Lincoln Electric SYNERGIC 7F IM559 manual

Synergic 7F and Synergic 7FH OPERA TOR’S MANUAL IM559 June, 2003 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 READI[...]

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. ________________________________________________[...]

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[...]

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[...]

iv SAFETY iv 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 circuits ?[...]

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[...]

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

A-1 SYNERGIC 7F & FH A-1 INST ALLA TION TECHNICAL SPECIFICA TIONS – SYNERGIC 7F AND SYNERGIC 7FH SYNERGIC 7F SYNERGIC 7F SYNERGIC 7FH CONTROL WIRE FEED - (4 - ROLL) K678-2 40-42 V ± 10% 50/60 Hz 4.0 Amps K679-1 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 11.25” (285.8 mm) 7.1[...]

A-2 INST ALLA TION SYNERGIC 7F & FH A-2 GENERAL DESCRIPTION The Synergic 7F is a CSA / NRTL/C certified semiautomatic constant speed wire feeder designed specifically for use with the Invertec Power Wave type power sources. This boom or fixture mounting wire feeder consists of a Synergic 7F Control Box and the choice of the standard Synergic 7F[...]

A-3 INST ALLA TION SYNERGIC 7F & FH 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 fittin[...]

A-4 INST ALLA TION SYNERGIC 7F & FH 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 timer[...]

A-5 INST ALLA TION SYNERGIC 7F & FH A-5 INST ALLA TION OF THE SYNERGIC 7F COMPONENTS Safety Precautions Mounting the Wire Feed Unit (K679-1 or -2) Mount the wire feed unit by means of the insulated mounting bracket attached to the bottom of the gear- box. Reference L9777 dimension print at the rear of this manual to find the size and location o[...]

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

A-7 INST ALLA TION SYNERGIC 7F & FH A-7 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 insert is used. Fine wire chisel point tube must have largest rad[...]

A-8 INST ALLA TION SYNERGIC 7F & FH A-8 Gun Cable Connections: Wire Feeder to Gun a. Check that the drive rolls, feeder guide tubes and gun connector guide tube are appropriate for the electrode size being used. If necessary, change them per the section on “Wire Feed Drive Roll and Guide Tube Kits”. b. Connect gun to gun connector making su[...]

A-9 INST ALLA TION SYNERGIC 7F & FH A-9 ELECTRICAL INST ALLA TION Input Cable: Synergic 7F Control 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 continituity between the 14-pin pl[...]

A-10 INST ALLA TION SYNERGIC 7F & FH A-10 OPTIONAL FEA TURES INST ALLA TION K648, K649 or K642 Input Cable Assembly - See Electrical Installation section for instructions. K299 50-60 Lb. Wire Reel for Customer Mounting - The K299 is available for use with the Synergic 7F Wire Feed Models. The reel for 50 or 60 pound coils is shipped with the ne[...]

B-1 OPERA TION B-1 SYNERGIC 7F & FH OPERA TING INSTRUCTIONS Safety Precautions Duty Cycle The Synergic 7F 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 7F is supplied and controlled f[...]

B-2 OPERA TION B-2 SYNERGIC 7F & FH 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 l[...]

B-3 OPERA TION B-3 SYNERGIC 7F & FH 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.[...]

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:[...]

B-5 OPERA TION B-5 SYNERGIC 7F & FH Wire Reel Loading - Readi-Reels and Spools (Using K162H Spindle Kit with 2” (51mm) spindle) TO MOUNT A 30 LB (14 kg) READI-REEL PACKAGE USING THE MOLDED PLASTIC K363-P TYPE ADAPTER: 1) Make certain that the threaded locking collar is tight and securely locks the adapter on the spindle (see figure above). 2)[...]

B-6 OPERA TION B-6 SYNERGIC 7F & FH 4) Tighten the cover as much as possible by hand. DO NOT hammer on the spinner nut arms. 5) Cut and remove only the tie wire holding the free end of the coil. Insert the free end into one of the holes in the cover and secure it by bending it back. Cut and remove the remaining tie wires. Always be sure the fre[...]

B-7 OPERA TION B-7 SYNERGIC 7F & FH 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- sur[...]

B-8 OPERA TION B-8 SYNERGIC 7F & FH 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-[...]

B-9 OPERA TION B-9 SYNERGIC 7F & FH Explanation of Prompting and Error Messages Display Prompt or Error HI Indicates arc voltage is above 80V DC. -- - Indicates selected Run-In speed will be the same as the weld speed. To enter a different Run-In speed simply press the increase arrow key with Run-In selected. HX X Indicates wire feed overload. [...]

C-1 ACCESSORIES C-1 K643 (Control Cable Extension) Consists of an 8-conductor control cable with 14-pin connectors on each end for extending the control cable between the power source and the control cable. Available in lengths of 17 ft (5m), 25 ft (7.6m), 33 ft (10m), and 50 ft (15m). K682-2 (Water Connection Kit) Includes water cooled gun tube fi[...]

C-2 ACCESSORIES C-2 READI-REEL ADAPTERS: K363P - Adapts Lincoln Readi-Reel coils of electrode 30 lb (14 kg) and 22 lb (10 kg) to a 2 ” (51mm) spindle. Durable molded plastic one piece construction. Designed for easy loading; adapter remains on spindle for quick changeover. (used with K162H) K438 - Adapts Lincoln Readi-Reel coils of electrode 50-6[...]

D-1 MAINTENANCE D-1 SYNERGIC 7F & FH Wire Reel Mounting - 50 (22.7kg) and 60lb (27.2kg) Coils 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 Reel Mounting - Readi[...]

E-1 TROUBLESHOOTING E-1 SYNERGIC 7F & FH TROUBLESHOOTING GUIDE This Troubleshooting Guide is designed to be used by the machine Owner/Operator. Unauthorized repairs per- formed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety, please observe all safety notes[...]

E-2 TROUBLESHOOTING E-2 SYNERGIC 7F & FH 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 PR[...]

E-3 TROUBLESHOOTING E-3 SYNERGIC 7F & FH 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 PR[...]

E-4 TROUBLESHOOTING E-4 SYNERGIC 7F & FH 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 PR[...]

E-5 TROUBLESHOOTING E-5 SYNERGIC 7F & FH 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 PR[...]

E-6 TROUBLESHOOTING E-6 SYNERGIC 7F & FH 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 PR[...]

E-7 TROUBLESHOOTING E-7 SYNERGIC 7F & FH 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 PR[...]

E-8 TROUBLESHOOTING E-8 SYNERGIC 7F & FH 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 PR[...]

E-9 TROUBLESHOOTING E-9 SYNERGIC 7F & FH 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 PR[...]

E-10 TROUBLESHOOTING E-10 SYNERGIC 7F & FH 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 [...]

E-1 1 TROUBLESHOOTING E-1 1 SYNERGIC 7F & FH 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. CAUTIO[...]

E-12 TROUBLESHOOTING E-12 SYNERGIC 7F & FH 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, i[...]

F-1 DIAGRAMS F-1 SYNERGIC 7F & FH ELECTRODE INPUT CABLE GAS SOLENOID W 539 ASSEMBLY W GUN TRIGGER 541 CONNECTION SWITCH P.M. DUAL PROCEDURE OPTIONAL GUN R R U U B B TACH B 67 GAS F G H K L I A N E D C B A C B A J M E B A C D J15 J8 UNIT WIRE FEED 1 2 CABLE SHIELDED CABLE SHIELDED 3 1 2 B R 67 U 512 3 4 N.A. 530 531 519 522 520 W B INPUT CABLE R[...]

F-2 DIAGRAMS F-2 SYNERGIC 7F & FH service this machine. Power Source before connecting the wire feeder. H=TACH ELECTRIC Only qualified persons should install, use or G=TACH E=519 14 PIN L=82 K=42 CAN KILL SHOCK IN CABLE. 14 PIN G PLUG F PIN# I K ELECTRODE L 67 M N 14-SOCKET BOX RECEPTACLE, FRONT VIEW C=2 I=TRIG. A=539 K=530 N=67 J=TRIG. Turn OF[...]

F-3 DIAGRAMS F-3 SYNERGIC 7F & FH DIMENSION PRINT 10.00 2.38 10.32 .41 1.57 11.26 M17740 SYNERGIC 7F CONTROL BOX 13.31 (2 HOLES FOR MOUNTING) 6.16 R .14 5.24 2.62 R .28 4-7-95 CONTROL BOX DIMENSION PRINT[...]

F-4 DIAGRAMS F-4 SYNERGIC 7F & FH 1.00 6.25 6.75 4.67 REMOTE 6.67 7.16 7.50 1.72 3.18 .25 .25 .281 7.00 11.25 1.44 TYP. OUTLET 1.31 .81 1.00 8.06 .87 INLET INPUT 3.36 6.21 GAS FITTING MOUNTING WIRE FEED UNIT) (10 HOLES FOR CONNECTOR CLOSED TRIGGER CONNECTOR CONNECTOR GAS FITTING DIRECTION WIRE FEED TOP VIEW CLEARANCE ENVELOPE OF QUICK RELEASE A[...]

NOTES SYNERGIC 7F & FH[...]

NOTES SYNERGIC 7F & FH[...]

W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TENÇÃO 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 U[...]

W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TENÇÃO 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 fro[...]

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