Lincoln Electric IM557 User Manual

Download

Page 1

Operator’s Manual

RETURN TO MAIN MENU

Synergic 7 and 7H

For use with machines having Code Numbers:

10250, 10251

Save for future reference

Date Purchased

Code: (ex: 10859)

Serial: (ex: U1060512345)

IM557 | Issue D ate Sept- 13

www.lincolnelectric.com/register

Authorized Service and Distributor Locator:

www.lincolnelectric.com/locator

Page 2

THANK YOU FOR SELECTING

AT ALL

TIMES.

SPECIAL SITUATIONS

Additional precautionary measures

A QUALITY PRODUCT BY LINCOLN ELEC TRIC.

PLEASE EXAMINE CARTON AND EQUIPMENT FOR DAMAGE IMMEDIATELY

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.

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. And, most importantly, think before you

act and be careful.

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.

KEEP YOUR HEAD OUT OF THE FUMES.

DON’T get too close to the arc. Use corrective lenses if necessary to stay a reasonable distance away from the arc.

READ and obey the Material Safety Data Sheet (MSDS) and the warning label that appears on all containers of welding materials.

USE ENOUGH VENTILATION or exhaust at the arc, or both, to keep the fumes and gases from your breathing zone and the general area.

IN A LARGE ROOM OR OUTDOORS, natural ventilation may be adequate if you keep your head out of the fumes (See below).

USE NATURAL DRAFTS or fans to keep the fumes away from your face.

If you de velop unusual symptoms, see your supervisor. Perhaps the welding atmosphere and ventilation system should be checked.

WEAR CORRECT EYE, EAR & BODY PROTECTION

PROTECT your eyes and face with welding helmet properly fitted and with proper grade of filter plate (See ANSI Z49.1).

PROTECT your body from welding spatter and arc flash with protective clothing including woolen clothing, flame-proof apron and gloves, leather leggings, and high boots.

PROTECT others from splatter, flash, and glare with protective screens or barriers.

IN SOME AREAS, protection from noise may be appropriate.

BE SURE protective equipment is in good condition.

Also, wear safety glasses in work area

DO NOT WELD OR CUT containers or materials which previously had been in contact with hazardous substances unless they are properly cleaned. This is extremely dangerous.

DO NOT WELD OR CUT painted or plated parts unless special precautions with ventilation have been taken. They can release highly toxic fumes or gases.

PROTECT compressed gas cylinders from excessive heat, mechanical shocks, and arcs; fasten cylinders so they cannot fall.

BE SURE cylinders are never grounded or part of an electrical circuit.

REMOVE all potential fire hazards from welding area.

ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FOR IMMEDIATE USE AND KNOW HOW TO USE IT.

Page 3

SECTION A:

Diesel Engines

Gasoline Engines

WARNINGS

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

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.

SAFETY

1.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.

1.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.

1.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.

1.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.

1.h. To avoid scalding, do not remove the radiator pressure cap when the engine is

hot.

ELECTRIC AND MAGNETIC FIELDS MAY BE DANGEROUS

2.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

FOR ENGINE POWERED EQUIPMENT.

1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running.

1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors.

1.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.

2.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physician before welding.

2.c. Exposure to EMF fields in welding may have other health effects which are now not known.

2.d. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:

2.d.1. Route the electrode and work cables together - Secure them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.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.

2.d.4. Connect the work cable to the workpiece as close as possible to the area being welded.

2.d.5. Do not work next to welding power source.

Page 4

SAFETY

ELECTRIC SHOCK CAN KILL.

3.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.

3.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.

3.c. In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head, nozzle or semiautomatic welding gun are also electrically “hot”.

3.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.

3.e. Ground the work or metal to be welded to a good electrical (earth) ground.

3.f. Maintain the electrode holder, work clamp, welding cable and welding machine in good, safe operating condition. Replace damaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically “hot” parts of electrode holders connected to two welders because voltage

two can be the total of the open circuit voltage of both welders.

3.i. When working above floor level, use a safety belt to protect yourself from a fall should you get a shock.

between the

ARC RAYS CAN BURN.

4.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.

4.b. Use suitable clothing made from durable flame-resistant material to protect your skin and that of your helpers from the arc rays.

4.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.

5.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 within applicable OSHA PEL and ACGIH TLV limits 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.

5. b. The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment, maintenance of the equipment and the specific welding procedure and application involved. Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV limits.

5.c. 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.j. Also see It ems 6.c. and 8.

5.d. Shielding gases used for arc welding can displace air and

injury or death. Always use enough ventilation, especially in confined areas, to insure breathing air is safe.

5.e. 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.

5.f. Also see item 1.b.

cause

Page 5

SAFETY

WELDING AND CUTTING SPARKS CAN CAUSE FIRE OR EXPLOSION.

6.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.

6.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.

6.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.

6.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).

6.e. Vent hollow castings or containers before heating, cutting or welding. They may explode.

6.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.

6.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.

6.h. Also see item 1.c.

CYLINDER MAY EXPLODE IF DAMAGED.

7.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.

7.b. Always keep cylinders in an upright position securely chained to an undercarriage or fixed support.

7.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.

7.d. Never allow the electrode, electrode holder or any other electrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outlet when opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use.

7.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.

8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment.

8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations.

6.I. Read and follow NFPA 51B “ Standard for Fire Prevention During Welding, Cutting and Other Hot Work”, available from NFPA, 1 Batterymarch Park, PO box 9101, Quincy, Ma 022690-9101.

6.j. Do not use a welding power source for pipe thawing.

8.c. Ground the equipment in accordance with the U.S. National Electrical Code and the manufacturer’s recommendations.

Refer to

http://www.lincolnelectric.com/safety

for additional safety information.

Welding Safety Interactive Web Guide for mobile devices

Page 6

TABLE OF CONTENTS

Page

Installation .......................................................................................................Section A

Technical Specifications ........................................................................................A-1

General Description...............................................................................................A-2

Recommended Processes and Equipment ...........................................................A-2

Standard Features.................................................................................................A-2

Keypad and Display Description............................................................................A-4

Safety Precautions ................................................................................................A-5

Installation of the Synergic 7 Components ............................................................A-5

Attaching Wire Reel Stand ..............................................................................A-5

Wire Feed Drive Roll and Guide Tube Kits............................................................A-6

Standard 4-Roll Kits (KP655 and KS656) .......................................................A-6

Procedure to Install Drive Roll and Guide Tubes...................................................A-6

Gun and Cable Assemblies ...................................................................................A-7

GMAW Guns ...................................................................................................A-7

Innershield Guns .............................................................................................A-7

Gun and Cable Connections..................................................................................A-7

Wire Feeder to Gun.........................................................................................A-7

For GMA Gun Cables......................................................................................A-7

Synergic 7 Water Connections ..............................................................................A-8

GMAW Shielding Gas............................................................................................A-8

Gas Guard Regulator ......................................................................................A-8

Electrical Installation..............................................................................................A-9

Optional Features Installation..............................................................................A-10

Operation ............................................................................................................Section B

Safety Precautions ................................................................................................B-1

Duty Cycle .............................................................................................................B-1

Keypad Setup and Operation ................................................................................B-1

Procedure Selector Switch ....................................................................................B-4

Dual Procedure Remote Control (K1449-1)...........................................................B-4

Wire Reel Loading .................................................................................................B-5

Idle Roll Pressure Setting ......................................................................................B-9

Gas Guard Regulator Setting ................................................................................B-9

Making a Weld.....................................................................................................B-10

Wire Reel Changing.............................................................................................B-10

Wire Feed Overload Protection ...........................................................................B-10

Grounding Lead Protector ...................................................................................B-11

Explanation of Prompting and Error Messages ...................................................B-11

Accessories .....................................................................................................Section C

Optional Features..................................................................................................C-1

Maintenance ....................................................................................................Section D

Safety Precautions ................................................................................................D-1

Routine Maintenance.............................................................................................D-1

Periodic Maintenance............................................................................................D-1

Troubleshooting ..............................................................................................Section E

Safety Precautions.................................................................................................E-1

Troubleshooting Guide ..........................................................................................E-2

Procedure for Replacing PC Boards....................................................................E-12

Diagrams ..........................................................................................................Section F

Wiring.....................................................................................................................F-1

Input Connection....................................................................................................F-2

Dimension Print......................................................................................................F-3

Parts Lists ...................................................................................................P-278 Series

Page 7

A-1

INSTALLATION

TECHNICAL SPECIFICATIONS – SYNERGIC 7 AND 7H

WIRE FEEDER - (4 - ROLL)

Model

SYNERGIC 7 SYNERGIC 7H

A-1

Type

Wire Speed Range:

IPM M/M

Wire Size Capabilities:

Solid Electrodes

Cored Electrodes

Input Power:

Temperature Rating:

Operating Storage

The following is for both the Synergic 7 and Synergic 7H models:

K631-3

50 - 770

1.25 - 19.5

.025 - 1/16”

0.6 - 1.6mm

.045 - 3/32”

1.2 - 2.4mm

K631-4

80 - 1200

2.00 - 30.5

.025 - .045”

0.6 - 1.2mm

.045”

1.2mm

40-42 V ± 10%

50/60 Hz

4.0 Amps

-20°C to +40°C

-40°C to +40°C

NRTL/C

Size & Weight Without Wire Stand With K377 Wire Stand

4-Roll Feeder:

Length Width Height Total Weight

(Less Electrode)

SYNERGIC 7 & 7H

269 mm (10.60")

295mm (11.60”) 282mm (11.11”)

12.9 kg (28.5 lbs.)

550 mm (21.66")

295mm (11.60”) 432mm (17.00”)

17.5 kg (38.5 lbs.)

Page 8

A-2

INSTALLATION

GENERAL DESCRIPTION

The Synergic 7 is a semiautomatic constant speed wire feeder designed specifically for use with the Invertec Power Wave type power sources. A serial communication link is supplied through the control cable of the Synergic 7 enabling information to be shared between the power source and wire feeder. The Synergic 7 comes factory equipped with a gas solenoid valve with gas fittings and standard Lincoln gun connector. These models includes a 3-1/2 digit LED display with rotating knob encoder controls for setting the wire feed speed and voltage and a dual procedure selector switch. A tactile-feel keypad provides selection of operating mode, function selection, timer and crater fill selection and parameter adjustment. Two keys provide Cold Feed and Gas Purge functions, and connector receptacles are provided for an optional dual procedure remote control and dual procedure switch.

The unit has 3 operating modes: 2-step trigger, 4-step 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.) or (memory) ammeter. In addition, when 4-step 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, as well as 6 Burnback settings.

A-2

b) Feeds .045 - (1.2mm) cored wire for Outershield

GMA or Innershield processes.

Recommended power sources are The Lincoln Electric Company Synergic type Invertec® Power Wave power sources with 42VAC auxiliary power, and a 14-pin connector receptacle.

STANDARD FEATURES

Wire Drive Features:

Wire Drive Unit - Incorporates low voltage permanent

magnet motor and highly efficient two-reduction spur gearbox which operates in any position. The non-fluid lubricant wonʼt leak.

“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 and drive rolls.

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 Synergic 7 is available in 2 models:

Ordering Speed Range Wire Size Range

Information Model Drive IPM (m/m) IN. (MM)

K631-3 Synergic 4-Roll 50 - 770 .025 - 3/32

7 (1.25 - 19.5) (0.6 - 2.4)

K631-4 Synergic 4-Roll 80 - 1200 .025 - .045

7H (2.00 - 30.5) (0.6 - 1.2)

RECOMMENDED PROCESSES AND EQUIPMENT

The Synergic 7 wire feed unit has the following wire feeding capabilities:

a) Feeds .025 - 1/16” (0.6-1.6mm) solid wire for

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).

The Synergic 7H wire feed unit has the following wire feeding capabilities:

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 speeds.

Selectable 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.

Solid-State Dynamic Braking -

motor to minimize wire overrun during weld termination. Solid-state design requires no maintenance.

Quickly stops wire feed

a) Feeds .025 - .045” (0.6-1.2mm) solid wire for

gas-metal-arc processes.

SYNERGIC 7 & 7H

Page 9

A-3

Crater Fill - Provides crater feed speed adjustment (in

4-step trigger mode) independent of weld, cold inch, 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 on Synergic 7 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.

INSTALLATION

A-3

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.

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.

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.

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 LEDʼs for viewing at almost any angle. Mode and Timer function keys and indicator lights are concealed behind a hinged “drop-door” cover.

Encoder Controls - Rotating encoders provide continuous knob control for setting both Wire Feed Speed and Volts/Trim procedures.

Procedure Switch - Permits selection of A or B procedures, as set by the procedure controls and memory pair selected at the Power Wave power source. Setting switch to center “Gun Switch” position allows selection of A or B procedures with the optional Dual Procedure Switch.

Keypad - Consists of 7 membrane keys with tactilefeel embossed domes. All keys are generously spaced to provide easy selection, even if wearing welding gloves.

Selectable Burnback Time - Provides front panel selection of 6 Burnback times. This feature provides selectable Burnback time (default = 0ms) if required to prevent electrode from sticking in weld puddle at finish of weld.

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.

Digital “Memory” Ammeter - Weld Feed Speed (WFS) display may be selectable to display welding amps only while welding and the last welding amps monitored at the end of the weld will be displayed for 5 seconds after the weld has stopped. This allows checking actual weld current after the 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.

SYNERGIC 7 & 7H

Page 10

A-4

INSTALLATION

KEYPAD AND DISPLAY DESCRIPTION

Keypad - Seven key, membrane

L9571-1

type with “snap” tactile feel and

COL D FEED GAS PURGE

2- STEP

4- STEP

LOCK SPOT

PREFL OW

STD

COLD FEED

embossed domes. Long life design. Spatter resistant surface.

TRIM/VOLTS

Display - 3-1/2 digit 7-segment

RUN- I N

LED with (+) or (-) polarity indica-

WFS

tors. .56” (14.2mm) character height. Displays arc voltage in

POSTF LOW

volts, wire speed in IPM or m/m and

all timers in seconds.

CRATER SPOT

Indicator Lights - Extra bright red LEDʼs for viewing at almost any angle. Always indicates the mode being used and which function or timer is being displayed.

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 Feed, and the last speed selected is stored in memory for the next Cold feeding.

VO LTS

WFS

A-4

Function Select key enables operator to choose which function will be displayed as shown by the appropriate

TRIM

indicator light. Pressing the key causes lights to sequence

RUN- I N

(top to bottom) starting from the current indicated position. The function displayed will be adjustable with the rotating encoder controls or arrow keys:

Adjusting either encoder knob automatically transfers display (and indicator light) to the function being adjusted.

Top Light - Indicates display of preset voltage or percent trim when not welding and arc voltage while welding (as indicated by top light “blinking”), and continues for 5 seconds after the weld has stopped (memory vpltmeter). 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, and setting with arrow keys.

Bottom Light - Indicates Weld Feed Speed (WFS) is being displayed, and is adjustable with the Wire Feed Speed rotating encoder control. If selected, this light will “blink” while welding, indicating that the display has been selected to display welding amps, and continues for 5 seconds after the weld is stopped (memory ammeter).

Timer/Crater Select or gas timers, or crater speed as indicated by the appropriate light. Pressing the key causes lights to sequence

CRATER

(left to right, top to bottom) starting from the current indicated selection. Any parameter not available in the mode

SPOT

selected is skipped over.

key enables operator to choose spot

GAS PURGE

2- STEP

STD

4- STEP

LOCK

SPOT

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.

SYNERGIC 7 & 7H

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.

Page 11

A-5

INSTALLATION

INSTALLATION OF THE SYNERGIC 7 COMPONENTS

Safety Precautions

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 and could remain energized several seconds after the gun trigger is released.

• Turn OFF input power at welding power source before installation 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.

Observe all additional Safety Guidelines detailed throughout this manual.

A-5

Attaching Wire Reel Stand

The mounting hardware for mounting the wire reel stand is included with the wire feeder. (Screws and washers are inserted in their respective mounting holes.) To connect:

1) Remove the three 3/8" (9.5 mm) hex head screws from the back of the wire feed unit.

2) Place the wire reel stand mounting bracket in position against the back of the wire feed unit.

3) Replace and tighten the screws. The long screw and plain washer go into the top hole.

SYNERGIC 7 & 7H

Page 12

A-6

INSTALLATION

Wire Feed Drive Roll and Guide Tube Kits

NOTE: The maximum sizes the Synergic 7 will feed

satisfactorily are the 3/32” (2.4mm) cored and 1/16” (1.6mm) solid electrodes. The maximum sizes the Synergic 7H 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.

Steel Wire Sizes:

* .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

4-Roll

A-6

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 and could remain energized several seconds after the gun trigger is released.

• Turn OFF input power at welding power source before installation 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.

Observe all additional Safety Guidelines detailed throughout this manual.

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. Also requires K489-2 Fast-Mate Adapter.

Standard 4-Roll Kits (KP655 and KP656)

1) Turn OFF welding power source.

2) Release both quick release levers by sliding the levers sideways into the open positions.

3) Remove clamping screw & clamping collar from the drive shaft closest to the incoming side of the feeder.

4) Install drive roll onto keyed shaft. (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.

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.

SYNERGIC 7 & 7H

Page 13

A-7

INSTALLATION

A-7

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 point tube must have largest radius next to drive roll. Tighten in place.

11) Re-latch both quick release levers.

12) To start new electrode, straighten the first 6"

(150mm) and cut off the first 1" (25 mm). Insert free end through the incoming tube. Press gun trigger and push wire into the drive roll.

TO SET IDLE ROLL PRESSURE, see Idle Roll Pressure Setting.

Gun and Cable Assemblies

GMAW Guns

Gun Cable Connection: Wire Feeder to Gun

Lay the cable out straight. Insert the connector on the welding conductor cable through the large hole in the front panel of the Synergic 7 and into the brass conductor block on the front of the gearbox. Make sure it is all the way in and tighten the hand wheel. Keep this connection clean and bright. Connect the control cable polarized plug into the mating 5 cavity receptacle on the front of the control section below the keypad.

For GMA Gun Cables:

Install the barbed fitting and union nut to the 5/8-18 female inert gas fitting on the front of the Synergic 7 wire drive. Connect the 3/16" I.D. gas hose from the gun cable to the barbed fitting. When the gun is to be removed, this fitting can be easily detached by loosening the union nut.

An expanding line of Magnum gun and cable assemblies are available to allow welding with solid and cored electrodes using the GMAW process. See the appropriate Magnum literature for descriptions of the 200 to 550 ampere air cooled gun and cables that are available. Gun cable lengths range from 10 ft. (3.0 m) to 25 ft. (7.6 m) and feed electrode sizes .025" (0.6 mm) to 5/64" (2.0 mm). The entire line of Magnum Fast-Mate gun and cable assemblies can also be used by installing a K489-1 Fast-Mate adapter kit.

Innershield Guns

K126 and K115 gun and cable assemblies are available to allow welding with Innershield electrodes. Gun cable lengths range from 10 ft. (3.0 m) to 15 ft. (4.5 m). The 350 ampere K126 with Synergic 7 will feed electrode sizes .062" (1.6 mm) to 5/64" (2.0 mm). The 450 ampere K115 with Synergic 7 will feed 5/64" (2.0 mm) electrode.

Three smoke extraction gun and cable assemblies are available, 250 ampere K309, 350 ampere K206 and the 500 ampere K289. All gun cable lengths are 15 ft. (4.5 m). Both the K206 and K309 with Synergic 7 will feed electrode sizes .062" (1.6 mm) to 5/64" (2.0 mm). K289 with Synergic 7 will feed 5/64" (2.0 mm) electrode. These guns require the use of the K184 vacuum unit for use with Synergic

SYNERGIC 7 & 7H

Page 14

A-8

INSTALLATION

A-8

Synergic 7 Water Connections (for WaterCooled Guns)

These Synergic 7 models must have a K590-4 Water Connection Kit installed. See Options Installation section.

1) Using male quick-connect fittings (included with

appropriate Synergic 7 input cable assemblies), connect the water hoses to the coolant inlet and outlet on the back of the Synergic 7. Connect the other ends of these hoses to the appropriate ports on the water cooling units.

2) In the event the water line fittings on your water

cooled gun are incompatible with the female quick connects on the front of the Synergic 7, male quickconnects are provided for installation on 3/16 (5 mm) I.D. hose (Customer to provide appropriate clamps). The feeder connectors self seal when disconnected.

GMAW Shielding Gas

WARNING

CYLINDER may explode if damaged.

• Keep cylinder upright and chained to support.

• Keep cylinder away from areas where it may be damaged.

• Never lift welder with cylinder attached.

• Never allow welding electrode to touch cylinder.

• Keep cylinder away from welding or other live electrical circuits.

BUILDUP OF SHIELDING GAS may harm health or kill.

• Shut off shielding gas supply when not

in use.

SEE AMERICAN NATIONAL STANDARD Z-49.1, “SAFETY IN WELDING AND CUTTING” PUBLISHED BY THE AMERICAN WELDING SOCIETY.

------------------------------------------------------------------------

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 7 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 Synergic 7 or, if used, on the inlet of the Gas Guard regulator. (See Below).

Gas Guard Regulator - The Gas Guard Regulator is an optional accessory (K659-1) on these models.

Install the 5/8-18 male outlet of the regulator to the 5/8-18 female gas inlet on the back panel of the Synergic 7. Secure fitting with flow adjuster key at top. Attach gas supply to 5/8-18 female inlet of regulator per instructions in the “Gas Connections” Section.

SYNERGIC 7 & 7H

Page 15

A-9

ELECTRICAL INSTALLATION

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 and could remain energized several seconds after the gun trigger is released.

• Turn OFF input power at welding power source before installation 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.

Observe all additional Safety Guidelines detailed throughout this manual.

Input Cable: Synergic 7 Wire Feeder to Power Wave Synergic Type Power Sources

NOTE: CSAnrtl certification of the Synergic 7 models is with

input cable assemblies identified by carton date codes 010161, or above. These assemblies have grounding lead continuity between the 14-pin plug pin B and the 8-socket plug pin E per diagram below.

B=GND

E=GND

14-PIN PLUG, FRONT VIEW

K649 - (Used with Power Wave 450/500) Consists of an 8-conductor control cable with a 14-pin control cable plug and a 4/0 (107mm2) 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).

K675 - (Used with Power Wave 450/500) Similar to K649 but includes a gas hose with a 5/8-18 male fitting for the Synergic 7 inlet. It is rated at 500 amps, 60% duty cycle and is available in lengths of 7 ft. ( 2 m), 25 ft. (7.6 m) and 50 ft. (15 m).

K641- (Used with Power Wave 450/500 and Synergic 7/7H with water quick connection) Similar to K649 but includes a gas hose with a 5/8-18 male fitting for the Synergic 7 inlet and water hoses with quick-connect male fittings to connect between the water cooler and the Synergic 7 water connections. 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).

K648 - (Used with Power Wave 450) Consists of an 8-conductor control cable with a 14-pin plug and a 4/0 (107 mm 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).

8-PIN PLUG, FRONT VIEW

INSTALLATION

K676 - (Used with Power Wave 450) Similar to K648 but

includes a gas hose with a 5/8-18 male fitting for the Synergic 7 inlet. It is rated at 500 amps, 60% duty cycle and is available in lengths of 7 ft. (2 m), 25 ft. (7.6 m) and 50 ft. (15 m).

K640 - (Used with Power Wave 450 and Synergic 7/7H with water quick-connection) Similar to K648 but includes a gas hose with a 5/8-18 male fitting for the Synergic 7 inlet and water hoses with quick-connect male fittings to connect between the water cooler and Synergic 7 water connections. It is rated at 500 amps, 60% duty cycle and is available in lengths of 7 ft. (2 m), 25 ft. (7.6 m) and 50 ft. (15 m).

K651 - (Used with Power Wave 350) Consists of an 8-conductor control cable with a 14-pin plug and 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).

K677-7 - (Used with Power Wave 350) Similar to K651 but includes a gas hose with a 5/8-18 male fitting for the Synergic 7 inlet. It is rated at 350 amps, 60% duty cycle and is available in 7 ft. (2 m) length.

K650 - (Used with Power Wave 350 and Synergic 7/7H with water quick connection) Similar to K651 but includes a gas hose with a 5/8-18 male fitting for the Synergic 7 inlet and water hoses with quick-connect male fittings to connect between the water cooler and the Synergic 7 water connections. 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 a 14-pin control cable plug, without trode 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 cables. Available in lengths of 17 ft (5 m), 25 ft (8 m), 33 ft (10 m) and 50 ft (15 m).

With input power disconnected from the power source, install the input cable per connection diagram

S21041 in the rear of this manual and follow exactly the instructions on the diagram or perform the following:

1) Connect the end of the control cable with the 14pin cable plug to the mating receptacle on the power source.

2) Connect the electrode lead of that same cable end to the power source output terminal of the desired polarity.

3) Route the other end of the electrode cable through

)

the large oval hole in the rear panel of the Synergic 7 case. Connect to the brass block on the side of the gearbox using the bolt provided.

A-9

elec-

SYNERGIC 7 & 7H

Page 16

A-10

4) Connect the remaining end of the control cable with the 8-socket cable plug to the mating receptacle on the Synergic 7.

5) Install the input cable under the wire reel mounting stand strain relief clamp. Remove the screws holding the clamp to the base of the wire reel mounting assembly, put the input cable assembly under the clamp and reinstall the screws.

Work Cable

Connect a work lead of sufficient size and length (per the following table) between the proper output terminal on the power source and the work. Be sure the connection to the work makes tight metal-to-metal electrical contact.

Current

60% Duty

Cycle

300 Amps

400 Amps

Copper Work Cable Size, AWG *

Up to 100 ft Length (30m)

00 (67 mm2)

000 (85 mm

INSTALLATION

)

A-10

K163 Undercarriage (Requires K303, K376, K377, or

K378) The undercarriage includes casters, wheels, a handle and related hardware. Casters are mounted at the front and the wheels to the rear of the platform. The handle is bolted to the front of the platform so the Synergic 7 can be tilted back and wheeled like a twowheel truck. Instruction sheet M13424 for assembly installing the K303, K376, K377, or K378 wire stand is provided with the undercarriage.

K683-1 - Dual Procedure Switch Dual Procedure Switch mounts to gun with appropriate bracket, provided, per the installation instructions included with the kit. 3-pin switch cord plug connects to 3-pin remote receptacle on the front panel of the Synergic 7 Wire Feed Unit.

K1449-1 - Dual Procedure Remote Control Provides remote rotating knob encoder control of Wire Feed Speed and Volts/Trim, along with a dual procedure selector switch, which disables comparable front panel controls when the remote control is connected.

500 Amps

* For pulse welding applications, the next larger cable

size is recommended.

000 (85 mm

)

OPTIONAL FEATURES INSTALLATION

K178-1 Mounting Platform - Synergic 7 Models on

Synergic Power Sources (Requires a K303, K376, K377, K378 or K445 Wire Reel Assembly) This is a turntable type platform for mounting the Synergic 7 on the top of Synergic power sources. Bolt the platform to the lift bail per instructions (M16260) supplied with the platform.

K162-H Spindle for Mounting Readi-Reels and 2" (51 mm) I.D. Spools (60 lb/27 kg Capacity) (For use with K303 and K376 Wire Reel Stand) To mount the 2" spindle kit for Readi-Reels and 10 through 60 pound spools, remove the shaft for the standard 50-60 pound wire coils from the mounting framework. Install the spindle per the instructions shipped with the kit.

When used with Readi-Reels, a Readi-Reel Adapter is required.

For 8" O.D. (200 mm) spools, a K468 Spindle Adapter is available.

The 4-pin plug of the remote control connects to the mating receptacle on the bottom of the Synergic 7 Control box.

K590-4 - Water Connection Kit Install per the instructions shipped with the kit.

K648, K649, K651 or K642 Input Cable Assembly See Electrical Installation section for instructions

K675, K676 or K677 Input Cable Assembly (Gas) See Electrical Installation and Shielding Gas Connections sections for instructions.

K640, K641 or K650 Input Cable Assembly (Water & Gas) See Electrical Installation, Water Connections and Shielding gas connections sections for instructions.

K376 50-60 Lb. Wire Reel Mounting Stand (without dust shield) and K303 50-60 Lb. Wire Reel Mounting Stand (with dust shield) The assembly includes a framework to which is attached the 50-60 lb. wire reel, a mounting spindle, a lift bail, and a cable clamp for fastening the input cable assembly. It is easily mounted to the basic wire feed unit by three bolts. The reel mounting spindle is the pull knob type with a built-in brake.

The brake pad is adjustable for proper braking at low or high wire feed speeds.

SYNERGIC 7 & 7H

Page 17

A-11

INSTALLATION

A-11

Wire Reel Dust Shield for K376 50-60 Lb. Wire Reel Mounting Stand - If the user desires to protect the

wire from falling dirt and dust, there is a shield available to cover the wire reel. Order part number S14543. Instructions are included with the kit.

Wire Reel Dust Shield Door for K303 and K376 (when equipped with an S14543 shield) - In

extremely dusty and dirty locations, this door kit can be added to those units having the shield kit (S14543). This door kit includes a hinged door and sliding bottom seal. When these parts are attached to the reel support per the instructions included, the unit becomes a completely enclosed housing. Order part number M11514.

K377 - Small Mounting Stand for Readi-Reel Coils or 10-44 Pound (4.5-20 kg) Spools with 2" I.D. - This assembly includes a small frame to which is attached a wire reel spindle similar to the K162 Spindle. The unit is supplied with the K363 Readi-Reel Adapter for using the Lincoln "Readi-Reel Electrode Coils". Without the adapter, the unit is capable of handling spools with a 2" (51mm) I.D., a 12" (30mm) maximum O.D., and a 4" (101mm) width. For spools with an 8" (200mm) O.D., a K468 spindle adapter is available. The spindle has an adjustable braking system. See Installation section “Attaching the Wire Reel Stand” for mounting to wire feed unit.

K1524-1 Universal Wire Reel Stand - The assembly includes a reel stand, a 2" (51 mm) O.D. spindle with adjustable brake, rubber mounting feet, and a cable clamp for fastening the input cable. It is easily mounted to the wire feed unit by three bolts. The wire feeder reel stand assembly fits on top of the power source and is correctly positioned by using a hole in the base that accommodates the power source lift bale. The 2" (51mm) O.D. spindle can be set on one of two mounting locations on the stand, depending on what coil of wire and spindle adapter is being used. The upper hole mounts 50-60 lb coils, the lower hole mounts 1030 lb, 13-14 lb, and 8" O.D. coils. Installation instructions are included with the kit.

K1555-1 Insulated Lift Bale Kit for K1524-1 - A lift bale can be added to the K1524-1 Universal Wire Reel Stand. The K1555-1 provides electrical insulation between the wire stand assembly and the lift hook. It is easily mounted to the wire stand with three bolts and a threaded plate. Installation instructions are included with the kit.

K1556-1 Caster Kit for K1524-1 - A light duty caster kit can be added to the K1524-1 Universal Wire Reel Stand. The K1556-1 includes 4 2" O.D. light duty casters that mount in place of the rubber feet on the wire stand base. Installation instructions are included with the kit.

K378 - Small Mounting Stand for 13-14 Pound Innershield Coils - This assembly includes the same smaller frame as used in the K377 and a fully enclosed canister system for de reeling of the 14 pound (6 kg) coil. This system has a fixed brake for this coil. See Installation section “Attaching the Wire Reel Stand” for mounting to wire feed unit.

K659-1 - Gas Guard Regulator - Adjustable flow regulator with removable adjustor key for CO2 and Argon blend gases. Mounts onto feeder inlet, and reduces gas waste and arc start "blow" by reducing surge caused by excess pressure in supply hose.

K1557-1 Swivel Platform for K1524-1 - A swivel platform can be added to the K1524-1 Universal Wire Reel Stand. The K1557-1 includes a pivot top plate and a base assembly. The pivot top plate mounts to the underside of the base of the wire stand assembly using four screws. The swivel base mounts to the power source lift bale with hardware provided or it can be mounted to a surface of choice with four customer provided bolts. Installation instructions are provided with the kit.

SYNERGIC 7 & 7H

Page 18

B-1

OPERATION

B-1

OPERATING INSTRUCTIONS

Safety Precautions

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 and could remain energized several seconds after the gun trigger is released.

• Turn OFF input power at welding power source before installation 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.

Observe all additional Safety Guidelines detailed throughout this manual.

Duty Cycle

The Synergic 7 models are rated at 60% duty cycle * a maximum current of 600 amps.

* Based on a 10 minute time period (6 minutes on, and 4 minutes off).

KEYPAD SETUP AND OPERATION

Power-Down Save

Power to the Synergic 7 is supplied and controlled from the power source. The Synergic 7 automatically senses the loss of power when the power source is turned off.

Procedure settings, including mode, crater speed, cold feed speed , run-in speed, weld speed, timers and acceleration are automatically saved when power is removed. Arc Voltage setting is retained by the synergic power source. 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. The power source may automatically overwrite any or all of these settings following power-up recall.

Operation Keys

COLD FEED

GAS PURGE

Cold Feed feeder but not the power source or solenoid valve. This cold feed speed is digitally displayed and is adjustable (with “Arrow keys”) only while pressing the Cold Feed Key. The last setting is held in memory for next Cold feeding.

Gas Purge noid valve but not the wire feeder or power source.

key energizes the wire

key energizes the sole-

for

SYNERGIC 7 & 7H

2- STEP

STD

4- STEP

LOCK SPOT

Mode Selection

Mode Select

key ( behind “dropdoor” cover) 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 position.

Top Light

- Indicates 2-Step

(Standard) Trigger Mode.

1. Trigger closure energizes the

solenoid valve, then the wire feeder and the power source after Preflow time (See Timer/ Crater Section).

2. Releasing the trigger turns off the

wire feeder and power source and then the solenoid valve after Postflow time.

Middle Light - Indicates 4-Step (Lock) Trigger Mode. These models have selectable 4-step with crater fill or, as shipped, 4-step with current interlock. (See 4-step trigger mode selection for method of switching).

The 4-step modes function as follows:

1. Trigger closure energizes the power

source and wire feeder after the preflow time.

2. Trigger release enables 4-step lock,

leaving the feeder and power source as in step 1.

a) 4-step with current interlock will only

lock if weld current is flowing. Breaking weld arc stops wire feed and power source output.

b) 4-step with crater fill will lock without

welding.

3. Closing the trigger a second time

continues welding.

a) 4-step with current interlock contin-

ues welding without changing the settings from step 2.

b) 4-step with crater fill continues weld-

ing but changes to the crater settings.

4. Releasing the trigger turns off wire

feeder and power source and then gas solenoid after postflow time.

Bottom Light - Indicates Spot Weld Mode. Trigger closure energizes the solenoid valve, then wire feeder and the power source. The spot on timer starts when current flows. The wire feeder and power source then solenoid valve are all turned off when the spot on timer times out even through the trigger is still closed.

Page 19

B-2

VO LTS

WFS

OPERATION

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 displayed since they cannot be displayed simultaneously. Only one function or timer indicator light can be on at one time and therefore it always indicates what is being displayed. The arrow keys allow you to adjust the Run-in speed timer or crater speed being displayed. The encoder knobs allow rotational adjustment of weld wire feed speed and Arc Volts/Trim.

Note: If an indicator light is skipped, that parameter may not be enabled. Refer to section covering that parameter.

Function Select key enables operator to choose which function will

TRIM

be displayed as indicated by the

RUN- I N

appropriate light. Pressing the key causes lights to sequence (top to bottom) starting from the current indicated position. If a timer or crater speed is being displayed when the Function Select key is pressed, then the indicator light of the last function selected before the timer/crater key was chosen will come on and become the starting point for the sequencing.

Adjusting either encoder knob automatically transfers display (and indicator light) to the function being adjusted (Volts/Trim or Wire Feed Speed).

Top Light - indicates Voltmeter Function has been selected and arc voltage (in volts) will be displayed along with electrode polarity when the trigger has been pressed. When the trigger is not pressed, this will serve as a preset voltage/trim function and the preset voltage/trim will be displayed. The top light “blinks” when arc voltage is being displayed and stays lit when preset voltage/trim is displayed. The last welding voltage displayed before the weld is stopped, will continue to be displayed for 5 seconds

operator monitoring.

after welding to permit

B-2

The preset voltage/trim may be adjusted, using the Volts/Trim encoder knob. The synergic preset voltage/trim level may be adjusted within the range synergically set by the power source for the process and weld Feed Speed being used.

matically determines whether preset voltage or percent trim will be displayed. Preset voltage is indicated by one digit only to the right of the decimal point, while percent trim always displays two digits to the right of the decimal point.

Middle Light

Function has been selected and the Run-In speed setting is being displayed in IPM or m/m (see section for English or Metric display).

As shipped these models are setup for minimum rated fixed Run-In speed with display function deactivated. They may be user-selected to activate or deactivate adjustable Run-In display. (See section for selection of Run-In and resetting fixed RunIn speed).

Wire will be fed at the Run-In speed rate until arc current begins to flow. Once arc current flows, wire will be fed at the Weld speed rate. Decreasing Run-In speed below its lower limit (using the down arrow key) causes the display to read “- - -”. This indicates that the Run-In speed will be kept the same can reset a different Run-In speed simply by pressing the up arrow key.

The Run-In speed will also be the same the weld speed setting if rapid restrike welding applications are used, where the arc is restruck in a fraction of a second after the previous welding arc was stopped.

Bottom Light

Speed (WFS) Function has been selected and the weld speed setting is being displayed in IPM or m/m (see section for English or Metric speed display). The range of Weld Feed Speed is synergically set by the power source for the process being used, and is adjustable using the Wire Feed Speed encoder knob on the front of the Synergic 7 Control.

If selected (see Memory Ammeter Selection section), the bottom light will “blink” while welding, indicating that the display has been selected to display welding amps. The last welding current displayed before the weld is stopped will continue to be displayed for 5 seconds after welding to permit operator monitoring.

as the weld speed setting. You

The power source auto-

- Indicates Run-In Speed

- Indicates Weld Feed

SYNERGIC 7 & 7H

Page 20

B-3

OPERATION

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)

CRATER

SPOT

starting from the current indicated position. Any parameter not available in the mode selected is skipped over. If a function is being displayed when the Timer/Crater Select key is pressed,

GAS PURGE

TRIM

VOLTS

RUN- I N

WFS

then the light of the last parameter selected before the function was chosen will come on and become the starting point for the sequencing.

Acceleration Selection

Pressing both the “Gas Purge” key and then the function select key at the same time causes the acceleration setting to be displayed. The display will indicate “A-X” where X will be a number from 1 through 5 with 5 being the fastest acceleration. This number can be adjusted using the arrow keys. To exit this function, press any other key except the arrow key, gas purge or function select key.

Burnback Time Selection

If necessary, for higher wire feed speeds, burnback time maybe selected to prevent the electrode from sticking in the weld puddle a the end of the weld.

B-3

Pressing both the Gas Purge Key then the function

Top Left Light

is being displayed in seconds. This is the time the shielding gas flows before the wire feed and power source are activated.

- indicates preflow time

select key at the same time, displaying acceleration setting per above, then pressing the function key a second time, while holding gas purge pressed, displays the burnback time selection. Default is “b0" which is zero delay. Selecting “b1" through “b5" increases delay from 10 m sec to 50 m sec in 10 m

Top Right Light

time is being displayed in seconds. This is the time the shielding gas flows

- indicates postflow

sec increments. To exit this function press any other key except the arrow keys, gas purge or function select key.

after the wire feed and power source are deactivated.

Middle Light

- indicates that crater feed speed is being displayed. Crater speed is only available when 4-step trigger with crater fill is selected. (See 4-step trigger mode selection section). It is activated by Step 3 and deactivated by Step 4 of the 4-step sequence.

Bottom Light

- indicates spot on time is

being displayed in seconds. NOTE: if unit is not

in spot mode then this light will be skipped over in the selection sequence.

Increase Arrow - key increases the setting of the parameter selected to be displayed, except Wire Feed Speed and Volts/Trim which are controlled by the encoder knobs.

GAS PURGE

CRATER SPOT

GAS PURGE

Selection of English or Metric Speed Display Units

Pressing both the Gas Purge key and then timer select key at the same time causes the speed display units to toggle between IPM (no decimal point displayed) and m/m (a decimal point displayed). If the speed display units were IPM, then they will change to m/m. If the speed display units were m/m, then they will change to IPM. If the display is showing the volts/trim or one of the timers when the keys are pressed, the display will be changed to weld speed to indicate the selected speed display units.

Run-In Selection

Pressing both the Gas Purge key then the Cold Feed key at the same time causes Run-In function to toggle on or off, as indicated by the Run-In indicator light turning on or remaining off in the function select sequence.

Decrease Arrow - key decreases the setting of the parameter selected to be displayed, except Wire Feed Speed and Volts/Trim which are controlled by the encoder knobs.

Arrow Keys use the “Accelerating Digit” method for setting changes, where holding the arrow key causes setting change rate to accelerate from slow to fast. Releasing arrow key resets to slow setting change.

SYNERGIC 7 & 7H

COLD FEED

As shipped, the Run-In function is off with a fixed setting of 50 IPM (1.27 m/min.). Therefore, the Run-In indicator light will not sequence with the function select key, but the fixed setting will still be used for actual Run-In speed.

Activation of adjustable Run-In speed using the above dual key press will permit Run-In speed to be adjusted with the arrow keys, (See Section 3.3.4), and the Run-In indicator light will return to the function key sequence. Repressing the above dual key again removes the Run-In light from the function key sequence, but replaces the fixed Run-In speed with the adjusted Run-In speed setting, until readjusted.

Page 21

B-4

OPERATION

B-4

GAS PURGE

2- STEP

STD

4- STEP

LOCK SPOT

GAS PURGE

4-Step Trigger Mode

Dual Procedure Remote Control (K1449-1)

Selection

Pressing both the Gas Purge key and then the Trigger mode select key causes the 4-step mode light to turn on and will toggle the 4-step trigger mode between:

4-step with current interlock (as shipped)

Crater light will not turn on.

and

4-step with crater fill.

Crater light will turn on for crater speed set-

ting with arrow keys.

(See Mode Selection and Display Control Keys sections).

Memory Ammeter Selection

Pressing both the Gas Purge key then the Up Arrow key at the same time causes the WFS light to “blink” for about 3 seconds while display shows weld amps reading with electrode polarity symbol. This indicates that while welding, the display will show welding amps, indicated by “blinking” WFS indicator light, which continues for 5 seconds after the weld is stopped (memory ammeter) before returning to displaying WFS (light not “blinking”.)

Pressing both the Gas Purge and Up Arrow key again, returns WFS display to wire speed while welding.

When this option is connected to the feeder control receptacle the front panel knob controls are disabled and procedure control is transferred to the knob encoder controls of the remote, which function in the exact same manner.

NOTE: The dual procedure overlay must be present on the Power Wave power source for the Procedure Selector switch to function. If this overlay is not used, only Procedure A will be selected no matter what position the Procedure switch is in.

If using the optional K683-1 Dual Procedure Switch to select A or B along with the remote, both the front panel and remote Procedure selector switches must be set to “Gun Switch” (center) position.

Procedure Selector Switch

The toggle switch on the front panel provides selection of Procedure A or Procedure B, as set with the front panel knob controls. Rotating the knob encoder changes only the procedure selected by this switch. Also, this switch selects the A or B memory pair selected at the Power Wave power source.

Setting the toggle switch to the center “Gun Switch” position permits the Procedure A or Procedure B to be selected by the optional K683-1 Dual Procedure Switch. The K1449-1 Dual Procedure Remote Control can be used with this panel Procedure Switch in any position.

SYNERGIC 7 & 7H

Page 22

B-5

OPERATION

B-5

WIRE LOADING

Loading a 22 to 30 Lb. (10 to 14 kg) Readi-Reel Package Using the Molded Plastic K363-P Readi-Reel Adapter:

The Spindle should be located in the LOWER mounting hole of the K1524-1 Universal Stand if used.

1) Depress the Release Bar on the Retaining Collar and

remove it from the spindle. NOTE: Earlier spindles used a threaded collar. See Figure B.1a or B.1b.

2) Place the Adapter on the spindle.

3) Re-install the Retaining Collar. Make sure that the Release Bar “pops up” and that the collar retainers fully engage the retaining groove on the spindle.

4) Rotate the spindle and adapter so the retaining spring is at the 12 o'clock position.

5) Position the Readi-Reel so that it will rotate in a direction when feeding so as to be de-reeled from the bottom of the coil.

6) Set one of the Readi-Reel inside cage wires on the slot in the retaining spring tab.

7) Lower the Readi-Reel to depress the retaining spring and align the other inside cage wires with the grooves in the molded adapter.

8) Slide the cage all the way onto the adapter until the retaining spring "pops up" fully.

WARNING

Check to be sure the Retaining Spring has fully returned to the locking position and has SECURELY locked the Readi-Reel Cage in place. Retaining Spring must rest on the cage, not the welding electrode.

___________________________________________

9) To remove Readi-Reel from Adapter, depress retaining spring tab with thumb while pulling the Readi-Reel cage from the molded adapter with both hands. Do not remove adapter from spindle.

FIGURE B.1a (Threaded Locking Collar)

2 IN. O.D. SPINDLE ADAPTER

RETAINING SPRING

BRAKE

HOLDING

GROOVES

READI-REEL

INSIDE CAGE WIRES THREADED

LOCKING

LLAR

FIGURE B.1b (Retaining Collar)

SYNERGIC 7 & 7H

Page 23

B-6

OPERATION

B-6

TO MOUNT 10 TO 44 lb (4.5 to 20 kg) SPOOLS (12 in./300 mm DIAMETER) OR 13-14 lb (6 kg)

INNERSHIELD COILS:

The spindle should be located in the lower mounting hole of the K1524-1 Universal Stand if used.

[For 8 in. (200 mm) spools, a K468 spindle adapter must first be slipped onto the spindle.]

[For 13 to 14 lb (6 kg) Innershield coils, a K435 Coil Adapter must be used.]

1. Depress the Release Bar on the Retaining Collar and remove it from the spindle. spindles used a threaded collar. See Figure B.5a or B.5b.

2. Place the spool on the spindle, making certain the spindle brake pin enters one of the holes in the backside of the spool. Be certain the wire comes off the reel in a direction so as to de-reel from the bottom of the coil.

3. Re-install the Retaining Collar. Make sure that the Release Bar “pops up” and that the collar retainers fully engage the retaining groove on the spindle.

NOTE: Earlier

2. While tightly holding the electrode, cut off the bent end and straighten the first six inches. Cut off the first inch. (If the electrode is not properly straightened, it may not feed or may not go into the outgoing guide tube, causing a “birdnest”.)

3. Insert the free end through the incoming guide tube.

4. Press the cold inch key or gun trigger and push the electrode into the drive roll.

WARNING

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts such as output terminals or internal wiring.

• When inching with the gun trigger, electrode and drive mechanism are “hot” to work and ground and could remain “hot” for several seconds after the gun trigger is released.

------------------------------------------------------------------------

5. Inch the electrode through the gun.

ELECTRODE FEEDING AND BRAKE ADJUSTMENT

1. Turn the Readi-Reel or spool until the free end of the electrode is accessible.

Adjust the brake tension with the thumbscrew on

6. the spindle hub until the reel turns freely but with little or no overrun when wire feeding is stopped. Do not overtighten.

SYNERGIC 7 & 7H

Page 24

B-7

OPERATION

B-7

WIRE REEL LOADING – 50 AND 60 LB COILS (K303 OR K376 WIRE REEL STAND)

ADJUSTABLE WIRE REEL BRAKE

The mount for standard 50 and 60 pound electrode coils includes a two-position brake assembly. Generally the brake should be at the inner position (nearest to the wire reel shaft) for wire feed speeds below 400 in./min (10 m/min). It should be at the outer position for the faster wire speeds often used when feeding smaller diameter electrode.

To adjust the brake position, remove the wire reel. Pull the cotter pin that holds the brake shoe to the arm, move the shoe and replace the cotter pin. Do not bend the cotter pin - it is held in place by a friction fit.

TO MOUNT A 50 OR 60 LB COIL:

1. To remove the wire reel from its shaft, grasp the spring loaded knob and pull out. This straightens the knob so it seats into the shaft when released. Remove the reel.

2. Lay the reel flat on the floor. Loosen the spinner nut and remove the cover plate. See Figure B.2.

CAUTION

Always be sure the free end of the coil is securely held while the tie wires are being cut and until the wire is feeding through the drive rolls. Failure to do this will result in “back lashing” of the coil, which may tangle the wire. A tangled coil will not feed. It must be untangled or discarded.

------------------------------------------------------------------------

8. 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.

Replace the reel on the wire feeder. Grasp the shaft knob, pull it out and swing it across the reel hub, locking the reel in place.

FIGURE B.2 – LOADING A 50 OR 60 LB COIL.

SPINNER

NUT

COVER

PLATE

3. Place the coil of electrode on the reel so it unwinds as the reel rotates clockwise. DO NOT cut the tie wires at this time.

4. Be sure the coil is placed so the spring loaded arms will not interfere with the later removal of the coil tie wires.

5. When loading 0.030 to 0.045” electrode, be certain the coil is placed on the reel so the spring loaded arms are at the center of the slots in the cardboard coil liner. This provides the positive compression of the coil sides needed for troublefree wire feeding.

6. Put the cover plate on the reel so the four arms of the cover plate straddle and are in line with the spring loaded arms of the reel.

7. Tighten the cover as much as possible by hand. DO NOT hammer on the spinner nut arms.

COIL

REEL

SLOTS

CARDBOARD COIL LINER

TIE WIRE

SPRING LOADED ARM

SYNERGIC 7 & 7H

Page 25

B-8



OPERATION

B-8

WIRE REEL LOADING – 50 AND 60 LB COILS (K1524-1 UNIVERSAL WIRE REEL STAND)

TO MOUNT A 50 to 60 lb (22.7 to 27.2 kg) COIL: (USING K1504-1 COIL REEL) (FOR 50 to 60 lb READI-REELS A K438 READI-REEL ADAPTER MUST BE USED.)

The spindle should be located in the UPPER mounting hole.

1. With the K-1504-1 Coil Reel mounted on the 2 in. (51 mm) spindle (or with reel laying flat on the floor) loosen the spinner nut and remove the reel cover. See Figure B.3.

2. Before cutting the tie wires, place the coil of electrode on the reel so it unwinds from the bottom as the reel rotates.

3. Tighten the spinner nut against the reel cover as much as possible by hand, using the reel cover spokes for leverage. DO NOT hammer on the spinner nut arms.

4. Cut and remove only the tie wire holding the free end of the coil. Hook the free end around the rim of the reel cover and wrap it around to secure. Cut and remove the retaining tie wires.

FIGURE B.3 – K1504-1 COIL REEL.

SPINNER NUT

COVER PLATE

SLOTS

CARDBOARD COIL LINER

COIL

TIE WIRE

SPRING LOADED ARM

REEL

CAUTION

Always be sure the free end of the coil is securely held while the tie wires are being cut and until the wire is feeding through the drive rolls. Failure to do this will result in “backlash” of the coil, which may tangle the wire. A tangled coil will not feed, so it must either be untangled or discarded.

____________________________________

5. Be sure the coil is engaged with the spindle brake pin and the Release Bar and Retaining Collar “pops up” and that the collar retainers fully engage the retaining groove on the spindle.

Feeding Electrode

1) Turn the reel until the free end of the electrode is accessible. While tightly holding the electrode, cut off the bent end.

2) Straighten the first 6” (150mm) and cut off the first

1” (25mm). Insert the free end through the incoming guide tube. Press the Cold Inch key or the gun trigger and push the electrode into the drive roll. Feed the electrode through the gun. (If the electrode is not properly straightened, it may not feed or may not go into the outgoing guide tube causing a “birdnest”.)

WARNING

When feeding with the gun trigger, the electrode and drive mechanism are always “HOT” to work and ground and could remain “HOT” several seconds after the gun trigger is released.

___________________________________________

SYNERGIC 7 & 7H

Page 26

B-9

OPERATION

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, surface condition, lubrication, and hardness. The optimum idle roll setting can be determined as follows:

1) Release the incoming idle roll pressure arm, then press end of gun against a solid object that is electrically isolated from the welder output and press the gun trigger for several seconds.

2) If the wire “birdnests”, jams, or breaks at the drive roll, the idle roll pressure is too great. Back the pressure setting out 1/2 turn, run new wire through gun, and repeat above steps.

3) If the only result is drive roll slippage, disengage the gun locking nut, and pull the gun cable forward about 6” (150mm). There should be a slight waviness in the exposed wire. If there is no waviness, the pressure is too low. Increase the pressure setting 1/4 turn, reconnect the gun, tighten the locking nut, and repeat the above steps.

B-9

4) After the outgoing pressure is set, determine how many turns away from full pressure the setting is. Set both idle roll tensions to this setting. Engage both idle rolls before welding. In most applications, best wire feeding will occur when both idle roll pressures are set the same.

Gas Guard Regulator Setting

1) With the gas supply shut off, the Gas Guard regulator flow adjusting key should be set to maximum (full clockwise) which is rated to be 60 SCFH (28 lts/ min).

2) Adjust gas supply flow rate for a level higher than will be required, then adjust Gas Guard flow adjusting key counterclockwise to the desired gas flow rate.

SYNERGIC 7 & 7H

Page 27

B-10

OPERATION

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.

B-10

12) To stop welding, release the gun trigger and then pull the gun away from the work after the arc goes out and Postflow time, if used, is over.

13) If necessary to optimize arc starting, adjust wire

speed acceleration, and/or Run-In speed. (See the appropriate sections for adjusting procedures).

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 Feed Speed. (Set for each procedure if using a Dual Procedure function). (See the appropriate sections for adjusting procedures).

5) Adjust the voltage or percent trim, if desired, (for each procedure if using a Dual Procedure function) using the encoder knob in “Volts/Trim” function (refer to Volts/Trim section). The final setting can be adjusted according to the desired arc voltage while welding.

6) Use Timer/Crater Select and Arrow keys to set desired timers, or crater speed if 4-step trigger with Crater fill has been selected. (Refer to the Timer/Crater section).

7) Feed the electrode through the gun and cable and then cut the electrode within approximately .38” (9.5mm) of the end of the contact tip for solid wire, and within approximately .75” (19mm) of the extension guide for cored wire.

8) Connect work cable to metal to be welded. Work cable must make good electrical contact to the work. The work must also be grounded as stated in “Arc Welding Safety Precautions”.

WARNING

When using an Open Arc process, it is necessary to use correct eye, head, and body protection

____________________________________

9) If used, be sure shielding gas valve is turned on.

10) Position electrode over joint. End of electrode

may be lightly touching the work.

11) Lower welding helmet, close gun trigger and start

welding. Hold the gun so the contact tip to work distance gives the correct electrical stickout as required for the procedure being used.

Wire Reel Changing

At the end of a coil, remove the last of the old electrode coil from the conductor cable by either pulling it out at the nozzle end of the gun or by using the following procedure:

1) Cut the end of the electrode off at the gun end. Do not break it off by hand because this puts a slight bend in the wire making it difficult to pull it back through the nozzle.

2) Disconnect the gun cable from the gun connector on the Synergic 7 Wire Feed Unit and lay the gun and cable out straight.

3) Using pliers to grip the wire, pull it out of the cable from the connector end.

4) After the electrode has been removed, reconnect the gun cable to the Synergic 7.

Load a new reel of electrode per the instructions in the Wire Reel Loading sections.

Wire Feed Overload Protection

The Synergic 7 has solid-state overload protection of the wire drive motor. If the wire drive motor becomes overloaded for an extended period of time, the protection circuitry turns off the power source, wire feed and solenoid and then displays H30. This indicates the wire drive motor is overloaded and the number indicates the time remaining in seconds before the unit will automatically reset. The number continues to decrement every second until it reaches 0. At that time, the unit resets automatically and the previous display will return indicating the unit is ready to operate again. Overloads can result from improper tip size, liner, drive rolls, or guide tubes, obstructions or bends in the gun cable, feeding wire that is larger than the rated capacity of the feeder or any other factors that would impede normal wire feeding. (See section on Avoiding Wire Feeder Problems.)

SYNERGIC 7 & 7H

Page 28

B-11

OPERATION

B-11

Grounding Lead Protector

The frame of the Synergic 7 wire feeder is grounded to the frame of the power source by a lead in the control cable. An overload protector prevents welding current from damaging this lead if the electrode circuit touches the wire feeder frame while the electrode is electrically hot.

If such a grounding lead fault occurs, the wire feeder display will show "GLP", and the trigger circuit will be disabled. To reset the circuit, release the trigger, make sure that the electrode is not touching the wire feeder frame, and then either press any key on the keypad or close the trigger. When the GLP circuit is reset, the "GLP" display is removed and the wire feeder is returned to normal operating mode.

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.

HXX Indicates wire feed overload. XX indicates

time remaining in seconds before unit resets automatically. See sections on Routine Maintenance, Periodic Maintenance, and Troubleshooting Guide Problem 24.

EP Indicates problem in EPROM assembly. See

Troubleshooting Guide Problem 24.

uP Indicates problem in microprocessor RAM.

See Troubleshooting Guide Problem 24.

EXX Indicates various system problems. XX will

be a number from 01 to 10. Turn off power to feeder. Wait 5 seconds. Turn power back on. If error persists, see Troubleshooting Guide Problem 24. If error does not reoccur, be sure to check all wire feed speed, acceleration, and timer settings before you proceed.

Er EEPROM error. Usually occurs at power-up.

Indicates one or more of the recalled settings is out of acceptable limits. Press any key to return to normal operation. Be sure to check all wire feed speed, acceleration, and timer settings before you proceed.

GLP Indicates that the Grounding Lead Protector

circuit was activated due to excessive current flow into the wire feeder frame. When the Grounding Lead Protector circuit is activated the wire feeder is disabled, i.e. the trigger output to the power source is opened up, the motor is stopped, and the gas solenoid is turned off. To resume normal operation, release the trigger, make sure that the electrode is not touching the wire feeder frame, and then either press a key on the keypad or close the trigger. See Problem 24 in the Troubleshooting Guide.

SYNERGIC 7 & 7H

Page 29

C-1

ACCESSORIES

C-1

OPTIONAL FEATURES

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

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.

17 ft. (5 m), 25 ft. (7.6 m), 33 ft. (10 m) and 50 ft. (15 m).

K648 - (Used with Power Wave 450) Consists of an 8conductor control cable with a 14-pin plug and a 4/0 (107 mm 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).

K676 - (Used with Power Wave 450) Similar to K648 but includes a gas hose with a 5/8-18 male fitting for the Synergic 7 inlet. It is rated at 500 amps, 60% duty cycle and is available in lengths of 7 ft. (2 m), 25 ft. (7.6 m) and 50 ft. (15 m).

K651 - (Used with Power Wave 350) Consists of an 8conductor control cable with a 14-pin plug and 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).

) electrode cable with stud terminal. It is rated

* 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

8-conductor control cable with a 14-pin control cable plug and a 4/0 (107mm2) 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).

K642 (Control Cable Only) - Consists of an 8 conductor control cable with a 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).

SYNERGIC 7 & 7H

Page 30

C-2

ACCESSORIES

C-2

UNIVERSAL WIRE REEL STAND (K1524-1)

Includes a 2" (51mm) O.D. Spindle with adjustable brake and two locations for mounting the spindle to allow for the mounting of 50 - 60lb, 10 - 30 lb, 13 14lb, and 8" O.D. coils with proper spindle adapters. (See OPERATION section) Capable of being mounted on the top of a suitable power source or surface without the need for any other mounting kit. Optional features available for this stand include:

• K1555-1 insulated lift bale

• K1556-1 caster kit

• K1557-1 swivel platform.

60 LB. (27.2 KG) COIL ADAPTER (K1504-1)

Permits 50-60 lb. (22.7-27.2 Kg) coils to be mounted to a 2" (51mm) spindle.

K1551-1 INSULATED LIFT BALE: Provides a

bolt on lift bale with an electrically insulated lift hook.

K1556-1 CASTER KIT: Comes with 4 light duty

2" O.D. casters which mount in place of the rubber feet on the wire stand. Use in light duty applications where portability is required. Can be used in combination with the K1557-1 swivel platform.

K1557-1 SWIVEL PLATFORM: Allows for the

mounting of the wire feeder reel stand assembly on top of a suitable power source if the need for the wire feeder reel stand assembly to swivel is desired. Also has mounting holes in the base feet for mounting to any surface that it can be fastened to. Comes with a rotating tool tray to hold gun tips, guide tubes, drive rolls, etc. Will work in combination with the K1556-1 caster kit.

WIRE REEL ASSEMBLY:

K303 - 50-60 lb. (22.7-27.2 kg) Wire reel mounting

stand. Assembly includes a framework to which is attached the 50-60 lb. (22.7-27.2 kg) wire reel, a mounting spindle, a dust shield, a lift bail, and a cable clamp for fastening the input cable assembly. The reel mounting spindle is the pull knob type with a builtin brake. The brake pad is adjustable for proper braking at low or high wire feed speeds. In extremely dusty and dirty locations a wire reel dust shield door kit can be added to this unit.

This door kit, which includes a hinged door and sliding bottom seal, makes the housing completely enclosed. Order part number M11514.

K376 - Same as K303 above but without dust shield. A dust shield that covers the wire reel and protects the wire from falling dirt and dust is available for this unit. Order part number S14543. This unit will also accept the M11514 door kit (see K303 above) but only if already equipped with optional dust shield (S14543).

K377 - Small mounting stand for Readi-Reel coils or 10-30 lb. (4.5-14 kg) spools with 2" (51 mm) I.D. This assembly includes a small frame to which is attached a 2" (51 mm) O.D. wire reel spindle and a K363P Readi Reel adapter for using the Lincoln "Readi-Reel Electrode Coils". Without the adapter, the unit is capable of handling spools with a 2" (51 mm) I.D., a 12" (305 mm) maximum O.D., and a 4" (101 mm) width.

K378 - Small mounting stand for 13-14 lb. (6 kg) Innershield coils. This assembly includes the same smaller frame as used in the K377 and a fully enclosed canister system for de-reeling of the 14 lb. (6 kg) coil. This system has a fixed brake for this coil.

K445 - 50-60 lb. (22.7-27.2 kg) Readi-Reel mounting stand. This assembly includes framework to which is attached a 2" (51 mm) O.D. spindle with adjustable brake and 50-60 lb. (22.7-27.2 kg) (K438) Readi-Reel adapter. Includes a lift bail and cable clamp for fastening the input cable assembly. Does not include a dust shield. A dust shield that covers the wire reel and protects the wire from falling dirt and dust is available for this unit. Order part number S14543. This unit will also accept the M11514 door kit (see K303 above) but only if already equipped with optional dust shield (S14543).

SYNERGIC 7 & 7H

Page 31

C-3

ACCESSORIES

C-3

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 frame-work 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.

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• Innershield Linconditioner gun and cable assemblies are rated 350 amps, 60% duty cycle. Maximum size for Synergic 7 models is 5/64" (2.0 mm). Not recommended for Synergic 7H models. (Consult sales specifications for appropriate models)

K289• Innershield Linconditioner gun and cable assemblies are rated 500 amps, 60% duty cycle. Maximum size for Synergic 7 models is 5/64" (2.0 mm). Not recommended for Synergic 7H models. (Consult sales specifications for appropriate models)

K309• Innershield Linconditioner gun and cable assemblies are rated 250 amps, 60% duty cycle. Maximum size for Synergic 7 models is 5/64" (2.0 mm). Not recommended for Synergic 7H models. (Consult sales specifications for appropriate models)

• K179 type vacuum unit not recommended for use with Synergic 7.

The following Lincoln gun and cable assemblies are equipped with a Fast-Mate™ connector. They can be used with these Synergic 7 models by installing a K489-1 Fast-Mate™ adapter kit.

GUN AND CABLE ASSEMBLIES:

K126 Innershield gun and cable assemblies are rated

at 350 amps, 60% duty cycle. Maximum wire size for Synergic 7 models is 5/64" (2.0 mm). Not recommended for Synergic 7H 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 7 models is 5/64" (2.0 mm). Not recommended for Synergic 7H models. (Consult sales specifications for appropriate models)

K470 Magnum 300 GMAW gun and cable assemblies are rated 300 amps, 60% duty cycle. (Consult sales specifications for appropriate models)

K471 Magnum 400 GMAW gun and cable assemblies are rated 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)

K684 - Magnum “Water Cooled” FM water cooled GMAW gun and cable assemblies are rated 450 amps, 100% duty cycle (CO cations 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).

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)

). (Consult sales specifi-

SYNERGIC 7 & 7H

Page 32

C-4

K566 * - GMAW process Magnum 250XA X-TRAC-

TOR 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 7.

ACCESSORIES

MISC. OPTIONS:

K590-4 (Water Connection Kit) - Includes water sup-

ply quick-connectors already attached to mounting insulators and internal connection hoses for easy installation on the front and rear panels of the Synergic 7 case. Also includes water cooled gun tube fittings and self-sealing outlet and inlet quick-connectors for mounting to the front of the Synergic 7 case.

K659-1 (Gas Guard Regulator) - Adjustable flow regulator with removable adjustor key for CO2 and Argon blend gases. Mounts onto wire drive gas inlet, and reduces gas waste and arc start "blow" by reducing surge caused by excess pressure in supply hose.

C-4

K1449-1 (Dual Procedure Remote Control) - Includes

a remote control box with a 16ft. (5m) length control cable with 4-pin plug for the mating receptacle on the bottom of the Synergic 7 control box. The remote control box contains 2 rotating knob encoders, one controls arc voltage and the other controls weld wire feed speed, and a procedure selector switch which function the same as comparable controls on the front panel, which are disabled when the remote is connected.

K683-1 (Dual Procedure Switch) - Kit includes gun switch, and mountings for Lincoln Innershield and Magnum guns, with 15 ft. (4.5 m) control cable and 3pin plug.

K163 Undercarriage - For all Synergic 7 wire reel stand combinations. Includes mounting frame, front casters, 10" (254 mm) O.D. rear wheels, and handle. Use when portability is required.

K178-1 Swivel Platform - For all Synergic 7 wire reel stand combinations. For mounting wire feeder wire reel stand assembly on top of suitable Lincoln Idealarc power sources. Recommended input cable length is 7 ft. (2 m) when using the K178-1 on the Invertec power sources.

SYNERGIC 7 & 7H

Page 33

D-1

MAINTENANCE

Safety Precautions

WARNING

MAINTENANCE

Wire Reel Mounting - 50 (22.7kg) and 60lb (27.2kg) Coils with 1” Spindle

To prolong the life of the reel shaft, periodically coat it with a thin layer of grease.

D-1

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 and could remain energized several seconds after the gun trigger is released.

• Turn OFF input power at welding power source before installation 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.

Observe all additional Safety Guidelines detailed throughout this manual.

Routine Maintenance

Drive Rolls and Guide Tubes

After feeding every coil of wire, inspect the drive roll section. Clean it as necessary. Do not use a solvent for cleaning the idle roll because it may wash the lubricant out of the bearing. The driver roll and guide tubes are stamped with the wire sizes they will feed. If a wire size other than that stamped on the roll(s) is to be used, the roll(s) and guide tubes must be changed.

The drive rolls for .035” (0.9mm) through .052” (1.3mm) cored electrode and 1/16” (1.6mm) through 3/32” (2.4mm) electrode have a double set of teeth so they can be reversed for additional life. Drive rolls for .023" (0.6 mm) through .052" (1.3 mm) solid electrodes and aluminum sizes have no teeth, but use two grooves so they also can be reversed for additional life.

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, 10 through 44lb (4.5-20kg) Spools and 5060lb Coils with K1504-1 Adapter

No routine maintenance required. Do not lubricate 2” (51mm) spindle.

Avoiding Wire Feeding Problems

Wire feeding problems can be avoided by observing the following gun handling procedures:

a) Do not kink or pull cable around sharp corners.

b) Keep the electrode cable as straight as possible

when welding or loading electrode through cable.

c) Do not allow dolly wheels or trucks to run over

cables.

d) Keep cable clean by following maintenance

instructions.

e) Use only clean, rust-free electrode. The Lincoln

electrodes have proper surface lubrication.

f) Replace contact tip when the arc starts to become

unstable or the contact tip end is fused or deformed.

g) Do not use excessive wire spindle brake settings.

Periodic Maintenance

Wire Drive Motor and Gearbox

See section on Wire Feed Drive Roll and Guide Tube Kits for roll changing instructions.

SYNERGIC 7 & 7H

Every year inspect the gearbox and coat the gear teeth with a moly-disulfide filled grease. Do not use graphite grease.

Every six months check the motor brushes. Replace them if they are less than 1/4” long.

Gun and Cable Maintenance

See appropriate Operatorʼs Manual.

Page 34

E-1

TROUBLESHOOTING

WARNING

Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. 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 and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.

__________________________________________________________________________

E-1

This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three-step procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).

Look under the column labeled “PROBLEM (SYMPTOMS)”. This column describes possible symptoms that the machine may exhibit. Find the listing that best describes the symptom that the machine is exhibiting.

Step 2. POSSIBLE CAUSE.

The second column labeled “POSSIBLE CAUSE” lists the obvious external possibilities that may contribute to the machine symptom.

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 and could remain energized several seconds after the gun trigger is released.

• Turn OFF input power at welding power source before installation 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.

Step 3. RECOMMENDED COURSE OF ACTION

This column provides a course of action for the Possible Cause, generally it states to contact your local Lincoln Authorized Field Service Facility.

If you do not understand or are unable to perform the Recommended Course of Action safely, contact your local Lincoln Authorized Field Service Facility.

Observe all additional Safety Guidelines detailed throughout this manual.

CAUTION

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.

SYNERGIC 7 & 7H

Page 35

E-2

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

POSSIBLE

CAUSE

RECOMMENDED

COURSE OF ACTION

E-2

1. Rough wire feeding or wire not feeding but drive rolls turning.

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.

Partially flashed or melted contact tip.

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 necessary.

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.

2. Variable or “hunting” arc.

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.

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 changing Synergic 7 control board. If problem persists refer to Power Source trouble shooting information.

CAUTION

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.

SYNERGIC 7 & 7H

Page 36

E-3

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

POSSIBLE

CAUSE

RECOMMENDED

COURSE OF ACTION

E-3

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.

a. Improper procedures or tech-

niques.

b. Improper gas shielding.

a. Tip overheating due to prolonged

or excessive high current and/or duty cycle welding.

a. See Problem 1.

a. See “Gas Metal Arc Welding

Guide” (GS-100).

b. Clean gas nozzle. Make certain that gas

diffuser is not restricted. Make certain that gas cylinder is not empty or turned off. Make certain gas solenoid valve is operating and gas flow rate is proper.

Remove gun liner and check rubber seal for any sign of deterioration or damage. Be sure set screw in brass connector is in place and tightened against the liner bushing.

a. Do not exceed current and duty

cycle rating of gun.

A light application of high temperature antiseize lubricant (such as Lincoln E2607 Graphite Grease) may be applied to tip threads.

a. Correct problems causing motor

overload.

6. Drive roll does not turn although arc voltage is present and solenoid is on.

Defective wire feed motor or gearbox.

a. Defective wire feed motor or con-

trol PC board.

b. Replace.

a. Set Run-in speed to maximum.

Disconnect wire drive plug P5 from PC board. Measure voltage across pin 1 (+) of J5 and pin 2 (-) of J5 on PC board with trigger closed. If voltage is ≥24 VDC, then replace motor assembly. If ≤24 VDC, replace Control PC board (see Procedure for replacing PC boards).

CAUTION

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.

SYNERGIC 7 & 7H

Page 37

E-4

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

POSSIBLE

CAUSE

RECOMMENDED

COURSE OF ACTION

E-4

7. No control of wire feed.

8. No wire feed, solenoid, or arc voltage. LED display indicated Synergic 7 has input power.

Problem with serial communications.

b. Defective wire feed motor tach or

control PC Board.

a. Faulty gun or gun trigger switch.

b. Defective control PC board or

gun connector.

a. If WFS and preset Volts/Trim parame-

ters on wire feeder display do not match those on power source display, see Problem 14.

b. Measure voltage across pin 2 (+) of J3

and pin 3 (-) of J3 on PC board with motor running. If voltage is 1.5-3.5V then replace control PC board (see Procedure for Replacing PC Boards). If not, then replace tachometer.

a. Remove gun. Check continuity

between trigger pins with trigger closed. If no continuity repair or replace gun.

b. Remove gun. Check voltage across

trigger sockets on gun connector.

If voltage > ± 11 VDC then gun is defective.

If voltage is < ± 11 VDC then check the voltage across pin 2 (+) and pin 8 (-) of connector J1 on control PC board.

If the voltage is still < ± 11 VDC then replace control PC board. (See Procedure for replacing PC boards). Otherwise, either the gun connector or wiring harness is faulty.

CAUTION

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.

SYNERGIC 7 & 7H

Page 38

E-5

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

POSSIBLE

CAUSE

RECOMMENDED

COURSE OF ACTION

E-5

9. Wire feed motor runs and solenoid turns on but no arc voltage present.

a. Power source is defective.

b. Input cable is defective.

c. Wiring harness or Control PC

board is defective.

a. If arc voltage is present when wire feeder is

connected to the other input receptacle (#1 or #2) of power source then power source is defective. Otherwise, select a stick procedure on power source, connect a known good input cable (see step b) to wire feeder #1 receptacle of power source, and jumper across sockets C and D of 8-socket input cable plug. If no arc voltage is present (refer to display on power source) then power source is defective.

b. Disconnect input cable from power source and

wire feeder. Check continuity between socket C of 8-socket plug and pin C of 14-pin plug of the input cable, and between socket D of 8socket plug and pin D of 14-pin plug of the input cable. Replace cable if no continuity.

c. Check continuity between pin C of 8-pin recep-

tacle and pin 7 of plug P1, and between pin D of 8-pin receptacle and pin 6 of plug P1. If no continuity then harness is faulty, otherwise replace Control PC board. (See procedure for replacing PC boards.)

10. Speed does not change when

weld current flows.

11. Voltmeter does not function or

read properly when arc voltage is present.

a. Run-in and weld speeds are set

to the same value or run-in is set to ---.

b. Power Source may be defective

or there may be a problem with the Serial communications.

a. Electrode sensing lead or connec-

tions may be intermittent.

b. Serial communication problem.

a. Set run-in and weld speeds to desired set-

tings.

b. Make sure that parameters on power source

display, such as WFS, match those on wire feeder display. If not, refer to Problem 14. Otherwise, replace control PC board. (See procedure for replacing PC boards.)

a. Check continuity from brass block on wire

feeder to pin F of 8-pin control cable receptacle on wire feeder. If there is no continuity, repair faulty connection.

b. Make sure that parameters on power source

display, such as WFS, match those on wire feeder display. If not, refer to Problem 14. Otherwise, replace Control PC board. (See procedure for replacing PC boards.)

CAUTION

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.

SYNERGIC 7 & 7H

Page 39

E-6

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

POSSIBLE

CAUSE

RECOMMENDED

COURSE OF ACTION

E-6

12. Arrow keys do not change Weld

speed or volts/trim.

13. WFS knob does not change

Run-in speed.

14. WFS and preset Volts/Trim para-

meters on wire feeder display do not match those on power source display.

a. This is normal, as only the WFS and

volts/trim knobs will adjust these settings.

a. This is normal, as only the arrow

keys will adjust this setting.

a. Power source is defective.

b. Problem with serial communica-

tions in control cable.

c. Problem with wire feeder harness

or Control PCB.

a. Refer to operation section of this manual

a. Refer to operation section of this manual.

a. If parameters on power source and wire

feeder display match when wire feeder is connected to the other input receptacle (#1 or #2) of power source then power source is defective.

b. Disconnect input cable from power source

and wire feeder. Check continuity between socket G of 8-socket plug and pin G of 14 pin plug of the input cable. Check continuity between socket H of 8-socket plug and pin H of 14-pin plug of the input cable. Replace cable if no continuity.

c. Remove molex plug P1 from J1 on Control

PCB. Check continuity from pin G of 8-pin receptacle on wire feeder to pin 4 of plug P1, and from pin H of 8-pin receptacle to pin 3 of plug P1. If no continuity then repair harness, otherwise replace Control PCB. (See procedure for replacing PC boards.)

15. Display does not change when

WFS and/or Volts/Trim knobs are turned.

a. A remote control kit is connected.

b. Broken harness wire(s) or harness

disconnected from Encoder board(s) or Control board.

c. Defective Encoder boards and/or

Control board.

a. When a remote control kit is connected to

the Wire Feeder, the WFS and Volts/Trim knobs of the Wire Feeder become inactive and the WFS and Volts/Trim knobs of the remote control kit must be used.

b. Check for continuity between correspond-

ing harness leads of molex plug P2 on Control board and molex plugs P12 and P13 on Encoder boards (refer to wiring diagram). If any of these continuity tests fail, repair or replace harness.

c. If b. is not the problem and neither the WFS

or Volts/Trim knobs are properly adjusting then replace the Control board. If one of the knobs is properly adjusting, plug the harness, P12 or P13, from the working board into the nonfunctional board. If the previously nonfunctional board is now working then replace the Control board, otherwise replace the nonfunctional Encoder board. (See procedure for replacing PC boards.)

CAUTION

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.

SYNERGIC 7 & 7H

Page 40

E-7

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

POSSIBLE

CAUSE

RECOMMENDED

COURSE OF ACTION

E-7

16. Wire feeder's display does not

change when WFS and/or Volts/Trim knobs of the remote control kit are turned.

a. Loose connection to Remote con-

trol receptacle, J16.

b. Faulty Remote PC board.

c. Faulty remote cable.

d. Faulty remote wiring harness.

e. Faulty wire feeder harness or

remote cable receptacle.

f. Faulty Control board or Remote

PC board.

a. Make sure that remote cable connec-

tions are tight.

b. If either the WFS knob, the Volts/Trim

knob, or the dual procedure switch of the remote control kit is operating properly then replace the Remote PC board.

c. Remove remote cable from wire feed-

er and unplug connector P2 from J2 in remote control kit. Check continuity between pin 1 of J2 and socket B of remote receptacle, between pin 2 of J2 and socket A of remote receptacle, between pin 3 of J2 and socket D of remote receptacle, and between pin 4 of J2 and socket C of remote receptacle. If any of these continuity tests fail then repair or replace remote cable.

d. Remove plug from J1 on Remote PC

board and unplug connector P2 from J2 in remote control kit. Check continuity between pin 1 of P2 and pin 2 of P1, between pin 2 of P2 and pin 3 of P1, between pin 3 of P2 and pin 4 of P1, and between pin 4 of P2 and pin 5 of P1. If any of these tests failed, repair or replace remote wiring harness.

e. Remove plug from J2 on Control

board of wire feeder and remove remote cable from wire feeder. Check continuity between socket A of remote receptacle J16 and pin 14 of plug P2, between socket B of remote receptacle and pin 7 of plug P2, between socket C of remote receptacle and pin 15 of plug P2, and between socket D of remote receptacle and pin 16 of plug P2. If any of these tests failed then repair or replace wiring harness. Check continuity between either of the four pins of receptacle J16. If there is continuity between either of the pins then receptacle is faulty.

f. Try replacing Remote PC board. If

this does not solve the problem then replace Control board of wire feeder. (See procedure for replacing PC boards.)

CAUTION

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.

SYNERGIC 7 & 7H

Page 41

E-8

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

POSSIBLE

CAUSE

RECOMMENDED

COURSE OF ACTION

E-8

17. Dual procedure is not functioning

when using the local dual procedure switch.

18. Optional gun dual procedure

switch is not functioning properly.

a. Optional gun dual procedure

switch or remote control kit may be connected.

b. Serial communication problem.

c. Faulty local dual procedure switch,

wiring harness, or Control board.

a. Local dual procedure switch is not in "Gun"

position, and/or remote control kit's dual procedure switch is not in "Gun" position.

b. Faulty remote control kit.

c. Serial communication problem.

d. Faulty optional gun dual proce-

dure switch.

e. Faulty wiring harness or optional

gun dual procedure amphenol.

a. When the dual procedure switch is in the “Gun”

position then either the remote or the optional gun dual procedure switch must be used to select between procedures “A” and “B”.

b. Make sure that parameters on power source dis-

play, such as WFS, match those on wire feeder display. If not, refer to Problem 14.

c. Disconnect harness plug from J2 on Control

board. Check continuity between plug pins 1 and 12 when local dual procedure switch is in position "A", but not when in "Gun" or "B". Now check continuity between plug pins 5 and 12 when local dual procedure switch is in position "B", but not when in "Gun" or "A". If any of these continuity tests fail, repair or replace switch or switch harness to correct problem. Otherwise, replace Control board. (See procedure for replacing PC boards.)

a. Place local dual procedure switch in "Gun" posi-

tion and, if a remote control kit is attached, place its dual procedure switch in "Gun" position also.

b. If a remote control kit is attached, remove it. If

this solves the problem, refer to Problem 19.

c. Make sure parameters on power source display,

such as WFS, match those on wire feeder display. If not, refer to Problem 14.

d. Remove switch. Make sure there is continuity

between switch pins with switch closed, and no continuity with switch open. If either of these tests failed, repair or replace switch.

e. Remove optional gun dual procedure switch and

disconnect harness plug from J2 on Control board. Check that there is continuity between pin A of receptacle J17 and pin 13 of plug P2. Check that there is continuity between pin C of receptacle J17 and pin 4 of plug P2. Check no continuity between pins A and C of receptacle J17. If any of these continuity tests fail, repair or replace switch amphenol J17 or switch harness.

f. Faulty local dual procedure switch. g. Faulty Control board.

f. Perform step c. of Problem 17. g. Replace Control PC board. (See procedure for

replacing PC boards.)

CAUTION

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.

SYNERGIC 7 & 7H

Page 42

E-9

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

POSSIBLE

CAUSE

RECOMMENDED

COURSE OF ACTION

E-9

19. Dual procedure switch of remote

control kit is not functioning properly.

a. Local dual procedure switch is not

in "Gun" position, and/or an optional gun dual procedure switch is attached.

b. Faulty communication between

wire feeder and remote control kit.

c. Faulty dual procedure switch,

wiring harness, or PC board in remote control kit.

a. Local dual procedure switch should be

in "Gun" position if a remote control kit is attached. If an optional gun dual procedure switch is attached and both the local dual procedure switch and remote's dual procedure switch are in "Gun" position then the optional gun dual procedure switch is used to switch between procedures "A" and "B".

b. If knobs on remote control kit are not

operating properly, refer to Problem

16.

c. Disconnect harness plug from Remote

PC board. Check that there is continuity between plug pins 7 and 8 when dual procedure switch is in position "A", but not when in "Gun" or "B". Now check that there is continuity between plug pins 6 and 7 when dual procedure switch is in position "B", but not when in "Gun" or "A". If any of these tests failed, repair or replace switch or switch harness. Otherwise replace Remote PC board.

20. Purge key does not turn on sole-

noid but trigger closure does.

21. Cold Feed key does not turn on

wire feed motor but trigger closure does.

22. Display and/or indicator lights do

not change when the arrow or select keys are pressed.

a. Defective keypad or Display PC

board is defective.

a. Defective keypad or Display PC

board is defective.

a. Defective keypad or Display PC

board.

a. Check continuity between sockets 5

and 1 of keypad connector when purge key is closed. If not, then replace keypad, otherwise replace Display PC board. (See Procedure for Replacing PC boards).

a. Check continuity between sockets 4

and 1 of keypad connector when Cold Feed key is closed. If not, then replace keypad, otherwise replace Display PC board. (See Procedure for Replacing PC boards).

a. Ring out keypad. Replace if defec-

tive. If not, then replace Display PC board. (See Procedure for Replacing PC boards).

CAUTION

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.

SYNERGIC 7 & 7H

Page 43

E-10

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

POSSIBLE

CAUSE

RECOMMENDED

COURSE OF ACTION

E-10

23. Display is blank a. Power source is OFF.

b. Feeder supply fuse or circuit

breaker at power source is blown or tripped.

c. Display or Control PC board is

bad

a. Turn ON power source.

b. Check input cable and feeder unit for

short in 41 and 42 circuit. Check for shorted motor. Replace fuse or reset circuit breaker.

c. Observe LED mounted on Control PC

board. It should blink on and off at a controlled rate of 1 second ON and 1 second OFF. If so, then replace Display PC board. If not, replace Control PC board. (See Procedure for Replacing PC boards)

CAUTION

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.

SYNERGIC 7 & 7H

Page 44

E-11

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

24. Display shows any of the following:

TROUBLESHOOTING

POSSIBLE

CAUSE

E-11

RECOMMENDED

COURSE OF ACTION

---

HXX

EXX

a. Voltmeter function is selected and arc

voltage is > 80 VDC.

a. Run-in speed is selected but is dis-

abled.

a. See Problem 5 or see Section on

Safety Precautions.

a. EEPROM error.

a. Where XX is a number from 1 to 10.

System error.

a. EPROM checksum error.

a. Normal operation. Voltmeter only reads 0-

80 VDC.

a. Run-in speed is now = weld speed. To re

enable Run-in speed simply press the increase arrow key.

a. XX indicates time in seconds before unit

will automatically reset.

a. Parameter recalled at power-up was out of

range. Press any key to reset. Check all settings before proceeding to weld. If this condition persists then ROM assembly X8 on the Control PC board is faulty. Replace Control PC board. (See procedure for replacing PC boards.)

a. Turn off power to feeder. Wait for 5 sec-

onds. Turn power back on. If EXX is displayed again then ROM assembly X8 on the Control board is faulty. Replace Control PC board. (See procedure for replacing PC boards.)

a. Turn off power to feeder. Wait 5 seconds.

Turn power back on. If EP is displayed again then ROM assembly X8 on Control PC board is faulty. Replace Control PC board. (See procedure for replacing PC boards.)

GLP

a. Microprocessor RAM error.

a. Grounding Lead Protector circuit is

activated, due to excessive current flow into the wire feeder frame.

b. Faulty GLP reed switch, harness, or

Control PCB.

a. Turn off power to feeder. Wait 5 seconds.

Turn power back on. If uP is displayed again then ROM assembly X8 on the Control PC board is faulty. Replace Control PC board. (See procedure for replacing PC boards.

a. To return to normal operating mode,

release the trigger, and press any key on the keypad. If "GLP" is still displayed or if it appears again before the trigger is closed then proceed to step b. Otherwise, before proceeding to weld make sure that the electrode is not touching the wire feeder frame.

b. Replace GLP reed switch CR1 if it is

shorted. Check the wiring harness between GLP reed switch CR1 and the Control board. Repair or replace faulty harness. If the reed switch and the wiring harness are both OK then replace the Control board.

CAUTION

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.

SYNERGIC 7 & 7H

Page 45

E-12

TROUBLESHOOTING

Procedure for Replacing PC Boards

WARNING

ELECTRIC SHOCK can kill.

• Have a qualified individual install and service this equipment.

• Turn the power source input power off at the disconnect switch before working on this equipment.

• Do not touch electrically hot parts.

---------------------------------------------------------------------

Before replacing a PC board which is suspected of being defective, visually inspect the PC board in question for any electrical or mechanical its components and conductors on the back of the board.

damage to any of

E-12

a. If there is no

install a new one and see if this remedies the problem. If the problem is remedied, reinstall the old PC board to see if the problem still exists. If it does

no longer exist with old PC board:

1. Check the PC board harness connector pins for corrosion, contamination, or looseness.

2. Check leads in the plug harness for loose or intermittent connection.

b. If PC board is visibly damaged electrically

possibly subjecting the new PC board to the same cause of failure, check for possible shorts, opens, or grounds caused by:

1. Frayed or pinched lead insulation.

2. Poor lead termination, such as a poor contact or a short to adjacent connection or surface.

3. Shorted or open motor leads, or other external leads.

visible damage to the PC board,

, before

4. Foreign matter or interference behind the PC boards.

c. If PC board is visibly damaged mechanically,

inspect for cause, then remedy before installing a replacement PC board.

If there is damage to the PC board or if replacing PC board corrects problem, return it to the local Lincoln Electric Field Service Shop.

SYNERGIC 7 & 7H

Page 46

F-1

DIAGRAMS

F-1

SYNERGIC 7 & 7H

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the

machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.

Page 47

F-2

DIAGRAMS

INPUT CONNECTION DIAGRAM

F-2

8-16-96

S21041-1

service this machine.

Only qualified persons should install, use or

Power Source before connecting the wire feeder.

Turn OFF the power switch on the Welding

N.A. WELDING CABLE MUST BE SIZED FOR CURRENT

SHOCK

ELECTRIC

WARNING

CAN KILL

AND FUTURE DUTY CYCLE OF APPLICATION.

ON POWER SOURCE TO PROPER POLARITY.

POWER SOURCE AND SET-UP PROCEDURE

CHANGE POLARITY, TURN POWER "OFF",

REVERSE ELECTRODE AND WORK CABLES AT

N.B. DIAGRAM SHOWS ELECTRODE POSITIVE. TO

IN CABLE.

N.C. PINS NOT LISTED ARE NOT CONNECTED

PRESENT IN YOUR EQUIPMENT.

(SEE APPROPRIATE WIRING DIAGRAM)

ONLY AND EACH MAY OR MAY NOT BE

FUNCTIONS ARE LISTED FOR REFERENCE

C=2

B=42

K=42

A=41

D=4

I=41

G=81

E=GND

H=82

N=67

F=67

8-PIN BOX RECEPTACLE, FRONT VIEW

AND 8-SOCKET CABLE PLUG, REAR VIEW

M=81

ELECTRODE CABLE

TO WORK

SYNERGIC 7 & 7H

B=GND

D=4

L=82

C=2

14-SOCKET BOX RECEPTACLE, FRONT VIEW

AND 14-PIN CABLE PLUG, REAR VIEW

POWER SOURCE TO WIRE FEEDER CABLE

PIN#

PLUG

GROUNDING LEAD

FUNCTION

GND

LEAD

PIN#

PLUG

DAB

TRIGGER CIRCUIT

ELECTRODE

-SERIAL COMM LOOP

42V AC

+SERIAL COMM LOOP

42V AC

Page 48

F-3

DIMENSION PRINT

F-3

9.42

.77

20102

11.60

8.09

3-13-92

4.03

LN-7GMA 4 ROLL

WIRE DRIVE & CONTROL BOX AS'BLY

DIMENSION PRINT

1.28

9.70

3/8-16 HEX. HD. SCREWS

FOR MTG. CONTROL BOX

TO WIRE REEL STAND

(3 PLACES)

TOLERANCE ~.125

11.11

SYNERGIC 7 & 7H

Page 49

PARTS LIST FOR

SYNERGIC 7 & 7H

P-278P-278

This parts list is provided as an informative guide only.

It was accurate at the time of printing. These pages are only updated on the Service Navigator DVD and in Lincoln Electricʼs ofﬁcial Parts Book (BK-34).

When ordering parts, always refer to Lincoln Electricʼs ofﬁcial Parts Book (BK-34) for the latest pages.

SYNERGIC 7 & 7H

Page 50

P-278-A

MAIN ASSEMBLY

P-278-A

SYNERGIC 7 & 7H

02-19-2007

Page 51

P-278-A.1

Synergic 7 & 7F

See P-246 for Codes 10098, 10099, 10100, 10100, 10100, 10101, 10198, 10199

See P266 for Codes 10189, 10190, 10191, 10254

Do Not use this Parts List for a machine if its code number is not listed. Contact the Service Department for any code numbers not listed.

Use the Main Assembly drawing on the left hand page and the table below to determine which sub assembly page and column the desired part is located on for your particular code machine.

Sub Assembly Item

No.

SUB ASSEMBLY

PAGE NAME

Optional Equipment

PAGE NO.

CODE NO.

10250 111• 1

10251 111• 1

10252 1 1 • 1 1

P278-B.1

Miscellaneous Items

P278-B.2

Control Box Assembly

P278-C

Rear & Side Panels

P278-D

Case Front (Not Water Cooled)

P278-E

Case Front (Water Cooled)

P278-F

Wire Drive Assembly

P278-G

10253 1 1 • 1 1

SYNERGIC 7 & 7H

02-19-2007

Page 52

P-278-B.1

OPTIONAL EQUIPMENT LISTING

Miscellaneous Options Available for your machine are listed below:

# Indicates a change this printing.

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PART NUMBER

Undercarriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K163

Platform to Mount on Idealarcs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K178-1

50-60# Reel & Brake Assembly on Mounting Stand W/Shroud . . . . . . . . . . . . . . . . .Order K303

50-60# Reel & Brake Assembly on Mounting Stand . . . . . . . . . . . . . . . . . . . . . . . . . .Order K376

30# Spindle & Readi-Reel Adapter on Small Mounting Stand . . . . . . . . . . . . . . . . . .Order K377

14# Reel with Canister on Small Mounting Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K378

Spindle & 50-60# Readi-Reel Adapter on Open Mounting Stand . . . . . . . . . . . . . . . .Order K445

Wire Reel Spindle Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K162H

Water Connection Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K590-4

Readi-Reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K563-P

Spindle Adapter for 8” Spools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K568

Adapter for 14# Innershield Coil to 2” Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K435

Adapter for 50-60# Readi-Reel to 2” Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K438

Gas Guard Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K659-1

Dual Procedure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K683-All

Dual Procedure Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K1449-1

* Control Cable Assembly W/Gas Water Hoses W/Stud Connector (500A 60% Duty) .Order K640 * Control Cable Assembly W/Gas Water Hoses W/Twist-Mate Connector

(500A 60% Duty) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K641

* Control Cable W/O Weld Cable & Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K642

* Control Cable Extension W/O Weld Cable & Hoses . . . . . . . . . . . . . . . . . . . . . . . . . .Order K643

* Control Cable Assembly W/Stud Connector (500A 60% Duty) . . . . . . . . . . . . . . . . . .Order K648

* Control Cable Assembly W/Twist-Mate Connector (500A 60% Duty) . . . . . . . . . . . . .Order K649

* Control Cable Assembly W/Gas & Water Hoses W/Twist-Mate Connection

(350A 60% Duty) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K650

* Control Cable Assembly W/Twist-Mate Connector (350A 60% Duty) . . . . . . . . . . . . .Order K651

* Control Cable Assembly W/Gas Hose & Twist-Mate Connector (500A. 60% Duty) . .Order K675

* Control Cable Assembly W/Gas Hose & Stud Connector (500A. 60% Duty) . . . . . . .Order K676

* Control Cable Assembly W/Gas Hose & Twist-Mate Connector (350A. 60% Duty) . .Order K677

* Remote Control Extension Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K1450

Drive Roll Kit (4 Roll .023,.025 Stl) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order KP653-025S

Drive Roll Kit (4 Roll .045,.052 Stl) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order KP655-052

Drive Roll Kit (4 Roll .045,.052 Stl & Cored) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order KP655-052C

Drive Roll Kit (4 Roll .052-1/16 Stl) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order KP655-1/16

Drive Roll Kit (4 Roll .068, 5/64, 3/32 Stl. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order KP655-3/32

Drive Roll Kit (4 Roll .035 Alum.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order KP656-035A

Drive Roll Kit (4 Roll 3/3/64 Alum.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order KP656-3/64A

Drive Roll Kit (4 Roll 1/16 Alum.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order KP656-1/16A

P-278-B.1

Consult Field Service Shop for Available Length.

SYNERGIC 7 & 7H

02-19-2007

Page 53

P-278-B.2

MISCELLANEOUS ITEMS

(THESE ITEMS ARE NOT ILLUSTRATED)

P-278-B.2

# Indicates a change this printing.

Use only the parts marked “x” in the column under the heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 123456789

Warranty Decal S22127-1 1

Warning Label M16196 1

Drive Roll Decal (Not Water Cooled) S20101 1

Drive Roll Decal (Water Cooled) S20860 1

Wiring Diagram (Complete Unit) L9972 1

Wiring Diagram (Control Box) L9973 1

Quick Connect Fitting (Male) (Water Cooled Model) S19663 1

Hose Nipple (Non Water Cooled) T15008 1

Inert Arc Nut (Non Water Cooled) T15007-1 1

EC Conformity Decal T13086-130 1

SYNERGIC 7 & 7H

02-19-2007

Page 54

P-278-C

Control Box Assembly

P-278-C

Part of 2A

10A



SYNERGIC 7 & 7H

02-19-2007

Page 55

P-278-C.1

# Indicates a change this printing.

Use only the parts marked “x” in the column under the heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 123456789

1 Control Box Side Assembly L9912 1 X 2A Harness, Includes: M18044 1 X

Remote Connection Assembly (J18) Plug and Lead Assembly (P1)

Toroid (P8) 2B Self Tapping Screw S8025-96 4 X 3A Rectifier Bridge T13637-1 1 X 3B #8-32x1.00 RHS CF000176 1 X 3C Plain Washer S9262-3 1 X 3D Lock Washer T4291-A 1 X 3E #8-32 HN CF000042 1 X 4A Control P.C. Board Asbly G2992-[ } 1 X 4B Snap in P.C. Board Support S19300-2 7 X 5 Bushing T14614-3 1 X 6 Wire Clamp S20379 1 X 7 Display P.C. Board Asbly L9122-[ } 1 X 8 7 Key Keypad L9571-1 1 X 9 Plug & Lead Assembly S18250-452 1 X 10A Amphenol & Lead Asbly M18041 1 X 10B Self Tapping Screw S8025-96 8 X 11 Keypad Cover Asbly S22430 1 X 12 Reed Switch Asbly (Not Shown) S12334-55 1 X 13 Clamp (Not Shown) T12563-7 2 X

SYNERGIC 7 & 7H

02-19-2007

Page 56

P-278-D

Rear & Side Panels

P-278-D

SYNERGIC 7 & 7H

02-19-2007

Page 57

P-278-D.1

Column 1, Non Water Cooled Column 2, Water Cooled

P-278-D.1

# Indicates a change this printing.

Use only the parts marked “x” in the column under the heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 123456789

1 Cover & Hinge Assembly M17144 1 X • 1 Cover & Hinge Assembly M17134 1 • X 2A 3/8-16 x 1.25 HHCS CF000105 1 X X 2B Lock Washer E106A-16 1 X X 2C Plain Washer S9262-120 2 X X 2D 3/8-16 HN CF000067 1 X X 3A 1/4-20 x .750 HHCS CF000014 1 X X 3B Lock Washer E106A-2 1 X X 3C 1/4-20 HN CF000017 1 X X 4 Door Bumper T14882 1 X X 5 Spacer T15040-1 1 X X 6A Water Inlet/Outlet Cover M17894 1 X • 6A Water Inlet/Outlet Insulator M18021 1 • X 6B Self Tapping Screw S8025-92 4 X X 7A Rear Panel Assembly S22221 1 X X 7B Self Tapping Screw (Not Shown) S8025-92 3 X X 8A Cover and Tab Assembly S22220 1 X X 8B Self Tapping Screw S8025-92 4 X X 9 Gas Solenoid & Bracket Asbly M16847 1 X X 9A Self Tapping Screw S8025-91 1 X X

SYNERGIC 7 & 7H

02-19-2007

Page 58

P-278-E

Case Front (Not Water Cooled)

P-278-E

Part of 3A

11A

11B

Part of 12

11A

Part of 12

SYNERGIC 7 & 7H

02-19-2007

Page 59

P-278-E.1

# Indicates a change this printing.

ITEM DESCRIPTION PART NO. QTY. 123456789

1A Case Front M17932 1 X 1B Self Tapping Screw (Not Shown) S8025-91 2 X 1C Self Tapping Screw (Not Shown) S8025-92 1 X 2 Nameplate M17993 1 X 2 Nameplate (7H) M17994 3A Knob T10491 2 X 3B Insulation Tube T7028-241 2 X 3C Shaft Seal T14034 2 X 3D Encoder P.C. Board Assembly M17797-[ ] 2 X 4 Connector T14557-3 1 X 5A Water Inlet/Outlet Cover M17894 2 X 5B Self Tapping Screw S8025-91 4 X 6 Toggle Switch T10800-22 1 X 7A Connector & Lead Assembly (Not Shown) S13100-189 1 X 7B Self Tapping Screw (Not Shown) S8025-96 4 X 8A Encoder Cover Spotwelded Assembly S22359 1 X 8B Plain Washer S9262-27 1 X 8C #10-24 HN CF000010 1 X 8D Lock Washer (Not Shown) E106A-1 1 X 9 Lock Washer T9695-8 1 X 10 1/2-13 HJN CF000054 1 X 11A Outlet Hose T10642-186 1 X 11B E1813-0#-7.50 (Sleeving) CS001639 1 X 12 Gas Solenoid & Bracket Assembly M16847 1 X 13 Self Tapping Screw S8025-91 4 X

Use only the parts marked “x” in the column under the heading number called for in the model index page.

This part is obsolete and no longer available.

SYNERGIC 7 & 7H

02-19-2007

Page 60

P-278-F

Case Front (Water Cooled)

P-278-F

Part of 3A

Part of 7



11A

Part of 7

Part of 12

11B

Part of 12

11A

11B



SYNERGIC 7 & 7H

02-19-2007

Page 61

P-278-F.1

# Indicates a change this printing.

ITEM DESCRIPTION PART NO. QTY. 123456789

1A Case Front M17931 1 X 1B Self Tapping Screw (Not Shown) S8025-91 1 X 1C Self Tapping Screw (Not Shown) S8025-92 1 X

2 Nameplate M17995 2 Nameplate (7H) M17996 1 X 3A Knob T10491 2 X 3B Insulation Tube T7028-241 2 X 3C Shaft Seal T14034 2 X 3D Encoder P.C. Board Assembly M17797-[ ] 2 X 4 Toggle Switch T10800-22 1 X 5A Encoder Cover Spotwelded Assembly S22359 1 X 5B Plain Washer S9262-27 1 X 5C #10-24 HN CF000010 1 X 5D Lock Washer (Not Shown) E106A-1 1 X 6A Water Inlet/Outlet Insulator M18021 2 X 6B Self Tapping Screw S8025-91 4 X 7 Quick Connect & Nut S19664 4 X 8 Hose Clamp S20710-6 4 X 9 Lock Washer T9695-8 4 X 10 Flex Tube T10642-211 2 X 11A Outlet Hose T10642-186 1 X 11B E1813-0#-7.50 (Sleeving) CS001639 1 X 12 Gas Solenoid & Bracket Assembly M16847 1 X 13 Self Tapping Screw S8025-91 4 X 14 Euro Connector Assembly M16871 1 X 15 Hose Clamp S10888-35 1 X

Use only the parts marked “x” in the column under the heading number called for in the model index page.

This part is obsolete and no longer available.

SYNERGIC 7 & 7H

02-19-2007

Page 62

Wire Drive Assembly

P-278-GP-278-G

22C

22A

21E

22B

21K

21N

21D

21G

21F

21H

21A

21J

1312

19A

19B



SYNERGIC 7 & 7H

02-19-2007

Page 63

P-278-G.1

# Indicates a change this printing.

Use only the parts marked “x” in the column under the heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 123456789

1A Wire Drive Assembly (Synergic 7) L9348-3 1 X 1A Wire Drive Assembly (Synergic 7F) L9348-4 1 X 1B 1/4-20x.625 HHCS CF000013 3 X 1C Lock Washer E106A-2 3 X 1D Plain Washer S9262-98 3 X 2 Molded Hand Screw T13858 1 X 3A Conductor Block S17798-1 1 X 3B Plain Washer S9262-23 3 X 3C Lock Washer E106A-2 3 X 3D 1/4-20 x 1.75 HHCS CF000016 2 X 3E Bent Bolt S20629-1 1 X 3F 1/4-20 HN CF000017 1 X 3G Sems Screw #10-24x.375 1 X 4 1/2-13 x .75 HHCS CF000020 1 X 5 Locator Bushing T14031 1 X 6 Drive Motor Asbly, Includes: (Synergic 7) M16763-1 1 X 6 Drive Motor Asbly, Includes: (Synergic 7H) M16763-2 1 X 6A Drive Motor M14907 1 X 6B Pinion Gear (Synergic 7) S17980-2 1 X 6B Pinion Gear (Synergic 7H) S17980-1 1 X 6C Roll Pin T9967-33 1 X 6D Toroid Assembly (Not Shown) S20498 1 X 6E Ring Magnet (Not Shown) S18011 1 X 6F Plain Washer (Not Shown) S9262-70 1 X 6G Brush (Specialty) (Not Shown) M16718-F 2 X 6G Brush (Stature) (Not Shown) M14907-N 2 X 6H Brush Cap (Specialty) (Not Shown) M14907-G 2 X 6H Brush Cap (Stature) (Not Shown) M14907-P 2 X 7 Motor Insulator / Spacer S20861 1 X 8 Switch Mounting Housing S21227 1 X 9A #10-24 x 1.00 RHS CF000038 1 X 9B Lock Washer E106A-1 1 X 9C Plain Washer S9262-27 1 X 10 Hall Effect Switch S20374 1 X 11 Plain Washer S9262-60 3 X 12 Lock Washer E106A-1 3 X 13 #10-24 x .75 RHS CF000072 3 X 14 Gear Box Insulation (Lower) S16139-2 1 X 15 Upper Insulation S19918 1 X 16 Mounting Plate S20099 1 X 17 1/4-20 x .625 FHS CF000345 2 X 18 Base Plate Welded Assembly S20097 1 X 19A 3/8-16 x .625 HHCS CF000018 2 X 19B Lock Washer E106A-16 2 X 20 Fastener Button T14659-1 2 X 21 Swing Arm Asbly, Includes: M16445 1 X 21A Bearings & Shaft Asbly T13244-1 1 X 21B Roll Pin T9967-25 1 X 21C Plain Washer (Not Shown) S9262-60 1 X 21D Pin M8809-122 1 X 21E Spring T10247-11 1 X

SYNERGIC 7 & 7H

02-19-2007

Page 64

P-278-G.2

# Indicates a change this printing.

Use only the parts marked “x” in the column under the heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 123456789

21F Plain Washer S9262-3 2 X 21G Socket Head Screw T9447-21 2 X 21H Release Lever Assembly S19965 1 X 21J Knob S19922 1 X 21K Swing Arm M16446 1 X 21L Pivot Block Shaft (Not Shown) S19921 1 X 21M Spacer (Not Shown) S20244 2 X 21N Tension Rod S19920 1 X 22A Clamping Screw S22729 2 X 22B Collar Assembly S21193 2 X 22C Key M8776-94 2 X 23 Thumb Screw S19924 3 X 24 Pin S19828 1 X 25 Swing Arm Spacer S19923 2 X

SYNERGIC 7 & 7H

02-19-2007

Page 65

NOTES

SYNERGIC 7 & 7H

Page 66

NOTES

SYNERGIC 7 & 7H

Page 67

NOTES

SYNERGIC 7 & 7H

Page 68

CUSTOMER ASSISTANCE POLICY

The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equipment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln Electric for advice or information about their use of our products. We respond to our customers based on the best information in our possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customer’s particular purpose, with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any warranty with respect to the sale of our products.

Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service requirements.

Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com for any updated information.

Lincoln Electric IM557 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual