Lincoln Electric NA-5N, NA-5S, NA-5SF, NA-5NF User Manual
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SVM131-A
NA-5
AUTOMATIC WELDING SYSTEMS
July, 1997
For use with the following models:
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
... and thoughtful operation on
your part. DO NOT INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT READING THIS MANUAL AND THE
SAFETY PRECAUTIONS CONTAINED THROUGHOUT. And,
most importantly, think before
you act and be careful.
NA-5N
NA-5NF
NA-5S
NA-5SF
View Safety Info View Safety Info View Safety Info View Safety Info
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World's Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors
SERVICE MANUAL
Sales and Service through Subsidiaries and Distributors Worldwide
22801 St. Clair Ave. Cleveland, Ohio 44117-1199 U.S.A.Tel. (216) 481-8100
SAFETY
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer, birth defects, and other reproductive harm.
The Above For Diesel 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 saf ety highlights.F or additional saf ety information, it is strongly recommended that you purchase 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.
The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
The Above For Gasoline Engines
ii
FOR ENGINE
powered equipment.
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.
____________________________________________________
1.c. Do not add the fuel near an open flame weld-
ing arc or when the engine is running. Stop
the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on
contact with hot engine parts and igniting. Do
not spill fuel when filling tank. If fuel is spilled,
wipe it up and do not start engine until fumes
have been eliminated.
____________________________________________________
1.d. Keep all equipment safety guards, co vers and
devices in position and in good repair.Keep
hands, hair, clothing and tools away from Vbelts, gears, fans and all other moving parts
when starting, operating or repairing equipment.
____________________________________________________
1.e. In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.
___________________________________________________
1.f. Do not put your hands near the engine fan.Do not attempt to
override the governor or idler by pushing on the throttle control rods while the engine is running.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
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1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
ELECTRIC AND
MAGNETIC FIELDS
may be dangerous
2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines
2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
2.d.1.
Route the electrode and work cables together - Secure
them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
2.d.5. Do not work next to welding power source.
Mar ‘95
SAFETY
iiii
ELECTRIC SHOCK can kill.
3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.
3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.
In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
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
accidental contact with the workpiece or ground) use
the following equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
3.f.
Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition.Replace
damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
ARC RAYS can burn.
4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
FUMES AND GASES
can be dangerous.
5.a.Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases.When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.
5.b.
Do not weld in locations near chlorinated hydrocarbon
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
form phosgene, a highly toxic gas, and other irritating
products.
5.c. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
5.d. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
vapors
to
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5.e. Also see item 1.b.
Mar ‘95
SAFETY
iiiiii
WELDING SPARKS can
cause fire or explosion.
6.a.
Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
the welding sparks from starting a fire.
materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.
6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact can
cause overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or
welding.They may explode.
Sparks and spatter are thrown from the welding arc. Wear oil
6.f.
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
welding area.
6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate circuits.
This can create fire hazards or overheat lifting chains or
cables until they fail.
6.h. Also see item 1.c.
Remember that welding sparks and hot
though
they have
Preparation
for Welding and Cutting of
CYLINDER may explode
if damaged.
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
7.c. Cylinders should be located:
•Away from areas where they may be struck or subjected to
physical damage.
• A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
FOR ELECTRICALLY
powered equipment.
8.a.Tur n off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
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Mar ‘95
SAFETY
iviv
PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suivantes:
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter
toujours tout contact entre les parties sous tension et
la peau nue ou les vétements mouillés. Porter des
gants secs et sans trous pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand
on soude dans des endroits humides, ou sur un
plancher metallique ou des grilles metalliques,
principalement dans les positions assis ou couché
pour lesquelles une grande partie du corps peut être
en contact avec la masse.
c. Maintenir le por te-électrode, la pince de masse, le
câble de soudage et la machine à souder en bon et sûr
état defonctionnement.
d. Ne jamais plonger le por te-électrode dans l’eau pour
le refroidir.
e. Ne jamais toucher simultanément les par ties sous
tension des porte-électrodes connectés à deux
machines à souder parce que la tension entre les deux
pinces peut être le total de la tension à vide des deux
machines.
f. Si on utilise la machine à souder comme une source
de courant pour soudage semi-automatique, ces
precautions pour le porte-électrode s’applicuent aussi
au pistolet de soudage.
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.
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.
6. Eloigner les matériaux inflammables ou les recouvrir afin
de prévenir tout risque d’incendie dû aux étincelles.
7. Quand on ne soud
de la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
8. S’assurer que la masse est connectée le plus prés possible
de la zone de travail qu’il est pratique de le faire. Si on
place la masse sur la charpente de la construction ou
d’autres endroits éloignés de la zone de travail, on
augmente le risque de voir passer le courant de soudage
par les chaines de levage, câbles de grue, ou autres
circuits. Cela peut provoquer des risques d’incendie ou
d’echauffement des chaines et des câbles jusqu’à ce qu’ils
se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de
tôles galvanisées plombées, ou cadmiées ou tout autre
métal qui produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les
vapeurs du solvant pour produire du phosgéne (gas
fortement toxique) ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.
e pas, poser la pince à une endroit isolé
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du rayonnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
l‘arc.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage.Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pantalons sans revers, et chaussures montantes.
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REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la debrancher à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
Mar.‘93
RETURN TO MAIN INDEX
MASTER TABLE OF CONTENTS FOR ALL SECTIONS
vv
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 Circuitr y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-11
Security of Weld Procedure Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . B-12
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section C
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
Listing of Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
Page
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
NOTES
vivi
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NA-5
TABLE OF CONTENTS
- 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
Section ASection A
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NA-5
A-2
INSTALLATION
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)
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
CORED WIRE SOLID WIRE
A-2
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)
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NA-5
A-3
CONTROL
CABLE
TO
POWER
SOURCE
TACHOMETER
CABLE
INSTALLATION
FIGURE A.1 – BASIC CONTROL AND WIRE DRIVE SYSTEM.
CONTROL BOX
HEAD MOUNTING PARTS
(WITH INSULATION
AND HARDWARE)
4 FT (1.2 M) CABLE
(DRIVE MOTOR TO
CONTROL BOX)
MOTOR
A-3
WIRE
STRAIGHTENER
4 FT (1.2 M) ELECTRODE CABLES
[(TWO 4/0) CONTACT ASSEMBLY
TO CONTROL BOX]
GEAR BOX
CROSS
SEAM
ADJUSTER
CONTACT
ASSEMBLY
(OPTIONAL)
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NA-5
A-4
INSTALLATION
A-4
MECHANICAL
INSTALLATION
WARNING
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 followed when installing the control box and
mounting head.
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.
FIGURE A.2 – CONTROL BOX
CARRIAGE MOUNTING.
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.
ADAPTER
PLATE
TRAVEL
CARRIAGE
CONTROL
BOX
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NA-5
INSTALLATION
A-5A-5
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.
FIGURE A.3 – CONTROL BOX
FIXTURE MOUNTING.
VIEW FROM BACK
0.41
(10.41)
13.77
(349.76)
1.34
(34.04)
1.71
(43.43)
0.28 (7.11) SLOTS
4 PLACES
0.562 DIA (14.27)
2 HOLES
12.75
(323.85)
12.00
(304.8)
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.
FIGURE A.4 – WELDING HEAD
MOUNTING HOLES.
APPROXIMATE
0.531 DIA.
(13.49)
2.88
(73.15)
INSULATOR
SIZE
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1.09
(27.68)
VIEW FROM BOTTOM
1.71
(43.43)
1/4-20 THREAD HOLES
NOTE: DIMENSIONS ARE IN INCHES
WITH MILLIMETERS IN
PARENTHESES.
1/4-20
THREAD HOLES
12.00
(304.8)
FRONT
0.43
(10.92)
3.50
(88.9)
NA-5
4.265
(108.33)
4.5
(114.30)
NOTE: DIMENSIONS ARE IN INCHES
WITH MILLIMETERS IN
PARENTHESES.
2.62
(66.55)
INSTALLATION
A-6A-6
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.
FIGURE A.5 – MOUNT TO CARRIAGE
OVERHANG DIMENSION.
19 IN.
(483 MM)
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.
ELECTRICAL
INSTALLATION
WARNING
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 system. This section also provides basic con-
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
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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NA-5
A-7
INSTALLATION
A-7
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 extension cable for the NA-5NF or NA-5SF, order
an appropriate length of the needed electrode 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.
FIGURE A.6 – CONTROL BOX
ELECTRICAL CONNECTIONS.
CLAMP
BAR
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 DC1500 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.
POWER
SOURCE
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FROM
TO
WELDING
HEAD
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 power
sources.
NA-5
INSTALLATION
A-8A-8
ELECTRODE POLARITY
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.
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.
FIGURE A.7 – TERMINAL STRIP
LOCATION.
TERMINAL
STRIPS
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.
WARNING
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.
ELECTRIC SHOCK
can kill.
• Turn off input power to
the welding power
source using the
disconnect switch
before working on this
equipment.
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NA-5
INSTALLATION
A-9A-9
FIGURE A.8 – CONNECTION OF NA-5 (ALL) TO A DC-600.
P
TO NA-5 INPUT
CABLE PLUG
B
.A.
P
NOTE: DIAGRAM SHOWS ELECTRODE CONNECTED POSITIVE.
A
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.
CONNECT TO CABLES FROM NA-5
WIRE CONTACT ASSEMBLY
B
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".
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.
CONNECT
TO WORK
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-600'S WITH CODES 8288 AND
ABOVE ARE PREFERRED. FOR ADDITIONAL INSTALLATION INSTRUCTIONS,
SEE NA-5 OPERATING MANUAL.
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CLEVELAND, OHIO U.S.A.
NA-5
INSTALLATION
FIGURE A.9 – CONNECTION OF NA-5 (ALL) TO A DC-650 PRO
A-10A-10
P
CONTROL
CABLE
P
TO NA-5 INPUT
CABLE PLUG
CONNECT TO CABLES FROM
NA-5 WIRE CONTACT ASSEMBLY
A
R
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.
P
6
CONNECT TO CABLES FROM NA-5
WIRE CONTACT ASSEMBLY
CONNECT
TO WORK
TO NA-5 INPUT
CABLE PLUG
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 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.
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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.
CLEVELAND, OHIO U.S.A.
NA-5
INSTALLATION
FIGURE A.10 – CONNECTION OF NA-5 (ALL) TO A R3S-400, -600, OR -800
WITH NO LINE VOLTAGE COMPENSATOR (OBSOLETE).
B
B
A-11A-11
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
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.
FOR ADDITIONAL INSTALLATION INSTRUCTIONS, SEE NA-5 OPERATING MANUAL.
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 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 #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 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".
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CLEVELAND, OHIO U.S.A.
NA-5
INSTALLATION
FIGURE A.11 – CONNECTION OF NA-5 (ALL) TO A SAM-400 MOTOR
GENERATOR OR ENGINE WELDER.
BOLT TO CABLES
P
N.B.
FROM NA-5
WIRE CONTACT
ASSEMBLY
A-12A-12
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
TURN POWER SOURCE OFF.
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.
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 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
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 #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 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".
FOR ADDITIONAL INSTALLATION INSTRUCTIONS, SEE NA-5 OPERATING MANUAL.
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CLEVELAND, OHIO U.S.A.
NA-5
INSTALLATION
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.
"TAP"
P
BOLT TO CABLES
FROM NA-5
WIRE CONTACT
ASSEMBLY
A-13A-13
PP
.
.
SAM POWER SOURCE SETTINGS
TURN POWER SOURCE OFF.
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.
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 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 #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 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".
FOR ADDITIONAL INSTALLATION INSTRUCTIONS, SEE NA-5 OPERATING MANUAL.
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CLEVELAND, OHIO U.S.A.
NA-5
INSTALLATION
FIGURE A.13 – CONNECTION OF NA-5 TO DC-1000 OR DC-1500.
A-14A-14
POWER SOURCE
CONTROL
CABLE
P
BOLT TO CABLES FROM
NA-5 WIRE CONTACT
ASSEMBLY
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
WORK PIECE. FOR CONVENIENCE, THIS EXTENDED #21 LEAD SHOULD BE TAPED ALONG THE WELDING WORK CABLE.
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
MUST BE PROPERLY GROUNDED.
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.
CONNECT TO WORK
INPUT CABLE PLUG
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CLEVELAND, OHIO U.S.A.
NA-5
INSTALLATION
FIGURE A.14 – CONNECTION OF NA-5 TO DC-400 OR CV-400.
POWER SOURCE
A-15A-15
N.H.
32
C
B
A
31
4
TO NA-5 INPUT CABLE PLUG
N.E.
CONTROL
CABLE
2
N.D. AND N.H.
GND
NEGATIVE
POSITIVE
N.D.
21
N.B. AND N.C.
N.A.
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 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.
FOR ADDITIONAL INSTALLATION INSTRUCTIONS, SEE NA-5 OPERATING MANUAL.
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.
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CLEVELAND, OHIO U.S.A.
NA-5
NOTES
A-16A-16
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NA-5
TABLE OF CONTENTS
- 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
Section BSection B
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NA-5
B-2
OPERATING INSTRUCTIONS
B-2
SAFETY PRECAUTIONS
WARNING
ELECTRIC SHOCK
can kill.
• Do not touch electrically live parts or electrode with skin or wet
clothing.
• Insulate yourself from
work or ground.
• Always wear dry insulating gloves.
FUMES AND GASES
can be dangerous.
• Keep your head out of
fumes.
• Use ventilation or
exhaust to remove
fumes from breathing
zone.
WELDING SPARKS
can cause fire or
explosion.
• Keep flammable material away.
• Do not weld on containers that have held
combustibles.
1. Be sure there is enough electrode in
the machine to complete the weld.
2. If submerged arc welding, fill flux
hopper with new or freshly screened
flux. All reused flux must be screened
100% through an 8 mesh screen
[0.065 to 0.075 in. (1.6 to 1.9 mm)
opening]. Turn the switch on the
hopper to “On.”
3. Start the power source.
4. Turn the “Power Control” switch on the
wire feeder control to “On.”
5. Position the welding head at the start
of the weld. Be sure the travel carriage
or other travel mechanism is set to
move in the proper direction.
6. Set the travel switch to “Automatic
Travel.” When set to “Hand Travel”,
the travel system operates without
welding.
7. For best starts, cut the electrode to a
sharp point.
8. Press the “Inch Down” button to feed
the electrode out of the nozzle.
a. For most applications, when hot
starting, leave the electrode
1/4 in. (6.4 mm) or more away
from the work.
b. When cold starting some
submerged arc welding, inch the
electrode down until it touches the
work and the flux valve opens.
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ARC RAYS
can burn.
• Wear eye, ear, and
body protection.
Observe additional Safety Guidelines
detailed in the beginning of this manual.
OPERATOR’S
INSTRUCTIONS
Once the system is properly set up, the
operator can make production welds
without readjusting the controls
following simple instructions:
using the
NA-5
9. Press the “Start” button.
10. While welding, turn the cross seam
adjuster handwheel as needed to keep
the arc in the joint.
11. At the end of the weld, press the
“Stop” button.
12. If needed, press the “Inch Up” button
to get the electrode up and out of the
way. Remove the work and reload the
fixture.
NOTE: When the contact tip in the end of the
nozzle wears during repetitive welding, it
must be replaced. Check the contact tip for
wear if weld quality seems to be
deteriorating.
OPERATING INSTRUCTIONS
B-3B-3
CONTROLS AND
THEIR FUNCTIONS
The operator controls for the NA-5 are
illustrated in Figure B.1. Refer to the figure
and the following explanations of the
controls.
EXPOSED CONTROLS (WITH
LOCKABLE COVER DOWN)
1. CIRCUIT BREAKER. Protects the
circuit from severe wire feed motor
overloads and short circuits. Press to
reset.
2. CONTROL POWER. Turns input
control power “On” and “Off.” Also
used as an emergency “Off” in case
of malfunction.
3. ELECTRODE “HOT” LIGHT.
Comes on when the “Start button” is
pressed and the electrode circuit
becomes electrically hot.
FIGURE B.1 – NA-5 CONTROLS.
4. INCH UP AND INCH DOWN. Press to
inch electrode up or down.
5. MODE SELECTOR SWITCH AND
LIGHTS. Used to preset the voltage
and wire feed speed for the various
modes of operation (Strike, Start,
Weld, and Crater).
6. SET-ACTUAL BUTTON. When
pressed, will display the actual wire
speed and voltage in the wire speed
and volts meters. When the button is
not pressed, the set wire speed and
voltage is displayed.
7. START. Begins welding cycle.
8. STOP. Initiates the stopping cycle at
the end of the weld.
9. TRAVEL. Turn to “Off” for no travel,
“Hand Travel” for travel without
welding, and “Automatic Welding” for
welding operations.
10. VOLTS METER. Displays the set or
actual voltage for each mode (Strike,
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
16
12
3
17
10
15
13
7
striking.
13. BURNBACK AND ELECTRODE
BACKUP TIME. Controls the length
of burnback delay time after the stop
circuit is energized.
14. WELD CONTROLS. Controls the
voltage and wire speed during the
welding mode.
15. CRATER CONTROLS (OPTIONAL).
Sets the ending current and voltage
for an adjustable period of time.
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1
9
2
14
5
4
NA-5
6
8
16. START CONTROLS (OPTIONAL).
Sets the starting current and voltage
for an adjustable period of time.
17. WELD TIME (OPTIONAL). Controls
the time of the weld mode.
OPERATING INSTRUCTIONS
B-4B-4
SETUP INSTRUCTIONS
Use the following steps to set up the NA-5
welding system prior to welding:
1. If using a multi-process power source
(SAM, DC-400, DC-600, DC-1000,
OR DC-1500 type), make connections and settings per the power
source connection diagram (Figures
A.8 to A.14) for the process being
used.
AUTO TAB
When using the NA-5 with the DC400 or CV-400 power source, the
auto tab jumper on the NA-5 voltage
PC board must be connected in order
for the inch down circuit to function.
When the auto tab jumper is
connected, the cold starting feature
of the NA-5 is disabled and only the
hot starting technique can be used. If
the cold start technique is to be used,
the optional Diode must be installed
on the DC-400 or CV-400.
2. Set the power source and NA-5
circuit polarity per information on
Electrode Polarity
Installation.
3. Depending on the procedures and
applications, decide:
a. The means of arc striking and
whether to start the travel with
the “Start” button or the arc.
b. Whether the initial bead size or
penetration requires use of the
optional “Start Controls.”
See the
Sequences
4. Depending upon the procedures and
applications:
a. Select the arc and travel stopping
Starting and Stopping
section.
sequence. See the
Stopping Sequences
b. Decide if the control of the ending
bead size or crater fill requires
the use of optional “Crater
Controls”. See the
Stopping Sequences
in Section A,
Starting and
section.
Starting and
section.
5. Set the head position relative to the
work as required for the fixture,
application, and procedures. See
IM305 Sec. T3.2.3.
6. Rotate the wire straightener, if used,
until the top of the straightener faces
the wire reel. This is required for
smooth feeding of the electrode into
the straightener.
7. Refer to the instructions for the wire
contact assembly being used. See
IM305 Sec. T2.2.6, T2.2.7, T2.5.3, or
T2.5.4.
8. The mount for standard 50 and 60 lb
(22.7 and 27.2 kg) electrode coils
includes a two-position brake
assembly. Generally the brake should
be at the inner position (nearest to
the wire reel shaft) for wire feed
speeds below 400 in./min (10 m/min).
It should be at the outer position for
faster wire speeds. To adjust the
brake position, remove the wire reel.
Pull the cotter pin that holds the
brake shoe to the arm, move the
shoe, and replace the cotter pin. Do
not bend the cotter pin — it is held in
place by a friction fit.
9. Load the wire reel per IM305 Sec.
T3.2.2 or install the Speed-Feed
drum or reel per Sec. T2.5.7-A or -B.
10. Straighten the first 6 in. (152.4 mm)
of electrode and push it through the
wire straightener to the drive rolls. To
use the cored wire straightener,
remove the knurled nut at the top and
feed the wire through the nut, down
through the straightener, and into the
drive rolls. Screw the nut back onto
the straightener. Feed the wire
through the nozzle tip and adjust
the straightener for optimum
straightness. With wire contact
assemblies, except the K231, adjust
until the electrode is straight as it
comes out of the nozzle. Do not
completely straighten the wire when
using the K231 contact nozzle
because the nozzle relies on the
small curvature of the electode for
proper electrical contact within the
contact tip.
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NA-5
OPERATING INSTRUCTIONS
B-5B-5
11. Set the travel speed as specified by
the procedures. With the wire feeder
travel switch set to “Hand Travel”, the
travel runs without welding, permitting
accurate measurement of travel
speed. When using a Lincoln travel
carriage, adjust the speed with the
rheostat and the direction with the
toggle switch on the carriage control
panel.
12. Connect the work lead to the work or
a suitable piece of scrap. Clip the
end of the electrode to a sharp point.
13. Preset the “Start” (if used), “Weld”,
and “Crater” (if used) controls to the
wire speed and voltage specified in
the procedure.
14. Make several test welds, readjusting
the controls in the following order:
a. Set the “Arc Striking”, “Inch Wire
Speed”, and “Volts” controls for
optimum arc striking. The
optimum strike control settings for
most processes will be typically 4
to 5 volts higher than the weld
mode voltage setting and 40% to
50% of the weld mode wire feed
speed setting (possibly lower if
cold starting is used).
b. If striking is still not satisfactory,
refer to the section on
Travel Starting and Stopping
IM305 Sec. T3.5.2 for information
on wire feed motor acceleration.
c. If installed, adjust the “Start
Controls” to set the welding
procedures for the time set on the
timer to provide the bead size,
penetration, or other factor as
needed for the application.
d. If installed, adjust the “Crater
Controls” to set the welding
procedures for the set time after
the “Stop” button is pressed to
provide the bead size or fill the
crater as needed for the
application.
e. Set the “Burnback Time” to
provide the stopping characteristics needed.
Setting
or
STARTING AND STOPPING
SEQUENCES
MEANS OF ARC STRIKING
The NA-5 Codes utilize “hot start” arc
striking which operates as follows:
1. With the electrode not touching the
work, press the “Start” button.
2. The electrically “hot” electrode
inches down as set by the “Inch Wire
Speed” control.
3. When the electrode makes contact
with the work, the arc strikes and the
circuit automatically switches from
“Strike” settings to “Weld” (or “Start”,
if used) settings.
NA-5 models above Code 8300 offer both
“hot start” arc striking, as described
above, or “Cold Start” arc striking which
operates as follows:
1. Press the “Inch Down” button until the
tip of the electrode touches the work,
automatically stops, and the flux (if
used) is automatically dispensed.
NOTE: If inch speed is set too high, the
electrode may stop with too much force on
its tip, resulting in possible poor starting.
2. The arc establishes when the “Start”
button is pressed, and the circuit
automatically switches to “Weld” (or
“Start”, is used) settings. Should the
arc not start immediately, the wire will
retract slightly until the arc is
established and then feed down in the
normal manner.
Use either the standard “on-the-fly” travel
starting or rewire the controls for “standstill”
travel starting as described in the
Travel Starting and Stopping
Optional “Start Controls”
Recommended for applications where
penetration, bead size, and other
characteristics must be carefully controlled
at the start.
Setting
section.
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NA-5
OPERATING INSTRUCTIONS
B-6B-6
The starting sequence is as described above
except that when the arc strikes, the
machine welds at the wire speed and
voltage set by the “Start Controls” panel until
the time set on the thumbwheel switch
elapses. The circuit then automatically
switches to the “Welding Controls” wire
speed and voltage. Actual settings depend
on application requirements.
Available options for applications with
particularly difficult starting.
1. K238 High Frequency Generator See IM305 Sec. T2.5.8.
SETTING TRAVEL
STARTING AND STOPPING
Standard machines can be connected for a
variety of starting and stopping sequences.
STARTING SEQUENCES
“On-the-Fly” Travel Starting
When shipped, all models are connected for
“On-the-Fly” travel starting. The starting
sequence is as follows:
1. With the electrode NOT touching the
work, press the “Start” button. This
starts both the wire feed and travel
motors.
2. When the electrically “hot” electrode
touches the work to start the arc,
there is relative motion between the
end of the electrode and the work.
This “scratching” type contact helps
assure consistent arc striking.
This sequence is recommended for most
welding applications including:
1. Roundabouts and any other weld
which ends at its starting point. A
K337 Weld Timer Module to control
the welding cycle duration can be
installed.
2. Welds started on a run-out tab.
3. Any application for improved arc
striking.
“Standstill” Travel Starting
All models can be reconnected so the travel
remains at a standstill until the arc starts.
“Standstill” travel starting is used when the
electrode
location.
For consistent arc striking with “Standstill”
travel starting, always clip the end of the
electrode to a sharp point before starting.
must
be started at a precise
STOPPING SEQUENCES
As shipped, the travel stops when the “Stop”
button is pressed, producing a small crater
area.
When the end of the weld overlaps the
beginning, changing the stopping sequence
to stop the travel later spreads the crater
over a longer area.
RECONFIGURING THE TRAVEL
SEQUENCES
WARNING
ELECTRIC SHOCK
can kill.
• Turn off input power to
the welding power source
using the disconnect
switch before working on
this equipment.
To change the travel sequence, turn off all
input power to the NA-5 control box. Open
the control box. The logic board is mounted
on the back of the box in the upper right
hand corner. To change the travel circuit for
the various modes of starting and stopping,
follow the information in the wiring diagram
for the NA-5 being used. Table B.1 also
shows information on reconfiguring the
travel sequences.
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NA-5
OPERATING INSTRUCTIONS
TABLE B.1 – TRAVEL SEQUENCE LEAD AND SWITCH POSITIONS.
Travel Starts Travel Stops Older Models Newer Models*
B-7B-7
With “Start” With “Stop” Lead #691 to Pin 6
Button Button Lead #692 to Pin 5
With Arc Striking With Arc Stopping Lead #691 to Pin 6
Lead #692 to Pin 7
With Arc Striking With Stop Button Lead #691 to Pin 5
Lead #692 to Pin 7
With “Start” With End Crater Lead #691 to Pin 6
Button Fill Time (With Lead #692 to Pin 9
optional procedure
module installed in
crater receptacle1)
With “Start” After Burnback Lead #691 to Pin 6
Button Time (with Lead #692 to Pin 8
optional procedure
module installed
in crater
receptacle1)
1234 1234
Switch #1 Switch #2
1234 1234
Switch #1 Switch #2
1234 1234
Switch #1 Switch #2
1234 1234
Switch #1 Switch #2
1234 1234
Switch #1 Switch #2
1
If the optional procedure module is installed in the crater receptacle,
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
cedure board. If the procedure module is not installed, the switch
should be in the down position and the 583C to 584C jumper plug
should be reinstalled on the procedure board.
*NOTE:
Indicates switch in up position
Indicates switch in down position
Indicates switch position does not matter
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NA-5
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