Lincoln Electric IM559 Replace contact tip, Tions in control cable, Trouble shooting information

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E-2	TROUBLESHOOTING	E-2

	Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

POSSIBLE AREAS OF MISADJUSTMENTS(S)

RECOMMENDED

COURSE OF ACTION

1. Rough wire feeding or wire not	a. Gun cable kinked and/or twisted.	a. Inspect gun cable and replace if
feeding but drive rolls turning.		necessary.
	b. Wire jammed in gun and cable.	b. Remove wire from gun and cable
		feed in new wire. Note any
		obstructions in gun and cable.
		Replace gun and cable if neces-
		sary.
	c. Incorrect position of drive rolls with	c. See Wire Feed Drive Roll and
	grooves.	Guide Tubs Kits section for proper
		installation of drive roll.
	d. Drive rolls loose.	d. Remove, clean, install and tighten.
	e. Gun cable dirty.	e. Clean cable or replace liner.
	f. Worn drive roll.	f. Replace.
	g. Electrode rusty and/or dirty.	g. Replace.
	h. Worn nozzle or cable liner.	h. Replace.
	i. Partially flashed or melted contact tip.	i. Replace contact tip.
	j. Incorrect idle roll pressure.	j. Set idle roll pressure per section
		on Idle Roll Pressure Setting.
	k. Improper liner, tip or guide tube.	k. Install proper equipment.

2. Variable or “hunting” arc.	a. Wrong size, worn and/or melted	a. Replace tip - remove any spatter
	contact tip.	on end of tip.
	b. Worn work cable or poor work	b. Inspect - Repair or replace as
	connection.	necessary.
	c. Loose electrode connections.	c. Be sure electrode lead is tight in
		wire feeder contact block, gun
		nozzle and gun tip tight.
	d. Wrong polarity.	d. Check connection at output studs
		for polarity required by welding
		process.
	e. Problem with serial communica-	e. Make sure control cable connections are
	tions in control cable.	tight. Check for consistent WFS. Make sure
		parameters on Power Source display, such

		as WFS, match those on wire feeder display,
		if not, try changing Synergic 7F control board.
		If problem persists refer to Power Source
		trouble shooting information.

CAUTION

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

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 Recommended Processes and Equipment Standard FeaturesWire Feed Features General DescriptionControl Features Y P a D a N D D I S P L a Y Description Mounting the Control Box K678-2 Safety PrecautionsConnecting Wire Feed Unit to Control Box Electric Shock can killAluminum Wire Sizes Procedure to Install Drive Roll and Guide TubesWire Feed Drive Roll and Guide Tube Kits Steel Wire Sizes RollInnershield Guns Gun and Cable Assemblies with Standard L. E. ConnectionsGun Cable Connection Gmaw GunsCylinder may explode if damaged Gun Cable Connections Wire Feeder to GunSynergic 7F Water Connections for Water-Cooled Guns Gmaw Shielding Gas60% Duty Cycle Up to 100 ft Length 30m Electrical InstallationWork Cable CurrentK648, K649 or K642 Input Cable Assembly See Optional Features InstallationElectrical Installation section for instructions Operating Instructions Power-Down SaveMode Selection OperationDisplay 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 Replace WeldingIng and gas flow rate is proper IngControl PC board see Procedure for No control of wire feedTers on wire feeder display do not Defective wire feed motor tach orOr there may be a problem with Wire feed motor runs and solenoid Power source is defectiveWiring harness or Control PC Speed does not change when Run-in and weld speeds are setRemote control kit must be used Meters on wire feeder display doNot match those on power Problem with wire feeder harnessTroubleshooting Faulty local dual procedure switch Dure switch Be connectedBetween procedures a and B Display. If not, refer to ProblemFaulty communication between Local dual procedure switchDual procedure switch is used to Switch between procedures aBad Breaker at power source is blownOr tripped Circuit breaker Display or Control PC board isX8 on Control PC board is faulty See Problem 5 or see Section onCedure for replacing PC boards Eprom checksum error Onds. Turn power back on. If EP isSwitch 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