Lincoln Electric IM557 manual General Description, Recommended Processes and Equipment

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INSTALLATION

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GENERAL DESCRIPTION

The Synergic 7 is a semiautomatic constant speed wire feeder designed specifically for use with the Invertec Power Wave type power sources. A serial communication link is supplied through the control cable of the Synergic 7 enabling information to be shared between the power source and wire feeder. The Synergic 7 comes factory equipped with a gas solenoid valve with gas fittings and standard Lincoln gun connector. These models includes a 3-1/2 digit LED display with rotating knob encoder controls for setting the wire feed speed and voltage and a dual pro- cedure selector switch. A tactile-feel keypad provides selection of operating mode, function selection, timer and crater fill selection and parameter adjustment. Two keys provide Cold Feed and Gas Purge functions, and connector receptacles are provided for an optional dual procedure remote control and dual procedure switch.

The unit has 3 operating modes: 2-step trigger, 4-step trig-

ger and spot. Three functions can be selected: Volts or Trim Preset/arc (memory) voltmeter, Run-in speed and weld speed (IPM or m/min.) or (memory) ammeter. In addition, when 4-step trigger mode is selected, crater fill WFS is also adjustable. Up to three timers are available depending on the mode: preflow, postflow and spot, and 5 acceleration rates are selectable, as well as 6 Burnback settings.

The Synergic 7 is available in 2 models:

Ordering

 

 

Speed Range

Wire Size Range

Information

Model

Drive

IPM (m/m)

IN. (MM)

 

 

 

 

 

K631-3

Synergic

4-Roll

50 - 770

.025 - 3/32

 

7

 

(1.25 - 19.5)

(0.6 - 2.4)

 

 

 

 

 

K631-4

Synergic

4-Roll

80 - 1200

.025 - .045

 

7H

 

(2.00 - 30.5)

(0.6 - 1.2)

 

 

 

 

 

RECOMMENDED PROCESSES AND EQUIPMENT

The Synergic 7 wire feed unit has the following wire feeding capabilities:

a)Feeds .025 - 1/16” (0.6-1.6mm) solid wire for gas-metal-arc processes.

b)Feeds .045 - 3/32” (1.2-2.4mm) cored wire for Outershield GMA or Innershield processes up to 5/64” (2.0 mm).

The Synergic 7H wire feed unit has the following wire feeding capabilities:

a)Feeds .025 - .045” (0.6-1.2mm) solid wire for gas-metal-arc processes.

b)Feeds .045 - (1.2mm) cored wire for Outershield GMA or Innershield processes.

Recommended power sources are The Lincoln Electric Company Synergic type Invertec® Power Wave power sources with 42VAC auxiliary power, and a 14-pin connector receptacle.

STANDARD FEATURES

Wire Drive Features:

Wire Drive Unit - Incorporates low voltage permanent magnet motor and highly efficient two-reduction spur gearbox which operates in any position. The non-fluid lubricant won’t leak.

“Quick Release” Wire Feed System - Provides a completely tool-less means for releasing and opening the idle roll pressure arm, precisely adjusting the idle roll pressure and changing the incoming and outgoing guide tubes and drive rolls.

Drive Rolls and Guide Tubes - Provide long life, positive feeding and precise alignment of electrode. Minimizes “birdnest” or mill-thru of wire if properly set. (Ordered separately.)

Tachometer Feedback - Provides proper wire feed acceleration and speed accuracy, independent of fluc- tuations in line voltage and wire loading, for reliable arc starting and weld consistency.

Run-in Speed Setting - Allows the arc striking speed “Run-in” to be adjusted independently of the weld feed speed for starting optimization.

Cold Feed Speed - Provides cold feed speed adjustment independent of weld, run-in and crater speeds.

Selectable Acceleration - Provides front panel selec- tion of 5 acceleration rates. This feature in combina- tion with Run-in Speed provides the ability to easily optimize starting on any process or procedure.

Solid-State Dynamic Braking - Quickly stops wire feed motor to minimize wire overrun during weld termina- tion. Solid-state design requires no maintenance.

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 Reel Changing Wire Feed Overload ProtectionMaking 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