Lincoln-electric IM539 Synergic 7F and 7FH User Manual

Synergic 7F and Synergic 7FH OPERATOR’S MANUALSemiautomatic Wire Feeders or Controls with code numbers 10189, 10190 & 10191IM539October, 1999Safet

– 10 –OPTIONAL FEATURESDRIVE ROLL AND GUIDE TUBE KITS:Steel Wire Sizes: 4-Roll* .068 - 3/32” (1.7 - 2.4mm) Cored KP655-3/32* 1/16” (1.6mm) Cored or

– 11 –MISCELLANEOUS OPTIONS:K682 Water Connection Kit - Includes water cooled guntube fittings and self-sealing outlet and inlet quick-connectors for

– 12 –SPECIFICATIONS FOR SYNERGIC 7FAND SYNERGIC 7FHSYNERGIC 7F SYNERGIC 7F SYNERGIC 7FHCONTROLWIRE FEED - (4 - ROLL)K678-1.025 - 1/16”0.6 - 1.6

– 13 –INSTALLATIONSafety PrecautionsINSTALLATION OF THE SYNERGIC 7F COMPONENTSMounting the Wire Feed Unit (K679-1 or -2)Mount the wire feed unit by me

PROCEDURE TO INSTALL DRIVEROLL AND GUIDE TUBESStandard 4-Roll Kits (KP571 and KP572)1) Turn off welding power source.2) Release both quick release l

– 15 –8) Back out the screws for the incoming and outgoingguide tubes.9) Install the longer guide tube in the rear hole nearthe incoming drive roll.

– 16 –GMAW Shielding GasCustomer must provide a cylinder of shielding gas, apressure regulator, a flow control valve, and a hosefrom the flow valve to

– 17 –Electrical InstallationInput Cable: Synergic 7F Control to Power WaveSynergic Type Power SourcesK648 - (Used with Power Wave 450) Consists of a

– 18 –OPTIONAL FEATURESINSTALLATIONK648 or K649 Input Cable Assembly - See ElectricalInstallation section for instructions.K299 50-60 Lb. Wire Reel fo

– 19 –OPERATING INSTRUCTIONSSafety PrecautionsDuty CycleThe Synergic 7F models are rated at 60% duty cycle* for a maximum current of 600 amps.* Based

– 2 –PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDRENAWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE O

– 20 –Display Control KeysThe function select, timer/craterselect, arrow keys and rotationalencoders all effect the display.Pressing the function sele

– 21 –Timer/Crater Select - key enablesoperator to choose crater speed, spotor gas timers as indicated by theappropriate light. Pressing key causeslig

– 22 –Wire Reel Loading - Readi-Reels andSpools (Using K162H Spindle Kit with 2”(51mm) spindle)TO MOUNT A 30 LB (14 KG) READI-REELPACKAGE USING THE MO

– 23 –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 freeend

– 24 –Idle Roll Pressure SettingThe idle roll pressure is set at the factory, backed outthree turns from full pressure on 4-roll feeders. This isan a

– 25 –Making a Weld1) Use only Power Wave model “synergic” powersources.2) Properly connect the electrode and work leads forthe correct electrode po

– 26 –Explanation of Prompting and Error MessagesDisplay Prompt or ErrorHI Indicates arc voltage is above 80V DC.--- Indicates selected Run-In speed w

– 27 –Wire Reel Mounting - 50 (22.7kg) and60lb (27.2kg) CoilsTo prolong the life of the reel shaft, periodically coat itwith a thin layer of grease.No

– 28 –TROUBLESHOOTING GUIDEThis Troubleshooting Guide is designed to be used by the machine Owner/Operator. Unauthorized repairsperformed on this equ

– 29 –PROBLEM1. Rough wire feeding or wire notfeeding but drive rolls turning.2. Variable or “hunting” arc.POSSIBLE CAUSEa. Gun cable kinked and/or tw

– 3 –FOR ENGINEpowered equipment.7.a. Turn the engine off before troubleshooting and maintenancework unless the maintenance work requires it to be run

PROBLEMSPROBLEM3. Poor arc striking with sticking or“blast-offs”, weld porosity,narrow and ropy looking bead,or electrode stubbing into platewhile wel

– 31 –PROBLEM7. No control of wire feed.8. No wire feed, solenoid, or arcvoltage. LED display indicatedSynergic 7F has input power.POSSIBLE CAUSEa.

– 32 –PROBLEM9. Wire feed motor runs andsolenoid turns on but no arcvoltage is present.10. Speed does not change whenweld current flows.11. Voltmeter

– 33 –PROBLEM14. Cold Feed key does not turnon wire feed motor but triggerclosure does.15. Display and/or indicator lightsdo not change when the arrow

– 34 –PROBLEM18. Dual Procedure is notfunctioning when using theremote dual procedure switch.19. Dual Procedure is notfunctioning when using thelocal

– 35 –PROBLEM20. Wire feed speed is consistentand adjustable, but operates at thewrong speed.21. Display shows any of thefollowing:HI- - -HXXErEXXEPuP

– 36 –Procedure for Replacing PC BoardsBefore replacing a PC board which is suspected ofbeing defective, visually inspect the PC board inquestion for

– 37 –641514J13J412J110L68PIN 1R.F. CHOKEP10P1151CLEVELAND, OHIO U.S.A.L9778A17 WIRING DIAGRAM SYNERGIC 7F J2P.C. BOARDJ103J111211J6J5

– 38 –service this machine.Power Source before connecting the wire feeder.H=TACHELECTRICOnly qualified persons should install, use orG=TACH D=522E=519

– 39 – DIMENSION PRINT10.002.3810.32.411.5711.26M17740 SYNERGIC 7F CONTROL BOXA13.31(2 HOLESFOR MOUNTING)6.16R .145.242.62R .28CONTROL BOX DI

-4-PRÉCAUTIONS DE SÛRETÉPour votre propre protection lire et observer toutes les instructionset les précautions de sûreté specifiques qui parraissent

– 40 –1.006.256.754.67REMOTEA6.677.167.501.723.18.25.25.2817.0011.251.44 TYP.OUTLET1.31.811.008.06.87INLETINPUT3.366.21GAS FITTINGMOUNTING WIRE FEED U

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– 5 –TABLE OF CONTENTSPageGENERAL DESCRIPTION...7RECOMM

– 6 –Thank Youfor selecting a QUALITY product by Lincoln Electric.We want you to take pride in operating this LincolnElectric Company product ••• as m

GENERAL DESCRIPTIONThe Synergic 7F is a semiautomatic constant speedwire feeder designed specifically for use with thePower Wave™ type power sources.

Crater Fill - Provides crater feed speed adjustment (in4-step trigger mode) independent of weld, cold feed,or run-in speeds.Solid-State Overload Prote

– 9 –Keypad - Seven key, membranetype with “snap” tactile feel andembossed domes. Long lifedesign. Spatter resistant surface.Display - 3-1/2 digit 7