Lincoln Electric IM557 manual Table of Contents

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TABLE OF CONTENTS

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				Page
		Installation		Section A
		Technical Specifications		A-1
		General Description		A-2
		Recommended Processes and Equipment		A-2
		Standard Features		A-2
		Keypad and Display Description		A-4
		Safety Precautions		A-5
		Installation of the Synergic 7 Components		A-5
		Attaching Wire Reel Stand		A-5
		Wire Feed Drive Roll and Guide Tube Kits		A-6
		Standard 4-Roll Kits (KS655 and KS656)		A-6
		Procedure to Install Drive Roll and Guide Tubes		A-6
		Gun and Cable Assemblies		A-7
		GMAW Guns		A-7
		Innershield Guns		A-7
		Gun and Cable Connections		A-7
		Wire Feeder to Gun		A-7
		For GMA Gun Cables		A-7
		Synergic 7 Water Connections		A-8
		GMAW Shielding Gas		A-8
		Gas Guard Regulator		A-8
		Electrical Installation		A-9
		Optional Features Installation		A-10

Operation				Section B
		Safety Precautions		B-1
		Duty Cycle		B-1
		Keypad Setup and Operation		B-1
		Procedure Selector Switch		B-4
		Dual Procedure Remote Control (K1449-1)		B-4
		Wire Reel Loading		B-5
		Idle Roll Pressure Setting		B-9
		Gas Guard Regulator Setting		B-9
		Making a Weld		B-10
		Wire Reel Changing		B-10
		Wire Feed Overload Protection		B-10
		Grounding Lead Protector		B-11
		Explanation of Prompting and Error Messages		B-11

		Accessories		Section C
		Optional Features		C-1

		Maintenance		Section D
		Safety Precautions		D-1
		Routine Maintenance		D-1
		Periodic Maintenance		D-1

		Troubleshooting		Section E
		Safety Precautions		E-1
		Troubleshooting Guide		E-2
		Procedure for Replacing PC Boards		E-12

		Diagrams		Section F
		Wiring		F-1
		Input Connection		F-2
		Dimension Print		F-3

		Parts Lists		P-278 Series

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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 Size & Weight Without Wire Stand With K377 Wire Stand InstallationTechnical Specifications Synergic 7 and 7H Type K631-3 K631-4 Wire Speed RangeRecommended Processes and Equipment Standard FeaturesWire Drive Features General DescriptionControl Features RUN-IN WFS Y P a D a N D D I S P L a Y DescriptionElectric Shock can kill Safety PrecautionsAluminum Wire Sizes Procedure to Install Drive Roll and Guide TubesWire Feed Drive Roll and Guide Tube Kits Steel Wire Sizes RollGmaw Guns Gun Cable Connection Wire Feeder to GunGun and Cable Assemblies For GMA Gun CablesCylinder may explode if damaged Shut off shielding gas supply when not in useSynergic 7 Water Connections for Water- Cooled Guns Gmaw Shielding GasElectrical Installation Warning 60% Duty Cycle Up to 100 ft Length 30m Optional Features InstallationWork Cable CurrentInstallation Operating Instructions Mode SelectionPower-Down Save OperationDisplay Control Keys Preset voltage/trim may be adjustedCold Feed Memory Ammeter Selection Step Trigger Mode SelectionDual Procedure Remote Control K1449-1 Procedure Selector SwitchFigure B.1a Threaded Locking Collar Wire LoadingInnershield Coils Coil tie wires To remove the wire reel from its shaft, graspKnob so it seats into the shaft when released Cut the tie wires at this timeREADI-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. OptionsRoutine Maintenance MaintenanceMaintenance Avoiding Wire Feeding ProblemsLocate Problem Symptom 1TROUBLESHOOTINGE-1Troubleshooting Replace WeldingIng and gas flow rate is proper IngConnector J1 on control PC No control of wire feedTers on wire feeder display do not Defective wire feed motor tach orOr there may be a problem with Wire feed motor runs and solenoid Power source is defectiveWiring harness or Control PC Speed does not change when Run-in and weld speeds are setRemote control kit must be used Meters on wire feeder display doNot match those on power Problem with wire feeder harnessTroubleshooting Wiring harness, or Control board Dure switch Be connectedBetween procedures a and B Display. If not, refer to ProblemFaulty communication between Local dual procedure switchDual procedure switch is used to Switch between procedures aTroubleshooting 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