Lincoln-electric IM559 Synergic 7F and 7FH User Manual

Synergic 7F and Synergic 7FHOPERATOR’S MANUALIM559June, 2003Safety Depends on YouLincoln arc welding and cuttingequipment is designed and builtwith sa

A-3INSTALLATION SYNERGIC 7F & FHA-3Crater Fill - Provides crater feed speed adjustment (in4-step trigger mode) independent of weld, cold inch,or

A-4INSTALLATION SYNERGIC 7F & FHA-4Keypad - Seven key, membranetype with “snap” tactile feel andembossed domes. Long lifedesign. Spatter resis

A-5INSTALLATION SYNERGIC 7F & FHA-5INSTALLATION OF THE SYNERGIC 7F COMPONENTSSafety PrecautionsMounting the Wire Feed Unit (K679-1 or -2)Mount t

A-6INSTALLATION SYNERGIC 7F & FHA-6Wire Feed Drive Roll and Guide Tube KitsNOTE: The maximum sizes the Synergic 7F will feedsatisfactorily are t

A-7INSTALLATION SYNERGIC 7F & FHA-79) Install the longer guide tube in the rear hole nearthe incoming drive roll. Slide the tube in until ital

A-8INSTALLATION SYNERGIC 7F & FHA-8Gun Cable Connections: Wire Feederto Gun a. Check that the drive rolls, feeder guide tubes andgun connector

A-9INSTALLATION SYNERGIC 7F & FHA-9ELECTRICAL INSTALLATIONInput Cable: Synergic 7F Control to Power WaveSynergic Type Power SourcesNOTE: CSAnrt

A-10INSTALLATION SYNERGIC 7F & FHA-10OPTIONAL FEATURESINSTALLATIONK648, K649 or K642 Input Cable Assembly - SeeElectrical Installation section f

B-1OPERATIONB-1SYNERGIC 7F & FHOPERATING INSTRUCTIONSSafety PrecautionsDuty CycleThe Synergic 7F models are rated at 60% duty cycle *for a maximum

B-2OPERATIONB-2SYNERGIC 7F & FHDisplay Control KeysThe function select, timer/craterselect, arrow keys and rotationalencoders all effect the displ

FOR ENGINEpowered equipment.1.a. Turn the engine off before troubleshooting and maintenancework unless the maintenance work requires it to be running.

B-3OPERATIONB-3SYNERGIC 7F & FHTimer/Crater Select - key enablesoperator to choose crater speed, spotor gas timers as indicated by the appro-priat

B-4OPERATIONB-4Procedure Selector SwitchThe toggle switch on the front panel provides selectionof Procedure A or Procedure B, as set with the frontpan

B-5OPERATIONB-5SYNERGIC 7F & FHWire Reel Loading - Readi-Reels andSpools (Using K162H Spindle Kit with 2”(51mm) spindle)TO MOUNT A 30 LB (14 kg) R

B-6OPERATIONB-6SYNERGIC 7F & FH4) Tighten the cover as much as possible by hand.DO NOT hammer on the spinner nut arms.5) Cut and remove only the

B-7OPERATIONB-7SYNERGIC 7F & FHIdle Roll Pressure SettingThe idle roll pressure is set at the factory, backed outthree turns from full pressure on

B-8OPERATIONB-8SYNERGIC 7F & FHMaking a Weld1) Use only Power Wave model “synergic” powersources.2) Properly connect the electrode and work lead

B-9OPERATIONB-9SYNERGIC 7F & FHExplanation of Prompting and Error MessagesDisplay Prompt or ErrorHI Indicates arc voltage is above 80V DC.--- Indi

C-1ACCESSORIESC-1K643 (Control Cable Extension) Consists of an 8-conductorcontrol cable with 14-pin connectors on each end forextending the control c

C-2ACCESSORIESC-2READI-REEL ADAPTERS:K363P - Adapts Lincoln Readi-Reel coils of electrode 30 lb(14 kg) and 22 lb (10 kg) to a 2” (51mm) spindle. Dura

D-1MAINTENANCED-1SYNERGIC 7F & FHWire Reel Mounting - 50 (22.7kg) and60lb (27.2kg) CoilsTo prolong the life of the reel shaft, periodically coat i

iiSAFETYiiARC RAYS can burn.4.a. Use a shield with the proper filter and coverplates to protect your eyes from sparks andthe rays of the arc when weld

E-1TROUBLESHOOTINGE-1SYNERGIC 7F & FHTROUBLESHOOTING GUIDEThis Troubleshooting Guide is designed to be used by the machine Owner/Operator. Unauth

E-2TROUBLESHOOTINGE-2SYNERGIC 7F & FHObserve all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test

E-3TROUBLESHOOTINGE-3SYNERGIC 7F & FHObserve all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test

E-4TROUBLESHOOTINGE-4SYNERGIC 7F & FHObserve all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test

E-5TROUBLESHOOTINGE-5SYNERGIC 7F & FHObserve all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test

E-6TROUBLESHOOTINGE-6SYNERGIC 7F & FHObserve all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test

E-7TROUBLESHOOTINGE-7SYNERGIC 7F & FHObserve all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test

E-8TROUBLESHOOTINGE-8SYNERGIC 7F & FHObserve all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test

E-9TROUBLESHOOTINGE-9SYNERGIC 7F & FHObserve all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test

E-10TROUBLESHOOTINGE-10SYNERGIC 7F & FHObserve all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the te

FOR ELECTRICALLYpowered equipment.8.a. Turn off input power using the disconnectswitch at the fuse box before working onthe equipment.8.b. Install equ

E-11TROUBLESHOOTINGE-11SYNERGIC 7F & FHObserve all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the te

E-12TROUBLESHOOTINGE-12SYNERGIC 7F & FHProcedure for Replacing PC BoardsBefore replacing a PC board which is suspected ofbeing defective, visually

F-1DIAGRAMSF-1SYNERGIC 7F & FHELECTRODE INPUT CABLEGASSOLENOIDW539ASSEMBLYWGUNTRIGGER541CONNECTIONSWITCHP.M.DUAL PROCEDUREOPTIONAL GUNRRUUBBTACHB6

F-2DIAGRAMSF-2SYNERGIC 7F & FHservice this machine.Power Source before connecting the wire feeder.H=TACHELECTRICOnly qualified persons should inst

F-3DIAGRAMSF-3SYNERGIC 7F & FH DIMENSION PRINT10.002.3810.32.411.5711.26M17740 SYNERGIC 7F CONTROL BOX13.31(2 HOLESFOR MOUNTING)6.16R .14

F-4DIAGRAMSF-4SYNERGIC 7F & FH1.006.256.754.67REMOTE6.677.167.501.723.18.25.25.2817.0011.251.44 TYP.OUTLET1.31.811.008.06.87INLETINPUT3.366.21GAS

NOTESSYNERGIC 7F & FH

NOTESSYNERGIC 7F & FH

WARNINGAVISO DEPRECAUCIONATTENTIONWARNUNGATENÇÃOSpanishFrenchGermanPortugueseJapaneseChineseKoreanArabicREAD AND UNDERSTAND THE MANUFACTURER’S INSTRUC

WARNINGAVISO DEPRECAUCIONATTENTIONWARNUNGATENÇÃOSpanishFrenchGermanPortugueseJapaneseChineseKoreanArabicLEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE

ivSAFETYivPRÉCAUTIONS DE SÛRETÉPour votre propre protection lire et observer toutes les instruc-tions et les précautions de sûreté specifiques qui par

• Sales and Service through Subsidiaries and Distributors Worldwide •Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB

vvThank Youfor selecting a QUALITY product by Lincoln Electric. We want youto take pride in operating this Lincoln Electric Company product••• as much

viTABLE OF CONTENTSPageInstallation ...Section ATe

A-1SYNERGIC 7F & FHA-1INSTALLATIONTECHNICAL SPECIFICATIONS – SYNERGIC 7F AND SYNERGIC 7FHSYNERGIC 7F SYNERGIC 7F SYNERGIC 7FHCONTROLWIRE FEED -

A-2INSTALLATION SYNERGIC 7F & FHA-2GENERAL DESCRIPTIONThe Synergic 7F is a CSA / NRTL/C certified semiautomaticconstant speed wire feeder design