Lincoln Na5 Service Manual

							F-8TROUBLESHOOTING & REPAIRF-8
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
WIRE FEEDING PROBLEMS
PROBLEMS
(SYMPTOMS)POSSIBLE AREAS OF
MISADJUSTMENTS(S)RECOMMENDED
COURSE OF ACTION
The wire will not inch down but does
inch up properly.  The wire does not
feed in either direction when the start
button is pressed.
The wire will not inch down but does
inch up properly.  When the start
button is pressed the wire feeds up
instead of down.1.  Check to make sure that light 7J, on the logic board, is lit when the
inch down button is pressed.  If
not check the inch down switch
and associated leads.  See wiring
diagram.
2.  Check to make sure that light 7B, on the logic board,  is lit when the
start button is pressed.  If not
check the start button and associ-
ated leads.  See wiring diagram.
1. For codes below 8300 make sure the jumper plug is securely
installed in the harness receptacle
near the voltage board.
2.  Check to make sure light 7E, on the logic board, is on when the
inch down button is pressed.  If
light 7E is ON the power board
may be faulty.
3.  Check the 1/8 amp fuse on the voltage board .  Replace if faulty.1.  The logic board may be faulty.Replace.
2.  The power board may be faulty. Replace.
1.  Jumper the AUTO tabs on the voltage board.  (Above code
8300)  Press the inch down but-
ton.  If the wire inches down the
voltage board may be faulty.
Replace.
If the wire does NOT inch down
the logic board may be faulty.
Replace.
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							F-9TROUBLESHOOTING & REPAIRF-9
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
WIRE FEEDING PROBLEMS
PROBLEMS
(SYMPTOMS)POSSIBLE AREAS OF
MISADJUSTMENTS(S)RECOMMENDED
COURSE OF ACTION
NA-5 units above code 8300 with
“cold starting”.
The wire feeds up instead of down
when the start button is pressed.
The wire inches up and down prop-
erly.1.  Make sure the electrode wire is fed into the welding tip.
2.  Check the 1/8 amp fuse on the voltage board.  Replace if faulty.
3.  Make sure electrode polarity is correct and the same as the #67
and #21 leads at terminal strip
(TS1).  See wiring diagram.
4.  Make sure the welding power source is producing welding arc
voltage.  1.  Jumper the #2 and #4 leads atthe Lincoln CV power source.
Open circuit voltage should be
present at both the power source
and at the ACTUAL voltmeter
reading on the NA-5.  If open cir-
cuit voltage is present at the
power source but NOT at the NA-
5 ACTUAL voltmeter reading per-
form the 
#21-#67 External resis-
tance Test.
2.  With the start button pressed light 7K should be lit.  If it is not the
logic board may be faulty.
3.  Check contactor relay 3CR. Leads #2 and #4 are closed by
relay 3CR.  Make sure the relay is
functiioning properly.
4.  Check the control cable between the power source and the NA-5
control unit.  See wiring diagram.
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							F-10TROUBLESHOOTING & REPAIRF-10
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
WIRE FEEDING PROBLEMS
PROBLEMS
(SYMPTOMS)POSSIBLE AREAS OF
MISADJUSTMENTS(S)RECOMMENDED
COURSE OF ACTION
NA-5 units above code 8300 with
“cold starting”.
While pressing the inch down button
the wire does not stop when it touch-
es the work.
The wire will NOT inch up but does
inch down and weld properly.
The wire feeds UP when either inch
button is pressed.1.  Check the 1/8 amp fuse on the voltage board.  Replace if faulty.
2.  While pressing the inch down but- ton with the wire touching the
work piece, observe light 7G on
the logic board.  If the light goes
on but the wire does NOT stop
feeding the logic board may be
faulty.
1.  With the unit at idle (no buttons pressed) observe lights 1D, on
the power board, and light 7E, on
the logic board.  1D should be
ON.  7E should be OFF.  
2.  If 1D is OFF replace the power board.
3.  If 7E is ON replace the logic board.
1.  While pressing the inch down but- ton observe light 7E on the logic
board.  It should be ON.
2.  If light 7E is ON, while the inch down button is pressed, the
power board may be faulty.
Replace.
3.  If light 7E remains OFF,  while the inch down button is pressed,
the logic board may be faulty.
Replace.1.  Perform the #21-#67 External
ResistanceTest.
2.  Check the continuity of leads #667 and #621 to the voltage
board.  See wiring diagram.
3.  The logic board may be faulty.
4.  The voltage board may be faulty.
1.  Check the inch up switch (button) for proper operation.  Also check
associated leads for loose or
faulty connections.  See wiring
diagram.
1. Check the inch up and inch down switches (buttons) for proper oper-
ation and wiring.  See wiring dia-
gram.
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							F-11TROUBLESHOOTING & REPAIRF-11
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
WIRE FEEDING PROBLEMS
PROBLEMS
(SYMPTOMS)POSSIBLE AREAS OF
MISADJUSTMENTS(S)RECOMMENDED
COURSE OF ACTION
The wire feeds down when either
inch button is pressed.1.  Wth the unit at idle (no buttons pressed) observe light 7E on the
logic board.  It should be OFF.
2.  If light 7E is ON the logic board may be faulty.  Replace.
3.  If light 7E is OFF the power board may be faulty.  Replace.1.  Check the inch up and inch downswitches (buttons) for proper oper-
ation and wiring.  See wiring dia-
gram.
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							F-12TROUBLESHOOTING & REPAIRF-12
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 speed and voltage controls do
not function.  All of the mode lights
function properly.  
All the mode lights function properly. 
None of the speed controls operate
properly.
All the mode lights function properly.
None of the voltage controls operate
properly.1.  Check lights 1A and 1B located on the power board.  They should
both be ON.
2.  If both lights 1A and 1B are ON the control board may be faulty.
Replace.
1.  The control board may be faulty. Replace.
1.  The voltage board may be faulty. Replace.1.  If lights 1A and /or 1B are OFFperform the 
DC Power Supply
Test.
2.  Perform the T1 and T2
Transformer Test.
3.  The power board may be faulty. Replace.
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							F-13TROUBLESHOOTING & REPAIRF-13
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
Only the strike mode functions, when
the unit is at idle, regardless of the
selector switch position.
Only the strike mode functions while
welding.  The unit stays in the strike
mode and does not progress through
the welding sequence.    
The strike light is OFF and neither
strike control functions.  The other
mode lights work.  The unit will not
feed wire when the start button is
pressed.1.  The logic board may be faulty. Replace.
2.  The procedure board may be faulty.  
1.  While the unit is welding check light 7D on the logic board.  It
should be ON when welding cur-
rent is present.  If light 7D is ON
the logic board may be faulty.
3.  If light 7D is NOT lit when weld current is present  make sure the
weld cables have been properly
routed through the cable clamp
on the left side of the control box. 
1.  Check light 7D on the logic board. If it is off the logic board may be
faulty.  Replace.
2.  If the start light is on all the time the start board (if used) may be
faulty.  Replace or install jumper
plug in procedure board.
3.  If the crater light is on all the time the crater board (if used) may be
faulty.  Replace or install jumper
plug in procedure board.
4.  If the weld light is on all the time the logic board may be faulty.
Replace.
.  If light 7D is NOT lit, when weldcurrent is present,   connect a
jumper wire from terminal #528 to
#500 on terminal strip TS1.  See
wiring diagram.  If light 7D does
light check the CR4 reed switch
and associated leads and connec-
tions.  See wiring diagram.
2.  If 7D does NOT light, with the jumper wire in place, check the
#528 lead and the #500 lead
between the TS1 terminal strip
and the logic board.  See wiring
diagram.
3.  The logic board may be faulty. Replace.
1.  If light 7D is ON check the CR4
reed switch and associated leads.
See wiring diagram.
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							F-14TROUBLESHOOTING & REPAIRF-14
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 strike light does not light.   The
strike controls (voltage and wire feed
speed) do function normally.
The strike light comes on but the
strike controls (voltage and wire feed
speed) do not function normally.
The start light does not light.  The
start controls (voltage and wire feed
speed) may or may not function nor-
mally.  The NA-5 is at idle with the
selector switch in the “Start” position.
The start light is ON but the start
controls (voltage and wire feed
speed) do not function.  The NA-5 is
at idle with the selector switch in the
“Start” position.1.  The procedure board may be faulty.  Replace.
1.  The procedure board may be faulty.  Replace.
1.  Make sure the start option board is installed correctly.
2.  The procedure board may be faulty.  Replace.
1. If no other mode lights are lit the start option board may be faulty.
Replace.
2.  If the strike light is also lit (along with the start light) the logic board
may be faulty.
3.  If the weld and or crater lights are also lit (along with the start light)
the procedure board may be
faulty.
1.  Check the lead harness betweenthe start option board and the
procedure board for loose or
faulty connections.  See wiring
diagram.
1.  Check the lead harness between the start option board and the
procedure board for loose or
faulty connections.  See wiring
diagram.
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							F-15TROUBLESHOOTING & REPAIRF-15
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
When the start button is pressed and
the unit is welding,  the start mode is
skipped.  1.  Make sure the start option is in- stalled properly in the NA-5.
2.  Make sure the start timer is set for a time greater than zero sec-
onds.
3.  If the weld light goes ON as soon as (but not before) the arc is
struck and the start timer is set
for a time greater than zero sec-
onds, the start timer board may
be faulty.
4.  If the weld light goes ON before the arc is struck replace the start
option board with the jumper
plug.  If the weld light continues
to go ON before the arc is struck
the logic board may be faulty.
Replace.
5.  With the jumper plug installed: If the weld light does NOT go ON
until the arc is struck the start
option board may be faulty. 1.  Check the lead harness betweenthe start option boards and the
procedure board for loose or
faulty connections.  See wiring
diagram.
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							F-16TROUBLESHOOTING & REPAIRF-16
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
When welding the start timer does
not time out.  The unit stays in the
start mode.
The crater light does not light.  The
crater controls (voltage and wire
feed speed) may or may not func-
tion.  The NA-5 is at idle with the
selector switch in the ”Crater” pos-
tion.
The crater light is ON but the crater
controls (voltage and wire feed
speed) do not function.  The NA-5 is
at idle with the selector switch in the
“Crater” position.1.  When the weld is stopped check to see  if the crater (if used) or
burnback timer is functioning
properly.  If the crater and or burn-
back timer IS functioning properly
the start timer may be faulty.
2.  If the start, crater and burnback timers are not working properly
the procedure board may be
faulty.
1.  Make sure the crater option boards are installed correctly.
2.  The procedure board may be faulty.  Replace.
1.  If no other lights are lit the crater option board may be faulty.
Replace.
2.  If the strike light is also lit (along with the crater light) the logic
board may be faulty.
3.  If the weld and or start lights are also lit (along with the crater light)
the procedure board may be
faulty.1.  Check the lead harness betweenthe start option boards and the
procedure board for loose or
faulty connections.  See wiring
diagram.
1.  Check the lead harness between the crater option boards and the
procedure board for loose or
faulty connections.  See wiring
diagram.
1. Check the lead harness between the crater option boards and the
procedure board for loose or faulty
connections.  See wiring diagram.
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-17TROUBLESHOOTING & REPAIRF-17
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
At the end of the weld the crater light
does NOT light.
At the end of the weld the crater
timer does not time out.  The unit
stays in the crater mode.
No burnback/retract occurs at the
end of the weld.1.  Make sure the crater option is installed properly in the NA-5.
2.  Make sure the crater timer is set for a time greater than zero sec-
onds.
3.  The crater option and or timer board may be faulty.  Replace.
4.  The logic board may be faulty.
1.  Replace the crater option board with the jumper plug.  Set the
burnback timer for any time
greater than zero seconds.  If the
unit then stops after the weld and
burnback time, the crater timer
board may be faulty.  Replace.
2.  If the unit does not stop the pro- cedure board may be faulty. 
1.  Make sure the burnback timer is set for a time greater than zero
ohms.
2.  Be sure the jumper leads or dip switches on the logic board are
comfigured correctly for the burn-
back/retract desired.  See wiring
diagram.
3.  The burnback timer module may be faulty.  Replace.
4.  The procedure board may be faulty.1.  Check the lead harness betweenthe crater boards and the proce-
dure board for loose or faulty con-
nections.  See wiring diagram.
1.  Check the lead harness between the crater boards and the proce-
dure board for loose or faulty con-
nections.  See wiring diagram.
1.  Check the lead harness between the burnback module and the pro-
cedure board for loose or faulty
connections.
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