Lincoln Electric IM557 manual Optional Features Installation, Work Cable, Current

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A-10

INSTALLATION

A-10

 

 

 

4)Connect the remaining end of the control cable with the 8-socket cable plug to the mating recepta- cle on the Synergic 7.

5)Install the input cable under the wire reel mounting stand strain relief clamp. Remove the screws hold- ing the clamp to the base of the wire reel mounting assembly, put the input cable assembly under the clamp and reinstall the screws.

Work Cable

Connect a work lead of sufficient size and length (per the following table) between the proper output terminal on the power source and the work. Be sure the con- nection to the work makes tight metal-to-metal electri- cal 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.

OPTIONAL FEATURES

INSTALLATION

K178-1Mounting Platform - Synergic 7 Models on Synergic Power Sources (Requires a K303, K376, K377, K378 or K445 Wire Reel Assembly) This is a turntable type platform for mounting the Synergic 7 on the top of Synergic power sources. Bolt the platform to the lift bail per instructions (M16260) supplied with the platform.

K162-HSpindle for Mounting Readi-Reels and 2" (51

mm)I.D. Spools (60 lb/27 kg Capacity) (For use with

K303 and K376 Wire Reel Stand) To mount the 2" spin- dle kit for Readi-Reels and 10 through 60 pound spools, remove the shaft for the standard 50-60 pound wire coils from the mounting framework. Install the spindle per the instructions shipped with the kit.

When used with Readi-Reels, a Readi-Reel Adapter is required.

For 8" O.D. (200 mm) spools, a K468 Spindle Adapter is available.

K163 Undercarriage (Requires K303, K376, K377, or

K378) The undercarriage includes casters, wheels, a handle and related hardware. Casters are mounted at the front and the wheels to the rear of the platform. The handle is bolted to the front of the platform so the Synergic 7 can be tilted back and wheeled like a two- wheel truck. Instruction sheet M13424 for assembly installing the K303, K376, K377, or K378 wire stand is provided with the undercarriage.

K683-1- Dual Procedure Switch Dual Procedure Switch mounts to gun with appropriate bracket, provid- ed, per the installation instructions included with the kit. 3-pin switch cord plug connects to 3-pin remote receptacle on the front panel of the Synergic 7 Wire Feed Unit.

K1449-1- Dual Procedure Remote Control Provides remote rotating knob encoder control of Wire Feed Speed and Volts/Trim, along with a dual procedure selector switch, which disables comparable front panel controls when the remote control is connected.

The 4-pin plug of the remote control connects to the mating receptacle on the bottom of the Synergic 7 Control box.

K590-4- Water Connection Kit Install per the instruc- tions shipped with the kit.

K648, K649, K651 or K642 Input Cable Assembly See Electrical Installation section for instructions

K675, K676 or K677 Input Cable Assembly (Gas) See Electrical Installation and Shielding Gas Connections sections for instructions.

K640, K641 or K650 Input Cable Assembly (Water & Gas) See Electrical Installation, Water Connections and Shielding gas connections sections for instruc- tions.

K376 50-60 Lb. Wire Reel Mounting Stand (without dust shield) and

K303 50-60 Lb. Wire Reel Mounting Stand (with dust shield) The assembly includes a framework to which is attached the 50-60 lb. wire reel, a mounting spindle, a lift bail, and a cable clamp for fastening the input cable assembly. It is easily mounted to the basic wire feed unit by three bolts. The reel mounting spindle is the pull knob type with a built-in brake.

The brake pad is adjustable for proper braking at low or high wire feed speeds.

SYNERGIC 7 & 7H

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Contents Synergic 7 and 7H 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 Technical Specifications Synergic 7 and 7H InstallationType K631-3 K631-4 Wire Speed Range Size & Weight Without Wire Stand With K377 Wire StandWire Drive Features Standard FeaturesGeneral Description Recommended Processes and EquipmentControl Features RUN-IN WFS Y P a D a N D D I S P L a Y DescriptionElectric Shock can kill Safety PrecautionsWire Feed Drive Roll and Guide Tube Kits Procedure to Install Drive Roll and Guide TubesSteel Wire Sizes Roll Aluminum Wire SizesGun and Cable Assemblies Gun Cable Connection Wire Feeder to GunFor GMA Gun Cables Gmaw GunsSynergic 7 Water Connections for Water- Cooled Guns Shut off shielding gas supply when not in useGmaw Shielding Gas Cylinder may explode if damagedElectrical Installation Warning Work Cable Optional Features InstallationCurrent 60% Duty Cycle Up to 100 ft Length 30mInstallation Power-Down Save Mode SelectionOperation Operating InstructionsDisplay Control Keys Preset voltage/trim may be adjustedCold Feed Dual Procedure Remote Control K1449-1 Step Trigger Mode SelectionProcedure Selector Switch Memory Ammeter SelectionFigure B.1a Threaded Locking Collar Wire LoadingInnershield Coils Knob so it seats into the shaft when released To remove the wire reel from its shaft, graspCut the tie wires at this time Coil tie wiresREADI-REELS a K438 READI-REEL Adapter Must be Used Feeding ElectrodeGas Guard Regulator Setting Idle Roll Pressure SettingMaking a Weld Wire Reel ChangingWire Feed Overload Protection Grounding Lead Protector Explanation of Prompting Error MessagesOptional Features Accessories60 LB .2 KG Coil Adapter K1504-1 Universal Wire Reel Stand K1524-1READI-REEL Adapters K179 type vacuum unit not recommended for use with Synergic MISC. OptionsMaintenance MaintenanceAvoiding Wire Feeding Problems Routine MaintenanceLocate Problem Symptom 1TROUBLESHOOTINGE-1Troubleshooting Ing and gas flow rate is proper WeldingIng ReplaceTers on wire feeder display do not No control of wire feedDefective wire feed motor tach or Connector J1 on control PCWiring harness or Control PC Wire feed motor runs and solenoid Power source is defectiveSpeed does not change when Run-in and weld speeds are set Or there may be a problem withNot match those on power Meters on wire feeder display doProblem with wire feeder harness Remote control kit must be usedTroubleshooting Between procedures a and B Dure switch Be connectedDisplay. If not, refer to Problem Wiring harness, or Control boardDual procedure switch is used to Local dual procedure switchSwitch between procedures a Faulty communication betweenTroubleshooting HXX Procedure for Replacing PC Boards Electric Shock can kill Wiring Diagram Synergic DiagramsElectric Shock Can Kill Input Connection DiagramW I R E R E E L S T a N D Dimension PrintSynergic 7 & 7H Synergic 7 & 7H Synergic 7 & 7H Synergic 7 & 7H Precaucion Warnung
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