Lincoln Electric IM557 manual Troubleshooting

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E-7

TROUBLESHOOTING

E-7

 

 

 

 

Observe all Safety Guidelines detailed throughout this manual

 

 

 

 

PROBLEMS

(SYMPTOMS)

POSSIBLE

CAUSE

RECOMMENDED

COURSE OF ACTION

16.Wire feeder's display does not change when WFS and/or Volts/Trim knobs of the remote control kit are turned.

a. Loose connection to Remote con- trol receptacle, J16.

b. Faulty Remote PC board.

c. Faulty remote cable.

d. Faulty remote wiring harness.

e. Faulty wire feeder harness or remote cable receptacle.

f. Faulty Control board or Remote PC board.

a. Make sure that remote cable connec- tions are tight.

b. If either the WFS knob, the Volts/Trim knob, or the dual procedure switch of the remote control kit is operating properly then replace the Remote PC board.

c. Remove remote cable from wire feed- er and unplug connector P2 from J2 in remote control kit. Check continuity between pin 1 of J2 and socket B of remote receptacle, between pin 2 of

J2 and socket A of remote receptacle, between pin 3 of J2 and socket D of remote receptacle, and between pin 4 of J2 and socket C of remote recepta- cle. If any of these continuity tests fail then repair or replace remote cable.

d. Remove plug from J1 on Remote PC board and unplug connector P2 from J2 in remote control kit. Check conti- nuity between pin 1 of P2 and pin 2 of P1, between pin 2 of P2 and pin 3 of P1, between pin 3 of P2 and pin 4 of P1, and between pin 4 of P2 and pin 5 of P1. If any of these tests failed, repair or replace remote wiring har- ness.

e. Remove plug from J2 on Control board of wire feeder and remove remote cable from wire feeder. Check continuity between socket A of remote receptacle J16 and pin 14 of plug P2, between socket B of remote recepta- cle and pin 7 of plug P2, between socket C of remote receptacle and pin 15 of plug P2, and between socket D of remote receptacle and pin 16 of plug P2. If any of these tests failed then repair or replace wiring harness. Check continuity between either of the four pins of receptacle J16. If there is continuity between either of the pins then receptacle is faulty.

f.Try replacing Remote PC board. If this does not solve the problem then replace Control board of wire feeder. (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 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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