Lincoln Electric IM559 Procedure to Install Drive Roll and Guide Tubes, Steel Wire Sizes Roll

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A-6

INSTALLATION

A-6

 

 

 

Wire Feed Drive Roll and Guide Tube Kits

NOTE: The maximum sizes the Synergic 7F will feed satisfactorily are the 3/32” (2.4mm) cored and 1/16” (1.6mm) solid electrodes. The maximum sizes the synergic 7FH will feed satisfactorily are the .045 (1.2mm) cored and .045” (1.2mm) solid electrodes.

The electrode sizes that can be fed with each roll and guide tube are stencilled on each part. Check the kit for proper components.

Steel Wire Sizes:

4-Roll

*

.068 - 3/32” (1.7 - 2.4mm) Cored

KP655-3/32

*

1/16” (1.6mm) Cored or Solid

KP655-1/16

 

.045 - .052” (1.2 - 1.4mm) Solid

KP655-052S

 

.045 - .052” (1.2 - 1.4mm) Cored

KP655-052C

 

.035” (0.9-1.0mm) Cored

KP655-035C

 

.035” (0.9-1.0mm) Solid

KP655-035S

 

.030” (0.8mm) Solid

KP655-030S

 

.023” (0.6mm) Solid

KP655-025S

Aluminum Wire Sizes:

 

 

1/16” (1.6mm)

KP656-1/16A

 

 

KP647-1/16A**

 

3/64” (1.2mm)

KP656-3/64A

 

 

KP647-3/64A**

 

.040” (1.0mm)

KP647-040A**

 

.035” (0.9mm)

KP656-035A

Drive rolls for only cored electrode sizes are stencilled with a “C” suffix to the wire sizes.

Drive rolls for only solid electrode sizes are stencilled with an “S” suffix to the wire sizes.

Drive rolls for aluminum wire sizes are stencilled with an “A” suffix to the wire sizes.

* Not for Synergic 7FH model.

**For use with Binzel European guns. Installation instructions are included with these kits. Also requires K489-2 Fast-Mate Adapter.

PROCEDURE TO INSTALL DRIVE ROLL AND GUIDE TUBES

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.

Standard 4-Roll Kits (KP655 and KP656)

1)Turn off welding power source.

2)Release both quick release levers by sliding the levers sideways into the open positions.

3)Remove clamping screw & clamping collar from the drive shaft closest to the incoming side of the feeder.

4)Install drive roll onto keyed shaft. (Do not exceed the maximum wire size rating of the wire drive.) Replace collar and tighten clamping screw.

5)Back out the set screw for the middle guide tube. Install the middle guide tube and slide it up against the drive roll. DO NOT TIGHTEN THE MIDDLE GUIDE AT THIS TIME.

6)Install the outgoing drive roll following the same procedure as steps 3 & 4.

7)Center the middle guide between the two drive rolls and tighten in place.

8)Back out the screws for the incoming and outgoing guide tubes.

SYNERGIC 7F & FH

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Contents Synergic 7F and Synergic 7FH Mar ‘95 SafetyElectric Shock can kill Iii Welding Sparks can cause fire or explosionMar. ‘93 Précautions DE SûretéOn-Line Product Registration Please Examine Carton and Equipment For Damage ImmediatelyTable of Contents Type K678-2 K679-1 K679-2 Wire Speed Range InstallationModel Wire Feed Features Standard FeaturesGeneral Description Recommended Processes and EquipmentControl Features Y P a D a N D D I S P L a Y Description Connecting Wire Feed Unit to Control Box Safety PrecautionsElectric Shock can kill Mounting the Control Box K678-2Wire Feed Drive Roll and Guide Tube Kits Procedure to Install Drive Roll and Guide TubesSteel Wire Sizes Roll Aluminum Wire SizesGun Cable Connection Gun and Cable Assemblies with Standard L. E. ConnectionsGmaw Guns Innershield GunsSynergic 7F Water Connections for Water-Cooled Guns Gun Cable Connections Wire Feeder to GunGmaw Shielding Gas Cylinder may explode if damagedWork Cable Electrical InstallationCurrent 60% Duty Cycle Up to 100 ft Length 30mK648, K649 or K642 Input Cable Assembly See Optional Features InstallationElectrical Installation section for instructions Mode Selection Power-Down SaveOperation Operating InstructionsDisplay Control Keys Timer/Crater Select key enables Memory Ammeter Selection Procedure Selector Switch4-step with crater fill To Mount 10 to 44 lb 4.5-20kg Spool 12/300mm Diameter Feeding Electrode and Brake AdjustmentFeeding Electrode To Mount a 50-60lb 22.7-27.2kg CoilIdle Roll Pressure Setting Wire Loading of 13-14lb 6kg Innershield CoilsGas Guard Regulator Setting Wire Feed Overload Protection Wire Reel ChangingMaking a Weld Explanation of Prompting Error Messages Optional Features AccessoriesREADI-REEL Adapters Maintenance MaintenanceTroubleshooting Guide TroubleshootingReplace contact tip Trouble shooting informationTions in control cable Ing and gas flow rate is proper WeldingIng ReplaceTers on wire feeder display do not No control of wire feedDefective wire feed motor tach or Control PC board see Procedure forWiring harness or Control PC Wire feed motor runs and solenoid Power source is defectiveSpeed does not change when Run-in and weld speeds are set Or there may be a problem withNot match those on power Meters on wire feeder display doProblem with wire feeder harness Remote control kit must be usedTroubleshooting Between procedures a and B Dure switch Be connectedDisplay. If not, refer to Problem Faulty local dual procedure switchDual procedure switch is used to Local dual procedure switchSwitch between procedures a Faulty communication betweenOr tripped Breaker at power source is blownCircuit breaker Display or Control PC board is BadCedure for replacing PC boards Eprom checksum error See Problem 5 or see Section onOnds. Turn power back on. If EP is X8 on Control PC board is faultySwitch Requirements Procedure for Replacing PC Boards Electric Shock can killControl P.C Board DIAGRAMSF-1Input Connection Diagram DiagramsPrint Wire Feed Unit Dimension Print Synergic 7F & FH Synergic 7F & FH Precaucion Warnung
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