Lincoln Electric IM559 manual Troubleshooting Guide

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E-1	TROUBLESHOOTING	E-1

TROUBLESHOOTING GUIDE

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.

WARNING

This Troubleshooting Guide is designed to be used by the machine Owner/Operator. Unauthorized repairs per- formed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety, please observe all safety notes and precautions detailed in the Safety Section of this manual to avoid electrical shock or danger while troubleshooting this equipment.

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CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

SYNERGIC 7F & FH

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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 Installation Type K678-2 K679-1 K679-2 Wire Speed RangeModel General Description Standard FeaturesWire Feed Features Recommended Processes and EquipmentControl Features Y P a D a N D D I S P L a Y Description Electric Shock can kill Safety PrecautionsConnecting Wire Feed Unit to Control Box Mounting the Control Box K678-2Steel Wire Sizes Roll Procedure to Install Drive Roll and Guide TubesWire Feed Drive Roll and Guide Tube Kits Aluminum Wire SizesGmaw Guns Gun and Cable Assemblies with Standard L. E. ConnectionsGun Cable Connection Innershield GunsGmaw Shielding Gas Gun Cable Connections Wire Feeder to GunSynergic 7F Water Connections for Water-Cooled Guns Cylinder may explode if damagedCurrent Electrical InstallationWork Cable 60% Duty Cycle Up to 100 ft Length 30mOptional Features Installation K648, K649 or K642 Input Cable Assembly SeeElectrical Installation section for instructions Operation Power-Down SaveMode Selection Operating InstructionsDisplay Control Keys Timer/Crater Select key enables Procedure Selector Switch Memory Ammeter Selection4-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 ElectrodeWire Loading of 13-14lb 6kg Innershield Coils Idle Roll Pressure SettingGas Guard Regulator Setting Wire Reel Changing Wire Feed Overload ProtectionMaking a Weld Explanation of Prompting Error Messages Accessories Optional FeaturesREADI-REEL Adapters Maintenance MaintenanceTroubleshooting Troubleshooting GuideTrouble shooting information Replace contact tipTions in control cable Ing WeldingIng and gas flow rate is proper ReplaceDefective wire feed motor tach or No control of wire feedTers on wire feeder display do not Control PC board see Procedure forSpeed does not change when Run-in and weld speeds are set Wire feed motor runs and solenoid Power source is defectiveWiring harness or Control PC Or there may be a problem withProblem with wire feeder harness Meters on wire feeder display doNot match those on power Remote control kit must be usedTroubleshooting Display. If not, refer to Problem Dure switch Be connectedBetween procedures a and B Faulty local dual procedure switchSwitch between procedures a Local dual procedure switchDual procedure switch is used to Faulty communication betweenCircuit breaker Display or Control PC board is Breaker at power source is blownOr tripped BadOnds. Turn power back on. If EP is See Problem 5 or see Section onCedure for replacing PC boards Eprom checksum error 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