Lincoln Electric 7FH manual

Synergic 7F and Synergic 7FH OPERA TOR’S MANUAL Semiautomatic Wire Feeders or Controls with code numbers 10189, 10190 & 10191 IM539 October, 1999 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 thoughtful ope[...]

– 2 – 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 [...]

– 3 – FOR ENGINE powered equipment. 7.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. --------------------------------------------------------------------------------------- 7.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors. ---[...]

-4- PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions 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 à l’élec[...]

– 5 – T ABLE OF CONTENTS Page GENERAL DESCRIPTION ..................................................................................................7 RECOMMENDED PROCESSES AND EQUIPMENT .........................................................7 STANDARD FEATURES ...................................................................................[...]

– 6 – 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 referenc[...]

GENERAL DESCRIPTION The Synergic 7F is a semiautomatic constant speed wire feeder designed specifically for use with the 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 of High Speed Synergic 7FH wire feed unit and connecting cable assemblie[...]

Crater Fill - Provides crater feed speed adjustment (in 4-step trigger mode) independent of weld, cold feed, 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 fittings for easy installation of gas is standard [...]

– 9 – 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 indicators. .56” (14.2mm) character height. Displays arc voltage in volts, wire speed in IPM or m/m and all timers in seconds. Indicator Lights - Ext[...]

– 10 – OPTIONAL FEA TURES DRIVE 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 Solid KP655-1/16 .045 - .052” (1.2 - 1.4mm) Solid KP655-052S .045 - .052” (1.2 - 1.4mm) Cored KP655-052C .035” (0.9-1.0mm) Cored KP655-035C .035” (0.9-1.0mm) Solid KP655-035S .030?[...]

– 11 – MISCELLANEOUS OPTIONS: K682 Water Connection Kit - Includes water cooled gun tube fittings and self-sealing outlet and inlet quick- connectors for mounting onto the Synergic 7F Wire Drive mounting bracket. K659-1 - (Gas Guard Regulator) Adjustable flow regulator with removable adjustor key for CO 2 and Argon blend gases. Mounts onto Wire[...]

– 12 – SPECIFICA TIONS FOR SYNERGIC 7F AND SYNERGIC 7FH SYNERGIC 7F SYNERGIC 7F SYNERGIC 7FH CONTROL WIRE FEED - (4 - ROLL) K678-1 .025 - 1/16” 0.6 - 1.6mm .045 - 3/32” 1.2 - 2.4mm 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” (28[...]

– 13 – INST ALLA TION Safety Precautions INST ALLA TION OF THE SYNERGIC 7F COMPONENTS 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 gearbox. Reference L9777 dimension print at the rear of this manual to find the size and location of the mounting holes[...]

PROCEDURE T O INST ALL DRIVE ROLL AND GUIDE TUBES Standard 4-Roll Kits (KP571 and KP572) 1) Turn off welding power source. 2) Release both quick release levers by sliding the levers sideways into the open positions. 3 ) Remove hex screw & clamping collar from the drive shaft closest to the incoming side of the feeder. 4) Install drive roll onto[...]

– 15 – 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 insert is used. Fine wire chisel[...]

– 16 – GMA W Shielding Gas Customer must provide a cylinder of shielding gas, a pressure regulator, a flow control valve, and a hose from the flow valve to the gas inlet fitting of the Synergic 7F Wire Feed Unit. Connect a supply hose from the gas cylinder flow valve outlet to the 5/8-18 female inert gas fitting on the back panel of the Synergi[...]

– 17 – Electrical Installation Input Cable: Synergic 7F Control to Power Wave Synergic Type Power Sources 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 f[...]

– 18 – OPTIONAL FEA TURES INST ALLA TION K648 or K649 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 needed mounting shaft, hardware, and insula[...]

– 19 – 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 from the power source. The Syn[...]

– 20 – 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 last is the one that will be d[...]

– 21 – Timer/Crater Select - key enables operator to choose crater speed, spot or gas timers as indicated by the appropriate light. Pressing key causes lights to sequence (left to right, top to bottom) starting from the current indicated position. Any parameter not available in the mode selected is skipped over. If a function is being displayed[...]

– 22 – 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) Rotate the spindle and adapt[...]

– 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 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 free end of the coil is securely[...]

– 24 – 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 pressure varies with type of wire, surfac[...]

– 25 – 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-in and encoder knob to set Weld[...]

– 26 – 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. XX indicates time remaining i[...]

– 27 – 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-Reels and 10 through 30lb (4.[...]

– 28 – TROUBLESHOOTING GUIDE This Troubleshooting Guide is designed to be used by the machine Owner/Operator. Unauthorized repairs performed 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 and precautions detailed in the Saf[...]

– 29 – PROBLEM 1. Rough wire feeding or wire not feeding but drive rolls turning. 2. Variable or “hunting” arc. POSSIBLE CAUSE a. Gun cable kinked and/or twisted. b. Wire jammed in gun and cable. c. Incorrect position of drive rolls with grooves. d. Drive rolls loose. e. Gun cable dirty. f. Worn drive roll. g. Electrode rusty and/or dirty. [...]

PROBLEMS PROBLEM 3. Poor arc striking with sticking or “blast-offs”, weld porosity, narrow and ropy looking bead, or electrode stubbing into plate while welding. 4. Tip seizes in diffuser. 5. Unit shuts off while welding and “HXX” appears on display. 6. Drive roll does not turn although arc voltage is present and solenoid is on. POSSIBLE CA[...]

– 31 – PROBLEM 7. No control of wire feed. 8. No wire feed, solenoid, or arc voltage. LED display indicated Synergic 7F has input power. POSSIBLE CAUSE a. Defective Wire Feed Unit to Control box cable or harnessing. b. Defective wire feed motor tach or control PC Board. c. Problem with serial communications in input control cable. a. Faulty gun[...]

– 32 – PROBLEM 9. Wire feed motor runs and solenoid turns on but no arc voltage is present. 10. Speed does not change when weld current flows. 11. Voltmeter does not function or read properly when arc voltage is present. 12. Arrow keys do not change WFS or Volts/Trim. 13. Purge key does not turn on solenoid but trigger closure does. POSSIBLE CA[...]

– 33 – PROBLEM 14. Cold Feed key does not turn on wire feed motor but trigger closure does. 15. Display and/or indicator lights do not change when the arrow or select keys are pressed. 16. Display does not change when WFS and/or Volts/Trim knobs are turned. 17. Display is blank. POSSIBLE CAUSE a. Defective keypad or Display PC board is defectiv[...]

– 34 – PROBLEM 18. Dual Procedure is not functioning when using the remote dual procedure switch. 19. Dual Procedure is not functioning when using the local dual procedure switch. POSSIBLE CAUSE a. Gun has not been selected at the control box. b. Faulty Remote Dual Procedure Switch. c. Faulty Local Dual Procedure Switch. d. Defective Control Bo[...]

– 35 – PROBLEM 20. Wire feed speed is consistent and adjustable, but operates at the wrong speed. 21. Display shows any of the following: HI - - - HXX Er EXX EP uP POSSIBLE CAUSE a.Defective gearbox ratio sensing or control board. a. Voltmeter function is selected and arc voltage is > 80V DC. a. Run-In speed is selected but is disabled. a. S[...]

– 36 – Procedure for Replacing PC Boards Before replacing a PC board which is suspected of being defective, visually inspect the PC board in question 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, install a new one and see if this remed[...]

– 37 – 6 4 1 5 1 4 J13 J4 12 J1 10 L 6 8 PIN 1 R.F. CHOKE P10 P11 5 1 CLEVELAND, OHIO U.S.A. L9778 A 1 7 WIRING DIAGRAM SYNERGIC 7F J2 P.C. BOARD J10 3 J11 1 2 1 1 J6 J5 J3 J7 DPTT CONTROL P.C. BOARD INPUT CABLE RECEPTACLE A 2 B 4 C D R.F. TOROID ASSEMBLY ELECTRODE INPUT CABLE * * * J17 * J3 * * J14 3 4 3 4 3 4 5 6 7 8 ENCODER PC BOARD * J10 2 [...]

– 38 – service this machine. Power Source before connecting the wire feeder. H=TACH ELECTRIC Only qualified persons should install, use or G=TACH D=522 E=519 14 PIN L=82 K=42 CAN KILL SHOCK IN CABLE. 14 PIN G PLUG F PIN# C D H 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 OFF the power swi[...]

– 39 – DIMENSION PRINT 10.00 2.38 10.32 .41 1.57 11.26 M17740 SYNERGIC 7F CONTROL BOX A 13.31 (2 HOLES FOR MOUNTING) 6.16 R .14 5.24 2.62 R .28 CONTROL BOX DIMENSION PRINT[...]

– 40 – 1.00 6.25 6.75 4.67 REMOTE A 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 ARMS L C OF WIRE C L OF WI[...]

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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 MANUFACTURER’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 P ARA 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 P ARA 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 fr[...]

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