ESAB Syntronic 3
Synchronization control for push-pull drives
Instruction Manual
DOKP4M4080 2021 01 11 1.02
DOKP4M4080 1.02 -2- © ESAB/TBi 2021
DOKP4M4080 1.02 -3- © ESAB/TBi 2021
Contents
1 Important basic information ............................................................................................................. 4
1.1 Safety instructions .................................................................................................................................. 4
1.2 Symbols and signal words...................................................................................................................... 5
1.3 Notes on intended use ........................................................................................................................... 5
1.3.1 Field of application, transport and storage ......................................................................................... 5
1.3.2 Scope of delivery (standard) .............................................................................................................. 5
1.3.3 Disposal and recycling ....................................................................................................................... 5
1.4 Warranty ................................................................................................................................................. 6
2 Product description, technical data .................................................................................................. 6
2.1 Product description and function ............................................................................................................ 6
2.2 Specifications ......................................................................................................................................... 7
3 Operation of the product .................................................................................................................. 7
3.1 Connection ............................................................................................................................................. 8
3.2 Mounting points ...................................................................................................................................... 8
3.3 Commissioning & adjustment ................................................................................................................. 9
3.4 Display / control elements .................................................................................................................... 10
4 Cleaning and Maintenance ............................................................................................................ 10
4.1 Regular checks ..................................................................................................................................... 10
4.2 Repairs to the device ............................................................................................................................ 10
5 Troubleshooting ............................................................................................................................. 11
DOKP4M4080 1.02 -4- © ESAB/TBi 2021
1 Important basic information
1.1 Safety instructions
Danger!
Failure to observe the information and instructions in this manual may result in
injury or death and / or damage to equipment, components and the product. All
persons who work on the product or with the product must read this operating
manual in its entirety before beginning this work and observe all instructions.
▪ Please keep this operating manual for future reference and pass it on with the product.
▪ The accident prevention regulations and the safety-relevant regulations of the relevant company and
country must be strictly adhered to.
▪ Before installation and maintenance work, the power supply to the system must be disconnected.
▪ It must be ensured that the entire system remains switched OFF for the duration of the work. There is
a risk of fatal electric shock. There is also a risk of other system parts being destroyed through a shortcircuit.
▪ A welding system poses a variety of dangers for people. The product may only be used by qualified
personnel, this also applies to initial start-up and maintenance. In doing so, observe the instructions in
this operating manual as well as the operating instructions of any connected devices, such as welding
torch, power source, or wire feeder.
▪ The ESAB Syntronic 3 is only to be connected and operated within the bounds of its technical
specifications.
▪ The device may only be connected to electrical outlets which have been installed correctly.
▪ The specified voltage supply and the control voltage must be strictly adhered to. By applying too high a
supply voltage or through incorrect handling, the device can be destroyed, and life-threatening
situations can arise. Electrical short circuits must be avoided.
▪ The ESAB Syntronic 3 must be firmly fixed in suitable place by means of the screw connection option
provided.
▪ All electrical wiring must be protected from damage. The condition of the device must be checked
regularly by a specialist. Damage must be properly repaired before further use.
▪ Operation in potentially explosive areas is prohibited.
▪ The device should be protected from welding spatter, wetness and moisture.
▪ The device may only be operated within closed rooms.
▪ The accident prevention regulations and the safety-relevant regulations of the relevant company and
country must be strictly adhered to.
▪ Liability for the function of the device is in any case transferred to the owner or operator, as far as the
device is improperly maintained, repaired or changed or if the device is handled in a manner which
does not correspond to the intended use.
DOKP4M4080 1.02 -5- © ESAB/TBi 2021
1.2 Symbols and signal words
Symbol
Signal word
Meaning
Danger!
Description of a hazard with a high degree of risk, which can lead
to death or serious injuries if it is not avoided.
Warning!
Description of a hazard with a medium degree of risk, which can
lead to death or serious injuries if it is not avoided.
Caution!
Description of a hazard with a low degree of risk, which can lead
to minor or moderate injuries if it is not avoided
Note!
Important note!
Indication of a note that contributes to intended use, or to
information on the product.
1.3 Notes on intended use
1.3.1 Field of application, transport and storage
▪ The ESAB Syntronic 3 is only to be used within the specifications and for the purpose intended by
the manufacturer.
▪ The ESAB Syntronic 3 is intended exclusively for commercial and industrial use by qualified
specialists. For accidents and damage due to improper use of the product, the manufacturer
declines all liability.
▪ The installation, operation and maintenance provisions specified in these instructions must be
adhered to.
▪ The product must be protected against humidity and moisture during transport, storage, and use.
▪ The device is designed for use at ambient temperatures between 0°C and + 40°C. Beyond these
limits, special measures may need to be taken.
1.3.2 Scope of delivery (standard)
▪ ESAB Syntronic 3 including associated connection cable and power supply unit
▪ operating manual
1.3.3 Disposal and recycling
▪ Please do not dispose of the product in the household waste.
▪ The product must be disposed of in accordance with country-specific requirements
(directives, provisions, laws, regulations, standards, ...).
DOKP4M4080 1.02 -6- © ESAB/TBi 2021
1.4 Warranty
Our products are carefully checked before delivery. We guarantee that the product is free of material and
processing defects at the time of delivery, and functions as intended.
ESAB offers warranty for material and processing defects according to the requirements of the law. Wear
parts are always excluded from the warranty.
The warranty does not cover damage or functional defects which result from
▪ overloading, misuse, or using the product for a purpose for which it was not intended
▪ accidents
▪ failure to follow instructions in the manual
▪ improper installation or assembly
▪ lack of maintenance
▪ modification of the product compared to its original condition
▪ normal wear and tear
ESAB assumes no liability except for the replacement or repair of the defective parts. In the event of a
complaint, the ESAB Syntronic 3 must be returned to the manufacturer for inspection and repair.
2 Product description, technical data
2.1 Product description and function
The ESAB Syntronic 3 is needed for synchronization control between a ESAB MXH PP MIG torch and the
main drive of the wire feeder.
The Syntronic 3 ensures precise speed adjustment between both drives at every selected wire feed speed,
so that the wire can be conveyed without interference.
The Syntronic 3 is compatible with all common main feed devices.
The ESAB Syntronic 3 is used for the precise synchronization of two electric drives on the basis of their
motor voltages. Both wire feeds run in what is called sequential operation, meaning that the main wire feed
(master) specifies the required speed, and the subsequent wire feed (slave) is brought to the same speed.
For this purpose, the motor voltage of the main wire feed (master) is continuously measured, the appropriate
output value for the push-pull drive (slave) is calculated and provided at the output by the power amplifier,
which is included in the Syntronic 3.
The measuring input of the Syntronic 3 is electrically isolated and has a high resistance, so that feedback
effects on the main drive by the Syntronic 3 can be prevented. The main drive and its control thus continue to
work as if no other wire drive were connected. The characteristics of the welding machines are thus retained.
After the installation of a new system and following significant changes to the wire feed system (change of
wire diameter or wire material, change of conveyor length or use of a wire guide liner with different sliding
properties), the control characteristics of the Syntronic 3 may have to be adapted to the system. This
operation is performed at two operating points, one at low wire speed and one at high wire feed speed. All
other values are calculated by the Syntronic 3 itself.
The Syntronic 3 uses integrated circuits to protect the motor connected to the output from damage caused by
excessively high motor current, for example when the drive is mechanically locked. Activation of the
protection circuit briefly switched OFF the motor.
DOKP4M4080 1.02 -7- © ESAB/TBi 2021
2.2 Specifications
ESAB Syntronic 3
Item No.:
Supply voltage:
0700 025 311
100-240 V/AC 50/60 Hz
Power supply board
24V / DC
Control input
0 - 42 V DC, high impedance
Output
0-24V DC, max. 1.0 A
Power input
max. 25 W
Fuse protection
1A mT fuse 5x20mm
Temperature range for operation
0 - 40 °C
Display
current conveying force (at the motor output)
Wire feed speed
2 - 15 m/min
Please check the technical data which applies to your device before commissioning. You will find this on
the type plate which is attached to the device. If you have any questions about your device, please have
the serial number ready.
The ESAB Syntronic 3 has been constructed in accordance with the current state of the art and is operates
reliably providing that it is used as intended. The device bears the CE marking.
3 Operation of the product
The Syntronic 3 must be connected to the main drive of the feed unit and to the PP MIG torch. We
recommended mounting the Syntronic 3 firmly in or on the main feeder. For this purpose, four screw
connections with M5 threads are provided on the rear.
Danger!
The supply voltage to the welding machine must be disconnected before starting
installation work. It must be ensured that the entire system remains switched OFF
for the duration of the work. There is a risk of fatal electric shock.
DOKP4M4080 1.02 -8- © ESAB/TBi 2021
3.1 Connection
NOTE!
Connection to an excessively high supply voltage can destroy the ESAB Syntronic 3.
The correct supply voltage can be found on the rating plate.
Connection to other country-specific sockets is possible, for example by means of an
approved socket adapter.
3.2 Mounting points
View from below
4x M5 - 6mm deep
DOKP4M4080 1.02 -9- © ESAB/TBi 2021
3.3 Commissioning & adjustment
1. Connection: Generate main feeder motor "signal input" line;
2. Connection: Connect PP MIG torch motor;
3. Connection: Establish functional earth (FE);
4. Provide power supply unit with voltage (plug it in).
5. Open the pressure lever of the PP MIG torch;
6. Straighten out cable assembly;
7. Allow the welding wire to run in slowly;
8. After the wire has passed through the PP MIG torch, close the pressure lever;
9. set the wire feed of the welding machine to approx. 4 m/min;
10. start the wire transport;
11. Open cover on device if necessary;
12. use the potentiometer "Offset", set the required delivery force so that the green LED of the
delivery indicator lights up; stop the wire feed again;
13. next, set the wire feed on the welding machine to approx. 12 m/min;
14. start the wire transport again;
15. use the potentiometer "Scaling" to set the required delivery force so that the green LED of
the delivery indicator lights up;
16. Stop the wire feed again;
17. for fine adjustments, repeat steps 9 to 16 several times if necessary, until the correct value
(green LED) is shown on the display for both speeds;
Following successful adjustment, the display of the conveying force is no longer needed for
further operation, as it serves only for the purposes of comparison. Therefore, while
operating at different wire feed speeds, values other than "green LED" can be displayed as
the system now regulates the delivery force.
18. Close the device by screwing the lid on.
DOKP4M4080 1.02 -10- © ESAB/TBi 2021
3.4 Display / control elements
4 Cleaning and Maintenance
4.1 Regular checks
In order to ensure trouble-free operation of the device, the following checks should be carried out regularly:
• Check that all connections have been screwed on / connected properly and check for damaged areas;
• Check the device operation for faults. For fault analysis and troubleshooting see section 5.
• Clean the housing with a soft cloth. Do not use strong cleaning agents!
Defective parts must be replaced immediately if the safe functioning can no longer be guaranteed.
4.2 Repairs to the device
Repairs to the ESAB Syntronic 3 may only be carried out by the manufacturer or an authorized agent. In
the event of a complaint, the ESAB Syntronic 3 must be returned to the manufacturer for inspection and
repair.
DOKP4M4080 1.02 -11- © ESAB/TBi 2021
5 Troubleshooting
Fault
Possible causes
Measures
No wire feed at the
beginning of a
welding process
Wire feed at the welding power source
does not start
Check whether the torch is properly connected to
the power source. Consider tesing the functioning
of the torch button and the control line with a
continuity tester.
Wire feed of the welding power source
set incorrectly
Check that the drive inside the wire feeder case
has been set in accordance with the
manufacturer’s instructions.
Power supply of the ESAB Syntronic 3
absent or wrong
Check the power supply and associated
connecting cables.
Wire splatter is stuck to the contact tip
or the contact tip has been affected by
abrasion
Replace the contact tip.
Has the drive been equipped
appropriately with respect to the
welding wire used?
For ESAB MXH drive: Check that the right drive
rolls have been installed in accordance with the
operating instructions.
Other drives: Check with reference to
manufacturer's instructions.
Has the torch been equipped with wire
of an appropriate diameter and
material?
Check wire conduit (cable assembly and torch
neck) and contact tip.
Is contact pressure of the rolls set
correctly on the wire feeder?
Adjust contact pressure in accordance with wire
material and diameter
PP MXH motor does not start
Check whether "Signal Input" is connected and
has the right polarity
PP MXH motor is running / turning the
wrong way
Reverse the polarity of the motor cable
Wire feed stops
during the welding
process
Wire spool is empty
Check how much welding wire there is on the coil
in the wire feeder.
Wire splatter is stuck to the contact tip
or the contact tip has been affected by
abrasion
Renew contact tip, if necessary blow compressed
air through the burner neck, wire conduit channel
and wire conduit.
Is there a wire jam in the cable
assembly?
Open the PP MXH and gently pull on the end of
the welding wire.
If you can pull more than about 2 cm of wire from
the cable assembly before the wire is stretched
again, the Syntronic 3 needs to be readjusted.
The overload protection of the
Syntronic 3 has switched the motor off
Check wire conduit in cable assembly, torch neck
and contact tip
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