Lincoln Na5 Service Manual

							F-18TROUBLESHOOTING & REPAIRF-18
NA-5
Observe all Safety Guidelines detailed throughout this manual
If for any reason you do not understand the test procedures or are unabl\
e to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you p\
roceed. Call 216-383-2531 or 1-800-833-9353.
CAUTION
MODE FUNCTION PROBLEMS
PROBLEMS
(SYMPTOMS)POSSIBLE AREAS OF
MISADJUSTMENTS(S)RECOMMENDED
COURSE OF ACTION
The burnback timer does not time
out properly.
The weld light does not light.  The
weld controls (voltage and wire feed
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
controls (voltage and wire feed
speed) do not function.  The NA-5 is
at idle with the selector switch in the
“Weld” postion.1.  Test if the other timers (start, weld, crater) function properly.  If
they time out correctly the burn-
back  module may be faulty.
Replace.
2.  If the other timers (start, weld, crater) do NOT function correctly
the procedure board may be
faulty.
1.  The procedure board may be faulty.  Replace.
1.  If the option boards (start and crater) are not installed make
sure the jumper plugs are
installed in the procedure board.
2.  If the strike light is also lit (along with the weld light) the logic
board may be faulty.
3.  The procedure board may be faulty.  Replace.1.  Check the lead harness betweenthe burnback module and the pro-
cedure board for loose or faulty
connections.
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							F-19TROUBLESHOOTING & REPAIRF-19
NA-5
Observe all Safety Guidelines detailed throughout this manual
If for any reason you do not understand the test procedures or are unabl\
e to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you p\
roceed. Call 216-383-2531 or 1-800-833-9353.
CAUTION
MODE FUNCTION PROBLEMS
PROBLEMS
(SYMPTOMS)POSSIBLE AREAS OF
MISADJUSTMENTS(S)RECOMMENDED
COURSE OF ACTION
During the welding sequence the
weld light does not go ON.
While welding the  weld mode is
omitted in the welding sequence.
The weld timer is set for a longer
time than zero seconds.
The weld timer does not time out.
the unit stays in the weld mode. 1.  If the optional start timer is 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.
1.  The weld timer module may be faulty.  Replace.
1.  Set the burnback timer for a value greater than zero seconds.  Start
the weld sequence and then stop
it with the stop button.  Check to
see if the unit returns to the nor-
mal idle state.(Strike light ON and
“Hot Electrode” light OFF). • If the weld mode ends andthe 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.
1.  Check the lead harness between the weld timer and the procedure
board for loose or faulty connec-
tions.
1.  Check the lead harness between the weld timer and the procedure
board for loose or faulty connec-
tions.
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							F-20TROUBLESHOOTING & REPAIRF-20
NA-5
Observe all Safety Guidelines detailed throughout this manual
If for any reason you do not understand the test procedures or are unabl\
e to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you p\
roceed. Call 216-383-2531 or 1-800-833-9353.
CAUTION
FUNCTION  PROBLEMS
PROBLEMS
(SYMPTOMS)POSSIBLE AREAS OF
MISADJUSTMENTS(S)RECOMMENDED
COURSE OF ACTION
The start button does not initiate the
power source output or the wire
feed.  The mode selector switch is in
the strike position and the mode
strike light is lit.
The start button initiates the power
source output, but the wire does not
feed.1.  If the crater and or start option boards are NOT used the jumper
plugs must be installed in the pro-
cedure board receptacles.
2. With the unit at idle check light 7C on the logic board.  It should be
OFF.   Also check light 7B on the
logic board.  With the start button
pressed light 7B should go ON.  If
lights 7C and 7B are functioning
normally the logic board may be
faulty. 
1.  If the wire inches up properly, but does not feed when the start but-
ton is pressed,  the logic board
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
board may be faulty.
3.  The power board may be faulty.1.  If light 7C is ON check the stop button and associated leads for
“shorts” or “grounds”.  Light 7C
should be on ONLY when the
stop button is pressed.
2. If light 7B does NOT go on, when the start button is pressed, check
the start switch (button) and asso-
ciated leads for loose or faulty
connections.  See wiring diagram.
3.  Check the lead harness between the logic board and the procedure
board for loose or faulty connec-
tions.  See wiring diagram.
1.  If the wire does not feed when the inch up button is pressed perform
the 
Wire Drive Motor Test.
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							F-21TROUBLESHOOTING & REPAIRF-21
NA-5
Observe all Safety Guidelines detailed throughout this manual
If for any reason you do not understand the test procedures or are unabl\
e to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you p\
roceed. Call 216-383-2531 or 1-800-833-9353.
CAUTION
FUNCTION  PROBLEMS
PROBLEMS
(SYMPTOMS)POSSIBLE AREAS OF
MISADJUSTMENTS(S)RECOMMENDED
COURSE OF ACTION
The start button initiates the wire
feed, but does not activiate the
power source output.1.  Make sure that lead #690 is con- nected to the proper pin on the
logic board.  On newer logic
boards the dip switches must be
in the proper position.  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.
5.  The logic board may be faulty.1.  The CR3 relay may be faulty. Check or replace.
2.  Check the #2 and #4 leads between the CR3 relay and the
control cable receptacle.  See
wiring diagram.
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							F-22TROUBLESHOOTING & REPAIRF-22
NA-5
Observe all Safety Guidelines detailed throughout this manual
If for any reason you do not understand the test procedures or are unabl\
e to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you p\
roceed. Call 216-383-2531 or 1-800-833-9353.
CAUTION
TRAVEL FUNCTION PROBLEMS
PROBLEMS
(SYMPTOMS)POSSIBLE AREAS OF
MISADJUSTMENTS(S)RECOMMENDED
COURSE OF ACTION
The travel function will not operate
regardless of the travel switch posi-
tion.
The travel will not function with the
travel switch in the “Hand” travel
position.   The unit operates properly
with the travel switch in the “Auto”
position.1.  Check the travel switch for proper operation.   Also check associat-
ed leads for loose or faulty con-
nections.  
2.  Check the travel receptacle and associated leads for loose or
faulty connections.
3.  Make sure the travel unit is oper- ational.
1.  Check the travel switch and asso- ciated leads for loose or faulty
connectioins.1.  With the travel switch (S2) in the hand travel position, and the
115VAC input power applied to
the NA-5 unit,  check for 115VAC
at the travel receptacle.  115VAC
should be present at leads #531
to #532.  115VAC should also be
present at leads #25 to #531.  If
either of these two voltages are
missing or not correct check the
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.
1.  The travel switch may be faulty. Check or replace.  
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							F-23TROUBLESHOOTING & REPAIRF-23
NA-5
Observe all Safety Guidelines detailed throughout this manual
If for any reason you do not understand the test procedures or are unabl\
e to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you p\
roceed. Call 216-383-2531 or 1-800-833-9353.
CAUTION
TRAVEL FUNCTION PROBLEMS
PROBLEMS
(SYMPTOMS)POSSIBLE AREAS OF
MISADJUSTMENTS(S)RECOMMENDED
COURSE OF ACTION
The travel will not function with the
travel switch in the “Auto” postion.
The travel operates correctly with the
travel switch in the “Hand” position.
The travel runs continuously when
the travel switch is in the “Auto” posi-
tion.1.  Make sure the jumper leads #691 and #692 are connected properly
to the correct pins on the logic
board.  See wiring diagram.
2.  Check the travel switch (S2) and associated leads for loose or
faulty connections.  See wiring
diagram.
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 logic board may be faulty.
1.  Make sure the jumper leads #691 and #692 are connected properly
to the correct pins on the logic
board.  See wiring diagram.
2.  Check light 7H on the logic board. If light 7H is always ON the logic
board may be faulty.1.  If light 7H, located on the logic board, does light when the auto-
matic travel is active check the
CR2 relay.  Normal coil resis-
tance is 10,000 ohms.  The con-
tacts (terminals 2 and 4) should
“close” when 110VDC is applied
to the relay coil (terminals 1 +
and 3 -). 
1.  The 2CR relay may be faulty. The contacts (terminals 2 and 4)
may be stuck closed.
2.  Check the associated leads for misconnections.  See wiring dia-
gram.
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							F-24TROUBLESHOOTING & REPAIRF-24
NA-5
Observe all Safety Guidelines detailed throughout this manual
If for any reason you do not understand the test procedures or are unabl\
e to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you p\
roceed. Call 216-383-2531 or 1-800-833-9353.
CAUTION
FUNCTION PROBLEMS
PROBLEMS
(SYMPTOMS)POSSIBLE AREAS OF
MISADJUSTMENTS(S)RECOMMENDED
COURSE OF ACTION
After pressing the stop button, the
electrode “Hot” light goes OFF, but
the electrode wire remains electrical-
ly hot.  (The welding voltage is
always present).  The wire stops
feeding.
After pressing the stop button, the
weld light remains on and the wire
continues to feed.
The set and actual speed meter
readings match within a few IPM, but
both are in error.1.  Carefully disconnect the #2 lead from the power source terminal
strip.  The welding voltage should
be disabled.  If the welding volt-
age is still present the power
source is faulty.
2.  Check or replace the control cable between the power source
and the NA-5 unit.
1.  If a crater option module is used, check to make sure the logic
board jumper (#694) is on pin
P10.
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 logic board may be faulty.
1.  Made sure the calibration jumper on the speedmeter board is con-
nected properly.  See 
Operation
Section. 
1.  The 3CR relay may be faulty. The contacts (terminals 2 and 4)
may be stuck closed.
2.  Check the associated leads for misconnections.  See wiring dia-
gram.
1.  If, while pressing the stop button, light 7C does NOT go on,  check
the stop button and associated
leads.
1.  Remove the drive motor end cap and the tach cover plate from the
end of the wire drive motor.
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.
Return to Section TOC Return to Section TOC Return to Section TOCReturn to Section TOCReturn to Master TOCReturn to Master TOC Return to Master TOCReturn to Master TOC 
						

							F-25TROUBLESHOOTING & REPAIRF-25
NA-5
Observe all Safety Guidelines detailed throughout this manual
If for any reason you do not understand the test procedures or are unabl\
e to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you p\
roceed. Call 216-383-2531 or 1-800-833-9353.
CAUTION
FUNCTION PROBLEMS
PROBLEMS
(SYMPTOMS)POSSIBLE AREAS OF
MISADJUSTMENTS(S)RECOMMENDED
COURSE OF ACTION
The set speed and actual speed
meter readings do not match within a
few IPM.  One or both readings may
be erratic.
The set speed is adjustable and
steady.  The actual speed is uncon-
trollable.  The meter displays the
actual speed correctly. 1.  Contact your local Lincoln Authorized Field Service Facility.
1.  Contact your local Lincoln Authorized Field Service Facility.1.  Check the lead and switch conti-nuity of the SET speedmeter cir-
cuit.  See wiring diagram.
2.  Check the lead and switch conti- nuity of the ACTUAL speedmeter
circuit.  See wiring diagram.
3. Perform the 
Wire Speed
Accuracy Test
4.  Perform the Meter Circuit
Accuracy Test.
5.  The control board may be fault
1.  While the motor is running care- fully unplug the 15 pin molex from
the control board. A.  If the motor continues torun 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.
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							F-26TROUBLESHOOTING & REPAIRF-26
NA-5
Observe all Safety Guidelines detailed throughout this manual
If for any reason you do not understand the test procedures or are unabl\
e to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you p\
roceed. Call 216-383-2531 or 1-800-833-9353.
CAUTION
FUNCTION  PROBLEMS
PROBLEMS
(SYMPTOMS)POSSIBLE AREAS OF
MISADJUSTMENTS(S)RECOMMENDED
COURSE OF ACTION
The set speed is adjustable and
steady.  The actual speed reading is
incorrect and or erratic.
The set volts and actual volts read-
ings match within a few tenths of a
volt while welding.  However both
readings are inaccurate.1.  Check that the jumper plug is installed securely in the harness
receptacle near the voltage
board.  Codes below 8300 only.
2.  Check for loose or faulty connec- tions on leads #510A, #525A  and
#555 between the tach receptacle
and the control board.
3.  Check the tach cable from the tach board to the tach receptacle.
The shield in the cable should
NOT be grounded to the case.
1.  Put the Lincoln power source in the machine control mode.
Check to see if the power supply
can be set for the arc voltage
required for the process.  If not,
the power source may be faulty.
2.  The control cable may be faulty. Check or replace.1.  Remove the drive motor end cap and the tach cover plate from the
end of the wire drive motor.
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 
Tach Board
Feedback Test.
3.  If the Tach Board Feedback
Test 
is OK the control board may
be faulty.  Replace. 
1.  Check the voltage sensing leads for continuity.  (zero ohms).  #21
should have continuity to the
work piece and #67 should have
continuity to the wire feed head
assembly.  See wiring diagram.
2.  Perform the 
Voltmeter Accuracy
Test.
3. Perform the Meter Circuit
Accuracy Test.
4.  The voltage board may be faulty.
Return to Section TOC Return to Section TOC Return to Section TOCReturn to Section TOCReturn to Master TOCReturn to Master TOC Return to Master TOCReturn to Master TOC 
						

							F-27TROUBLESHOOTING & REPAIRF-27
NA-5
Observe all Safety Guidelines detailed throughout this manual
If for any reason you do not understand the test procedures or are unabl\
e to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you p\
roceed. Call 216-383-2531 or 1-800-833-9353.
CAUTION
FUNCTION  PROBLEMS
PROBLEMS
(SYMPTOMS)POSSIBLE AREAS OF
MISADJUSTMENTS(S)RECOMMENDED
COURSE OF ACTION
The actual volts reading does NOT
match the set volts reading within a
few tenths of a volt.  One reading
may be erratic.  The NA-5 does not
shut off. 1.  NA-5 units with a G1556-2 (or higher) voltage board do not con-
trol the actual strike voltage to
match the set strike voltage.  The
actual strike voltage is a function
of the set strike voltage and the
OCV contrtol characteristics of
the welding power source.
NA-5 controls with a G1556-3 (or
higher) voltage board must have
the jumper plug connected to the
4-cavity receptacle on the board,
unless the pulsed power filter
board option is connected.
2.  Make sure the shutdown “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.1.  If the actual reading is the prob- lem check the actual volts switch
and associated leads.  See wiring
diagram.
2.  If the set reading is the problem check the set volts switch and the
asociated leads.  See wiring dia-
gram.
3.  Perform the 
Voltmeter Accuracy
Test
4.  Perform the Meter Circuit
Accuraty Test.
5. The voltage board may be faulty.
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