Lincoln Electric IM557 Dure switch Be connected, Between procedures a and B, Faulty Control board

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E-8

TROUBLESHOOTING

E-8

 

 

 

 

Observe all Safety Guidelines detailed throughout this manual

 

 

 

 

PROBLEMS

(SYMPTOMS)

POSSIBLE

CAUSE

RECOMMENDED

COURSE OF ACTION

17. Dual procedure is not functioning

a. Optional gun dual procedure

a. When the dual procedure switch is in the “Gun”

when using the local dual proce-

switch or remote control kit may

position then either the remote or the optional gun

dure switch.

be connected.

dual procedure switch must be used to select

 

 

between procedures “A” and “B”.

 

b. Serial communication problem.

b. Make sure that parameters on power source dis-

 

 

play, such as WFS, match those on wire feeder

 

 

display. If not, refer to Problem 14.

 

c. Faulty local dual procedure switch, c. Disconnect harness plug from J2 on Control

 

wiring harness, or Control board.

board. Check continuity between plug pins 1 and

 

 

12 when local dual procedure switch is in position

 

 

"A", but not when in "Gun" or "B". Now check con-

 

 

tinuity between plug pins 5 and 12 when local dual

 

 

procedure switch is in position "B", but not when in

 

 

"Gun" or "A". If any of these continuity tests fail,

 

 

repair or replace switch or switch harness to cor-

 

 

rect problem. Otherwise, replace Control board.

 

 

(See procedure for replacing PC boards.)

 

 

 

18. Optional gun dual procedure

a. Local dual procedure switch is not in "Gun"

a. Place local dual procedure switch in "Gun" posi-

switch is not functioning properly.

position, and/or remote control kit's dual

tion and, if a remote control kit is attached, place

 

procedure switch is not in "Gun" position.

its dual procedure switch in "Gun" position also.

 

b. Faulty remote control kit.

b. If a remote control kit is attached, remove it. If

 

 

this solves the problem, refer to Problem 19.

 

c. Serial communication problem.

c. Make sure parameters on power source display,

 

 

such as WFS, match those on wire feeder display.

 

 

If not, refer to Problem 14.

 

d. Faulty optional gun dual proce-

d. Remove switch. Make sure there is continuity

 

dure switch.

between switch pins with switch closed, and no

 

 

continuity with switch open. If either of these tests

 

 

failed, repair or replace switch.

 

e. Faulty wiring harness or optional

e. Remove optional gun dual procedure switch and

 

gun dual procedure amphenol.

disconnect harness plug from J2 on Control

 

 

board. Check that there is continuity between pin

 

 

A of receptacle J17 and pin 13 of plug P2. Check

 

 

that there is continuity between pin C of recepta-

 

 

cle J17 and pin 4 of plug P2. Check no continuity

 

 

between pins A and C of receptacle J17. If any of

 

 

these continuity tests fail, repair or replace switch

 

 

amphenol J17 or switch harness.

f. Faulty local dual procedure switch. f. Perform step c. of Problem 17.

g. Faulty Control board.

g. 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 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 Type K631-3 K631-4 Wire Speed Range InstallationTechnical Specifications Synergic 7 and 7H Size & Weight Without Wire Stand With K377 Wire StandGeneral Description Standard FeaturesWire Drive Features 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 killSteel Wire Sizes Roll Procedure to Install Drive Roll and Guide TubesWire Feed Drive Roll and Guide Tube Kits Aluminum Wire SizesFor GMA Gun Cables Gun Cable Connection Wire Feeder to GunGun and Cable Assemblies Gmaw GunsGmaw Shielding Gas Shut off shielding gas supply when not in useSynergic 7 Water Connections for Water- Cooled Guns Cylinder may explode if damagedElectrical Installation Warning Current Optional Features InstallationWork Cable 60% Duty Cycle Up to 100 ft Length 30mInstallation Operation Mode SelectionPower-Down Save Operating InstructionsPreset voltage/trim may be adjusted Display Control KeysCold Feed Procedure Selector Switch Step Trigger Mode SelectionDual Procedure Remote Control K1449-1 Memory Ammeter SelectionWire Loading Figure B.1a Threaded Locking CollarInnershield Coils Cut the tie wires at this time To remove the wire reel from its shaft, graspKnob so it seats into the shaft when released 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 SynergicAvoiding Wire Feeding Problems MaintenanceMaintenance Routine Maintenance1TROUBLESHOOTINGE-1 Locate Problem SymptomTroubleshooting Ing WeldingIng and gas flow rate is proper ReplaceDefective wire feed motor tach or No control of wire feedTers on wire feeder display do not Connector J1 on control PCSpeed does not change when Run-in and weld speeds are set Wire feed motor runs and solenoid Power source is defectiveWiring harness or Control PC Or there may be a problem withProblem with wire feeder harness Meters on wire feeder display doNot match those on power Remote control kit must be usedTroubleshooting Display. If not, refer to Problem Dure switch Be connectedBetween procedures a and B Wiring harness, or Control boardSwitch between procedures a Local dual procedure switchDual procedure switch is used to 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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