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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
PROBLEMS
(SYMPTOMS)
POSSIBLE
CAUSE
RECOMMENDED
COURSE OF ACTION
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.
h. Worn nozzle or cable liner.
i.
Partially flashed or melted contact tip.
j. Incorrect idle roll pressure.
k. Improper liner, tip or guide tube.
a. Wrong size, worn and/or melted
contact tip.
b. Worn work cable or poor work
connection.
c. Loose electrode connections.
d. Wrong polarity.
e. Problem with serial communica-
tions in control cable.
a. Inspect gun cable and replace if
necessary.
b. Remove wire from gun and cable
feed in new wire. Note any
obstructions in gun and cable.
Replace gun and cable if neces-
sary.
c. See Wire Feed Drive Roll and
Guide Tubs Kits section for proper
installation of drive roll.
d. Remove, clean, install and tighten.
e. Clean cable or replace liner.
f. Replace.
g. Replace.
h. Replace.
i. Replace contact tip.
j. Set idle roll pressure per section
on Idle Roll Pressure Setting.
k. Install proper equipment.
a. Replace tip - remove any spatter on end of
tip.
b. Inspect - Repair or replace as necessary.
c. Be sure electrode lead is tight in wire feeder
contact block, gun nozzle and gun tip tight.
d. Check connection at output studs for polari-
ty required by welding process.
e. Make sure control cable connections are
tight. Check for consistent WFS. Make sure
parameters on Power Source display, such
as WFS, match those on wire feeder display,
if not, see Problem 14, otherwise try chang-
ing Synergic 7 control board. If problem per-
sists refer to Power Source trouble shooting
information.
1. Rough wire feeding or wire not
feeding but drive rolls turning.
2. Variable or “hunting” arc.