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Lincoln Electric IM557 manual

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Table of contents for the manual

  • Page 1

    Synergic 7 and 7H OPERA TOR’S MANUAL IM557 August, 2005 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thought- ful operation on your part. DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS M[...]

  • Page 2

    FOR ENGINE powered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors. ________________________________________________[...]

  • Page 3

    ii SAFETY ii ARC RA YS can burn. 4.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. 4.b. Use suitable clothing made from durable flame-resistant material to protect your skin[...]

  • Page 4

    FOR ELECTRICALL Y powered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations. 8.c. Ground the equipment in accordance with the U.S. National Electrical C[...]

  • Page 5

    iv SAFETY iv Mar. ‘93 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instruc- tions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. Les[...]

  • Page 6

    v v Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay[...]

  • Page 7

    vi vi T ABLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications ........................................................................................A-1 General Description .........................................................[...]

  • Page 8

    A-1 INST ALLA TION SYNERGIC 7 & 7H A-1 TECHNICAL SPECIFICA TIONS – SYNERGIC 7 AND 7H SYNERGIC 7 SYNERGIC 7H WIRE FEEDER - (4 - ROLL) K631-3 50 - 770 1.25 - 19.5 .025 - 1/16” 0.6 - 1.6mm .045 - 3/32” 1.2 - 2.4mm -20°C to +40°C -40°C to +40°C K631-4 80 - 1200 2.00 - 30.5 .025 - .045” 0.6 - 1.2mm .045” 1.2mm Model Type Wire Speed Ran[...]

  • Page 9

    A-2 INST ALLA TION SYNERGIC 7 & 7H A-2 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 [...]

  • Page 10

    A-3 INST ALLA TION SYNERGIC 7 & 7H A-3 Crater Fill - Provides crater feed speed adjustment (in 4-step trigger mode) independent of weld, cold inch, or run-in speeds. Solid-State Overload Protection - No circuit breaker to reset. Front panel display indicates time remaining before automatic reset. Gas Solenoid Valve - Complete with inlet fitting[...]

  • Page 11

    A-4 INST ALLA TION SYNERGIC 7 & 7H A-4 Keypad - Seven key, membrane type with “snap” tactile feel and embossed domes. Long life design. Spatter resistant surface. Display - 3-1/2 digit 7-segment LED with (+) or (-) polarity indica- tors. .56” (14.2mm) character height. Displays arc voltage in volts, wire speed in IPM or m/m and all timers[...]

  • Page 12

    A-5 INST ALLA TION SYNERGIC 7 & 7H A-5 INST ALLA TION OF THE SYNERGIC 7 COMPONENTS Safety Precautions Attaching Wire Reel Stand The mounting hardware for mounting the wire reel stand is included with the wire feeder. (Screws and washers are inserted in their respective mounting holes.) To connect: 1) Remove the three 3/8" (9.5 mm) hex head[...]

  • Page 13

    A-6 INST ALLA TION SYNERGIC 7 & 7H A-6 Wire Feed Drive Roll and Guide T ube Kits NOTE: The maximum sizes the Synergic 7 will feed satisfactorily are the 3/32” (2.4mm) cored and 1/16” (1.6mm) solid electrodes. The maximum sizes the Synergic 7H will feed satisfactorily are the .045 (1.2mm) cored and .045” (1.2mm) solid electrodes. The elect[...]

  • Page 14

    A-7 INST ALLA TION SYNERGIC 7 & 7H A-7 8) Back out the screws for the incoming and outgoing guide tubes. 9) Install the longer guide tube in the rear hole near the incoming drive roll. Slide the tube in until it almost touches the roll. Tighten in place. 10) Install the remaining guide tube in the front hole. Be certain that the proper plastic [...]

  • Page 15

    A-8 INST ALLA TION SYNERGIC 7 & 7H A-8 Synergic 7 W ater Connections (for W ater- Cooled Guns) These Synergic 7 models must have a K590-4 Water Connection Kit installed. See Options Installation section. 1 ) Using male quick-connect fittings (included with appropriate Synergic 7 input cable assemblies), con- nect the water hoses to the coolant [...]

  • Page 16

    A-9 INST ALLA TION SYNERGIC 7 & 7H A-9 ELECTRICAL INST ALLA TION Input Cable: Synergic 7 Wire Feeder to Power Wave Synergic Type Power Sources NOTE: CSAnrtl certification of the Synergic 7 models is with input cable assemblies identified by carton date codes 010161, or above. These assemblies have grounding lead continuity between the 14-pin pl[...]

  • Page 17

    A-10 INST ALLA TION SYNERGIC 7 & 7H A-10 4 ) Connect the remaining end of the control cable with the 8-socket cable plug to the mating recepta- cle on the Synergic 7. 5) Install the input cable under the wire reel mounting stand strain relief clamp. Remove the screws hold- ing the clamp to the base of the wire reel mounting assembly, put the in[...]

  • Page 18

    A-1 1 INST ALLA TION SYNERGIC 7 & 7H A-1 1 Wire Reel Dust Shield for K376 50-60 Lb. Wire Reel Mounting Stand - If the user desires to protect the wire from falling dirt and dust, there is a shield avail- able to cover the wire reel. Order part number S14543. Instructions are included with the kit. Wire Reel Dust Shield Door for K303 and K376 (w[...]

  • Page 19

    B-1 OPERA TION B-1 SYNERGIC 7 & 7H OPERA TING INSTRUCTIONS Safety Precautions Duty Cycle The Synergic 7 models are rated at 60% duty cycle * for a maximum current of 600 amps. * Based on a 10 minute time period (6 minutes on, and 4 minutes off). KEYP AD SETUP AND OPERA TION Power-Down Save Power to the Synergic 7 is supplied and controlled from[...]

  • Page 20

    B-2 OPERA TION B-2 SYNERGIC 7 & 7H Display Control Keys The function select, timer/crater select, arrow keys and rotational encoders all effect the display. Pressing the function select key will cause a function to be displayed. Pressing the timer/crater select key will cause a timer or crater feed speed to be displayed. Whichever is pressed la[...]

  • Page 21

    B-3 OPERA TION B-3 SYNERGIC 7 & 7H Timer/Crater Select - key enables operator to choose crater speed, spot or gas timers as indicated by the appro- priate light. Pressing key causes lights to sequence (left to right, top to bottom) starting from the current indicated posi- tion. Any parameter not available in the mode selected is skipped over. [...]

  • Page 22

    B-4 OPERA TION B-4 Procedure Selector Switch The toggle switch on the front panel provides selection of Procedure A or Procedure B, as set with the front panel knob controls. Rotating the knob encoder changes only the procedure selected by this switch. Also, this switch selects the A or B memory pair select- ed at the Power Wave power source. NOTE:[...]

  • Page 23

    B-5 OPERA TION B-5 SYNERGIC 7 & 7H WIRE LOADING Loading a 22 to 30 Lb. (10 to 14 kg) Readi-Reel Package Using the Molded Plastic K363-P Readi-Reel Adapter: The Spindle should be located in the LOWER mounting hole of the K1524-1 Universal Stand if used. 1) Depress the Release Bar on the Retaining Collar and remove it from the spindle. NOTE: Earl[...]

  • Page 24

    B-6 OPERA TION B-6 SYNERGIC 7 & 7H TO MOUNT 10 TO 44 lb (4.5 to 20 kg) SPOOLS (12 in./300 mm DIAMETER) OR 13-14 lb (6 kg) INNERSHIELD COILS: The spindle should be located in the lower mounting hole of the K1524-1 Universal Stand if used. [For 8 in. (200 mm) spools, a K468 spindle adapter must first be slipped onto the spindle.] [For 13 to 14 lb[...]

  • Page 25

    B-7 OPERA TION B-7 SYNERGIC 7 & 7H WIRE REEL LOADING – 50 AND 60 LB COILS (K303 OR K376 WIRE REEL ST AND) ADJUSTABLE WIRE REEL BRAKE The mount for standard 50 and 60 pound electrode coils includes a two-position brake assembly. Generally the brake should be at the inner position (nearest to the wire reel shaft) for wire feed speeds below 400 [...]

  • Page 26

    B-8 OPERA TION B-8 SYNERGIC 7 & 7H WIRE REEL LOADING – 50 AND 60 LB COILS (K1524-1 UNIVERSAL WIRE REEL ST AND) TO MOUNT A 50 to 60 lb (22.7 to 27.2 kg) COIL: (USING K1504-1 COIL REEL) (FOR 50 to 60 lb READI-REELS A K438 READI-REEL ADAPTER MUST BE USED.) The spindle should be located in the UPPER mount- ing hole. 1. With the K-1504-1 Coil Reel[...]

  • Page 27

    B-9 OPERA TION B-9 SYNERGIC 7 & 7H Idle Roll Pressure Setting The idle roll pressure is set at the factory, backed out three turns from full pressure on 4-roll feeders. This is an approximate setting. For small wire sizes and aluminum wire up to 9 or 10 turns out may be required to minimize “birdnesting”. The optimum idle roll pres- sure va[...]

  • Page 28

    B-10 OPERA TION B-10 SYNERGIC 7 & 7H Making a Weld 1 ) Use only Power Wave model “synergic” power sources. 2) Properly connect the electrode and work leads for the correct electrode polarity. 3) Use Mode Selection key to set desired operating mode. (Refer to Mode Selection section.) 4) Use Function Select and Arrow keys to set desired Run-i[...]

  • Page 29

    B-1 1 OPERA TION B-1 1 SYNERGIC 7 & 7H Grounding Lead Protector The frame of the Synergic 7 wire feeder is grounded to the frame of the power source by a lead in the con- trol cable. An overload protector prevents welding current from damaging this lead if the electrode circuit touches the wire feeder frame while the electrode is electrically h[...]

  • Page 30

    C-1 ACCESSORIES C-1 17 ft. (5 m), 25 ft. (7.6 m), 33 ft. (10 m) and 50 ft. (15 m). K648 - (Used with Power Wave 450) Consists of an 8- conductor control cable with a 14-pin plug and a 4/0 (107 mm 2 ) electrode cable with stud terminal. It is rated at 500 amps, 60% duty cycle and is available in lengths of 7 ft (2 m), 17 ft (5 m), 25 ft (7.6 m), 33 [...]

  • Page 31

    C-2 ACCESSORIES C-2 WIRE REEL ASSEMBL Y : K303 - 50-60 lb. (22.7-27.2 kg) Wire reel mounting stand. Assembly includes a framework to which is attached the 50-60 lb. (22.7-27.2 kg) wire reel, a mounting spindle, a dust shield, a lift bail, and a cable clamp for fastening the input cable assembly. The reel mounting spindle is the pull knob type with [...]

  • Page 32

    C-3 ACCESSORIES C-3 K541 Magnum 400 Short Neck GMAW gun and cable assemblies are rated 400 amps, 60% duty cycle. (Consult sales specifications for appropriate models) K598 Magnum 550 GMAW gun and cable assemblies are rated 550 amps, 60% duty cycle. (Consult sales specifications for appropriate models) K206 • Innershield Linconditioner gun and cab[...]

  • Page 33

    C-4 ACCESSORIES C-4 SYNERGIC 7 & 7H K566 * - GMAW process Magnum 250XA X-TRAC- TOR gun and cable assemblies are rated 250 amps, 60% duty cycle. (Consult sales specifications for appropriate models). * K179 type vacuum unit not recommended for use with Synergic 7. MISC. OPTIONS: K590-4 ( Water Connection Kit) - Includes water sup- ply quick-conn[...]

  • Page 34

    D-1 MAINTENANCE D-1 SYNERGIC 7 & 7H Wire Reel Mounting - 50 (22.7kg) and 60lb (27.2kg) Coils with 1 ” Spindle To prolong the life of the reel shaft, periodically coat it with a thin layer of grease. No maintenance of the two-position adjustable brake is needed. If the brake shoe wears through to the metal, replace the brake assembly. Wire Ree[...]

  • Page 35

    E-1 TROUBLESHOOTING E-1 SYNERGIC 7 & 7H W ARNING Observe all additional Safety Guidelines detailed throughout this manual. ELECTRIC SHOCK can kill. • Do not touch electrically live parts such as output terminals or internal wiring. • When inching with gun trigger, electrode and drive mechanism are “ hot ” to work and ground and could re[...]

  • Page 36

    E-2 TROUBLESHOOTING E-2 SYNERGIC 7 & 7H 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. CAUTION Observe all Safety Guidelines detailed throughout this manual PRO[...]

  • Page 37

    E-3 TROUBLESHOOTING E-3 SYNERGIC 7 & 7H Observe all Safety Guidelines detailed throughout this manual 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. CAUTION PRO[...]

  • Page 38

    E-4 TROUBLESHOOTING E-4 SYNERGIC 7 & 7H Observe all Safety Guidelines detailed throughout this manual 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. CAUTION PRO[...]

  • Page 39

    E-5 TROUBLESHOOTING E-5 SYNERGIC 7 & 7H Observe all Safety Guidelines detailed throughout this manual 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. CAUTION PRO[...]

  • Page 40

    E-6 TROUBLESHOOTING E-6 SYNERGIC 7 & 7H Observe all Safety Guidelines detailed throughout this manual 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. CAUTION PRO[...]

  • Page 41

    E-7 TROUBLESHOOTING E-7 SYNERGIC 7 & 7H Observe all Safety Guidelines detailed throughout this manual 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. CAUTION PRO[...]

  • Page 42

    E-8 TROUBLESHOOTING E-8 SYNERGIC 7 & 7H Observe all Safety Guidelines detailed throughout this manual 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. CAUTION PRO[...]

  • Page 43

    E-9 TROUBLESHOOTING E-9 SYNERGIC 7 & 7H Observe all Safety Guidelines detailed throughout this manual 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. CAUTION PRO[...]

  • Page 44

    E-10 TROUBLESHOOTING E-10 SYNERGIC 7 & 7H Observe all Safety Guidelines detailed throughout this manual 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. CAUTION P[...]

  • Page 45

    E-1 1 TROUBLESHOOTING E-1 1 SYNERGIC 7 & 7H 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. CAUTION Observe all Safety Guidelines detailed throughout this manual[...]

  • Page 46

    E-12 TROUBLESHOOTING E-12 SYNERGIC 7 & 7H Procedure for Replacing PC Boards Before replacing a PC board which is suspected of being defective, visually inspect the PC board in ques- tion for any electrical or mechanical damage to any of its components and conductors on the back of the board. a . If there is no visible damage to the PC board, in[...]

  • Page 47

    F-1 DIAGRAMS F-1 SYNERGIC 7 & 7H P10 PIN 1 CONNECTOR CAVITY 1 ( C O M P O N E N T S I D E O F P . C . B O A R D ) PIN NUMBERING SEQUENCE ** J6 1 ( C O M P O N E N T S I D E O F P . C . B O A R D ) C A V I T Y N U M B E R I N G S E Q U E N C E * R.F. CHOKE L 82 81 H 67 G F 4 2 D R C B A * J2 P11 2 4 1 J2 J1 J4 8 W W P8 2 W GUN 7 6 5 4 3 2 1 4 3 [...]

  • Page 48

    F-2 DIAGRAMS F-2 SYNERGIC 7 & 7H E=GND F=67 8-PIN BOX RECEPTACLE, FRONT VIEW M=81 C=2 N=67 H=82 D=4 14-SOCKET BOX RECEPTACLE, FRONT VIEW G=81 AND 14-PIN CABLE PLUG, REAR VIEW B=GND I=41 TRIGGER CIRCUIT 2 GND L 4 N I PIN ELECTRODE CABLE 42 D PLUG PIN# TRIGGER CIRCUIT 41 C FUNCTION 42V AC +SERIAL COMM LOOP -SERIAL COMM LOOP 14 81 67 LEAD K 82 M E[...]

  • Page 49

    F-3 DIAGRAMS F-3 SYNERGIC 7 & 7H 20102 3-13-92 DIMENSION PRINT 11.60 8.09 9.70 3/8-16 HEX. HD. SCREWS FOR MTG. CONTROL BOX TO WIRE REEL STAND (3 PLACES) 9.42 .77 4.03 1.28 11.11 TOLERANCE ~.125 WIRE DRIVE & CONTROL BOX AS'BLY LN-7GMA 4 ROLL DIMENSION PRINT[...]

  • Page 50

    NOTES SYNERGIC 7 & 7H[...]

  • Page 51

    NOTES SYNERGIC 7 & 7H[...]

  • Page 52

    NOTES SYNERGIC 7 & 7H[...]

  • Page 53

    NOTES SYNERGIC 7 & 7H[...]

  • Page 54

    W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL F ABRICANTE PARA EL[...]

  • Page 55

    W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE PARA ESTE EQUIP AMENTO E AS P ARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust to remove fumes f[...]

  • Page 56

    • Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com • World's Leader in Welding and Cutting Products •[...]