/2A SLOW BLOW
5
6
4
3
2
1
*
RELAY MODULE 4 9 563
9 510 582
O
514 2
I
J28 (C) POWER FUSE 2
P28 (S) 5 500 581 1 5 563
510P
TRAVEL RECEPT.
519
510
J5 N.P. 4 1/ 8 AMP
601
635
602
510P
1 500
601
OPTION BOARD 4
602
ELECTRODE LEAD BOLTED A 532 4 2 510P 8 FAST BLOW
510
5
6
4
3
2
1
*
(CRATER FILL USE) 532 2 610 1 1 584C
AND TAPED CONNECTION B 25 10 FUSE
J28 (S) 5 5 2
N.R. 531A 585 564
C 531 * CR3 * 525 3
*
OPTION BOARD 631 1 1 3 589 4
* 4 583S
D GND 510 7
WELD TIMER BOARD (START USE)
11 610 6 682 6 5 500
12
10
J29 (C) (OPTIONAL) 610 682 500 6

1
7
9
8
3
2
5
6
ORANGE WHITE S
FLUX OR WATER 531B 3 681 3 BLUE BLUE 6 515 D
ORANGE RED RED E
5 R
655
515
500
SOLENOID J4 FLUX RECEPTACLE 4 2 3 500
510P
500 500
588A
515
583
584
588
655
632
635
520
562
500
O
87 530 1
I
P29 (C)
A 87 F
11
N.E.
12
10
11
7
9
8
3
2
5
6
J29 (S) 531 667
B 531
621 12
510P
C GND
588A
E B
515
583
584
588
655
632
635
520
562
500
P29 (S) IT
A 6 H
N.H 587 W
J3 MOTOR RECEPTACLE D
B 4
A
541 *
C 5 A
B 539
592 3
WHITE
531B
BLUE
BLUE
RED
C 626
601
RED
602
687 2
N.C. D 627
688 1
E 67 T1 CONTROL
531B 12 540
532 P.C. BOARD
YELLOW
F 531B 8
BLACK
BYPASS COM
YELLOW
10 525
BLACK
531B
584S
TIMER BOARD 532
583S
588A
562S
584C
510P
562S
562C
583C
562C
541
531
532
510P
588A
626
539
627
87
31
9
32
532
635
515
500
500
588
655
588
655
515
515
632
632
635
655
520
520
500
9 510 E
1
(BURNBACK TIME) J2 TACH. RECEPTACLE LU

O
4
I
500 637 B
A 14
563 3 *
TS2 13 628
515
655
JUMPER
500
B 525A
O
PLUGS
511 1 AUTO
I
1 520
1
2
4
5
C 555
6
511A 2
10
10
11
11
13
13
8 N.N.
12
12
510P
15
15
14
14
1
1
2
7
3
5
8
8
6
6
4
4
9
9
D 510A * 7
7 510P
WELD TIME
* METER 500 6
* * *
A 2 T2 F 632
CRATER RECEPT. START RECEPT. 6
541
539
627
626
5
ORANGE
RECEPT. N.B.
67
ORANGE
ELECTRODE
5
ELECT
WORK
21
B 4
67
528
BROWN
CIRCUIT 512
BROWN
500
TS1 2
500 6
C 31 POLARITY VOLTAGE P.C. BOARD
S 3 511
517
11
15
13
14
12
519
10
*BURNBACK
655 4
1
5
4
3
2
2
5
3
4
TERMINALS
6
CONTROL
BLACK
SET-ACTUAL D 32
WHITE
TS 5 511A
681
528
689
610
N.D.
500
500
BLUE
3
RED
515 CABLE REMOTE INTERFACE
+
-
3 E 21
UP
TO 4 510P
S7 I 2 N.J. MODULE (OPTIONAL)
RECEPT. F A 510A
POWER 15 586
584C
583C
510P
581A
515
584S
564A
588
583S
565
561
O 1
632
563
520
525A
564
581
510A
560 555
635
WHITE
WHITE
500
525A
COM DOWN
566
G B
555
START SOURCE
RED
11
621
RED
528
667
689
500
500
PROCEDURE BOARD
S5 ARM. H C 581A 1
510P
581A
TACH.
601
514
516
511
512
602
500
I GREEN 631 500 6

N.R. PICK-UP
SWITCHES
*
SIGNALS
P.C. BD. 586 5
J1 INPUT RECEPTACLE TERMINAL
24V.
STRIP JUMPER 592 4
581A WELDING
582 2
NOZZLE N.K. 592
START
WHITE 515 3
S4
592
ELECTRICAL SYMBOLS PER E1537 531A 625
500
COM STOP
531A 31 32 R
WORK CABLE TO RF BYPASS 627 R1 INCH DOWN
25 610 682 500 582
N.A. SPEEDMETER BOARD CALIBRATION JUMPER IS TO BE CONNECTED FOR NA-5 HEAD AND DRIVE ROLL P.C. BOARD UP
531 500
POWER SOURCE WORK 532 531 532
EMPLOYED PER CHART BELOW: (CONNECTED TO PIN "95" OR "21" WHEN SHIPPED. 621 667 87 531 ELECTRODE S3
626
5A CIRCUIT 586 STOP
TRAVEL SW. "HOT" LIGHT RED RED
BREAKER POWER SW. S6
SPEEDMETER NA-5 HEAD DRIVE ROLL WIRE SIZE RATED SPEED S2 LT1
CB1 S1
N.G. 531-532 115VAC 1/8 AMP FUSE
PIN RATIO PART NUMBER RANGE RANGE
531-25 115VAC (SWITCHED) 250 VAC
57F 57/1 S12778 SINGLE .035-.052 40-778 I.P.M.
57 57/1 S12515 SINGLE 1/16-3/32 38-762 I.P.M.
95 95/1 S12514 SINGLE 3/32-5/32 22-428 I.P.M. N.H. 531-87 115 VAC (SWITCHED) 1/2 AMP.
95S 95/1 S12515 SINGLE 1/16-3/32 23-456 I.P.M. PROCEDURE KIT

N.J. CONNECT #67 BLACK (ELECTRODE) LEAD AND #21 WHITE (WORK) LEAD TO APPROPRIATE TERMINAL STRIP
S13161-052 TWIN .045-.052 RECEPTACLE
POLARITY CONNECTIONS WHICH MATCH ELECTRODE AND WORK CABLE POLARITY CONNECTIONS TO POWER SOURCE.
S13161-5/64 TWIN 1/16-5/64 560 1
N.K. LEAD CONNECTED TO MOTOR FRAME WHICH IS ELECTRICALLY COMMON WITH ELECTRODE DRIVE ROLL AND DRIVEN ELECTRODE.
S14904(OUTER) 564 2
TWIN
/ 3 32
S14905(INNER) NOTE: NA-5 MOTORS INSULATED FOR HIGH FREQUENCY STARTING DO NOT HAVE THIS CONNECTION. REFER TO 500 3
142 142/1 S12514 SINGLE 3/32-7/32 15-289 I.P.M. HI-FREQUENCY INSTALLATION INSTRUCTIONS FOR REQUIRED #67 ELECTRODE VOLTAGE SENSING LEAD CONNECTION. 500
515 4
142T 142/1 S14904(OUTER) N.L. REMOVE JUMPER PLUG TO INSTALL OPTIONAL KIT. IF KIT IS REMOVED, REPLACE JUMPER PLUG. 635 5
TWIN 5/64-1/8 15-300 I.P.M. *
S14905(INNER) 520 6
21 SINGLE .035-.052 100-2070 I.P.M. N.M. NOT PRESENT ON EARLIER VOLTAGE P.C. BOARDS.
21/1 S12778 632 7
N.N. BLUE JUMPER LEAD NOT PRESENT ON EARLIER VOLTAGE P.C. BOARDS. THE JUMPER IS TO BE CONNECTED TO THE 510P 8
= EARLIER SPEEDMETER BOARDS DID NOT HAVE THESE PINS. W 9
= SINGLE "21" PIN ON HIGH SPEED BOARD ONLY. "COM" TAB, UNLESS SPECIFIED ON THE POWER SOURCE CONNECTION DIAGRAM TO BE CONNECTED TO THE "AUTO" TAB
W 10
TO DISABLE THE "COLD" STARTING FEATURE.
564A 11
N.B. REMOVE START RECEPTACLE JUMPER PLUG FROM PROCEDURE BOARD TO INSTALL OPTIONAL PROCEDURE N.P. EARLIER RELAYS HAD SAME TERMINAL NUMBERS BUT IN A DIFFERENT ORIENTATION. 114A 12
N.L.
MODULE AS START PROCEDURE CONTROL. IF MODULE IS REMOVED, REPLACE JUMPER PLUG.
N.R. POTENTIOMETERS AND SWITCHES MOUNTED ON P.C. BOARD ARE CONNECTED TO FRAME, FOR ESD.
N.C. REMOVE CRATER RECEPTACLE JUMPER PLUG FROM PROCEDURE BOARD TO INSTALL OPTIONAL PROCEDURE JUMPER PLUG
(NOT PRESENT ON EARLIER BOARDS)
MODULE AS CRATER PROCEDURE CONTROL AND CONNECT LOGIC BOARD LEAD #694 TO PIN #P10.
IF MODULE IS REMOVED, REPLACE JUMPER PLUG AND LOGIC BOARD LEAD #694 TO PIN #P8.
N.D. CONTROL BOARD JUMPER LEAD CONNECTED TO PIN "F" WHEN SHIPPED. SEE OPERATING MANUAL FOR
USE OF PIN "S" JUMPER CONNECTION.
N.E. VOLTAGE BOARD RED JUMPER LEAD CONNECTED TO PIN "S" AND WHITE JUMPER LEAD CONNECTED TO
PIN "B" WHEN SHIPPED, FOR USE TYPICALLY WITH DC-[ ]TYPE POWER SOURCES. REFER TO CONNECTION
*
DIAGRAM FOR ALTERNATE CONNECTIONS, AND JUMPER CONNECTIONS FOR R3S, SAM AND SAF OR SA CAVITY NUMBERING SEQUENCE
POWER SOURCES WITH K224. EARLIER VOLTAGE BOARDS DO NOT CONTAIN PIN "D". (COMPONENT SIDE OF P.C. BOARD)
N.F. LOGIC BOARD DIP SWITCHES OR JUMPERS TO BE SET TO SUIT DESIRED APPLICATIONS PER CHARTS BELOW:
NA-5 SHIPPED CONNECTED FOR INDICATED METHODS OF TRAVEL & BURNBACK.
METHODS OF TRAVEL
1 3 1 4 1 4 7 1 4 7 10 1 4 7 10 13
FOR EARLIER LOGIC P.C. FOR LOGIC P.C. BOARDS WITH 1 2 3 4

2 4 2 5 2 5 8 2 5 8 11 2 5 8 11 14
BOARDS WITH JUMPERS DIP SWITCHES
3 6 3 6 9 3 6 9 12 3 6 9 12 15
CONNECT 1 2 3 4 1 2 3 4
SAMPLE SWITCH
START/STOP WITH SWITCHES LEAD #691 to P6

LEAD #692 to P5 SWITCH POSITION 1 IS UP

SWITCH #1 SWITCH #2
SWITCH POSITION 2 IS DOWN
CONNECT 1 2 3 4 1 2 3 4
SWITCH POSITIONS 3 AND 4 ARE NOT APPLICABLE
START/STOP WITH WELD CURRENT LEAD #691 to P6
LEAD #692 to P7 METHODS OF BURNBACK J28 J29
SWITCH #1 SWITCH #2
CONNECT 1 2 3 4 1 2 3 4 FOR EARLIER LOGIC P.C. FOR LOGIC P.C. BOARDS WITH
START WITH WELD CURRENT
LEAD #691 to P5 BOARDS WITH JUMPERS DIP SWITCHES
STOP WITH STOP SWITCH
LEAD #692 to P7 USE OF OPTIONAL CRATER MODULE
SWITCH #1 SWITCH #2 CONNECT 1 2 3 4 1 2 3 4
1 2 3 4 1 2 3 4 WIRE FEED STOP WITH LEAD #690 TO P4 CRATER BOARD INSTALLED? FOR EARLIER LOGIC P.C. FOR LOGIC P.C. BOARDS WITH
START WITH START SWITCH CONNECT
LEAD #691 to P6 CONTACTOR DELAY LEAD #693 TO P3 BOARDS WITH JUMPERS DIP SWITCHES
STOP AFTER CRATER TIME SWITCH #1 SWITCH #2
(OPTIONAL PROCEDURE MODULE
LEAD #692 to P9
SWITCH #1 SWITCH #2 CONNECT 1 2 3 4 1 2 3 4 YES CONNECT 1 2 3 4 1 2 3 4
INSTALLED IN CRATER RECEPTACLE) LEAD #690 TO P4 LEAD #694 TO P10
INCH UP WITH CONTACTOR DELAY THIS SHEET CONTAINS PROPRIETARY INFORMATION UNLESS OTHERWISE SPECIFIED TOLERANCE 1-12-96D EQUIP.
START WITH START SWITCH CONNECT 1 2 3 4 1 2 3 4 LEAD #693 TO P1 SWITCH #1 SWITCH #2 SWITCH #1 SWITCH #2 OWNED BY THE LINCOLN ELECTRIC CO. AND IS ON HOLE SIZES PER E2056 8-24-84H 7-12-96P THE LINCOLN ELECTRIC CO. TYPE NA-5
ON 2 PLACE DECIMALS IS .02
STOP AFTER BURN-BACK TIME LEAD #691 to P6 CONNECT 1 2 3 4 1 2 3 4 NO CONNECT 1 2 3 4 1 2 3 4 NOT TO BE REPRODUCED, DISCLOSED OR USED 11-14-86L CLEVELAND, OHIO U.S.A.
SUBJECT WIRING DIAGRAM
(OPTIONAL PROCEDURE MODULE LEAD #692 to P8 INCH UP WITH NO CONTACTOR LEAD #690 TO P2 LEAD #694 TO P8
WITHOUT THE EXPRESS PERMISSION OF ON ALL ANGLES IS .5 OF A DEGREE 7-19-91J
SWITCH #1 SWITCH #2 SCALE NONE
G 1553
MATERIAL TOLERANCE t(" ") TO AGREE 7-10-92B SHT.
INSTALLED IN CRATER RECEPTACLE) DELAY LEAD #693 TO P1 THE LINCOLN ELECTRIC CO. DR DAD DATE 5-8-92 CHK REF. G1512
SUP'S'D'G 8-1-80
SWITCH #1 SWITCH #2 WITH PUBLISHED STANDARDS. 5-19-95D NO.
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
NA-5
LOGIC PC BOARD (L6242-1) SCHEMATIC
LED 7B 583S 610

PROCEDURE
564 PROCEDURE D1021 D1023 REMOTE INTERFACE
PC BOARD WELD TIME A6G
START TIME PC BOARD
515 OPTION
OVER OVER X705 WELD 24
P10 RED
D8C X705 X701 PROCEDURE
R722
9 B R741 A7E VAC R1001
R707
START F C 8 9 8 Q711 ENABLE D718
3 4 10 D1001
R742
D712 CR2 RED D1024
DISABLE LED 7H D1002
694 CR
R706 P5 C727 TRAVEL
581A 1 X707 N.C. D1022 1001
S801A 581 DZ702 3
A D1004
2 500 D722
X705 F1001
N.A. C706
692
D9C CR D1003 + C1001
X701 589
S5 13 E R720 1001 SWITCH 24V SIG.
D 581A
START 11 11 10 Q702
N.D. 12
R721
560 PROCEDURE D1005
X705 D1A
PC BOARD START
565 D708 X707 X701 C719
PROCEDURE 4 1 A PRESET R1002
500 6 A 689
B 3 13 12 MONITOR
PC BOARD 5 500 D1006
D9C 2 D1007
ENABLE
R705
WELD TIME N.B. CR SWITCH CR
OHMS
515 A7H
OVER 1002 COMMON 1002 SIGNAL
470
Q709 582
R738
D8C COMMOM
+ 610
C725 D1009
C705 + D3A D1008 + C1002
R704
691
R702
X701 515 A6G
5 SWITCH 24V SIG.
500 B 500
6 CR6 D8C
D9C 4 ELECTRODE D1010
LED 7C N.D. .047 D9C
R737
MFD HOT STOP
D710
R727
D726 CR R1003
C728 LT1 R 586 1003
D1011
582 R703 500 CR3 D1012
DZ701 CR
D9C D725
530 D720 D7J 1003
500 HOLD-LOW LED 7K
C704 P6 P8 X705
X702 584C PROCEDURE DISABLE D723
D9C C4D D1014
S6 10 C D1013 +
POWER C1003
13 X707 C 6 PC BOARD R735 682

STOP 515 5 CRATER
D 11 8 Q708 R725 SOURCE SWITCH 24V SIG.
9
R736
12 TIME Q704 OUTPUT
R709
D8C
R726
INITIATE D1015
R710
C724
500 INCH UP
C721
R708
D9C D709 R1004
+
515 C711 C708 500 500 CR D1016
PROCEDURE D1017
D8C 566 500 592 1004 CR
PC BOARD D9C A7H
1004 SIGNAL
BURNBACK D715 500 D9C COMMOM
X706
D7A SWITCH
R713
687 TIME OVER D716 D9C X707 610

SHUT- 10 C 688 SHUTDOWN N.E. COMMON D1018 + C1004 D1019
R711
C 8 5 6
LED7D DOWN 9 690 ENABLE A6G SWITCH 24V SIG.
500 P1 P4
C4M C5K
C729 N.D. 500
X706 D9C D1020
ARC CONTROL D9C
R712 D R733 C5E INCH DOWN
528 + 9 8 ENABLE
D714 Q707 CURRENT
R734
CR4 P7
C707 X706 CR5
CURRENT 588 C723
}
F
500 13 12 CURRENT PROCEDURE D719
X706 500 N.A. S801 (SEE PROCEDURE PC BOARD
515 D9C X702 584S PC BOARD
2 E D9C SCHEMATIC) MUST BE IN "STRIKE"
D8C A 3 11 10 681
START POSITION TO START WELD CYCLE.
1 561 R723
PROCEDURE 563
R714
TIME Q703 N.B. COMPONENTS INCLUDED WITH

PROCEDURE
R724
INITIATE PC BOARD STRIKE PROCEDURE Q710 OPTIONAL LINC-FILL BYPASS KIT
STRIKE
X702 DZ706 PCB
637 L701 X706 DISABLE PROCEDURE C720 (ALSO SEE SCHEMATIC A).
4 R739
VOLTAGE
A B 6 ENABLE N.C. LEAD 694 TO BE CONNECTED TO
PRESENT 500
R740
1 2 5
C2M PIN P10 IF OPTIONAL CRATER MODULE
12 X702 C726 A7H
D 11 610 (SEE SCHEMATIC E) IS INSTALLED, OR
CRATER 13 P2
R715
TO PIN P8 IF REMOVED.
500 A6G
515 TIME OVER N.D. LOGIC BOARD JUMPER LEADS ARE TO
Q701 BURNBACK X704 X704
2 4 D9C BE CONNECTED TO SUIT APPLICATION
D8C P9 A 3 B 6
TIME X706
1 5 PER CHARTS BELOW.
PROCEDURE INITIATE P3
R730
R717
B LED N.E. HOLD-LOW DISABLE IS USED WITH

D717 +
R716
PC BOARD 583C 3 4 7E
X703 587 CR1 G1556-1 AND EARLIER VOLTAGE BOARDS.
C709 X704 X704 4 FEED
13 9 B 6 9 X703 ARC CONTROL ENABLE IS USED WITH
C FORWARD LED 7G
LED 7J D 11 8 5 C 8 D721 LATER VOLTAGE BOARDS.
12 10 10 A3K
R728
592 DZ703 586 FEED D724
N.D. LEAD TO PIN
2 DZ705 ENABLE 585 FLUX OR NO.
693 Q706 B7J
METHODS OF TRAVEL NO.
C3K X705 X703 WATER
Q705 START-STOP 691 P6
592 R718 A 3 12 X703 R731
D
R729
1 D 11 WITH SWITCHES 692 P5
1 2
13 S3
R732
C722 START-STOP 691 P6
INCH WITH WELD CURRENT 692 P7
C712 C710
S4 UP 500 START WITH WELD CURRENT 691 P5
DZ704
INCH STOP WITH STOP SWITCH 692 P7
500 A7H
DOWN WHEN OPTIONAL START WITH START SWITCH 691 P6
D9C
500 PROCEDURE MODULE STOP AFTER CRATER TIME 692 P9
D9C IS INSTALLED IN START WITH START SWITCH 691 P6
CRATER RECEPTACLE STOP AFTER BURN-BACK TIME 692 P8
LEAD TO PIN
METHODS OF BURNBACK NO. NO.
FOR LOGIC P.C. BOARDS L6242-2 OR HIGHER USE G2974 SCHEMATIC FOR FOR REMOTE INTERFACE PC. BOARDS L6580-1 WIRE FEED STOP WITH 690 P4
COMPONENT VALUES AND CIRCUIT CONNECTIONS. OR HIGHER USE S21207 SCHEMATIC FOR CONTACTOR DELAY 693 P3
COMPONENT VALUES AND CIRCUIT CONNECTIONS. INCH UP WITH 690 P4
LOGIC P.C. BOARD CONTACTOR DELAY 693 P1
OPTIONAL REMOTE INTERFACE P.C. BOARD
INCH UP WITH NO 690 P2
C701 .22/100 DZ701 16V, 1W R704 47K R728 2.7K
C1001 THRU C1004 2/50 CONTACTOR DELAY 693 P1
C702 500/50 DZ702 16V, 1W R705 470 R729 1.5K
CR1001 THRU CR1004 SPDT, 24VDC FOR LEAD #694 CONNECTION SEE N.C.
C703 4.7/35 DZ703 3V, 1/2W R706 100 R730 68K
D1001 THRU D1004 1A, 600V NA-5 SHIPPED CONNECTED FOR INDICATED
C704 .047/100 DZ704 16V, 1W R707 4.7K R731 22K
F1001 1/8A FUSE METHODS OF TRAVEL AND BURNBACK.
C705 10/25 DZ705 3V, 1/2W R708 47K R732 47K
R1001 THRU R1004 150
C706 .047/100 DZ706 5.1V, 1/2W R709 470 R733 22K KEY TO SYMBOLS
C707 10/25 L701 5.6mH, 28mA R710 470 R734 47K COMPONENTS NOT ON P.C. BOARD POWER SUPPLY SOURCE POINT
C708 10/25 LED 7A R711 15K R735 22K
}
CR1 SPST 110 VDC RELAY COIL SCHEMATIC LOCATION REFERENCE
C709 10/25 THRU R712 470 R736 47K
RED CR2 (N.O. CONTACTS SHOWN ON
}
C710 LED 7E R713 4.7K R737 6.8K
CR3 SCHEMATIC A) HORIZONTAL CO-ORDINATE LETTER

THRU .022/25 LED 7G LIGHT R714 4.7K R738

}
47K
EMITTING CR4 REED SWITCH ACTUATED BY VERTICAL CO-ORDINATE NUMBER
C729 LED 7H R715 100K R739 10K
DIODE } WELDING CURRENT
}
D701 LED 7J R716 22K R740 15K SCHEMATIC IDENTIFICATION LETTER
CR5 OPTIONAL 110 VDC RELAY
THRU 1A, 400V LED 7K R717 4.7K R741 10K UNLESS OTHERWISE SPECIFIED, COMPONENT VALUES OF:
} COIL ACTUATED BY CR4
D712 Q701 2N 4123 R718 100 R742 15K CAPACITORS = MFD/VOLTS
CR6 OPTIONAL LINC-FILL
} }
D714 Q702 R720 2.7K X701 RESISTORS = OHMS, 1 2 /WATT
QUAD 2 SOLID-STATE PILOT RELAY
THRU 1A, 400V THRU 2N 5657 R721 1.5K X702 INPUT LT1 INDICATOR LIGHT SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT
D717 Q705 R722 68K X703
}
NAND S3
}
BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGE-
}
D718 Q706 R723 2.7K X704 GATE S4 SPST PUSH BUTTON SWITCH
THRU 1A, 1000V THRU 2N 4123 R724 1.5K X707 ABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY NOT
S5
D721 Q711 R725 2.7K X705 HEX SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS
S6
}
D722 R701 4.7K R726 1.5K X706 INVERTER HAVING A COMMON CODE NUMBER.
TIC 22V 600mA SECONDARY
THRU 1A, 400V R702 4.7K R727 68K X708 +15 V VOLTAGE
D726 R703 100 REGULATOR
(PRIMARY SHOWN ON SCHEMATIC A) ELECTRICAL SYMBOLS PER E1537 1-12-96D
L6682-4
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided
for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine. NA-5
LOGIC PC BOARD (L6242-2 & above) SCHEMATIC
2974 G
1 610
515
J1
22.1K
515 515 515
R51
583S 22.1K
J4
R22
68.1K
PROCEDURE 4 R52 J4
PC BOARD CR2
LED 7B 2
PROCEDURE
D12 D11 564
START TIME WELD TIME PC BOARD
1N4007 D18
OVER OVER WELD 1A
PROCEDURE 1000V J1
ENABLE 4 LED 7H
1.00K 9
R2
10 1 2 D22
X1 A X5 A R40
1A
R3
1.50K 8
10.0K 589 400V
START Q11 TRAVEL
C27
DISABLE N.F. 2N4401 515
15 .022
R54
16
J2 1N4004
581
50V
581A 1 S2 -1 100K
1 R6 R4 3 4
A 3 X5 B
X7 1 2 Q2
100 475 2 R20
2N5657
N.A. 2.67K
C6
S5 D13 500 J3
C31 C19 NOTES:
START 560 PROCEDURE
.022
R63
8
6 PC BOARD
2N4403 50V
500 500 4 R53 PRESET 100K
X7 B Q18 N.A. SWITCH (SEE PROCEDURE P.C. BOARD SCHEMATIC)
500 5 MONITOR
7.68K
ENABLE MUST BE IN "STRIKE" POSITION TO START WELD
S1 -2
3 14 N.F. 515 CYCLE
Q9 500
2N4401
N.B. COMPONENTS INCLUDED WITH OPTIONAL LINC-FILL
13
C32
11 1 BYPASS KIT (ALSO SEE SCHEMATIC A)
4 13 X1 B C25
12 3
2N4403
C R41
R55
X1 .022
2 515
Q12
50V N.C. DIP SWITCHES ARE TO BE SET TO SUIT APPLICATION
515 7.68K 100K
515 S1 -1
N.F. PER CHARTS BELOW
15 2
500 N.D. HOLD-LOW DISABLE IS USED WITH G1556-1 AND
R37
J5 6.81K
6
D26
EARLIER VOLTAGE BOARDS. ARC CONTROL ENABLE
4
16
R27
1 X1 D 68.1K
LED 7C D10 515 515 5 6 IS USED WITH LATER VOLTAGE BOARDS.
689
1.00K ELECTRODE N.E. SINCE COMPONENTS OR CIRCUITRY ON A PRINTED

R5
D25 HOT
CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE
J2
22.1K 530
OHMS
584C INTERCHANGEABILITY OF A COMPLETE BOARD, THIS
R11
R18
1.50K 9 3
470
J4
D15 13 10 9 8 PROCEDURE LT1 R CR3
HOLD-LOW DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR
X2 A X5 D 1 PC BOARD
11 8 ENABLE
X7 C CIRCUITRY OF CONTROLS HAVING A COMMON CODE NUMBER.
582 D32 12
J2 Q8
CRATER TIME R42 2N4401 N.F. SCHEMATIC SHOWN WITH DIP SWITCHES IN THE "UP" POSITION.
4 R17 R19 INITIATE
J1
475 22.1K 6
R10
100 C5 475
R9
R56
D27 4.7 475 CR6
S6 C24 LED 7K
D9 35V 100K D20
STOP .022 D23
1A 1A POWER
500 500 C11 C8 50V 682
1000V 400V SOURCE
.022 10
J2
50V 25V N.B.
500
1N4007 1N4004
OUTPUT
Methods of Travel
5
687 515 500
500 500
SHUT DOWN D16 J3 D8 500 1 2 3 4 1 2 3 4
565 2 515 Q4 Start/stop with switches

R25
2N5657
WELD TIME OVER 22.1K
2.67K
R24
PROCEDURE PC BOARD
C21 SWITCH #1 SWITCH #2
515 C37
S2 -4 .022
R62
515 9 N.F. 2N4403
8 9 50V
10 1 2 11 10
Q13 100K
J3 X7 D X6 A X5 E R43 1 2 3 4 1 2 3 4
8
566 3
Start/stop with weld
1.50K 7.68K
BURNBACK
R13
SHUT DOWN current

TIME OVER 7 10 500
C4 S1 -4 ENABLE N.D.
.022 12 11 N.F. 10 7 N.F. J2 SWITCH #1 SWITCH #2
50V
15.0K S1 -3 6 688
R29
5 6
D28 500 ARC CONTROL 1 2 3 4 1 2 3 4
LED 7D 9 8 Start with weld current

ENABLE
Stop with stop switch

3 4 Q7 SWITCH #1 SWITCH #2
R12 X6 B R33 2N4401
CR5
D14 100 22.1K CURRENT
J5 Start with start switch 1 2 3 4 1 2 3 4
C7
515 Stop after crater time
10 C26
R57
2 25V
(Optional procedure
100K 1N4007 J1 module installed in crater
528 D19
1A 3
C33
receptacle)
500 J3 588 1000V SWITCH #1 SWITCH #2
CURRENT 5 6 PROCEDURE
X6 C 7 PC BOARD 1 2
X8 2N4403
A R44 681
CR4 Q14
CURRENT 7.68K 500 Start with start switch 1 2 3 4 1 2 3 4
Stop after burn-back time

1 (Optional procedure
J3 584S
3 9 8 PROCEDURE Q3
B R23 module installed in crater
500 X2 X6 D 4 PC BOARD
2 2N5657 receptacle)
2.67K SWITCH #1 SWITCH #2
START J3 J3
100K
TIME PROCEDURE 6
9 563 C20
561
.022
R61
INITIATE PC BOARD
STRIKE PROCEDURE J3 PROCEDURE 50V
5 563
DISABLE DZ1 PCB
6
4 Q10 STRIKE Optional Crater Module Installed?
X2 C R39 2N4401 PROCEDURE
11 10 5 500
R32 X6 E ENABLE
22.1K 1 2 3 4 1 2 3 4
5.1V 100K Yes
475
C23
13 1W
R58
.022
11
X2 D 50V
515 515 12
SWITCH #1 SWITCH #2
515
515
1 2 3 4 1 2 3 4
500 No
475 515
15.0K
R34
D29
R14
1.50K
1 6
R47
3 4 SWITCH #1 SWITCH #2
CRATER X4 A X4 B
2 5 C36
TIME OVER
221K BURNBACK 3 4
J5 D30 B 2N4403
637 Q1 PROCEDURE TIME X8 R48
1 R15 Q17
R35 2N4401 PC BOARD INITIATE
J3 LED 7E 7.68K
VOLTAGE
100
583C 1
13
X6 F
12 C35 Methods of Burnback
PRESENT C2 C9 Q16 CR1
R30
D31 .022 D17 4.7 R46 2N4403 68.1K
R16
1 2 3 4 1 2 3 4
6
50V 35V
Wire feed stop with
13 4 9 7.68K
X3 B Q15 contactor delay
11 5 6 5 10
47.5K X4 C X5 C N.F. R45
X3 C 2N4401
12 8 J1
12 11 D21
22.1K 5
SWITCH #1 SWITCH #2
500 500 1N4007
S2 -3
C34 1A LED 7G
5 2.67K 1000V D24
6
1 585 FLUX OR
J5
R28
1A 1 2 3 4 1 2 3 4
3 WATER Inch up with contactor
X3 A R49 4 587 400V
2
515 515 515 100 1N4004 delay

(TO POWER P.C. BOARD)
500 FEED FORWARD
13 SWITCH #1 SWITCH #2
Q5
11
X3 D 2N5657
12
LED 7J D33 1 2 3 4 1 2 3 4
100K C22 Inch up with no contactor
1.00K
.022
R60
R36
delay
50V
D34
1.50K
SWITCH #1 SWITCH #2
R38
J5
586 FEED
3
592 J5 ENABLE
5 6 500
5 R50 X8 C
C3
100 NA-5 SHIPPED CONNECTED FOR INDICATED
.022 Q6
S4 D35 D6
50V R31 2N4401 S3 METHODS OF TRAVEL & BURNBACK.

INCH
DOWN 22.1K
515 INCH
100K C10
500 500 UP
J2 D5 X9 J4
.022
R59
500
628 2 6 515 50V
IN 7815 OUT
(HS) J1 GENERAL INFORMATION LAST NO. USED
D1 D2 2 500
515 GND
R- 63 Q- 18 B- 2 DZ1- 1
ELECTRICAL SYMBOLS PER E1537
1.50K
R1
BLU
CAPACITORS = MFD ( .022/50V UNLESS OTHERWISE SPECIFIED)
C- 37 LED- 7K J- 5
B1 LOGIC 500
LABELS D- 35 X- 9 S- 2
C12 RESISTORS = Ohms ( 1/4W UNLESS OTHERWISE SPECIFIED)
POWER
C1
500 SUPPLY DIODES = 1A, 400V (UNLESS OTHERWISE SPECIFIED)
22VAC .22 C13 SUPPLY VOLTAGE NET
50V
14 14 14 14 14 14 14 14 100V 4.7 D7
POWER SUPPLY SOURCE POINT
35V
B2 COMMON CONNECTION
T1C BLU LED 7A
X1 C15 X2 C16 X3 C17 X4 C18 X5 C28 X6 C29 X7 C30 X8
C14 D3 D4 FILENAME: G2974_2DA
FRAME CONNECTION
.022 4011 4011 4011 4011 4011 THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC CO.
J4 EARTH GROUND CONNECTION
50V AND IS NOT TO BE REPRODUCED, DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION OF THE LINCOLN ELECTRIC CO.
500 3
7 7 7 7 7 7 7 7 EQUIP.
Ch'ge.Sht.No.
NA-5
UNLESS OTHERWISE SPECIFIED TOLERANCE THE LINCOLN ELECTRIC CO. TYPE
500 ON HOLES SIZES PER E-2056
1-12-96D
J4 LOGIC CIRCUIT
ON 2 PLACE DECIMALS IS + .O2
ON 3 PLACE DECIMALS IS + .OO2
CLEVELAND, OHIO U.S.A. SUBJECT
500 5
NONE
ON ALL ANGLES IS + .5 OF A DEGREE SCALE
500 SHT.
LOGIC POWER SUPPLY DISTRIBUTION AND BYPASSING MATERIAL TOLERANCE ("t") TO AGREE
DR. MAB DATE
9-27-94
CHK. SUP'S'D'G. NO. G 2974
WITH PUBLISHED STANDARDS
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided
for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine. NA-5
POWER PC BOARD (L6252-1) SCHEMATIC
A B C D E F G H J K L M
A
525
CONTROL POWER AND
CB1
31 S1A EMERGENCY STOP A5H
531 R1
6682-1
531A 631
540
R106
1 PT
R104
102B C104 B2L
C119
500
FLUX OR
L
+
PT101A C107
531
SHT.
WATER SOLENOID A6H
R110
R113
SCR
NO.
RECEPTACLE 102
CR7 SCR
TRAVEL 101
531 87 500
RECEPTACLE
POWER CIRCUIT
QU101
NA-5 SCHEMATIC
541 A6H
10-3-81
C105 C106
C101
R103
C108
SUP'S'D'G
GND 25 C102
2 115 VAC
INPUT
666
532
PT
103B C121 C109
AUTO C1105 C1104 PT101B PT101C
R109
F101 C110
WIRE FEED PT102A PT103A
R105
87 SCR SCR BLU
MOTOR
R101
103 104
OFF ARMATURE
WIRE FEED
TP101
D103
MOTOR FIELD
S2 627 587
FEED
REF.
CR6 TRAVEL
SUBJECT
HAND C1106 WH BLK FORWARD
Q102
THE LINCOLN ELECTRIC CO. EQUIP.

LED C112
3 TO TACH
TYPE
D2G D6G
1C
R107
R111
PICK-UP
C103 LED
D101 D102 1E P.C. BOARD

CR2 Q101

CR1 C1105 RED LED C122
CHK
D1K R102 1D
D6K 626 Q103
R112
R108
F102 C120
7-2-92
32 S1B
532 C111
NONE
532 539
DATE
FIELD SUPPLY
SCALE
TP102 ARMATURE SUPPLY 500
4 A6H
DR DAD
GND FEED DIRECTION CIRCUIT
D108
X101
525
IN OUT
+15V
D104 D105 D110
R114
GND ANALOG
ANALOG
BLK RED + +
531B
2 18 POWER SUPPLY
C114 C116 510
115 VAC
5
WHT LED 1A
VAC ZERO-VOLT
18 DZ101 C117 + D111
R115
C113 C115 + REFERNCE
VAC
CR3 532
BLK RED
D3K T1A
D106
4 GND LED 1B
D107 500
YLW IN OUT
-10V
601
X102
THIS SHEET CONTAINS PROPRIETARY INFORMATION UNLESS OTHERWISE SPECIFIED TOLERANCECh'ge. Sht. No.
10 METER D109
11-20-81G
5-18-92N
9-11-92J
3-31-94E
9-7-84A
VAC SUPPLY
6 T1B YLW
602
D112 D113
610
RELAY
MATERIAL TOLERANCE t(" ") TO AGREE

ON ALL ANGLES IS .5 OF A DEGREE
BLK ORG POWER SUPPLY
WITH PUBLISHED STANDARDS.

LED 1F

C118
115 115
ON HOLE SIZES PER E2056

VAC VAC
TP
R116
BLK ORG 103
T2A BRN D114 D115
500
24
VAC INTERFACE OPTION
7 FOR POWER P.C. BOARDS L6252-2 OR HIGHER USE L8956

POWER SUPPLY
BRN
T2B
SCHEMATIC FOR COMPONENT VALUES AND CIRCUIT CONNECTIONS.
OWNED BY THE LINCOLN ELECTRIC CO. AND IS

NOT TO BE REPRODUCED, DISCLOSED OR USED
POWER P.C. BOARD R.F. BYPASS P.C. BOARD
WITHOUT THE EXPRESS PERMISSION OF

COMPONENTS NOT ON P.C. BOARD KEY TO SYMBOLS
THE LINCOLN ELECTRIC CO.

C101 .005/1400 D101 16A, 400 V Q101 2N4123 SCR 101 8A, 600V FOR R.F. BYPASS P.C. BOARDS M14133-1 OR CB1 5A. CIRCUIT BREAKER
C102 .15/200 D102 16A, 400 V Q102 2N5816 SCR 102 8A, 600V INPUT CONTROL CABLE CONNECTION
HIGHER USE S20995 SCHEMATIC FOR
C103 50/250 D103 16A, 400 V Q103 2N5816 SCR 103 16A, 400V CR1 SPST, N.O. FLUX OR WATER
COMPONENT VALUES AND CIRCUIT CONNECTIONS. POWER SUPPLY SOURCE POINT
C104 .15/200 D104 QU101 UJT SCR 104 16A, 400V CR2 SPST, N.O. TRAVEL
C105 .047/100 THRU 1A, 400 V CR3 SPST, N.O. POWER SOURCE OUTPUT
C1101 .0047/3000 ARC VOLTAGE BY-PASS COMMON CONNECTION TO ANALOG POWER
C106 .047/100 D111 R101 40, 12W TP101 CR6 SPST, N.O. SOLID STATE, OPTIONAL
C1102
C107 4.7/35 D112 R102 68K TP102 150V, 10J (SEE SCHEMATIC "C") LINC-FILL PILOT RELAY SUPPLY; 510 A5H
C1103 .0047/3000 FLUX SOLENOID BY-PASS
C108 .047/100 THRU 1A, 1000 V R103 100 TP103 CR7 OPTIONAL LINC-FILL BY-PASS CONTACTOR
C1104
C109 .022/25 D115 R104 100 SCHEMATIC LOCATION REFERENCE
C1105 .0047/3000 MOTOR FIELD BY-PASS
C110 .022/25 R105 10K, 2W X101 +15V VOLTAGE R1 2, 50W
C1106 HORIZONTAL CO-ORDINATE LETTER
C111 .022/25 DZ101 5.1 V., 1 /2 W R106 100 REGULATOR
C112 .022/25 R107 10K X102 -5V VOLTAGE S1 DPST, CONTROL POWER AND VERTICAL CO-ORDINATE NUMBER
C113 .22/100 F101 1/ 2A SLOW BLOW, R108 47K REGULATOR EMERGENCY STOP SCHEMATIC IDENTIFICATION LETTER
C114 500/50 POWER SUPPLIES FUSE R109 4.7K S2 SPDT, TRAVEL
FOR NA-5 CONTROL CODES

UNLESS OTHERWISE SPECIFIED, COMPONENT VALUES OF:
C115 500/50 F102 1/ 2A SLOW BLOW, R110 6.8K
CAPACITORS = MFD/VOLTS
C116 4.7/35 FIELD FUSE R111 680 T1A 36 VCT, 300mA SECONDARY
C117 18/15 R112 47K T1B 10 VAC, 600mA SECONDARY RESISTORS = OHMS, 1 2 /WATT
L 6682-1
C118 .02/600 LED 1A RED LIGHT R113 680 T1C SEE LOGIC SCHEMATIC "D" SINCE COMPONENTS OR CIRCUITRY ON A PRINTED
8993
C119 .047/100 THRU EMITTING R114 4.7K T2A 115VAC, 80mA SECONDARY
8400
C120 .022/25 LED 1F DIODE R115 3.3K T2B 24VAC, 30mA SECONDARY
INTERCHANGEABILITY OF A COMPLETE BOARD, THIS
C121 .02/600 R116 68K
C122 .022/25 PT101 1:1:1 DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS
PT102 PULSE OR CIRCUITRY OF CONTROLS HAVING A COMMON
PT103 TRANSFORMER CODE NUMBER.
A.N.S.I. ELECTRICAL SYMBOLS PER E1537
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not avail-
able from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in
danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine. NA-5
POWER PC BOARD (L6252-2 & above) SCHEMATIC
525
L 8956
J3
EARTH GROUND CONNECTION

P1
540 3
POWER P.C. BOARD SCHEMATIC

VOLTAGE NET
COMMON CONNECTION
100
FRAME CONNECTION
R6
LAST NO. USED
SHT.
5
NO.
C19
22
24
D- 15
.047 PT1
CONTROL POWER AND
C-
R-
100V 0.2mH
SUPPLY
EMERGENCY STOP
S1A CB1
31
531 531A 631 6
LABELS
4.75K
6.81K
13.7K
R1
R20
R10
R9
NA-5,NA-5R
2 OHMS
2 C24
FLUX OR WATER 50 WATTS C7
4.7
SOLENOID RECEPTACLE
SUP'S'D'G.
100
TRAVEL 500 35V
R4
RECEPTACLE 531 87 PT2
0.2mH C4
3 1
531
.15 QU1
UNLESS OTHERWISE SPECIFIED)

1 2N6027
200V
SUBJECT
C6
541

C5 .047
EQUIP.
TYPE
2 4
GND 5 1 .047 100V 2
100V
J2 J2
(UNLESS OTHERWISE SPECIFIED)

.0047 J1
25 3000 531A 631 3
GND
332
SCR1 SCR2
R21
CHK.
.0047
532 2N6398 2N6398 P1 BLUE
3000 1 0.2mH 3
0.2mH
PT1
PT1
10K
2W
R5

Q9
WIRE FEED
NONE
TP1 600mA
5/12/92

M
PT3 MOTOR ARMATURE
M F D ( .022/50V
40V

150V 1
1.50K
C2
1/4W
0.2mH
R19
GENERAL INFORMATION
45J SCR3 SCR4
CR7 .15
100
200V
0.5A 2N6403 2N6403
R3
SCALE
125V C1 C21
DATE
CR1
1A, 400V
.0047
F1
P1
RESISTORS = Ohms (
666 .02 BLACK
115VAC 1400V 2
600V
C8 3 3
CAPACITORS =
6
INPUT J1 .047
PT2
D3 100V 0.2mH PT3
33.2K
DIODES =
FEED FORWARD
R22
16A 0.2mH
K.K.
400V P1
12W
AUTO
40
R1
J1 2 4 4
C10
J3
C9
DR.
WHT
4
CR6
LED1D
LED1C
.0047 587
627 C3
OFF 3000 50
539
LED1E
MOTOR FIELD
250V
C12
WIRE FEED
CR2 Q2
600mA
R2 40V
S2
HAND .0047
10K
TRAVEL J1 133K
R7
P1 Q1 Q3
3000
681
NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE
600mA
R11
1 R18 600mA
RED
WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY

626 40V 40V
133K
C22
D1 D2
C20
0.5A
F2
125V
16A 16A
C11
400V 400V
47.5K
47.5K
R12
SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE

R8
ARMATURE SUPPLY
32 J2
532 D8
2
S1B 525
FIELD SUPPLY +15V

FIELD DIRECTION
X1 ANALOG
Ch'ge.Sht.No.
J2
GND TP2
IN 7815 OUT
CIRCUIT
3 150V 500
(HS) J3
45J P1
525
FOR THE NA-5R ONLY:
531B
4.75K
4
GND
R14
THE TRAVEL RECEPTACLE,THE TRAVEL SWITCH,
D4
D5
J3
P1
AND CR2 ARE REMOVED ON THE NA-5R. C14 525
UNLESS OTHERWISE SPECIFIED TOLERANCE

B1 7
531B BLK RED 500
CR3 IS SHOWN IN THE OPTIONAL BURNBACK KIT C16
50V
ON ALL ANGLES IS + .5 OF A DEGREE

4.7

510
ON HOLES SIZES PER E-2056

D10
MATERIAL TOLERANCE ("t") TO AGREE

RECEPTACLE WHICH IS DRAWN BELOW.THE
18 35V
ANALOG
LED1A
BURNBACK KIT IS CONNECTED TO 631 AND 532. 115 VAC VAC ZERO VOLT
B2
REFERENCE
POWER SUPPLY
631 WHT
4
532 T1A C13 J3
18 P1
.22 510
NUMBER.
5 8
100V DZ1
3.32K
VAC
R15
2
1 5.1V C17
18 J3
C15 1W
402 15V P1
6 RED 510
NOTES :
532 BLK B3 500 9
CR3 50V
D11
404
3 YLW
500
D7
D6
N.A.
4 601 -10V
GND
LED1B
2
METER
SUPPLY
T1B IN OUT
10 VAC X2
NA-5R OPTIONAL BURNBACK J3
KIT RECEPTACLE P1
602 5
500
610
SHOWN WITH JUMPER YLW
J3
PLUG INSTALLED D9 P1
2 6
500
J2
J3
6 P1
CR3 1 500
610
D12 D13
531B BLK ORG B4 1N4007 1N4007
LED1F
RELAY
115 C18
TP3
T2A 115 VAC
VAC
150V
.02 POWER SUPPLY
45J 600V
B5
133K
133K
R17
R16
532 BLK ORG
D14 D15
1N4007 1N4007
BRN J2
500
L 8956
4 500
24 INTERFACE OPTION
VAC
T2B
POWER SUPPLY
BRN
FRANCE CANADA AUSTRALIA
NA-5
danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.
VOLTAGE PC BOARD SCHEMATIC
C
525
525
A5H
A
6682-3
L501 A5H R533
R541
R544
N.A. C507
667 + C524 WELD
R526
1 C520
RESPONSE PIN F 525 R534 B
+
500 JUMPER R510 R509 A5H
L
C1102 TP D519
R501
(RED) + 1 OCI501 5 D520 R527
R506
501 A6H
SHT.
R528
12
NO.
ARC 531B D515
C508 T501 +
VOLTAGE PIN S 14 DZ
4 A5D
POLARITY - C518 24 13 D 507
13 C509 115 DZ
VOLTAGE CIRCUIT
CW 14 2 2 6 4 -
TERMINALS A 10
R513
R535 R507 - VAC VAC 506
+ +
NA-5 SCHEMATIC
532
10-5-81
12 X502
R502
C519 + ACTUAL VOLTAGE A 8 +
C1101 11 B DZ A5D 637
1
R545
BUFFER
- C506 + 504 Q508
R539
C
R532
X502 D506 - Q501 C526 D5A
SUP'S'D'G
F501 C501 3
2
R538
C521 9 X502
D521 D522
R536
621 D517
R503
D502 CONTROL POWER SOURCE
AMP CW CONTROL INTERFACE
525 GAIN 510P
START
R514
R540
D516
A5H - B3C
R542
500 6
R543
7
R548
D 510 Q507
L502 A6H CW
R518
5
C525
R529
510P + D505 Q506
DZ X501 6
1 4
REF.
R537
B3C 503
SUBJECT
R515
R512
9
R505
R504
X501
EQUIP.
-
THE LINCOLN ELECTRIC CO. TYPE

D503 C527
+
B 8 D504
R547 525 D513 5
2 0CI502 AUTO-STOP
3 + A5H CIRCUIT
500

10 C505 510P
CHK
D501 D512 D9C
R508
C523 592 D514 B3C
C504
R516
D7A COM
AUTO-STOP AND
7-2-92
510P
B3C SHUTDOWN BYPASS AUTO
NONE
R511 R519
DATE
TAB JUMPER (BLUE)
ACTUAL VOLTAGE C517 + BYPASS
C512 +
R517
D514 +
SCALE
METER FILTER HOLD - LOW CIRCUIT
525
A5H
DR DAD
C511 SHUTDOWN
FROM
4 516 500 D508 PIN PIN PIN
687
R524
R522
R520
OPTION 2 A B D
X501 A6H
- D4B
AND VOLTAGE 1 514
635 C R546
PROCEDURE SETTING SBS
688A
+ START 501
P.C. BOARD 3 D518
+ RESPONSE D510 D507 5 4
E2E C510 C516 SET ACTUAL JUMPER
N.C. +
525 (WHITE) 7
688 DZ502 Q503
C R530
510P S7B S7B D4J A5H
-
R525 X502
6
R549
B3C VOLTS
ARC CONTROL D511
R521
517
R523
11
SET-ACTUAL
R531
5 SET VOLTAGE
BUFFER
ENABLE 4 2 3 1
D509
C522
+
C528
R601
688 500 C513
11-17-95G
CW D4J A6H
VOLTAGE P.C. BOARD RECEPTACLE FOR
CAL TP5 500
C604
R602
1 +5V OPTIONAL PULSED POWER FILTER P. C. SHUTDOWN
BOARD (SHOWN WITH JUMPER PLUG ENABLE A6H
X601
11-14-86L
TP4 2
7-10-92A
9-27-85E
3-6-92B
3-25-94
DM601 OUT INSTALLED.)
IN SHUTDOW CIRCUIT
4 D602
6 GND
R603
D601

601 A6E
E C

C603 A

518 + 602 A6E
+

C602
C601

D603 D604
510P 510
VOLTMETER VOLTMETER
B3C
B7G POWER SUPPLY

VOLTAGE P.C. BOARD VOLTMETER P.C. BOARD COMPONENTS NOT ON P.C. BOARD

KEY TO SYMBOLS

C501 .1/100 D501 R501 44.2K, 1/4W, 1% R526 47K F501 1 /8 AMP FAST C601 500/50 DM601 DIGITAL METER INPUT CONTROL CABLE CONNECTION
C504 4.0/50 THRU 1A, 400V R502 500 TRIMMER R527 47K BLOW FUSE C602 4.7/35
C505 .47/50 D522 R503 4.75K, 1/4W, 1% R528 22K SBS501 SILICON BILATERAL C603 .022/25 S7B SPDT, VOLTS SET-ACTUAL COMMON CONNECTION TO ANALOG POWER
C506 .022/25 DZ502 6.8V, 1 /2W R504 100K R529 22K SWITCH C604 .022/25
SUPPLY 510 A5H
C507 .022/25 DZ503 5.1V, 1/2W R505 27K R530 27K T501 24 VAC, 185 mf D601
C508 39/20 DZ504 20V, 1W R506 15K R531 100K SECONDARY D602
1A, 400V SCHEMATIC LOCATION REFERENCE
C509 .022/25 DZ505 6.2V, 1/2W R507 10K R532 27K TP501 150V, 10J D603
C510 1.8/20 DZ506 15V, 1W R508 2.2K R533 10K D604 NOTES:
HORIZONTAL CO-ORDINATE LETTER
C511 .022/25 DZ507 6.8V, 1/2W R509 2.7K R534 100 N.A. THESE CAPACITORS ARE LOCATED VERTICAL CO-ORDINATE NUMBER
C512 4.7/35 L501 33uH, 110mA R510 4.7K R535 1K
ON THE R.F. BYPASS BOARD.
C513 27/35 L502 33uH, 110mA R511 100K R536 10K R601 24.3K, 1/4W, 1% SCHEMATIC IDENTIFICATION LETTER
C514 4.7/35 OCI501 R512 1K R537 33K R602 2K TRIMMER (SEE SCHEMATIC A).
OPTO-ISOLATOR
C516 .022/25 OCI502 R513 2.7K R538 56K R603 2.80K, 1/4W, 1% N.B. SEE L6682-3A SCHEMATIC FOR
C517 .47/50 Q501 2N4123 R514 2K TRIMMER R539 27K
9147

SUPERSEDED G1556-1 VOLAGE UNLESS OTHERWISE SPECIFIED, COMPONENT VALUES OF:
C518 39/20 Q503 2N5816 R515 5.6K R540 5K TRIMMER X601 +5V VOLTAGE REGULATOR
BOARD. CAPACITORS = MFD/VOLTS
C519 .0047-.005/1400 Q505 2N4123 R516 100K R541 1K, 12W
C520 .022/25 Q506 2N4857 R517 1K R542 470 RESISTORS = OHMS, 1 2 /WATT
N.C. EARLIER VOLTAGE BOARDS DO
L 6682-3
C521 .022/25 Q507 2N5816 R518 100K R543 68K FOR VOLTMETER P.C. BOARDS SINCE COMPONENTS OR CIRCUITRY ON A PRINTED
NOT HAVE THIS RECEPTACLE, AND
8993
C522 .022/25 Q508 2N5816 R519 39K R544 15K L6685-1 OR HIGHER USE S21143
8400
C523 .022/25 X501 QUAD OP-AMP R520 15K R545 15K SCHEMATIC FOR COMPONENT LEAD 688A WAS 688.
C524 4.7/35 X502 QUAD OP-AMP R521 56K R546 270 VALUES AND CIRCUIT CONNECTIONS.
C525 .022/25 R522 330K R547 270 DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS
R523
N.B.
C526 .47/50 22K R548 100 OR CIRCUITRY OF CONTROLS HAVING A COMMON
C527 .01/200 R524 27K R549 270 CODE NUMBER.
C528 .022/25 R525 3.3K
A.N.S.I. ELECTRICAL SYMBOLS PER E1537
CONTROL CIRCUIT SCHEMATIC
B
525
6682-2
A5H 520
R230
Q207 C217 C219
R239
11 12 10
+10.00V
1 R243 C209
L
6 2 C221
525 512 CW LO
R221
SHT.
D206
R229
NO.
3 A5H
R235
R233
B4E
R238
R204
4 X203
R201
9 8 -
R209
C208 C224
CONTROL CIRCUIT
+ X201 10 2 B4J
C204 A R217 4
R211 - - X204
NA-5 SCHEMATIC
3 1 6 2
10-4-81
5 + D A
R203
+ 11 11
X202 5 5 7 3 1 +
4 C202 1 + + Q204 C229
R226
C218 C212 X203 CW 11
SUP'S'D'G
R222
C203 C210 R231
R206
12 2 3 4 HI
R205
R207
R210
CONTROL
13 Q203 628
C216 CW 500 AMP
2 7
CAL
DZ203
D8A
R208
C201 C205 A6H
+10.00 V C220 QU201
REFERENCE
R236
C206 + ACTUAL SPEED BUFFER
SUPPLY Q205 Q206
510
REF.
SUBJECT
C225
EQUIP.
A5H TACH SIGNAL CONVERTER D208 C223
540
511 A1H
510P
D205
C211

B4E C227
R237
R234
R228
R227
X203
R232
CHK
DZ202
FROM OPTION - 511A C119
C214 + 525 13 511 B5J
3 525A
A5H
AND
PROCEDURE
632
SPEED
SETTING 12
B
14
R242 R218 PT
101A
+
7-2-92
PC BOARD C213
+ C228
NONE
L201 500
DATE
500 E2D N.A. N.B
C215 A6H
510P
SCALE
TO TACH 555
A6H B3C
PICK-UP
ARMATURE FIRING CIRCUIT
P.C. BOARD SET SPEED BUFFER
DR DAD
511 512
B3G B1G
4
L202
SET ACTUAL
S7A
SPEED
510A R212 R214
SET-ACTUAL
SPEEDMETER
CALIBRATION 512
519 JUMPER
R240 FAST-SLOW
- ACCELER - D204
142T 95S 142 95 57 57F 9 8 9 8
B1G JUMPER
C B
5 10
+
10
+ X204
R219
X203
R414
R412
R407
R405
R402
R409
PIN
R225
PIN
525 F
511 S
A5H
CW CW CW CW CW CW R241 525
CW
CAL CAL CAL CAL CAL CAL TP5
R413
R411
R401
R408
R406
R404
B3G A5H
R220
1 +5V
R213
C409 C408 C407 C406 C405 C404 X401 Q201 ACC
2
R223
4
DM401 OUT IN D202 DZ201
5-15-92N
11-9-90D
7-10-92A
7-19-91J
3-6-92B
TP4
+
GND
D402
R403
6 C403 E
C
D401
601 A6E
C207
Q202

+ 602
R224
+ A6E C222

C226
R216
R215
C402

C401 D203

D403 D404 D201

R410

500
510P 510
B3C C7E
586 A6H
FEED
ENABLE
7 SPEEDMETER SPEEDMETER
POWER SUPPLY
D7J
ACCELERATION CIRCUIT FEED ENABLE CIRCUIT

CONTROL P.C. BOARD TACHOMETER P.C. BOARD SPEEDMETER P.C. BOARD COMPONENTS NOT ON P.C. BOARD

KEY TO SYMBOLS

C201 .022/25 DZ201 6.8 V., 1 2/ W. R201 1K R227 6.8K OCI301 OPTO-INTERRUPTER C401 500/50 DM401 DIGITAL METER POWER SUPPLY SOURCE POINT
C202 .022/25 DZ202 16.0 V., 1 W. R203 500 TRIMMER R228 10K C402 4.7/35
C203 18/15 DZ203 3.0 V., 1 W. R204 1.00K, 1/4W, 1% R229 20K TRIMMER Q301 2N4123 C403 S7A SPDT SPEED SET-ACTUAL COMMON CONNECTION TO ANALOG POWER
C204 4.7/35 R205 2.94K, 1.4W, 1% R230 27K THRU .022/25
SUPPLY; 510 A5H
C205 .0033/200 L201 R206 15K R231 15 R301 1K C409
330 uH, 110mA
C206 .47/50 L202 R207 10K R232 100 R302 15K D401
SCHEMATIC LOCATION REFERENCE
C207 18/15 R208 100K TRIMMER R233 6.8K R304 1.3K D402
1A, 400V
C208 4/50 Q201 2N4123 R209 33K R234 2.7K D403 HORIZONTAL CO-ORDINATE LETTER
C209 .047/100 Q202 2N4123 R210 10K R235 10K D404
+5V VOLTAGE REGULATOR VERTICAL CO-ORDINATE NUMBER
C210 4.7/35 Q203 2N4123 R211 270 R236 15K X401
C211 .15/200 Q204 2N4125 R212 15K R237 10K R401 2K TRIMMER SCHEMATIC IDENTIFICATION LETTER
C212 .022/25 Q205 BS170 R213 47K R238 1M R402 17.8K, 1/4W, 1%
C213 .022/25 Q206 2N4123 R214 15K R239 15K R403 2.80K, 1/4W, 1% NOTES:
C214 4.7/35 Q207 2N5816 R215 100K R240 5.6K R404 2K TRIMMER

N.A. 511 IS CONNECTED TO 511A UNLESS OTHERWISE SPECIFIED, COMPONENT VALUES OF:
C215 18/15 R216 1K R241 15K R405 18.2K, 1/4W, 1%
BY CONNECTION TO CAPACITORS = MFD/VOLTS
C216 100pf/100 QU201 2N6027 R217 1K R242 270 R406 5K TRIMMER
C217 R218 1K R243 10 R407 VOLTAGE P.C. BOARD. RESISTORS = OHMS, 1 2 /WATT
33.2K, 1/4W, 1%
L 6682-2
THRU .022/25 R219 33K R408 5K TRIMMER SINCE COMPONENTS OR CIRCUITRY ON A PRINTED
N.B. THESE COMPONENTS ARE
9338
C229 X201 VOLTAGE REGULATOR R220 50K TRIMMER R409
9147
52.3K 1/4W, 1% CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE
X202 F- TO -V CONVERTER R221 15K R410 10 LOCATED ON POWER P.C.
D201 X203 QUAD OP-AMP R222 10K TRIMMER R411 5K TRIMMER BOARD (SEE SCHEMATIC A).
THRU X204 QUAD OP-AMP R223 33K R412 31.6K, 1/4W, 1% DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS
1A, 400 V
D206 R224 100K R413 5K TRIMMER OR CIRCUITRY OF CONTROLS HAVING A COMMON
D208 R225 1K R414 51.1K, 1/4W, 1% CODE NUMBER.
R226 10K
ELECTRICAL SYMBOLS PER E1537.
NA-5
PROCEDURE PC BOARD SCHEMATIC
OPTIONAL OPTIONAL OPTIONAL
L 8754

START MODULE WELD TIMER MODULE CRATER MODULE BURNBACK TIMER
NA-5 PROCEDURE
VOLTAGE NET
COMMON CONNECTION
FRAME CONNECTION
LAST NO. USED
SHT.
NO.
SCHEMATIC
J19 515
21
12
515 5
9
FROM LOGIC +5V TIMER BOARD TIMER BOARD
C-
D-
R-
SUPPLY
POWER
SUPPLIES
J19 500
ON LOGIC PCB 500 655 515 I O 500 655 515 I O
LABELS
500 15
-10V
J19 520
520 3
+10V
SUP'S'D'G.
FROM REF C1
VOLTAGE ON 18
OPTION BOARD OPTION BOARD

CONTROL PCB 15V
SUBJECT
TIMER BOARD TIMER BOARD
EQUIP.
TYPE
J19
510P 2
584 583 510P 520 515 562 588A 588 635 562 500 655 632 O I 515 655 500 584 583 510P 520 515 562 588A 588 635 562 500 655 632 O I 515 655 500
(UNLESS OTHERWISE SPECIFIED)

N.B. N.C.
CHK.
7 1 2 3 4 6 8 9 11 12 13 14 15 1 2 3 4 5 6 7 1 2 3 4 6 8 9 11 12 13 14 15 1 2 3 4 5 6
NONE
10-29-91
J9

J11 J11 J11 J11 J11 J11 J11 J11 J11 J11 J11 J11 J11 J9 J9 J9 J9 J9 J10 J10 J10 J10 J10 J10 J10 J10 J10 J10 J10 J10 J10 J8 J8 J8 J8 J8 J8
M F D ( .022/50V
1/4W
GENERAL INFORMATION
J19 START TIME INITIATE 520 515 500 515 500 520 515 500 515 500
584S 8
+10V +5V -10V +5V -10V +10V +5V -10V +5V -10V
SCALE
DATE
FILE: L8754_3DB
1A, 400V
J18 WELD TIME OVER
RESISTORS = Ohms (
565 2
CAPACITORS =
J19 CRATER TIME INITIATE
584C 7
DIODES =
J19 CURRENT
FM
588 9
LOGIC
PCB J19 START TIME OVER/WELD TIME INITIATE
583S 1
DR.
J19 CRATER TIME OVER/BURNBACK TIME INITIATE
583C 6
J18 BURNBACK TIME OVER

566 3
100 Hz
TIME BASE 1.6384 MHz
OUTPUT TEST POINT
1 16
Q12 Vdd
2 Q13 OUT2 9
3 Q14 Q8 14
4 Q6 Q9 13
X2
5 Q5 Q10 15
6 Q7 OUT1 10 TO SET
J19
10 632 SPEED BUFFER
7 Q4 CLK 11
R20 ON CONTROL PCB
8 12
Vss RES
10M TO SET
MC14060 7.68K J19
7-10-92N
7-12-96N
R21
1/2W 635 VOLTAGE BUFFER
3-6-92B
11
Ch'ge.Sht.No.
TIME BASE ON VOLTAGE PCB
Y1
FOR 515 C9
C2
DIGITAL TIMERS 22p 1.6384MHz
C3 +5V
47p 520
100V
100V +10V
UNLESS OTHERWISE SPECIFIED TOLERANCE

R19

2.21K

ON HOLES SIZES PER E-2056
500
MATERIAL TOLERANCE ("t") TO AGREE

N.E. -10V
FRAME
C6 C7
R10
R17
R13
R4
R7
R1
5.62K 5.62K 4.75K 5.62K 5.62K
LED1 LED2 LED3 LED4

4.75K
D1 D2 D3 D4
STRIKE START WELD CRATER Q1 Q2

600mA
CW CW
600mA
CW CW WELD
10K STRIKE 10K
40V 2W 10K 40V 2W 10K VOLTS
8 X1 A 9 3 X1 B 4 VOLTS 11 X1 C 10 2 D X1 1
R11
R2
R5
R8
2W 2W
N.E. N.E. N.E. N.E.
D5 D6 D7 D8 STRIKE WELD
SPEED 6 5 SPEED 12 13
STRIKE PROCEDURE
D9
J18 DISABLE
561 1
R14
R15
R18
R16
R9
R6
R3
R12
D10 47.5K 267 1.82K 47.5K 26.7K 332
26.7K 1.82K
STRIKE PROCEDURE
LOGIC D11
J19 ENABLE
PCB 13
563
STRIKE MODE SETTINGS WELD MODE SETTINGS
J19 WELD PROCEDURE ENABLE

14
564
515
PROCEDURE KIT +5V

N.D.
RECEPTACLE 520
J19 WELD PROCEDURE ENABLE +10V
564A 4
START WELD NOTES :
J18 START DISABLE 16
N.A. SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE

581
4
WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY
STRIKE 8 9 10 11 STRIKE 2 3 4 5 CRATER 14
NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE
X2 NUMBER.
S1 A S1 B C4 C8
C5 N.B. A JUMPER PLUG CONNECTS 584S TO 583S WHEN THE OPTIONAL START MODULE IS
LOGIC X1 4.7
MC14060
L 8754
NOT INSTALLED.
PCB 35V
PRESET MODE N.C. A JUMPER PLUG CONNECTS 584C TO 583C WHEN THE OPTIONAL START MODULE IS
C2 C1 4066B
J18 START DISABLE NOT INSTALLED. ALSO, LOGIC CIRCUIT 694 LEAD MUST BE MOVED FROM PIN P10
581A 5 SELECTOR 8
TO PIN P8.
N.E. 7
D12 N.D. 564 IS CONNECTED TO 564A BY A LEAD RECEPTACLE JUMPER PLUG, WHICH IS
J18 PRESET MONITOR ENABLE REMOVED WHEN THE OPTIONAL MULTI-PROCEDURE KIT IS INSTALLED.
560 6
N.E. R2, R5, R8, R11 AND S1 ARE CONNECTED TO FRAME BY PCB TRACES AND MOUNTING
SCREW, FOR ESD.
POWER SUPPLY DISTRIBUTION 500
AND BYPASSING -10V
OPTION & TIMER PC BOARD SCHEMATICS
F G J K L M
E
A B C 515
D E 515
H
D8C D8C
515
R915
0
TIMER BOARD
6682-5
D001 583 TIME
R016 D8C
6 X002 R017
OVER 4 OVER I
A D002
1 515 5
R015
515 INITIATE
R901 8
X901
A 10 5
D901
O
D8C 500 9 X901
L
C004 R916
D8C
D9C B 4 OVER
R013
SHT.
500 6 D902
NO.
D003 588A 500
D9C 1 15 9 7 1 15 9 7 1 15 9 7 N.C.
584 1 X002 R018 515 D9C
TIME R014 B 3 3 Q4 Q3 Q2 Q1 6 3 Q4 Q3 Q2 Q1 6 3 Q4 Q3 Q2 Q1 6
PE C PE C PE C
2 D004 D8C
INITIATE 13
NA-5 SCHEMATIC
520
10-2-81
13
CIRCUIT
CF 12 13 CF 12 CF 12
500 0 0 0
B1C
X902 X903 X904 1 15 9 7
D9C 4 4 4
SUP'S'D'G
INH INH INH 3 Q4 Q3 Q2 Q1 6
C002 C
R001
632 635
R007
R004
MR 10 MR 10 MR 10
B3F C4A 13 12
X002 X002 DP4 DP3 DP2 DP1 DP4 DP3 DP2 DP1 DP4 DP3 DP2 DP1 0
2 588
R012
13
C 11
8
D 10
Q001
CW
X001 X001
CW
2 14 11 5 2 14 11 5 2 14 11 5 X905
4
R005
R002
12 9 SPEED VOLTS INH
CURRENT
R008
4 A 3 9 B 8
R010
515 MR 10
R912
R903
R902
R908
R906
R911
R910
R907
R913
R905
R904
R909
5 6 DP4 DP3 DP2 DP1
R009
R003
R006
D8C
515 515 515 2 14 11 5
REF.
SUBJECT
EQUIP.
D8C D8C D8C

R011
Q002
510P

B3C
CHK
562 PROCEDURE
FROM
3 ENABLE
500
D9C
500
D9C
500
D9C
PROCEDURE
655
R914
500 PC BOARD 100 HZ TIME C907
7-2-92
OPTION BOARD D9C
S901A S901B S901C
BASE OUTPUT
NONE
500
DATE
MOST SIGNIFICANT DIGIT LEAST SIGNIFICANT DIGIT
D9C
SCALE
DR DAD
4
7-11-86D
1-31-86A
7-10-92A
3-6-92B
9-7-84A


6

OWNED BY THE LINCOLN ELECTRIC CO. AND IS ON HOLE SIZES PER E2056

7

FOR OPTION P.C. BOARD L6246-2 KEY TO SYMBOLS

OR HIGHER USE M16795 SCHEMATIC
COMMON CONNECTION TO ANALOG POWER SUPPLY
FOR COMPONENT VALUES AND
CIRCUIT CONNECTIONS.
SCHEMATIC LOCATION REFERENCE
TIMER P.C. BOARD OPTION P.C. BOARD HORIZONTAL CO-ORDINATE LETTER
8 C902
THRU .022/25
C001
THRU .022/25
Q001
Q002
2N 4125
2N 4123
VERTICAL CO-ORDINATE NUMBER
SCHEMATIC IDENTIFICATION LETTER
C906 C004
520 515 C907 100pf/100 X001 QUAD ANALOG N.C. X905 AND C906 ARE USED ONLY ON 100 SECOND
R001 5.6K SWITCH
TIMER BOARDS. BOARD JUMPER IS USED ON 10
B1C 14 D8C 14 D901 1A, 400 R002 10K, 2W MULTI-TURN POT X002 QUAD 2 INPUT
1A, 400 330 NAND GATE SECOND TIMER BOARDS.
D902 R003
X001 X002
R004 5.6K
C001 1 2 10 7 1112 13 C003 7

R901 R005 10K, 2W MULTI-TURN POT D001
510P 500
9 UNLESS OTHERWISE SPECIFIED, COMPONENT VALUES OF:
THRU 22K, 1/4W R006 1.8K THRU 1A, 400V

R915 R007 4.7K D004 CAPACITORS = MFD/VOLTS
B3C D9C
R916 1K R008 47K RESISTORS = OHMS, 1 2 /WATT
L 6682-5
515 N.C. R009 27K
8993
8400
X901 QUAD 2-INPUT NAND GATE R010 22K
SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT
D6C 16 16 16 16 X902 R011 47K
14 PROGRAMMABLE BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGE-
X901 THRU R012
X902 X903 X904 X905 DIVIDE-BY-N
X904 THRU 22K, 1/4W ABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY NOT
C902 1 2 7 12 13 C903 8 C904 8 8 C906 8 COUNTER
500 X905 R016 SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS
R017 1K HAVING A COMMON CODE NUMBER.
X906 3 DIGIT BCD THUMBWHEEL
D9C POWER SUPPLY DISTRIBUTION AND BYPASSING R018 1K
SWITCH ELECTRICAL SYMBOLS PER E1537
METER PC BOARD SCHEMATIC & LAYOUT
S 21143
514 515 511 512
SET ACTUAL
516 513 510A 510B
WIRE
VOLTS SPEED
TO DIGITAL METER 10 VAC
518 562 TP4 510C 510 +5V +5V
A 3 4 E C 2 1 B D 5
517 518 510 510C 602 601
6 3 4 10 8 2 1 7 9 5
B5 B6 B2 B3 B4 B1
J14 J14 J14 J14 J14 J14 J14 J14 J14 J14
D1
24.3K
D5
R1
C4 TP5
CW
D2
R2
X1
2K OUT IN C1
C2
500
4.7
50V
35V
GND D3
C3
2.8K
R3
TP4
D4
NOTES :
LABELS FILE: S21143_1CA
GENERAL INFORMATION
N.A. SINCE COMPONENTS OR CIRCUITRY ON A PRINTED
ELECTRICAL SYMBOLS PER E1537 FRAME CONNECTION
CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING SUPPLY VOLTAGE NET
THE INTERCHANGEABILITY OF A COMPLETE BOARD. CAPACITORS = M F D ( .022/50V UNLESS OTHERWISE SPECIFIED)


THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS RESISTORS = Ohms ( 1/4W UNLESS OTHERWISE SPECIFIED)
OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE NUMBER. DIODES = 1A, 400V (UNLESS OTHERWISE SPECIFIED) COMMON CONNECTION
UNLESS OTHERWISE SPECIFIED TOLERANCE Ch'ge.Sht.No. EQUIP.

ON HOLES SIZES PER E-2056 THE LINCOLN ELECTRIC CO. TYPE
LN-9, LN-9F, NA-5
ON 2 PLACE DECIMALS IS + .O2 3-25-94
ON 3 PLACE DECIMALS IS + .OO2 CLEVELAND, OHIO U.S.A. METER BOARD SCHEMATIC
SUBJECT
SCALE NONE
MATERIAL TOLERANCE ("t") TO AGREE SHT.
WITH PUBLISHED STANDARDS DR. FM DATE 9-23-93 CHK. SUP'S'D'G. NO. S 21143
517
ITEM REQ'D PART NO. IDENTIFICATION
R1
C4
R2
R3 601
C3
518 510C
510 602
J14
C2
D2 D4 D5
D1 D3
L6685-1 METER
X1
C1
NA-5
MISCELLANEOUS PC BOARDS
POWER BOARD LOGIC BOARD

1 2 AMP
POWER
BLOW
SLOW
TP2
R47 C35
C3
F1
NA-5 LOGIC R46
J2
SCR3
Q16
Q15
NA-5 POWER
LED1F L6242-2 LED 7E C34

R49
R13 D33
LED 7B
LED 7D
D12
R18
LED1B
R2
TP3
SLOW BLOW
LED 7J
C18
D35
LED1D
1 2 AMP
C10
D13 R17 TP1 R29 R12
R45
LED1C
C3
D28
D34
R16 LED 7C + C11
FIELD
C6
C5
D15 R38
PT1
R15 C7 R10 D14

C1 R50
J1
D14 D11 R32
J5
R36
R35
R59
C28
D10
D12
R31
R14
C29
C19
D29
C15
Q6
D30
F2
C17 D31
R5 C2
X2
R15
D9
B4
D17
R17 R34
C9
R16
R41
Q12
Q1
X7 X6 X2
DZ1 SCR4 R4
LED1E
C32
R11
D11
R3
R2
C16
R5
C17
C18
D9
C14
D13
D32
R6
D7 R40
D16
C27
D1
C6
B5
D6
D3
D2
D8 R54
D27
Q11
D15 X3 X4
C5 X5 X1
D26
D25
C24
R37
R19
L6252-2
R18 R52
C4
J2
J3
Q9 R24
R55 R39
C13
Q8
C25
R42 R33
C15
R51
C14
C26
Q13
J3
R25
R57
J4
B1
Q7
C22 R44
R56
C37
Q4 C33
Q2
DZ1
X8
Q3 Q10
R43
C21
Q1
Q14
C1
C21
SCR2
R62
C20
R48
SCR1
C36
C23
R58
R1
D4 R9
B2
R8 R7 R23 R1
D5
R11 R61 C30 LED 7A C31
J1
C20 Q18
C7 Q17 R53
D19
D20
D23
LED1A
Q3
C4
C2
X9
PT3
PT2
C11
D24
Q2
C19
D22
R63
R20
R28
B3
D21
R22
D18
R12
R3
R4
R27
C9
X1
C22
D8
D10
C16
C8
R19
R14
R6
R10
R20
C24
R22
C12
C10
R30 R60
R21
Q9
QU1
Q5
D6
LED 7K LED 7G LED 7H C13 D3
D4
D7
R9
C8 S1 S2
D5
D2
D1
+
C12
B2 B1
RESISTORES = OHMS
PROCEDURE BOARD BYPASS BOARD

B6
626
ITEM REQ'D PART NO. DESCRIPTION
627
B5
R11 R8 R5 R2
C6
M14133-1
R1
R3
R4
R6
R10
R12
R7
R9
531
C5
C5
BURNBACK
B4
C1 C9
START
J8 J9
R19
X1 C4
R13
R17
CRATER
WELD
J10 J11 J19 Q2
R16
R15
PROCEDURE
87
B3
C6 C7 C3
4DEL
3DEL
2DEL
1DEL
Q1
RF BYPASS
D4
D3
D2
D1
D9
R18
R14
D11
D8 D7 D6 D5
C3
C2
D10
667
B2
G1566-3
B1
R20
R21
Y1
X2
C1
C4
C8
4 3
D12 J18
5
FRAME C2
6
S1
12
7
GND
621
1
8
10 9
B1
B7
NA-5

Lincoln Electric Na-5s, Na-5nf, Na-5n, Na-5sf

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Lincoln Electric Na-5s, Na-5nf, Na-5n, Na-5sf

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RETURN TO MAIN INDEX SVM131-A

Return to Master TOC

Safety Depends on You

increased by proper installation

... and thoughtful operation on

CALIFORNIA PROPOSITION 65 WARNINGS

PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

FOR ENGINE 1.h. To avoid scalding, do not remove the

ELECTRIC SHOCK can kill. ARC RAYS can burn.

• DC Manual (Stick) Welder. hazardous to health. Avoid breathing these

5.e. Also see item 1.b.

WELDING SPARKS can CYLINDER may explode

8.a. Turn off input power using the disconnect

5. Toujours porter des lunettes de sécurité dans la zone de

7. Quand on ne soude pas, poser la pince à une endroit isolé

principalement dans les positions assis ou couché

2. Dans le cas de travail au dessus du niveau du sol, se protéger

MASTER TABLE OF CONTENTS FOR ALL SECTIONS

Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section B

Maintenance . . . . . . .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section D

Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section E

Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section G

Parts Listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-135

Figure A.9 — Connection of NA-5 (All) to a DC-650 Pro . . . . . . . A-10

TECHNICAL SPECIFICATIONS – NA-5

115 VAC @ 3 amps 50/60 Hz power

REQUIRED WELDING POWER SOURCE

NA-5 DC Constant Voltage

WIRE FEED SPEED and GEAR RATIOS

57:1 38 - 7.78 (0.96 - 19.8) 3/32 (2.4) 1/16 (1.6)

FIGURE A.1 – BASIC CONTROL AND WIRE DRIVE SYSTEM.

HEAD MOUNTING PARTS

[(TWO 4/0) CONTACT ASSEMBLY SEAM

MECHANICAL 1. Align the mounting holes in adapter

2. Install four hex head screws through

When placing the mounting holes, ensure

CONTROL BOX INSTALLATION

The control box can be mounted either on

To install the control box on a fixture, WELDING HEAD INSTALLATION

insulation are shipped with the NA-5

1/4-20 THREAD HOLES

CONTROL BOX TO WELDING

Insert the plugs on these cables into the

If the 4 ft (1.2 m) cables are not sufficient,

The NA-5N and NA-5S also include two 4 ft

terminals at one end of the the cable pair to

This section provides information on proper

DC-1500 type power sources. For

4. Connect work leads of sufficient size

ELECTRODE POLARITY FIGURE A.7 – TERMINAL STRIP

• Turn off input power to

Polarity is changed at the power source. TERMINAL

shipped connected for electrode positive. If

(+) and (-). The black lead (#67)

FIGURE A.8 – CONNECTION OF NA-5 (ALL) TO A DC-600.

P AND POSITON THE SWITCH ON POWER SOURCE TO PROPER

CONNECT TO CABLES FROM NA-5

ALL CODES: DC-600 CODES 8046-8200:

FOR NR-203 ELECTRODES:

DC-600 CODES 8000-8045:

SOURCE MUST BE PROPERLY GROUNDED.

CLEVELAND, OHIO U.S.A.

FIGURE A.9 – CONNECTION OF NA-5 (ALL) TO A DC-650 PRO