Lincoln Electric IM557 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

CAUSE

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 motor or con-	a. Set Run-in speed to maximum.
	arc voltage is present and sole-	trol PC board.	Disconnect wire drive plug P5
	noid is on.		from PC board. Measure voltage
			across pin 1 (+) of J5 and pin 2 (-)
			of J5 on PC board with trigger
			closed. If voltage is ≥24 VDC,
			then replace motor assembly. If
			≤24 VDC, 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 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 SettingWire Feed Overload Protection Wire Reel ChangingMaking a Weld 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