Lincoln Electric IM557 Arrow keys do not change Weld, Speed or volts/trim, Source display, Boards

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E-6

TROUBLESHOOTING

E-6

 

 

 

 

Observe all Safety Guidelines detailed throughout this manual

 

 

 

 

PROBLEMS

(SYMPTOMS)

POSSIBLE

CAUSE

RECOMMENDED

COURSE OF ACTION

12. Arrow keys do not change Weld

a. This is normal, as only the WFS and

a. Refer to operation section of this manual

speed or volts/trim.

volts/trim knobs will adjust these settings.

 

 

 

 

13. WFS knob does not change

a. This is normal, as only the arrow

a. Refer to operation section of this manual.

Run-in speed.

keys will adjust this setting.

 

 

 

 

14. WFS and preset Volts/Trim para-

a. Power source is defective.

a. If parameters on power source and wire

meters on wire feeder display do

 

feeder display match when wire feeder is

not match those on power

 

connected to the other input receptacle (#1

source display.

 

or #2) of power source then power source

 

 

is defective.

 

b. Problem with serial communica-

b. Disconnect input cable from power source

 

tions in control cable.

and wire feeder. Check continuity between

 

 

socket G of 8-socket plug and pin G of 14

 

 

pin plug of the input cable. Check continu-

 

 

ity between socket H of 8-socket plug and

 

 

pin H of 14-pin plug of the input cable.

 

 

Replace cable if no continuity.

 

c. Problem with wire feeder harness

c. Remove molex plug P1 from J1 on Control

 

or Control PCB.

PCB. Check continuity from pin G of 8-pin

 

 

receptacle on wire feeder to pin 4 of plug

 

 

P1, and from pin H of 8-pin receptacle to

 

 

pin 3 of plug P1. If no continuity then repair

 

 

harness, otherwise replace Control PCB.

 

 

(See procedure for replacing PC boards.)

 

 

 

15. Display does not change when

a. A remote control kit is connected.

a. When a remote control kit is connected to

WFS and/or Volts/Trim knobs

 

the Wire Feeder, the WFS and Volts/Trim

are turned.

 

knobs of the Wire Feeder become inactive

 

 

and the WFS and Volts/Trim knobs of the

 

 

remote control kit must be used.

 

b. Broken harness wire(s) or harness

b. Check for continuity between correspond-

 

disconnected from Encoder

ing harness leads of molex plug P2 on

 

board(s) or Control board.

Control board and molex plugs P12 and

 

 

P13 on Encoder boards (refer to wiring dia-

 

 

gram). If any of these continuity tests fail,

 

 

repair or replace harness.

 

c. Defective Encoder boards and/or

c. If b. is not the problem and neither the WFS

 

Control board.

or Volts/Trim knobs are properly adjusting

 

 

then replace the Control board. If one of

 

 

the knobs is properly adjusting, plug the

 

 

harness, P12 or P13, from the working

 

 

board into the nonfunctional board. If the

 

 

previously nonfunctional board is now work-

 

 

ing then replace the Control board, other-

 

 

wise replace the nonfunctional Encoder

 

 

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 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 Feed Overload Protection Wire Reel ChangingMaking 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
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