Lincoln Electric IM539 User Manual
Synergic 7F and Synergic 7FH
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Semiautomatic Wire Feeders or Controls with code numbers 10189, 10190 & 10191
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 operation on your part.
DO NOT INSTALL, OPERATE
OR REPAIR THIS EQUIPMENT
WITHOUT READING THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT.
importantly, think before you act
and be careful.
And, most
IM539
October, 1999
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
OPERATOR’S MANUAL
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
WARNING
ARC WELDING can be hazardous.
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 Standard Z49.1” from the American Welding Society, P.O. Box 351040,
Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the
Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
ELECTRIC SHOCK can
kill.
1.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.
1.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.
In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:
• Semiautomatic DC Constant Voltage (Wire)
Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
1.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically“hot”.
1.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.
1.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
1.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
1.g. Never dip the electrode in water for cooling.
1.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.
1.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
1.j. Also see Items 4.c. and 6.
ARC RAYS can burn.
2.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.
2.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
2.c. Protect other nearby personnel with suitable non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
FUMES AND GASES
can be dangerous.
3.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases.When welding, keep your
head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.
3.b. Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors to
form phosgene, a highly toxic gas, and other irritating
products.
3.c. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
3.d. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
3.e. Also see item 7b.
WELDING SPARKS can
cause fire or explosion.
4.a..Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
the welding sparks from starting a fire.
Remember that welding sparks and hot
materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.
4.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.
4.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact can
cause overheating and create a fire hazard.
4.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even though they have
been “cleaned.” For information purchase “Recommended
Safe Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
4.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
Apr. ‘93
– 2 –
4.f. Sparks and spatter are thrown from the welding arc. Wear oil
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.
4.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing through
lifting chains, crane cables or other alternate circuits. This can
create fire hazards or overheat lifting chains or cables until
they fail.
4.h. Also see item 7c.
7.c.Do not add the fuel near an open flame
welding arc or when the engine is running.
Stop the engine and allow it to cool before
refueling to prevent spilled fuel from
vaporizing on contact with hot engine parts
and igniting. Do not spill fuel when filling
tank. If fuel is spilled, wipe it up and do not
start engine until fumes have been
eliminated.
---------------------------------------------------------------------------------------
7.d. Keep all equipment safety guards, covers
and devices in position and in good repair.
Keep hands, hair, clothing and tools away
from V-belts, gears, fans and all other
moving parts when starting, operating or
repairing equipment.
CYLINDER may explode
if damaged.
5.a. Use only compressed gas cylinders
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
5.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
5.c. Cylinders should be located:
• Away from areas where they may be struck or subjected to
physical damage.
• A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
5.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
5.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
5.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
5.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,”available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
FOR ELECTRICALLY
powered equipment.
6.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
6.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.
6.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
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.e. In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.
7.f. Do not put your hands near the engine fan. Do not
attempt to override the governor or idler by pushing on
the throttle control rods while the engine is running.
7.g.To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
--------------------------------------------------------------------------------
7.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
ELECTRIC AND MAGNETIC FIELDS
may be dangerous
8.a. Electric current flowing through any
conductor causes localized Electric and
Magnetic Fields (EMF). Welding current
creates EMF fields around welding cables
and welding machines.
8.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
8.c. Exposure to EMF fields in welding may have other health
effects which are now not known.
8d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
8.d.1. Route the electrode and work cables together - Secure
them with tape when possible.
8.d.2. Never coil the electrode lead around your body.
8.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right side,
the work cable should also be on your right side.
8.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
8.d.5. Do not work next to welding power source.
7.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.
---------------------------------------------------------------------------------------
– 3 –
Mar. ‘93
PRÉCAUTIONS DE SÛRETÉ
zones où l’on pique le laitier.
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’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue ou
les vétements mouillés. Porter des gants secs et sans trous
pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble de
soudage et la machine à souder en bon et sûr état
defonctionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le total
de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
8. S’assurer que la masse est connectée le plus prés possible de
la zone de travail qu’il est pratique de le faire. Si on place la
masse sur la charpente de la construction ou d’autres endroits
éloignés de la zone de travail, on augmente le risque de voir
passer le courant de soudage par les chaines de levage,
câbles de grue, ou autres circuits. Cela peut provoquer des
risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté, voir
le code “Code for safety in welding and cutting” CSA Standard
W 117.2-1974.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie du
corps.
3. Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:
a. Utiliser un bon masque avec un verre filtrant approprié ainsi
qu’un verre blanc afin de se protéger les yeux du
rayonnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la peau
de soudeur et des aides contre le rayonnement de l‘arc.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse,
pantalons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la debrancher
à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur place.
-4-
Mar. ‘93
TABLE OF CONTENTS
Page
GENERAL DESCRIPTION..................................................................................................7
RECOMMENDED PROCESSES AND EQUIPMENT .........................................................7
STANDARD FEATURES ....................................................................................................7
Wire Drive Features ..........................................................................................................7
Control Features ...............................................................................................................8
KEYPAD AND DISPLAY DESCRIPTION ...........................................................................9
OPTIONAL FEATURES ..................................................................................................10-11
Drive Roll and Guide Tube Kits........................................................................................10
Input Cable Assemblies ...................................................................................................10
Wire Reel Assemblies......................................................................................................10
Readi-Reel Adapters........................................................................................................11
Spindle Adapters..............................................................................................................11
Gun and Cable Assemblies .............................................................................................11
Miscellaneous Options.....................................................................................................11
SPECIFICATIONS..............................................................................................................12
INSTALLATION..................................................................................................................13
Installation of Synergic 7F Components ..........................................................................14
Wire Feed Drive Roll and Guide Tube Kits ......................................................................14
PROCEDURE TO INSTALL DRIVE ROLL AND GUIDE TUBES......................................14
Standard 4-Roll Kits (KP571 and KP572) ........................................................................14
Gun and Cable Assemblies...........................................................................................15-16
Synergic 7F Water Connections (For Water-Cooled Guns).............................................16
GMAW Shielding Gas with Gas Guard Regulator ...........................................................16
Electrical Installation ........................................................................................................17
Input Cable: Synergic 7F Wire Feeder to Invertec Synergic Type Power Sources ...17
Work Cable ......................................................................................................................17
OPTIONAL FEATURES INSTALLATION..........................................................................18
OPERATING INSTRUCTIONS ........................................................................................19-26
Keypad Setup and Operation...........................................................................................19
Power-Down Save ......................................................................................................19
Operation Keys ...........................................................................................................19
Mode Selection ...........................................................................................................19
Display Control Keys...................................................................................................20
Timer/Crater Select.....................................................................................................21
Acceleration Selection .....................................................................................................21
Selection of English or Metric Speed Display Units .........................................................21
Run-In Selection ..............................................................................................................21
4-Step Trigger Mode Selection ........................................................................................22
Wire Reel Loading - Readi-Reels and Spools...............................................................22-24
Feeding Electrode and Brake Adjustment .......................................................................22
Adjustable Wire Reel Brake .............................................................................................23
Idle Roll Pressure Setting ................................................................................................24
Gas Guard Regulator Setting...........................................................................................24
Making a Weld .................................................................................................................25
Wire Reel Changing.........................................................................................................25
Wire Feed Overload Protection........................................................................................25
Explanation of Prompting and Error Messages ...............................................................26
MAINTENANCE .................................................................................................................27
Routine Maintenance .......................................................................................................27
Avoiding Wire Feeding Problems.....................................................................................27
Periodic Maintenance ......................................................................................................27
TROUBLESHOOTING GUIDE ........................................................................................28-35
Procedure for Replacing PC Boards................................................................................36
Gun Cable Connector Requirements to Permit Proper Connection to Wire Feed Unit ...36
WIRING DIAGRAM ............................................................................................................37
CONNECTION DIAGRAM..................................................................................................38
DIMENSION PRINTS.......................................................................................................39-40
PARTS MANUAL.......................................................................................................P-266 Series
– 5 –
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!
Please Examine Carton and Equipment For
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the time
the shipment is received.
Please record your equipment identification information below for future reference. This information can be found
on your machine nameplate.
Code Number _____________________________________
Serial Number _____________________________________
Model Name _____________________________________
Date of Purchase __________________________________
Whenever you request replacement parts for or information on this equipment always supply the information you
have recorded above.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
Damage Immediately
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or
loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to
this equipment.
– 6 –
GENERAL DESCRIPTION
The Synergic 7FH wire feed unit has the following
wire feeding capabilities:
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 assemblies. A serial communication
link is supplied through the input control cable of the
Synergic 7F enabling information to be shared
between the power source and wire feeder control.
The 4-Roll Synergic 7F wire feed units comes factory
a) Feeds .025 - .045” (0.6-1.2mm) solid wire for
gas-metal-arc processes.
b) Feeds .045 - (1.2mm) cored wire for Outershield
GMA or Innershield processes.
Recommended power sources are The Lincoln
Electric Company Synergic type Power Wave power
sources with 42V AC auxiliary power, and a 14-pin
connector receptacle.
equipped with gas solenoid valve with gas fittings and
standard Lincoln gun connector and connector for an
STANDARD FEATURES
optional dual procedure gun switch. Control includes a
3-1/2 digit LED display with rotating knob encoder
Wire Feed Features:
controls for setting the wire feed speed and voltage. A
tactile-feel keypad provides selection of operating
mode, function selection, timer selection and crater fill
selection and parameter adjustment. Two keys
provide Cold Feed and Gas Purge functions.
Wire Drive Unit - Incorporates low voltage permanent
magnet motor and highly efficient two-reduction spur
gearbox with insulated mounting bracket for mounting
and operation in any position. The non-fluid lubricant
won’t leak.
The unit has 3 operating modes: 2-step trigger, 4step trigger and spot. Three functions can be
selected: Volts or Trim Preset/arc (memory) voltmeter,
Run-in speed and weld speed (IPM or m/min.). In
addition, when 4-step trigger mode is selected, crater
fill WFS is also adjustable. In addition, when 4-step
“Quick Release” Wire Feed System - Provides a
completely tool-less means for releasing and opening
the idle roll pressure arm, precisely adjusting the idle
roll pressure and changing the incoming and outgoing
guide tubes.
trigger mode is selected, crater fill WFS is also
adjustable. Up to three timers are available depending
on the mode: preflow, postflow and spot, and 5
acceleration rates are selectable.
Drive Rolls and Guide Tubes - Provide long life,
positive feeding and precise alignment of electrode.
Minimizes “birdnest” or mill-thru of wire if properly set.
(Ordered separately.)
The K678-1 Synergic 7F control may be used with
either of the two available 4-roll wire feed units.
Ordering Speed Range Wire Size Range
Information Model Drive IPM (m/m) IN. (MM)
K679-1 Synergic 4-Roll 50 - 770 .025 - 3/32
7F (1.25 - 19.5) (0.6 - 2.4)
K679-2 Synergic 4-Roll 80 - 1200 .025 - .045
7FH (2.00 - 30.5) (0.6 - 1.2)
The feeder to control cable assemblies are available in two types:
K680-”L” Includes a control cable with a 14-pin MS style connector on each end, and a 4/0 weld
cable. Available in lengths “L” of 16ft (4.9m) or 25ft (7.6m).
K681-”L” Same as above but does not include weld cable available in lengths “L” of 12ft (3.6m),
16ft (4.9m) or 25ft (7.6m).
RECOMMENDED PROCESSES
AND EQUIPMENT
Tachometer Feedback - Provides proper wire feed
acceleration and speed accuracy, independent of
fluctuations in line voltage and wire loading, for
reliable arc starting and weld consistency.
Run-in Speed Setting - Allows the arc striking speed
“Run-in” to be adjusted independently of the weld feed
speed for starting optimization.
Cold Feed Speed - Provides cold feed speed adjustment
independent of weld, run-in and crater speed.
Adjustable Acceleration - Provides front panel
selection of 5 acceleration rates. This feature in
combination with Run-in Speed provides the ability to
easily optimize starting on any process or procedure.
The Synergic 7F wire feed unit has the following wire
feeding capabilities:
Solid-State Dynamic Braking - Quickly stops wire
feed motor to minimize wire overrun during weld
termination. Solid-state design requires no
a) Feeds .025 - 1/16” (0.6-1.6mm) solid wire for
maintenance.
gas-metal-arc processes.
b) Feeds .045 - 3/32” (1.2-2.4mm) cored wire for Outershield
GMA or Innershield processes up to 5/64” (2.0 mm).
– 7 –
Crater Fill - Provides crater feed speed adjustment (in
4-step trigger mode) independent of weld, cold feed,
or run-in speeds.
Crater Fill - Allows setting of crater fill WFS (when 4step with crater fill trigger mode is selected),
independent of weld, cold feed, and 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 on Synergic 7F
models. Also available as an option (K659-1) a Gas
Guard regulator for flow surge suppression.
English/Metric Speed Display - Provides front panel
selection of speed display in units of IPM or M/M.
4-Roll Drive - Both models employ 4-Roll Drive, with
2 driven rolls, providing optimal feeding force for
problem feeding situations, with low wire deformation
for improved feeding of soft wires.
Control Features:
Microcomputer Based Control - Provides precise
setting and display of all parameters and precision
timing functions. Optimizes wire drive control for crisp
acceleration and smooth response with precise
repeatability. Allows synergic control of various
welding processes by communicating information over
a serial link to the compatible power source.
Spot Mode - Allows a single timed weld cycle each
time the gun trigger is held closed. Duration (0.2-9.9
seconds) is set by the Spot ON timer.
Digital “Memory” Voltmeter - Displays arc voltage
from 0 to 80V DC, when welding gun trigger is
activated, with automatic polarity indication for positive
or negative electrode. The last welding voltage
monitored at end of weld is displayed for 5 seconds
after weld has stopped. This allows checking actual
voltage after weld has stopped.
Power-down Save - All settings, including mode,
Run-in speed, cold feed speed, crater speed, weld
speed, timers, English-Metric units and acceleration
are automatically saved when power is removed. This
feature does not require batteries and when power is
restored it will automatically return all settings to the
state they were in when power was removed.
However, the power source may overwrite any or all
of these parameters after Power-Up Recall is
complete.
Display and Indicator Lights - Wide temperature
range, long life, 3-1/2 digit 7-segment LED display
with .56” (14.2mm) character height permits easy
viewing even from long gun cable distances.
Individual red indicator lights are high intensity LED’s
for viewing at almost any angle.
Encoder Controls - Rotating encoders provide
continuous knob control for setting both Wire Feed
Speed and Volts/Trim procedures.
Keypad - Consists of 7 membrane keys with tactilefeel embossed domes. All keys are generously
spaced to provide easy selection, even if wearing
welding gloves.
2-Step or 4-Step Trigger Modes - Unit operates only
when trigger is pressed in 2-Step mode (normal)
operation. 4-Step Trigger Mode eliminates the need
to hold the gun trigger closed while welding.
Both models have user selectable 4-step with crater
fill, or as shipped, 4-step with current interlock.
Gas Preflow and Postflow Timers - Allows setting of
shielding gas preflow time (0-2.5 seconds) before
welding arc starts, and gas postflow time
(0-9.9 seconds), after welding arc stops.
– 8 –
KEYPAD AND DISPLAY
DESCRIPTION
Keypad - Seven key, membrane
Keypad - Seven key, membrane
type with “snap” tactile feel and
COLD FEED GAS PURGE
TRIGGER MODE
2-STEP
STD
4-STEP
LOCK
SPOT
PREFLOW POSTFLOW
type with “snap” tactile feel and
embossed domes. Long life
embossed domes. Long life
design. Spatter resistant surface.
design. Spatter resistant surface.
TRIM
VOLTS
/
V
Display - 3-1/2 digit 7-segment
Display - 3-1/2 digit 7-segment
RUN-IN
WFS
LED with (+) or (-) polarity
LED with (+) or (-) polarity
indicators. .56” (14.2mm) character
indicators. .56” (14.2mm) character
height. Displays arc voltage in
height. Displays arc voltage in
volts, wire speed in IPM or m/m and
volts, wire speed in IPM or m/m and
2
1
all timers in seconds.
all timers in seconds.
CRATER
SPOT
Indicator Lights - Extra bright red
Indicator Lights - Extra bright red
LED’s for viewing at almost any
LED’s for viewing at almost any
angle. Always indicates the mode
angle. Always indicates the mode
being used and which function or
being used and which function or
timer is being displayed. A function
timer is being displayed.
and a timer light will never be on at
the same time since they can only
be displayed one at a time.
V
VOLTS
Function Select key enables operator to
TRIM
/
choose which function will be displayed as
shown by the appropriate indicator light.
RUN-IN
Pressing the key causes lights to sequence
WFS
(top to bottom) starting from the current
indicated position. The function displayed will
be adjustable with the rotating encoders or
arrow keys.
Top Light - Indicates display of preset voltage
or percent trim when not welding and arc
voltage while welding (as indicated by top light
“blinking”). The power source automatically
determines whether preset voltage or percent
trim will be displayed, and adjustable with
Volts/Trim rotating encoder control.
Middle Light - Indicates Run-in speed is being
displayed. As shipped, these models are setup
for a 50 IPM (1.27m/min) fixed run-in speed
with display function deactivated. They may be
user-selected to activate or deactivate
adjustable Run-in display.
Bottom Light - Indicates Weld Feed Speed
(WFS) is being displayed, and is adjustable
with the Wire Feed Speed rotating encoder
control.
2-STEP
STD
4-STEP
LOCK
SPOT
Cold Feed key energizes the wire
feeder but not the power source or
solenoid valve. Cold feed speed is
adjustable and is displayed only
while pressing Cold Inch, and the
last speed selected is stored in
memory for next Cold feeding.
Gas Purge
key energizes the
solenoid valve but not the wire
feeder or power source.
Mode Select
key enables operator
to choose mode of operation shown
by the indicator lights. Pressing key
causes mode lights to sequence
(top to bottom) starting from the
current indicated selection.
Top Light - Indicates 2-step
(standard) trigger mode.
Middle Light - Indicates 4-step
(lock) trigger mode. This mode may
be selected to include crater fill or
weld current interlock.
Bottom Light - Indicates spot weld
mode.
PREFLOW POSTFLOW
2
1
CRATER
SPOT
Timer/Crater Select
key enables operator to
choose spot or gas timers, or crater speed as
indicated by the appropriate light. Pressing the
key causes lights to sequence (left to right, top
to bottom) starting from the current indicated
selection. Any parameter not available in the
mode selected is skipped over.
Top Left Light - indicates preflow time is being
displayed in seconds.
Top Right Light - indicates postflow time is
being displayed in seconds.
Middle Light - indicates Crater Feed Speed is
being displayed. This display will only occur if
4-step mode with crater fill is selected.
Bottom Light - indicates spot on time is being
displayed in seconds.
Increase arrow key increases the setting of
the parameter selected to be displayed.
Arrow keys do not function for Wire Feed
Speed or Volts/Trim settings, which are
adjusted using the rotating encoder knobs.
Decrease
arrow key decreases the setting of
the parameter selected to be displayed.
Arrow keys do not function for Wire Feed
Speed or Volts/Trim settings, which are
adjusted using the rotating encoder knobs.
– 9 –
OPTIONAL FEATURES
WIRE REEL ASSEMBLY:
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” (0.8mm) Solid KP655-030S
.023” (0.6mm) Solid KP655-025S
Aluminum Wire Sizes:
1/16” (1.6mm) KP656-1/16A
KP647-1/16A**
3/64” (1.2mm) KP656-3/64A
KP647-3/64A**
.040” (1.0mm) KP647-040A**
.035” (0.9mm) KP656-035A
Drive rolls for only cored electrode sizes are stencilled with a “C” suffix
to the wire sizes.
Drive rolls for only solid electrode sizes are stencilled with an “S” suffix
to the wire sizes.
Drive rolls for aluminum wire sizes are stencilled with an “A” suffix to the
wire sizes.
* Not for Synergic 7H model.
** For use with Binzel European guns. Installation instructions are
included with these kits.
INPUT CABLE ASSEMBLIES:
K649 - (Used with Power Wave 450/500) Consists of an 8conductor control cable with 14-pin control cable plug and a
4/0 (107 mm2) electrode cable with Twist-Mate™ connector.
It is rated at 500 amps, 60% duty cycle and is available in
lengths of 7 ft. (2 m), 17 ft (5 m), 25 ft (7.6 m), 33 ft (10 m),
and 50 ft (15 m).
K299 - Wire reel assembly for customer mounting. Includes
50 - 60 lb wire reel spindle shaft, adjustable brake,
insulation and mounting hardware.
READI-REEL ADAPTERS:
K363P - Adapts Lincoln Readi-Reel coils of electrode 30 lb
(14 kg) and 22 lb (10 kg) to a 2” (51mm) spindle. Durable
molded plastic one piece construction. Designed for easy
loading; adapter remains on spindle for quick changeover.
(used with K162H)
K438
- Adapts Lincoln Readi-Reel coils of electrode 50-60 lb
(22.7-27.2 kg) to a 2” (51mm) spindle. (used with K162H)
.
SPINDLE ADAPTERS:
K162H - Spindle for mounting Readi-Reels and 2” (51mm)
I.D. spools with 60 lb (27.2 kg) capacity. The shaft for the
standard wire coils is removed from the mounting framework and the K162H is installed in its place. Includes an
easily adjustable friction brake for control of overrun.
When used with Readi-Reels a Readi-Reel adapter is
required.
K435
- Permits 14 lb (6 kg) Innershield coils to be mounted
on 2” (51mm) O.D. spindles. For use with optional K162H
adapter.
K468
- Permits 8” (203mm) O.D. spools to be mounted on
2” (51mm) O.D. spindles. For use with optional K162H
adapter.
GUN AND CABLE ASSEMBLIES:
K648
- (Used with Power Wave 450) Consists of an 8conductor control cable with a 14-pin plug and a 4/0 (107
mm2) 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 ft (5 m), 25 ft (7.6 m), 33 ft (10 m) and 50 ft (15 m).
K651
- (Used with Power Wave 350) Consists of an 8conductor control cable with 14-pin control cable plug and a
2/0 (67 mm2) electrode cable with Twist-Mate™ connector.
It is rated at 350 amps, 60% duty cycle and is available in
lengths of 7 ft. (2 m), 17 ft (5 m), 33 ft (10 m), and 50 ft (15
m).
K642
- (Control Cable only) Consists of an 8-conductor
control cable with 14-pin control cable plug, without
electrode cable, and is available in lengths of 7 ft (2 m), 17 ft
(5 m), 25 ft (7.6 m), 33 ft (10 m) and 50 ft (15 m).
K643 (Control Cable Extension) Consists of an 8-conductor
control cable with 14-pin connectors on each end for
extending the control cable between the power source and
the control cable. Available in lengths of 17 ft (5m), 25 ft
(7.6m), 33 ft (10m), and 50 ft (15m).
The following Lincoln gun and cable assemblies are
compatible with both the Synergic 7F and Synergic 7FH
Wire Feed units:
K126
- Innershield® gun and cable assemblies are rated at
350 amps, 60% duty cycle. Maximum wire size for Synergic
7F models is 5/64” (2.0 mm). Not recommended for
Synergic 7FH models. (Consult sales specifications for
appropriate models).
K115
- Innershield gun and cable assemblies are rated at
450 amps, 60% duty cycle. Maximum wire size for Synergic
7F models is 5/64” (2.0 mm). Not recommended for
Synergic 7FH models. (Consult sales specifications for
appropriate models).
K470
- Magnum 300 GMAW gun and cable assemblies are
rated for 300 amps, 60% duty cycle. (Consult sales
specifications for appropriate models).
K471
- Magnum 400 GMAW gun and cable assemblies are
rated for 400 amps, 60% duty cycle. (Consult sales
specifications for appropriate models).
K497
- Magnum 200 GMAW gun and cable assemblies are
rated 200 amps, 60% duty cycle. (Consult sales
specifications for appropriate models).
– 10 –
K541 - Magnum 400 Short Neck GMAW gun and cable
assemblies are rated 400 amps, 60% duty cycle. (Consult
sales specifications for appropriate models).
K598
- Magnum 550 GMAW gun and cable assemblies are
rated 550 amps, 60% duty cycle. (Consult sales
specifications for appropriate models).
K206*
assemblies are rated 350 amps, 60% duty cycle. Maximum
size for Synergic 7F Wire Feed unit is 5/64” (2.0 mm). Not
recommended for Synergic 7FH Wire Feed unit. (Consult
sales specifications for appropriate models).
- Innershield Linconditioner gun and cable
MISCELLANEOUS OPTIONS:
K682 Water Connection Kit - Includes water cooled gun
tube fittings and self-sealing outlet and inlet quickconnectors for mounting onto the Synergic 7F Wire Drive
mounting bracket.
K659-1
with removable adjustor key for CO
Mounts onto Wire Drive gas inlet, and reduces gas waste
and arc start “blow” by reducing surge caused by excess
pressure in supply hose.
- (Gas Guard Regulator) Adjustable flow regulator
2
and Argon blend gases.
K289* - Innershield Linconditioner gun and cable
assemblies are rated 500 amps, 60% duty cycle. Maximum
size for Synergic 7F Wire Feed unit is 5/64” (2.0 mm). Not
recommended for Synergic 7FH Wire Feed unit. (Consult
sales specifications for appropriate models).
K309*
assemblies are rated 250 amps, 60% duty cycle. Maximum
size for Synergic 7F Wire Feed unit is 5/64” (2.0 mm). Not
recommended for Synergic 7FH Wire Feed unit. (Consult
sales specifications for appropriate models).
- Innershield Linconditioner gun and cable
The following Lincoln gun and cable assemblies are
equipped with a Fast-Mate™ connector. They can be
used with Synergic 7F Wire Feed unit by installing a
K489-2 Fast-Mate adapter kit.
K684
- Magnum “Super Cool” FM water cooled
GMAW gun and cable assemblies are rated 450
amps, 100% duty cycle (CO
2
). (Consult sales
specifications for appropriate models).
K498
- Magnum 200 FM GMAW gun and cable
assemblies are rated for 200 amps, 60% duty cycle.
(Consult sales specifications for appropriate models).
K683-1
and mountings for Lincoln Innershield and Magnum guns
with 15 ft (4.6 m) control cable and 3-pin plug.
- (Dual Procedure Switch) Kit includes gun switch
K534
- Magnum 250L FM GMAW gun and cable
assemblies are rated for 250 amps, 30% duty cycle.
(Consult sales specifications for appropriate models).
K478
- Magnum 300 FM GMAW gun and cable
assemblies are rated for 300 amps, 60% duty cycle.
(Consult sales specifications for appropriate models).
K479 - Magnum 400 FM GMAW gun and cable
assemblies are rated for 400 amps, 60% duty cycle.
(Consult sales specifications for appropriate models).
K556
* - GMAW process Magnum 400XA X-
TRACTOR gun and cable assemblies are rated at 400
amps, 60% duty cycle. (Consult sales specifications
for appropriate models).
K566
* - GMAW process Magnum 250XA X-
TRACTOR gun and cable assemblies are rated 250
amps, 60% duty cycle. (Consult sales specifications
for appropriate models).
* K179 type vacuum unit not recommended for use with
Synergic 7F.
– 11 –
SPECIFICATIONS FOR SYNERGIC 7F
AND SYNERGIC 7FH
Model
Type
Wire Speed Range:
IPM
M/M
Wire Size Capabilities:
Solid Electrodes
Cored Electrodes
Input Power:
Temperature Rating:
Operating
Storage
CONTROL
SYNERGIC 7F SYNERGIC 7F SYNERGIC 7FH
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
-20°C to +40°C
-40°C to +40°C
WIRE FEED - (4 - ROLL)
K679-1
50 - 770
1.25 - 19.5
.025 - 1/16”
0.6 - 1.6mm
.045 - 3/32”
1.2 - 2.4mm
K679-2
80 - 1200
2.00 - 30.5
.025 - .045”
0.6 - 1.2mm
.045”
1.2mm
Dimensions:
Height
Width
Depth
Weight
13.31” (338.1 mm)
10.32” (262.1 mm)
6.16” (156.5 mm)
13.25 lbs (6.0 Kg)
– 12 –
11.25” (285.8 mm)
7.16” (181.9 mm)
8.06” (204.7 mm)
16.5 lbs (7.5 Kg)
INSTALLATION
Safety Precautions
WARNING
b) Open the control box door by removing the two
door screws.
c) Mount the box.
d) Tighten the screws.
e) Close the control box door and replace the door
screws.
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts such
as output terminals or internal wiring.
Connecting Wire Feed Unit to Control Box
The Feeder to Control cable assemblies are available
• When inching with gun trigger, electrode
and drive mechanism are “hot” to work
and ground.
• Turn OFF welding power source before
installing or changing drive roll and/or
guide tubes.
• Welding power source must be connected
to system ground per the National
Electrical Code or any applicable local
codes.
• Only qualified personnel should
perform this installation.
in two types:
K680-”L” Includes a control cable with 14-pin MS-
K681-”L” Same as K680, but does not include
1. Making certain the cables are protected from any
Observe all additional Safety Guidelines detailed
throughout this manual.
INSTALLATION 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. The gearbox assembly is electrically
“hot” when the gun trigger is pressed. Therefore,
make certain the gearbox does not come in contact
with the structure on which the unit is mounted.
2. Connect the 14-socket cable connector to the
3. At the same end, connect the electrode lead to the
4. At the control box end, connect the 14-pin
style connectors on each end, and a 4/0
weld cable to route between the Wire
Drive and the Control Box. Available in
lengths “L” of 16ft. (4.9m) and 25ft.
(7.6m).
weld cable. Available in lengths “L” of
12ft. (3.6m), 16ft. (4.9m) and 25ft.
(7.6m).
sharp corners which may damage their jackets,
mount the cable assembly along the boom so the
end with the female MS-style connector pins is at
the wire feed unit.
receptacle on the back of the wire feed unit
connection box.
connection stud of the brass gun connection block
on the front of the wire feed unit.
connector of the cable to the mating receptacle on
the bottom of the control box.
The wire feed unit should be mounted so that the
drive rolls are in a vertical plane so dirt will not collect
in the drive roll area. Position the mechanism so it will
point down at about a 45° angle so the wire feed gun
cable will not be bent sharply as it comes from the
unit.
Mounting the Control Box (K678-1)
The same control box is used for both the Synergic 7F
and Synergic 7FH wire feed units and contains two
keyhole slots and one slot for mounting. Reference
M17740 dimension print in the rear of this manual for
size and location of these slots. Mount the box at
some convenient location close to the wire feed unit
which will enable the desired control cable assembly
to reach between the control box and the wire feed
unit.
a) Drill the required holes in the mounting surface,
partially install 1/4-20 screws.
Electrode Routing
The electrode supply may be either from reels, ReadiReels, spools or bulk packaged drums or reels.
Observe the following precautions:
1. The electrode must be routed to the wire feed unit
so that the bends in the wire are at a minimum,
and also that the force required to pull the wire
from the reel into the wire feed unit is kept at a
minimum.
2. The electrode is “hot” when the gun is energized
and must be insulated from the boom and
structure.
3. If more than one wire feed unit shares the same
boom, their wire and reels must be insulated from
each other and insulated from their mounting
structure.
– 13 –
Wire Feed Drive Roll and Guide Tube Kits
NOTE: The maximum sizes the Synergic 7F will feed
satisfactorily are the 3/32” (2.4mm) cored and
1/16” (1.6mm) solid electrodes. The
maximum sizes the synergic 7FH will feed
satisfactorily are the .045 (1.2mm) cored and
.045” (1.2mm) solid electrodes.
The electrode sizes that can be fed with each
roll and guide tube are stencilled on each part.
Check the kit for proper components.
PROCEDURE TO INSTALL DRIVE
ROLL AND GUIDE TUBES
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts such
as output terminals or internal wiring.
• When inching with gun trigger, electrode
and drive mechanism are “hot” to work
and ground.
• Turn OFF welding power source before
installing or changing drive roll and/or
guide tubes.
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” (0.8mm) Solid KP655-030S
.023” (0.6mm) Solid KP655-025S
Aluminum Wire Sizes:
1/16” (1.6mm) KP656-1/16A
KP647-1/16A**
3/64” (1.2mm) KP656-3/64A
KP647-3/64A**
.040” (1.0mm) KP647-040A**
.035” (0.9mm) KP656-035A
Drive rolls for only cored
electrode sizes are stencilled
with a “C” suffix to the wire sizes.
Drive rolls for only solid
electrode sizes are stencilled
with an “S” suffix to the wire sizes.
Drive rolls for aluminum wire sizes are stencilled with an
“A” suffix to the wire sizes.
* Not for Synergic 7H model.
** For use with Binzel European guns. Installation
instructions are included with these kits.
• Welding power source must be connected
to system ground per the National
Electrical Code or any applicable local
codes.
• Only qualified personnel should
perform this installation.
Observe all additional Safety Guidelines detailed
throughout this manual.
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 keyed shaft. Double grooved
drive rolls are to be installed with side stencilled for
correct wire size facing out and with slotted spacer
on top of roll. Two piece drive rolls use a spacer
between the rolls for .068” (1.7mm) and larger wire
sizes. (Do not exceed the maximum wire size
rating of the wire drive.) Replace collar and
tighten clamping screw.
5) Back out the set screw for the middle guide tube.
Install the middle guide tube and slide it up against
the drive roll. DO NOT TIGHTEN THE MIDDLE
GUIDE AT THIS TIME.
– 14 –
6) Install the outgoing drive roll following the same
procedure as steps 3 & 4.
7) Center the middle guide between the two drive
rolls and tighten in place.
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