Lincoln Electric IM559 manual Table of Contents

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		TABLE OF CONTENTS					vi
					Page
	Installation			Section A
	Technical Specifications				A-1
	GeneralDescription				A-2
	Recommended Processes and Equipment				A-2
	Standard Features				A-2, A-3
	Keypad and Display Description				A-4
	Safety Precautions				A-5
	Installation of the Synergic 7F Components				A-5
	Mounting the Wire Feed Unit (K679-1 or -2)				A-5
	Mounting the Control Box (K678-2)				A-5
	Connecting Wire Feed Unit to Control Box				A-5
	Electrode Routing				A-5
	Wire Feed Drive Roll and Guide Tube Kits				A-6
	Standard 4-Roll Kits (KP655 and KP656)				A-6
	Gun and Cable Assemblies With Standard L.E. Connection			.................................	A-7
	GMAW Guns				A-7
	Innershield Guns				A-7
	Gun Cable Connection				A-7
	Gun and Cable AssembliesWith Fast-Mode Connection				A-7
	GMAW Guns				A-7
	Gun Cable Connections: Wire Feeder to Gun				A-8
	Synergic 7F Water Connections				A-8
	GMAW Shielding Gas				A-8
	Gas Guard Regulator				A-8
	Electrical Installation				A-9
	Optional Features Installation				A-10

Operation				Section B
	Safety Precautions				B-1
	Duty Cycle				B-1
	Keypad Setup and Operation			B-1. B-2, B-3
	Procedure Selection Switch				B-4
	Dual Procedure Remote Control (K1449-1)				B-4
	Wire Reel Loading				B-5, B-6
	Idle Roll Pressure Setting				B-7
	Gas Guard Regulator Setting				B-7
	Making a Weld				B-8
	Wire Reel Changing				B-8
	Wire Feed Overload Protection				B-8
	Explanation of Prompting and Error Messages				B-9

	Accessories			Section C
	Optional Features				C-1

	Maintenance			Section D
	Safety Precautions				D-1
	Routine Maintenance				D-1
	Periodic Maintenance				D-1

	Troubleshooting			Section E
	Safety Precautions				E-1
	Troubleshooting Guide			E-2 thru E-11
	Procedure for Replacing PC Boards				E-12
	Gun Cable Connector Requirements to Permit Proper Connection to Synergic 7F Wire Feed Units				E-12

	Diagrams			Section F
	Wiring				F-1
	Input Connection				F-2
	Dimension Prints				F-3 - F-4

	Parts Lists				P-266

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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