Lincoln Electric IM559 Electrical Installation, Work Cable, Current, Amps 00 67 mm2 000 85 mm2

Page 16

A-9

INSTALLATION

A-9

 

 

 

ELECTRICAL INSTALLATION

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.

Input Cable: Synergic 7F Control to Power Wave Synergic Type Power Sources

NOTE: CSAnrtl certification of the Synergic 7 models is with input cable assemblies identified by carton date codes 010161, or above. These assemblies have grounding lead continituity between the 14-pin plug pin B and the 8-socket plug pin E per diagram below.

B=GND

E=GND

14-PIN PLUG, FRONT VIEW

8-PIN PLUG, FRONT VIEW

K648 - (Used with Power Wave 450) Consists of an 8-con- ductor control cable with a 14-pin plug and a 4/0 (107 mm2) electrode cable with stud terminal. It is rated at 500 amps, 60% duty cycle and is available in lengths of 7 ft (2 m), 17 ft (5 m), 25 ft (7.6 m), 33 ft (10 m) and 50 ft (15 m).

K649 - (Used with Power Wave 450/500) Consists of an 8- conductor control cable with a 14-pin control cable plug and a 4/0 (107mm2) electrode cable with Twist-Mate™ connector. It is rated at 500 amps, 60% duty cycle and is available in lengths of 7 ft (2 m), 17 ft (5 m), 25 ft (7.6 m), 33 ft (10 m) and 50 ft (15 m).

K642 (Control Cable Only) - Consists of an 8 conductor control cable with a 14-pin control cable plug, without electrode cable, and is available in lengths of 7 ft (2 m), 17 ft (5 m), 25 ft (7.6 m), 33 ft (10 m) and 50 ft (15 m).

K643 (Control Cable Extension) - Consists of an 8 conductor control cable with 14-pin connectors on each end for extending the control cable between the power source and the control cables. Available in lengths of 17 ft (5 m), 25 ft (8 m), 33 ft (10 m) and 50 ft (15 m).

With input power disconnected from the power source, install the input cable per connection diagram S22015 in the rear of this manual and follow exactly the instructions on the diagram or perform the follow- ing:

1)Connect the end of the control cable with the 14- pin cable plug to the mating receptacle on the power source.

2)Connect the electrode lead of that same cable end to the power source output terminal of the desired polarity.

3)Connect the 14-socket plug of the control cable to the mating receptacle on the bottom of the control box.

4)If not using a single continuous electrode cable from the Power Source to the Wire Feed Unit, bolt the electrode lead from the power source to the electrode lead to the wire feed unit using the nut and bolt supplied with the K680 Control to Feed Unit cable assembly. Insulate connection with elec- trical tape.

Work Cable

Connect a work lead of sufficient size and length (per the following table) between the proper output termi- nal on the power source and the work. Be sure the connection to the work makes tight metal-to-metal electrical contact.

 

Current

 

 

 

 

 

 

Copper Work Cable Size, AWG *

 

 

60% Duty

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Cycle

 

 

Up to 100 ft Length (30m)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

300 Amps

 

00 (67 mm2)

 

 

 

 

 

 

 

 

400 Amps

 

 

 

000 (85 mm2)

 

 

 

500 Amps

 

 

 

000 (85 mm2)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

*For pulse welding applications, the next larger cable size is recommended.

SYNERGIC 7F & FH

Page 15 Page 17
Image 16
Page 15 Page 17
Contents Synergic 7F and Synergic 7FH Safety Mar ‘95Electric Shock can kill Welding Sparks can cause fire or explosion IiiPrécautions DE Sûreté Mar. ‘93Please Examine Carton and Equipment For Damage Immediately On-Line Product RegistrationTable of Contents Type K678-2 K679-1 K679-2 Wire Speed Range InstallationModel Standard Features Wire Feed FeaturesGeneral Description Recommended Processes and EquipmentControl Features Y P a D a N D D I S P L a Y Description Safety Precautions Connecting Wire Feed Unit to Control BoxElectric Shock can kill Mounting the Control Box K678-2Procedure to Install Drive Roll and Guide Tubes Wire Feed Drive Roll and Guide Tube KitsSteel Wire Sizes Roll Aluminum Wire SizesGun and Cable Assemblies with Standard L. E. Connections Gun Cable ConnectionGmaw Guns Innershield GunsGun Cable Connections Wire Feeder to Gun Synergic 7F Water Connections for Water-Cooled GunsGmaw Shielding Gas Cylinder may explode if damagedElectrical Installation Work CableCurrent 60% Duty Cycle Up to 100 ft Length 30mK648, K649 or K642 Input Cable Assembly See Optional Features InstallationElectrical Installation section for instructions Power-Down Save Mode SelectionOperation Operating InstructionsDisplay Control Keys Timer/Crater Select key enables Memory Ammeter Selection Procedure Selector Switch4-step with crater fill Feeding Electrode and Brake Adjustment To Mount 10 to 44 lb 4.5-20kg Spool 12/300mm DiameterTo Mount a 50-60lb 22.7-27.2kg Coil Feeding ElectrodeIdle 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 Accessories Optional FeaturesREADI-REEL Adapters Maintenance MaintenanceTroubleshooting Troubleshooting GuideReplace contact tip Trouble shooting informationTions in control cable Welding Ing and gas flow rate is properIng ReplaceNo control of wire feed Ters on wire feeder display do notDefective wire feed motor tach or Control PC board see Procedure forWire feed motor runs and solenoid Power source is defective Wiring harness or Control PCSpeed does not change when Run-in and weld speeds are set Or there may be a problem withMeters on wire feeder display do Not match those on powerProblem with wire feeder harness Remote control kit must be usedTroubleshooting Dure switch Be connected Between procedures a and BDisplay. If not, refer to Problem Faulty local dual procedure switchLocal dual procedure switch Dual procedure switch is used toSwitch between procedures a Faulty communication betweenBreaker at power source is blown Or trippedCircuit breaker Display or Control PC board is BadSee Problem 5 or see Section on Cedure for replacing PC boards Eprom checksum errorOnds. Turn power back on. If EP is X8 on Control PC board is faultyProcedure for Replacing PC Boards Electric Shock can kill Switch RequirementsDIAGRAMSF-1 Control P.C BoardDiagrams Input Connection DiagramPrint Wire Feed Unit Dimension Print Synergic 7F & FH Synergic 7F & FH Precaucion Warnung
Top Page Image Contents