Lincoln Electric IM557 manual Making a Weld, Wire Reel Changing, Wire Feed Overload Protection

B-10 OPERATION B-10

Making a Weld

1)Use only Power Wave model “synergic” power sources.

2)Properly connect the electrode and work leads for the correct electrode polarity.

3)Use Mode Selection key to set desired operating mode. (Refer to Mode Selection section.)

4)Use Function Select and Arrow keys to set desired Run-in and encoder knob to set Weld Feed Speed. (Set for each procedure if using a Dual Procedure function). (See the appropriate sections for adjust- ing procedures).

5)Adjust the voltage or percent trim, if desired, (for each procedure if using a Dual Procedure function) using the encoder knob in “Volts/Trim” function (refer to Volts/Trim section). The final setting can be adjusted according to the desired arc voltage while welding.

6)Use Timer/Crater Select and Arrow keys to set desired timers, or crater speed if 4-step trigger with Crater fill has been selected. (Refer to the Timer/Crater section).

7)Feed the electrode through the gun and cable and then cut the electrode within approximately

.38” (9.5mm) of the end of the contact tip for solid wire, and within approximately .75” (19mm) of the extension guide for cored wire.

8)Connect work cable to metal to be welded. Work cable must make good electrical contact to the work. The work must also be grounded as stated in “Arc Welding Safety Precautions”.

WARNING

When using an Open Arc process, it is necessary to use correct eye, head, and body protection

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9) If used, be sure shielding gas valve is turned on.

10)Position electrode over joint. End of electrode may be lightly touching the work.

11)Lower welding helmet, close gun trigger and start welding. Hold the gun so the contact tip to work distance gives the correct electrical stickout as required for the procedure being used.

12)To stop welding, release the gun trigger and then pull the gun away from the work after the arc goes out and Postflow time, if used, is over.

13)If necessary to optimize arc starting, adjust wire speed acceleration, and/or Run-In speed. (See the appropriate sections for adjusting procedures).

Wire Reel Changing

At the end of a coil, remove the last of the old elec- trode coil from the conductor cable by either pulling it out at the nozzle end of the gun or by using the follow- ing procedure:

1)Cut the end of the electrode off at the gun end. Do not break it off by hand because this puts a slight bend in the wire making it difficult to pull it back through the nozzle.

2)Disconnect the gun cable from the gun connector on the Synergic 7 Wire Feed Unit and lay the gun and cable out straight.

3)Using pliers to grip the wire, pull it out of the cable from the connector end.

4)After the electrode has been removed, reconnect the gun cable to the Synergic 7.

Load a new reel of electrode per the instructions in the Wire Reel Loading sections.

Wire Feed Overload Protection

The Synergic 7 has solid-state overload protection of the wire drive motor. If the wire drive motor becomes overloaded for an extended period of time, the protec- tion circuitry turns off the power source, wire feed and solenoid and then displays H30. This indicates the wire drive motor is overloaded and the number indi- cates the time remaining in seconds before the unit will automatically reset. The number continues to decrement every second until it reaches 0. At that time, the unit resets automatically and the previous display will return indicating the unit is ready to oper- ate again. Overloads can result from improper tip size, liner, drive rolls, or guide tubes, obstructions or bends in the gun cable, feeding wire that is larger than the rated capacity of the feeder or any other factors that would impede normal wire feeding. (See section on Avoiding Wire Feeder Problems.)

SYNERGIC 7 & 7H