F-15-510
September, 1993
SYNERGIC CONTROL KIT for
MIGhty 4 HD WIRE FEEDER
P/N 23540449
INSTALLATION AND OPERATION
1. Remove cover from the wire feeder.
2. Using the small Allen wrench included with the kit, remove the potentiometer knobs from the SCHEDULE
"A" wire speed and voltage potentiometers.
3. Remove the nuts securing the potentiometers to the front panel of the feeder and remove the potentiomÂeters from the panel. Save the nuts as they will be required for future use.
4. Disconnect the plug from receptacle P4 of the speed control board and remove the potentiometers from
the feeder.
NOTE
The potentiometer harness should be dressed separately
from the main harness to aid in removal. However, if it is not
dressed separately, it may be necessary to cut tywraps to
allow removal.
5. Remove the black hole plug from the schedule select switch hole. Remove the black hole plug from the
SCHEDULE "B" wire speed hole and insert it into the SCHEDULE "A" voltage potentiometer hole. Remove
the large hole plug from the rear of the feeder.
6. Install the potentiometer of the Synergic Control Kit into the SCHEDULE "A" wire speed potentiometer hole
and the plate with two switches into the schedule select switch and SCHEDULE "B" wire speed holes.
Secure the potentiometer and pushbutton switches with the nuts removed in step 3 and the toggle switch
with the nut provided in the kit. Install one of the knobs removed earlier onto the potentiometer shaft using
the Allen wrench supplied.
7. Install the Amphenol connector of the Synergic Control Kit into the large hole in the rear of the feeder using
the self-tapping screws supplied. Connect the plug from the Synergic Control kit to the P4 connector
where the potentiometer harness was removed.
8. If "slow wire run-in" in the synergic mode is not desired, disconnect the male/female quick connect
terminals in the black wire from the pushbutton switch.
9. Reinstall the cover onto the wire feeder. Connect the feeder power cable and the speed control cable to
the power source. For synergic control, set the schedule select switch to the SCHEDULE "B" position. For
manual wire speed control, set the schedule select switch to the SCHEDULE "A" position.
10. When synergic operation is selected, the "slow wire run-in" feature, which is built into the PULSE ARC
Power Source, will be enabled. This feature improves arc starts; however, if the feeder has a digital meter
kit installed, the meter will display "run-in speed" until the arc is established. Pressing the pushbutton
switch will allow you to read the actual welding speed as commanded by the power source.
SYNERGIC CONTROL KIT
P/N 23540449 (INSTALLED)
SWITCH, PUSHBUTTON,
SPDT, 10 A, 125 V
P/N 994295
SWITCH, TOGGLE,
DPDT, 2-POS., 5 A, 120 V
P/N 950629
PLATE P/N 34384
F-15-510 9/93 3M PRINTED IN U.S.A.
HOUSING, CONTACT, 7-PIN
P/N 950446
RECEPTACLE, 10-PIN,
#16 (MS3102A-19-19S)
P/N 13735459
POTENTIOMETER, 10 K, 2 W
P/N 2062018
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