Lincoln Electric IM557 User Manual

Operator’s Manual

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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

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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.

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.

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

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

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

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.)

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

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

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.

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

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

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

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

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

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

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

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.

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

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.

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

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