Lincoln Electric IM559 manual Welding, Ing and gas flow rate is proper, Replace

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E-3	TROUBLESHOOTING	E-3

	Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

POSSIBLE AREAS OF MISADJUSTMENTS(S)

RECOMMENDED

COURSE OF ACTION

3. Poor arc striking with sticking or		a. Improper procedures or tech-	a. See “Gas Metal Arc Welding
	“blast-offs”, weld porosity, narrow	niques.	Guide” (GS-100).
	and ropy looking bead, or elec-
	trode stubbing into plate while	b. Improper gas shielding.	b. Clean gas nozzle. Make certain that gas
	welding.		diffuser is not restricted. Make certain that
			gas cylinder is not empty or turned off.
			Make certain gas solenoid valve is operat-
			ing and gas flow rate is proper.
			Remove gun liner and check rubber seal
			for any sign of deterioration or damage. Be
			sure set screw in brass connector is in
			place and tightened against the liner bush-
			ing.

4. Tip seizes in diffuser.		a. Tip overheating due to prolonged	a. Do not exceed current and duty
		or excessive high current and/or	cycle rating of gun.
		duty cycle welding.
			A light application of high temper-
			ature antiseize lubricant (such as
			Lincoln E2607 Graphite Grease)
			may be applied to tip threads.

5. Unit shuts off while welding and		a. See Problem 1.	a. Correct problems causing motor
	“HXX” appears on display.		overload.
		b. Defective wire feed motor or gearbox.	b. Replace.

6. Drive roll does not turn although		a. Defective Wire Feed Unit to	a. Remove Wire Feed Unit to Control
	arc voltage is present and sole-	Control box cable or harnessing.	Box Cable and Check A to A and
	noid is on.		B to B for continuity. If there is no
			continuity in either or both cases,
			replace cable. Otherwise, check
			Harnessing from A and B of MS
			connector on control box to con-
			trol board and A and B at Wire
			Feed Unit MS connector to Motor
			leads for continuity. If harnessing
			is O.K. proceed to b.
		b. Defective wire feed motor or con-	b. Set Run-In speed to maximum.
		trol PC board.	Disconnect wire drive plug P4
			from PC board. Measure voltage
			across pin 9(+) of J4 and pin 8(-)
			of J4 on PC board with pins 2 &
			12 jumpered together. If voltage
			is > 24V DC, then replace motor
			assembly. If < 24V DC, replace
			Control PC board (see Procedure
			for Replacing PC Boards).

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 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 Model InstallationType K678-2 K679-1 K679-2 Wire Speed Range 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 30mElectrical Installation section for instructions Optional Features InstallationK648, K649 or K642 Input Cable Assembly See Power-Down Save Mode SelectionOperation Operating InstructionsDisplay Control Keys Timer/Crater Select key enables 4-step with crater fill Procedure Selector SwitchMemory Ammeter Selection 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 ElectrodeGas Guard Regulator Setting Wire Loading of 13-14lb 6kg Innershield CoilsIdle Roll Pressure Setting Making a Weld Wire Reel ChangingWire Feed Overload Protection Explanation of Prompting Error Messages Accessories Optional FeaturesREADI-REEL Adapters Maintenance MaintenanceTroubleshooting Troubleshooting GuideTions in control cable Trouble shooting informationReplace contact tip 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