Lincoln Electric IM559 manual Safety Precautions, Electric Shock can kill, Electrode Routing

A-5 INSTALLATION A-5

INSTALLATION OF THE SYNERGIC 7F COMPONENTS

Safety Precautions

WARNING

ELECTRIC SHOCK can kill.

•Do not touch electrically live parts such as output terminals or internal wiring.

•When inching with gun trigger, electrode and drive mechanism are “hot” to work and ground and could remain energized several seconds after the gun trigger is released.

•Turn OFF input power at welding power source before installation or changing drive roll and/or guide tubes.

•Welding power source must be connected to system ground per the National Electrical Code or any applicable local codes.

•Only qualified personnel should perform this installation.

Observe all additional Safety Guidelines detailed throughout this manual.

Mounting the Wire Feed Unit (K679-1 or -2)

Mount the wire feed unit by means of the insulated mounting bracket attached to the bottom of the gear- box. Reference L9777 dimension print at the rear of this manual to find the size and location of the mount- ing holes. The gearbox assembly is electrically “hot” when the gun trigger is pressed. Therefore, make cer- tain the gearbox does not come in contact with the structure on which the unit is mounted.

The wire feed unit should be mounted so that the drive rolls are in a vertical plane so dirt will not collect in the drive roll area. Position the mechanism so it will point down at about a 45° angle so the wire feed gun cable will not be bent sharply as it comes from the unit.

Mounting the Control Box (K678-2)

The same control box is used for both the Synergic 7F and Synergic 7FH wire feed units and contains two keyhole slots and one slot for mounting. Reference M17740 dimension print in the rear of this manual for size and location of these slots. Mount the box at some convenient location close to the wire feed unit which will enable the desired control cable assembly to reach between the control box and the wire feed unit.

a)Drill the required holes in the mounting surface, partially install 1/4-20 screws.

b)Open the control box door by removing the two

door screws.

c)Mount the box.

d)Tighten the screws.

e)Close the control box door and replace the door screws.

Connecting Wire Feed Unit to Control Box

The Feeder to Control cable assemblies are available in two types:

K680-”L” Includes a control cable with 14-pin MS- style connectors on each end, and a 4/0 weld cable to route between the Wire Drive and the Control Box. Available in lengths “L” of 16ft. (4.9m) and 25ft. (7.6m).

K681-”L” Same as K680, but does not include weld cable. Available in lengths “L” of 12ft. (3.6m), 16ft. (4.9m) and 25ft. (7.6m).

1.Making certain the cables are protected from any sharp corners which may damage their jackets, mount the cable assembly along the boom so the end with the female MS-style connector pins is at the wire feed unit.

2.Connect the 14-socket cable connector to the receptacle on the back of the wire feed unit con- nection box.

3.At the same end, connect the electrode lead to the connection stud of the brass gun connection block on the front of the wire feed unit.

4.At the control box end, connect the 14-pin connec- tor of the cable to the mating receptacle on the bottom of the control box.

Electrode Routing

The electrode supply may be either from reels, Readi- Reels, spools or bulk packaged drums or reels. Observe the following precautions:

1.The electrode must be routed to the wire feed unit so that the bends in the wire are at a minimum, and also that the force required to pull the wire from the reel into the wire feed unit is kept at a minimum.

2.The electrode is “hot” when the gun is energized and must be insulated from the boom and struc- ture.

3.If more than one wire feed unit shares the same boom, their wire and reels must be insulated from each other and insulated from their mounting structure.

SYNERGIC 7F & FH