Lincoln Electric 7FH manual ARC Welding can be hazardous, Apr. ‘93

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WARNING

ARC WELDING can be hazardous.

PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information it is strongly recommended that you purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

ELECTRIC SHOCK can kill.

1.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands.

1.b. Insulate yourself from work and ground using dry insulation. Make certain the insulation is large enough to cover your full area of physical contact with work and ground.

In addition to the normal safety precautions, if welding must be performed under electrically hazardous conditions (in damp locations or while wearing wet clothing; on metal structures such as floors, gratings or scaffolds; when in cramped positions such as sitting, kneeling or lying, if there is a high risk of unavoidable or accidental contact with the workpiece or ground) use the following equipment:

Semiautomatic DC Constant Voltage (Wire) Welder.

DC Manual (Stick) Welder.

AC Welder with Reduced Voltage Control.

1.c. In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head, nozzle or semiautomatic welding gun are also electrically“hot”.

1.d. Always be sure the work cable makes a good electrical connection with the metal being welded. The connection should be as close as possible to the area being welded.

1.e. Ground the work or metal to be welded to a good electrical (earth) ground.

1.f. Maintain the electrode holder, work clamp, welding cable and welding machine in good, safe operating condition. Replace damaged insulation.

1.g. Never dip the electrode in water for cooling.

1.h. Never simultaneously touch electrically “hot” parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders.

1.i. When working above floor level, use a safety belt to protect yourself from a fall should you get a shock.

1.j. Also see Items 4.c. and 6.

ARC RAYS can burn.

2.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards.

2.b. Use suitable clothing made from durable flame-resistant material to protect your skin and that of your helpers from the arc rays.

2.c. Protect other nearby personnel with suitable non-flammable screening and/or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal.

FUMES AND GASES can be dangerous.

3.a. Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases.When welding, keep your head out of the fume . Use enough ventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. When welding with electrodes which require special ventilation such as stainless or hard facing (see instructions on container or MSDS) or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes, keep exposure as low as possible and below Threshold Limit Values (TLV) using local exhaust or mechanical ventilation. In confined spaces or in some circumstances, outdoors, a respirator may be required. Additional precautions are also required when welding on galvanized steel.

3.b. Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing, cleaning or spraying operations. The heat and rays of the arc can react with solvent vapors to form phosgene, a highly toxic gas, and other irritating products.

3.c. Shielding gases used for arc welding can displace air and cause injury or death. Always use enough ventilation, especially in confined areas, to insure breathing air is safe.

3.d. Read and understand the manufacturer’s instructions for this equipment and the consumables to be used, including the material safety data sheet (MSDS) and follow your employer’s safety practices. MSDS forms are available from your welding distributor or from the manufacturer.

3.e. Also see item 7b.

WELDING SPARKS can cause fire or explosion.

4.a..Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot

materials from welding can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily available.

4.b. Where compressed gases are to be used at the job site, special precautions should be used to prevent hazardous situations. Refer to “Safety in Welding and Cutting” (ANSI Standard Z49.1) and the operating information for the equipment being used.

4.c. When not welding, make certain no part of the electrode circuit is touching the work or ground. Accidental contact can cause overheating and create a fire hazard.

4.d. Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside. They can cause an explosion even though they have been “cleaned.” For information purchase “Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances”, AWS F4.1 from the American Welding Society (see address above).

4.e. Vent hollow castings or containers before heating, cutting or welding. They may explode.

Apr. ‘93

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Contents Synergic 7F and Synergic 7FH ARC Welding can be hazardous Apr. ‘93Cylinder may explode if damaged Mar. ‘93Précautions DE Sûreté Sûreté Pour Soudage a L’ArcTable of Contents Please Examine Carton and Equipment For Damage Immediately General Description Standard FeaturesWire Feed Features Recommended Processes and EquipmentControl Features Keypad Seven key, membrane type with snap tactile feel Causes mode lights to sequenceY P a D a N D D I S P L a Y Description Top to bottom starting fromOptional Features Drive Roll and Guide Tube KitsMiscellaneous Options Model Specifications for Synergic 7F Synergic 7FHType K678-1 K679-1 K679-2 Wire Speed Range Installation Safety PrecautionsSteel Wire Sizes Roll Procedure to Install Drive Roll and Guide TubesWire Feed Drive Roll and Guide Tube Kits Aluminum Wire SizesGmaw Guns Gun and Cable Assemblies with Standard L. E. ConnectionsGun Cable Connection Innershield GunsGmaw Shielding Gas Gun Cable Connections Wire Feeder to GunSynergic 7F Water Connections for Water-Cooled Guns Current Electrical InstallationWork Cable 60% Duty Cycle Up to 100 ft Length 30mInstallation section for instructions Optional Features InstallationK648 or K649 Input Cable Assembly See Electrical Operating Instructions Power-Down SaveOperation Keys Mode Selection Current indicated positionDisplay Control Keys Run-In Selection Acceleration SelectionSelection of English or Metric Speed Display Units To Mount 10 to 44 lb 4.5-20kg Spool 12/300mm Diameter Step Trigger Mode SelectionFeeding Electrode and Brake Adjustment To Mount a 50-60lb 22.7-27.2kg Coil Feeding ElectrodeGas Guard Regulator Setting Optional K659-1 Wire Loading of 13-14lb 6kg Innershield CoilsIdle Roll Pressure Setting Making a Weld Wire Reel ChangingWire Feed Overload Protection Explanation of Prompting Error Messages Wire Reel Mounting 50 22.7kg and 60lb 27.2kg Coils MaintenanceRoutine Maintenance Avoiding Wire Feeding ProblemsTroubleshooting Guide Problems Communications in control cableProblems When trigger is closed and no For continuity Refer to WiringWiring & connections Gun connector Trigger sockets on gun connectorProblems Cold Feed key does not turn Defective keypad or Display PC For replacing PC boards Problems with serial Dual Procedure is not Gun has not been selected atWith the remote switch open. If a Troubleshooting information. SeeHXX Procedure for Replacing PC Boards Electric Shock can kill Switch RequirementsInside Input I NControl BOX Dimension Print Wire Feed Unit Dimension Print Need Welding Training? How To Read Shop DrawingsNew Lessons in Arc Welding $700.00Precaucion Warnung