Lincoln Electric IM557 manual Troubleshooting

Page 36

E-2	TROUBLESHOOTING	E-2

	Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

POSSIBLE

CAUSE

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 on end of
	contact tip.	tip.
	b. Worn work cable or poor work	b. Inspect - Repair or replace as necessary.
	connection.
	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 polari-
		ty 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, see Problem 14, otherwise try chang-
		ing Synergic 7 control board. If problem per-
		sists 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 7 & 7H

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Contents Synergic 7 and 7H 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 Installation Technical Specifications Synergic 7 and 7HType K631-3 K631-4 Wire Speed Range Size & Weight Without Wire Stand With K377 Wire StandStandard Features Wire Drive FeaturesGeneral Description Recommended Processes and EquipmentControl Features Y P a D a N D D I S P L a Y Description RUN-IN WFSSafety Precautions Electric Shock can killProcedure to Install Drive Roll and Guide Tubes Wire Feed Drive Roll and Guide Tube KitsSteel Wire Sizes Roll Aluminum Wire SizesGun Cable Connection Wire Feeder to Gun Gun and Cable AssembliesFor GMA Gun Cables Gmaw GunsShut off shielding gas supply when not in use Synergic 7 Water Connections for Water- Cooled GunsGmaw Shielding Gas Cylinder may explode if damagedElectrical Installation Warning Optional Features Installation Work CableCurrent 60% Duty Cycle Up to 100 ft Length 30mInstallation Mode Selection Power-Down SaveOperation Operating InstructionsPreset voltage/trim may be adjusted Display Control KeysCold Feed Step Trigger Mode Selection Dual Procedure Remote Control K1449-1Procedure Selector Switch Memory Ammeter SelectionWire Loading Figure B.1a Threaded Locking CollarInnershield Coils To remove the wire reel from its shaft, grasp Knob so it seats into the shaft when releasedCut the tie wires at this time Coil tie wiresFeeding Electrode READI-REELS a K438 READI-REEL Adapter Must be UsedIdle Roll Pressure Setting Gas Guard Regulator SettingWire Reel Changing Wire Feed Overload ProtectionMaking a Weld Explanation of Prompting Error Messages Grounding Lead ProtectorAccessories Optional FeaturesUniversal Wire Reel Stand K1524-1 60 LB .2 KG Coil Adapter K1504-1READI-REEL Adapters MISC. Options K179 type vacuum unit not recommended for use with SynergicMaintenance MaintenanceAvoiding Wire Feeding Problems Routine Maintenance1TROUBLESHOOTINGE-1 Locate Problem SymptomTroubleshooting 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 Connector J1 on control PCWire 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 Wiring harness, or Control boardLocal dual procedure switch Dual procedure switch is used toSwitch between procedures a Faulty communication betweenTroubleshooting HXX Procedure for Replacing PC Boards Electric Shock can kill Diagrams Wiring Diagram SynergicInput Connection Diagram Electric Shock Can KillDimension Print W I R E R E E L S T a N DSynergic 7 & 7H Synergic 7 & 7H Synergic 7 & 7H Synergic 7 & 7H Precaucion Warnung