Lincoln Na5 Service Manual

							MECHANICAL
INSTALLATION
ELECTRIC SHOCK
can kill.
• Turn off input power to the welding power source
using the disconnect
switch before working on
this equipment.
INTRODUCTION
This section covers the basic requirements to
install the control box and welding head
shown in Figure A.1. This section will give
you mounting hole alignments, component
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
fixture. It is electrically grounded by a lead
in the input cable assembly.
To install the control box on the standard
travel carriage, use mounting kit T14469 and
perform the following steps. Also refer to
Figure A.2. 1. Align the mounting holes in adapter
plate M-13945 to the holes in the
travel carriage.
2. Install four hex head screws through the adapter plate and into the travel
carriage.
3. Secure the control box to the adapter plate with four lock washers and four
bolts, two from the bottom and two
from the back.
Before mounting the control box onto a
fixture,  you must  provide mounting holes in
the fixture per the measurements provided
in Figure A.3 or dimension print S16717.
When placing the mounting holes, ensure
the controls and meters are convenient to
the operator. 
INSTALLATIONA-4A-4
NA-5
WARNING
ADAPTER
 PLATE
TRAVEL
CARRIAGE
CONTROL
 BOX
FIGURE A.2 – CONTROL BOX CARRIAGE MOUNTING.
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							To install the control box on a fixture,
perform the following steps and refer to
Figure A.3.1. Align the mounting holes on the back and/or bottom of the control box with
the holes you put in the fixture
according to the measurements
provided in Figure A.3.
2. Secure the control box to the fixture using lock washers and hex head
screws at each of the mounting holes.  WELDING HEAD INSTALLATION
The welding head can be mounted either
with the standard head mounting hardware
or with the horizontal head and/or vertical lift
adjusters.  Design the installation of your
welding head so it meets the adjustability
requirements of your welding application.
Refer to Section C, Accessories, for more
information regarding the adjustable
mounting hardware.
The welding head and electrode are
electrically “hot” when welding. They must
be insulated from ground.
Standard head mounting hardware and
insulation are shipped with the NA-5
welding head.  If you are mounting the
welding head on a separate fixture, provide
the mounting holes for the standard head
mount as specified in Figure A.4. For best
arc striking, use a rigid mounting that
prevents the head from moving when the
electrode strikes the work.
FRONT
VIEW FROM BOTTOM
1/4-20 THREAD  HOLES
3.50
(88.9)
VIEW FROM BACK
1/4-20
THREAD HOLES
1.71
(43.43)
1.09
(27.68)
0.28 (7.11) SLOTS
 4 PLACES 0.41
(10.41)
0.43
(10.92) 13.77
(349.76)
12.75
(323.85)
0.562 DIA (14.27)
2 HOLES
12.00
(304.8)

12.00
(304.8)
NOTE:  DIMENSIONS ARE IN INCHES 
             WITH MILLIMETERS IN 
	    PARENTHESES.
1.34
(34.04)
1.71
(43.43)
APPROXIMATE
 INSULATOR
 SIZE
  2.62
(66.55) 

2.88
(73.15)
  4.265
(108.33) 0.531 DIA.
   (13.49)
NOTE:  DIMENSIONS ARE IN INCHES 
             WITH MILLIMETERS IN 
	    PARENTHESES.

4.5 
(114.30)
FIGURE A.4 – WELDING HEAD MOUNTING HOLES.
INSTALLATIONA-5A-5
FIGURE A.3 – CONTROL BOXFIXTURE MOUNTING.
NA-5
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							INSTALLATIONA-6A-6
NA-5
When mounting the welding head to the
standard travel carriage, (see 305-B sec.
T2.2.4) mount it so only a minimum of
overhang weight exists. Mount the head so
it stays within the dimension shown in Figure
A.5.
ELECTRICAL
INSTALLATION
ELECTRIC SHOCK
can kill.• Do not touch electrically live parts such as output
terminals or internal
wiring.
This section  provides information on proper 
wiring  procedures  for the NA-5 welding sys-
tem.  This section  also  provides  basic con- nection diagrams for connecting automatic
welding systems to various welding power
sources.
INPUT POWER REQUIREMENTS
350 volt-amperes of 115 VAC 50/60 Hz
power is required for the wire feed motor and
controls. Another 250 volt-amperes may be
required depending on the travel circuit.
CONTROL BOX TO WELDING
HEAD CONNECTIONS
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
power source to control cable assembly.
Properly insulate the bolted connection.
When the K335 or K338 extension cables are
used between the controls and heads, the 4 ft
(1.2 m) lengths of electrode cable are not
used.  If currents or duty cycles higher than
1000 amps at 80% duty cycle will be used,
add additional electrode cable per Table A.1.
TABLE A.1
FIGURE A.5 – MOUNT TO CARRIAGEOVERHANG DIMENSION.
   19 IN.
(483 MM)
WARNING
80% Duty Cycle
Below 1000 amps Two 4/0
1000 to 1300 amps Three 4/0
1300 to 1500 amps Four 4/0
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							The “F” models do not include the 4 ft (1.2
m) lengths of electrode cable as standard.
If you are not using a K335 or K338 exten-
sion cable for the NA-5NF or NA-5SF, order
an appropriate length of the needed elec-
trode cable.  Connect it between the wire
contact assembly and the control cable
assembly as described above. 
POWER SUPPLY TO CONTROL
BOX CONNECTIONS
At the NA-5 control box, in order to activate
the NA-5 weld current sensing switch, the
electrode cables of the control cable
assembly must be placed under the clamp
bar on the left-hand side of the control box,
as shown in Figure A.6.  This is required
for proper operation of the reed switch.
The nuts holding the clamp bar in place
need only to be pulled up snug.  Do not
overtighten.  If a carriage is used, the
electrode cables should also be clamped
to it with the cable clamp supplied on the
carriage.  Do not clamp the control cable
under the travel carriage clamp but route it
over its top.Insert the polarized connector of the K215
or K597* control cable into the matching
receptacle on the side of the control box.
With the power source off, connect the
control cable assembly to the power
source as follows:
1. If   using   the   multi-process power source (SAM, SA-800, SAF-600,
DC-400, DC-600, DC-1000, or DC-
1500 types), be sure it is properly set
for the welding process being used
per the connection diagram (Figures
A.8 to A.14). 
2. Connect the K215 control cable leads to the power source terminal
strip  exactly as specified on the
connection diagram.* Include all
jumpers on the terminal strips as
shown on the diagram. Do not put
on any other jumpers. If currents or
duty cycles higher than 1000 amps
at 80% duty cycle will be used, add
additional electrode cables to the
K215 assembly per Table A.1.
3 Depending on the  power source and the process to be used, the jumpers
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
other power sources, refer to the
appropriate connection diagram and
to IM305 Sec. T3.6.
4. Connect work leads of sufficient size and length per Table A.1. between
the “To Work” stud on the power
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 powersources.
INSTALLATIONA-7A-7
NA-5
FROM 
POWER
SOURCE
TO
WELDING
 HEAD
CLAMP
BAR
FIGURE A.6 – CONTROL BOXELECTRICAL CONNECTIONS. 
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							INSTALLATIONA-8A-8
NA-5
ELECTRODE POLARITY
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. 
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.
Proceed as follows:  1. Turn off the input power to the NA-5 control box by turning off the welding
power source.
2. Open the control box door and locate the terminal strips on the back of the
control box in the lower left-hand
corner as shown in Figure A.7.
3. On the right end of the lower terminal strip, interchange the black and white
leads going to the terminals marked
(+) and (-).  The  black lead (#67)
must be connected to the same
polarity as the electrode welding lead;
i.e. if the electrode is positive,
connect the black lead to the (+)
terminal on the terminal strip. The
white lead (#21) is connected to the
opposite polarity terminal.
POWER SOURCE
CONNECTION DIAGRAMS
The following section contains the wiring
diagrams necessary to connect the
applicable power source to the control box.
If there is no diagram, refer to power source
manual. 
ELECTRIC SHOCK
can kill.• Turn off input power to the welding power
source using the
disconnect switch
before working on this
equipment.
WARNING
TERMINAL
STRIPS
FIGURE A.7 – TERMINAL STRIP LOCATION. 
WARNING
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							INSTALLATIONA-9A-9
NA-5
FIGURE A.8 – CONNECTION OF NA-5 (ALL) TO A DC-600.     
N.A.	 ON EARLIER DC-600S, #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 F\
OR THE INSTALLATION. AN S-16586 - [ ] REMOTE VOLTAGE SENSING WORK 
	 LEAD IS AVAILABLE FOR THIS  PURPOSE. CONNECT IT DIRECTLY TO THE WORK PIE\
CE KEEPING IT SEPARATE FROM THE WELDING WORK CABLE CONNECTION
	 TO THE WORK PIECE. FOR CONVENIENCE, THIS EXTENDED #21 LEAD SHOULD BE TAP\
ED 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 MARK\
ED          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 TERMIN\
AL 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: CONN\
ECT 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-6\
00 CODES ABOVE 8200.
N.J.	 FOR PROPER NA-5 OPERATION, THE ELECTRODE CABLES MUST BE SNUGGED UNDER TH\
E CLAMP BAR ON THE LEFT SIDE OF THE NA-5 CONTROL BOX.	 NOTE:	 DIAGRAM SHOWS ELECTRODE CONNECTED POSITIVE. 
		
TO CHANGE POLARITY, TURN POWER OFF, REVERSE THE
	  	 ELECTRODE AND WORK CABLES  AT THE POWER SOURCE
		 AND POSITON THE SWITCH ON POWER SOURCE TO PROPER 
		 POLARITY. REFER TO NA-5 OPERATING MANUAL FOR REQUIRED
		 NA-5 CONTROL BOX POLARITY CONNECTIONS.


ALL CODES:
TURN OFF INPUT POWER
ADJUST THE POWER SOURCE: DC-600:
1.	 CONNECT ELECTRODE CABLES TO TERMINAL OF DESIRED POLARITY.
2.	 SET TOGGLE SWITCH TO SAME POLARITY AS THE ELECTRODE CABLE
	 CONNECTION.
3.	 SET TOGGLE SWITCH TO REMOTE.
4.	 SET MODE SWITCH TO THE DESIRED POSITION FOR THE PROCESS TO BE USED.
	
DC-600 CODES 8000-8045:
FOR SUB ARC:
1.	 SET MODE SWITCH TO CV SUB ARC.
2.	 WHITE LEAD ON CONTROL PC BOARD IS CONNECTED TO PIN M AND BLUE 
	 LEAD IS CONNECTED TO W.

 FOR ALL OPEN ARC PROCESSES EXCEPT NR-302 AND NR-203 ELECTRODES:
1.	 SET MODE SWITCH TO CV INNERSHIELD.
2.	 WHITE LEAD ON CONTROL PC BOARD IS CONNECTED TO PIN M AND BLUE 
	 LEAD IS CONNECTED TO W.


FOR NR-203 AND NR-302 ELECTRODES:
1.	 SET MODE SWITCH TO CV INNERSHIELD.
2.	 WHITE LEAD ON CONTROL PC BOARD IS CONNECTED TO PIN I 
	 AND BLUE LEAD IS CONNECTED TO S.DC-600 CODES 8046-8200:
FOR SUB ARC:
1.	 SET MODE SWITCH TO CV SUB ARC.
2.	 WHITE LEAD ON CONTROL PC BOARD IS CONNECTED TO PIN M.

FOR ALL OPEN ARC PROCESSES EXCEPT MR-203 ELECTRODES:
1.	 SET MODE SWITCH TO CV INNERSHIELD.
2.	 WHITE LEAD ON CONTROL PC BOARD IS CONNECTED TO PIN M.

FOR NR-203 ELECTRODES:
1.	 SET MODE SWITCH TO CV INNERSHIELD.
2.	 WHITE LEAD ON CONTROL PC BOARD IS CONNECTED TO PIN I.
DC-600 CODES ABOVE 8200:
FOR SUB ARC:
1.	 SET MODE SWITCH TO CV SUB ARC.
FOR ALL OPEN ARC PROCESSES:
2.	 SET MODE SWITCH TO CV INNERSHIELD.
FOR OPTIMUM PERFORMANCE WITH NA-5, DC-600S WITH CODES 8288 AND 
ABOVE ARE PREFERRED.  FOR ADDITIONAL INSTALLATION INSTRUCTIONS,
SEE NA-5 OPERATING MANUAL.

P
A
B
P
B
.
A.
TO NA-5 INPUT CABLE PLUG
CONNECT TO CABLES FROM NA-5
 
WIRE CONTACT ASSEMBLY
CONNECT TO WORK
CLEVELAND, OHIO U.S.A. 
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							INSTALLATIONA-10A-10
NA-5
FIGURE A.9 – CONNECTION OF NA-5 (ALL) TO A DC-650 PRO 
NOTE:  ABOVE DIAGRAMS SHOW ELECTRODE CONNECTED POSITIVE.  TO CHANGE POLA\
RITY, 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.
P
AR
P
A
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 CONNE\
CTING 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 FRO\
M THE WELDING WORK CABLE CONNECTION TO THE WORK PIECE.  FOR 
	 CONVENIENCE, THIS EXTENDED LEAD SHOULD BE TAPED ALONG THE WELDING WORK C\
ABLE.
N.E.	 TAPE UP CONNECTION.
N.F.	 FOR PROPER NA-5 OPERATION, THE ELECTRODE CABLES  MUST BE SNUGGED UNDER T\
HE 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 S\
ETTING.
N.H.	 THE JUMPERS ON THE NA-5 VOLTAGE BOARD MUST BE CONNECTED AS FOLLOWS: CONN\
ECT 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 TERMIN\
AL 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 MARK\
ED          NEAR THE POWER SOURCE TERMINAL STRIP.

P6
CONTROLCABLE
TO NA-5 INPUT
CABLE PLUG
CONNECT TO CABLES FROM  NA-5 WIRE CONTACT ASSEMBLY TO NA-5 INPUT
CABLE PLUG
CONNECT TO CABLES FROM NA-5 WIRE CONTACT ASSEMBLY
CONNECTTO WORK
CLEVELAND, OHIO U.S.A. 
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							INSTALLATIONA-11A-11
NA-5
FIGURE A.10 – CONNECTION OF NA-5 (ALL) TO A R3S-400, -600, OR -800WITH NO LINE VOLTAGE COMPENSATOR (OBSOLETE).
R3S POWER SOURCE SETTINGS
TURN POWER SOURCE OFF.

FOR ALL PROCESSES:
1.	 CONNECT ELECTRODE CABLE TO TERMINAL OF DESIRED POLARITY.
2.	 SET THE POLARITY SWITCH TO THE SAME POLARITY AS THE ELECTRODE
	  CABLE CONNECTION.
3.	 SET TOGGLE SWITCH TO REMOTE.
4.	 INSTALL VOLTAGE TRIANGLE IN A POSITION AS CLOSE AS POSSIBLE TO 
	 THE DESIRED ARC VOLTAGE. NA-5 SETTINGS
FOR SUB ARC:
1.	 RED LEAD ON VOLTAGE PC BOARD IS CONNECTED TO PIN S.
2.	 WHITE LEAD ON VOLTAGE PC BOARD IS CONNECTED TO PIN A.
FOR ALL OPEN ARC PROCESSES:
1.	 RED LEAD ON VOLTAGE PC BOARD IS CONNECTED TO PIN F.
2.	 WHITE LEAD ON VOLTAGE PC BOARD IS CONNECTED TO PIN A.
NOTE:	 ABOVE DIAGRAM SHOWS ELECTRODE CONNECTED POSITIVE.  TO CHANGE POLARITY, T\
URN 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.
N.A.	 ADD JUMPER FROM #75 TO #76, USING INSULATED COPPER WIRE.
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 F\
OR THE INSTALLATION.  AN  S -16586 [ ]  REMOTE VOLTAGE-SENSING WORK LEAD\

	 IS AVAILABLE FOR THIS PURPOSE.  CONNECT IT DIRECTLY TO THE WORK PIECE, K\
EEPING IT SEPARATE FROM THE WELDING WORK CABLE CONNECTION TO THE
	 WORK PIECE.  FOR CONVENIENCE, THIS EXTENDED #21 LEAD SHOULD BE TAPED ALO\
NG THE WELDING WORK CABLE.
N.D.	 TAPE UP BOLTED CONNECTION.
N.E.	 CONNECT THE NA-5 CONTROL CABLE GROUNDING LEAD TO THE FRAME TERMINAL MARK\
ED         , 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 TERMIN\
AL 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 T\
HE CLAMP BAR ON THE LEFT SIDE OF THE NA-5 CONTROL BOX.
FOR ADDITIONAL INSTALLATION INSTRUCTIONS, SEE NA-5 OPERATING MANUAL.

B
B
B
POSITIVE
CLEVELAND, OHIO U.S.A. 
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							INSTALLATIONA-12A-12
NA-5
FIGURE A.11 – CONNECTION OF NA-5 (ALL) TO A SAM-400 MOTORGENERATOR OR ENGINE WELDER. 
NOTE:	 TO CHANGE POLARITY, TURN POWER OFF, AND POSITION THE SWITCH ON POWER SOU\
RCE TO PROPER POLARITY.  REFER TO NA-5 OPERATING MANUAL FOR
	  REQUIRED NA-5 CONTROL BOX POLARITY CONNECTIONS.

N.A.	 REMOVE SAM PORTABLE FIELD CONTROL AND CONNECT NA-5 CONTROL CABLE.
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 F\
OR THE INSTALLATION.  AN S-16586-[ ] REMOTE VOLTAGE-SENSING WORK LEAD
	 IS AVAILABLE FOR THIS PURPOSE.  CONNECT IT DIRECTLY TO THE WORK PIECE, K\
EEPING IT SEPARATE FROM THE WELDING WORK CABLE CONNECTION TO 
	 WORK PIECE.  FOR CONVENIENCE, THIS EXTENDED #21 LEAD SHOULD BE TAPED ALO\
NG THE WELDING WORK CABLE.
N.D.	 TAPE UP BOLTED CONNECTION.
N.E.	 CONNECT THE NA-5 CONTROL CABLE GROUNDING LEAD TO THE FRAME TERMINAL MARK\
ED         , 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 TERMIN\
AL 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 TH\
E CLAMP BAR ON THE LEFT SIDE OF THE NA-5 CONTROL BOX. FOR ADDITIONAL INSTALLATION INSTRUCTIONS, SEE NA-5 OPERATING MANUAL.
NA-5 SETTINGS
FOR SUB ARC:
1.	 RED LEAD ON VOLTAGE PC BOARD IS CONNECTED TO PIN S.
2.	 WHITE LEAD ON VOLTAGE PC BOARD IS CONNECTED TO PIN A.
FOR ALL OPEN ARC PROCESSES:
1.	
 RED LEAD ON VOLTAGE PC BOARD IS CONNECTED TO PIN F.
2.	 WHITE LEAD ON VOLTAGE PC BOARD IS CONNECTED TO PIN A.
SAM  POWER SOURCE SETTINGS

FOR SUB ARC:
1.	 SET THE ELECTRODE POLARITY SWITCH TO THE VARIABLE 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 7 AND THE
	  CURRENT CONTROL TO 500.

FOR ALL OPEN ARC PROCESSES:
 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.  TURN POWER SOURCE OFF.
P

BOLT TO CABLES
FROM NA-5
WIRE CONTACTASSEMBLY
N.B.
N.B.
CLEVELAND, OHIO U.S.A. 
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							INSTALLATIONA-13A-13
NA-5
FIGURE A.12 – CONNECTION OF NA-5 (ALL) TO A SAM-650 ENGINE WELDER. 
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.

FOR ADDITIONAL INSTALLATION INSTRUCTIONS, SEE NA-5 OPERATING MANUAL.
SAM  POWER SOURCE SETTINGS

FOR SUB ARC:
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 7. 
4.	 CONNECT THE TAP CABLE TO THE 300-575, MAX, SLOPE STUD.
FOR ALL OPEN ARC PROCESSES:
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. NA-5 SETTINGS
FOR SUB ARC:
1.	 RED LEAD ON VOLTAGE PC BOARD IS CONNECTED TO PIN S.
2.	 WHITE LEAD ON VOLTAGE PC BOARD IS CONNECTED TO PIN A.
FOR ALL OPEN ARC PROCESSES:
1.	 RED LEAD ON VOLTAGE PC BOARD IS CONNECTED TO PIN F.
2.	 WHITE LEAD ON VOLTAGE PC BOARD IS CONNECTED TO PIN A.
 TURN POWER SOURCE OFF.

N.A.	 REMOVE SAM PORTABLE FIELD CONTROL AND CONNECT NA-5 CONTROL CABLE.
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 F\
OR THE INSTALLATION.  AN S-16586- [ ] REMOTE VOLTAGE-SENSING WORK
	 LEAD IS AVAILABLE FOR THIS PURPOSE.  CONNECT IT DIRECTLY TO THE WORK PIE\
CE, KEEPING IT SEPARATE FROM THE WELDING WORK CABLE CONNECTION 
	 TO THE WORK PIECE.  FOR CONVENIENCE, THIS EXTENDED #21 LEAD SHOULD BE TA\
PED 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 MARK\
ED          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 TERMIN\
AL 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 TH\
E CLAMP BAR ON THE LEFT SIDE OF THE NA-5 CONTROL BOX.
PP
P
.
.
TAP POWER SOURCE
TO NA-5 INPUTCABLE PLUG
BOLT TO CABLES
FROM NA-5 WIRE CONTACT
ASSEMBLY
CLEVELAND, OHIO U.S.A. 
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