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
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
i
SAFETY
i
WARNING
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 Above For Diesel Engines
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.
The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
The Above For Gasoline Engines
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.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.
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.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
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.
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.
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.
Mar ‘95
ii
SAFETY
ii
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.
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 below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.
3.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
between the 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.
3.j. Also see Items 6.c. and 8.
5.b.
Do not weld in locations near chlorinated hydrocarbon
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
form phosgene, a highly toxic gas, and other irritating
products.
5.c. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
5.d. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.e. Also see item 1.b.
vapors
to
Mar ‘95
iii
SAFETY
iii
WELDING 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.
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
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
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.
Sparks and spatter are thrown from the welding arc. Wear oil
6.f.
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.
Remember that welding sparks and hot
though
they have
Preparation
for Welding and Cutting of
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.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Mar ‘95
iv
SAFETY
iv
PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent
dans ce manuel aussi bien que les précautions de sûreté
générales suivantes:
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une
grande partie du corps peut être en contact avec la
masse.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état
defonctionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
8. S’assurer que la masse est connectée le plus prés possible
de la zone de travail qu’il est pratique de le faire. Si on place
la masse sur la charpente de la construction ou d’autres
endroits éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de levage, câbles de grue, ou autres circuits. Cela peut provoquer
des risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les
vapeurs du solvant pour produire du phosgéne (gas fortement toxique) ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.
2. Dans le cas de travail au dessus du niveau du sol, se protéger contre les chutes dans le cas ou on recoit un choc. Ne
jamais enrouler le câble-électrode autour de n’importe quelle
partie du corps.
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du
rayonnement de l’arc et des projections quand on soude
ou quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
l‘arc.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection
libres de l’huile, tels que les gants en cuir, chemise épaisse,
pantalons sans revers, et chaussures montantes.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code
de l’électricité et aux recommendations du fabricant. Le dispositif de montage ou la piece à souder doit être branché à
une bonne mise à la terre.
2. Autant que possible, I’installation et l’entretien du poste
seront effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la
debrancher à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
Mar. ‘93
for selecting a QUALITY product by Lincoln Electric. We want you
Thank You
to take pride in operating this Lincoln Electric Company product
••• as much pride as we have in bringing this product to you!
Please Examine Carton and Equipment For 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.
Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.
Model Number ___________________________________________________________________________
Code Number or Date Code_________________________________________________________________
Serial Number____________________________________________________________________________
Date Purchased___________________________________________________________________________
vv
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially important when identifying the correct replacement parts.
On-Line Product Registration
- Register your machine with Lincoln Electric either via fax or over the Internet.
• For faxing: Complete the form on the back of the warranty statement included in the literature packet
accompanying this machine and fax the form per the instructions printed on it.
• For On-Line Registration: Go to our
“Product Registration”. Please complete the form and submit your registration.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then
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.
vi
TABLE OF CONTENTS
Page
Installation .......................................................................................................Section A
Parts Lists...................................................................................................P-278 Series
A-1
INSTALLATION
TECHNICAL SPECIFICATIONS – SYNERGIC 7 AND 7H
WIRE FEEDER - (4 - ROLL)
Model
SYNERGIC 7SYNERGIC 7H
A-1
Type
Wire Speed Range:
IPM
M/M
Wire Size Capabilities:
Solid Electrodes
Cored Electrodes
Input Power:
Temperature Rating:
Operating
Storage
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
The following is for both the Synergic 7 and
Synergic 7H models:
Size & WeightWithout Wire StandWith K377 Wire Stand
4-Roll Feeder:
Length
Width
Height
Total Weight
(Less Electrode)
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.)
SYNERGIC 7 & 7H
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 won’t 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 LED’s
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
V
1
2
COLD FEED GAS PURGE
WFS
PREFLOW
POSTFLOW
SPOT
STD
LOCK
SPOT
RUN-IN
2-STEP
4-STEP
CRATER
TRIM/VOLTS
L9571-1
V
WFS
RUN-IN
TRIM
/
VOLTS
1
2
SPOT
CRATER
STD
LOCK
SPOT
2-STEP
4-STEP
COLD FEED
GAS PURGE
INSTALLATION
KEYPAD AND DISPLAY
DESCRIPTION
Keypad - Seven key, membrane
type with “snap” tactile feel and
embossed domes. Long life
design. Spatter resistant surface.
Display - 3-1/2 digit 7-segment
LED with (+) or (-) polarity indicators. .56” (14.2mm) character
height. Displays arc voltage in
volts, wire speed in IPM or m/m and
all timers in seconds.
Indicator Lights - Extra bright red
LED’s 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.
A-4
Function Select key enables operator to choose which
function will be displayed as shown by the appropriate
indicator light. Pressing the key causes lights to sequence
(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
(left to right, top to bottom) starting from the current indicated selection. Any parameter not available in the mode
selected is skipped over.
key enables operator to choose spot
Gas Purge
key energizes the solenoid valve but not the wire feeder or
power source.
Top Left Light - indicates preflow time is being displayed in
seconds.
Top Right Light - indicates postflow time is being displayed in seconds.
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
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.
current indicated selection.
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,
Top Light - Indicates 2-step (standard) trigger mode.
which are adjusted using the rotating encoder knobs.
Middle Light - Indicates 4-step
(lock) trigger mode. This mode may
be selected to include crater fill or
weld current interlock.
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.
Bottom Light - Indicates spot weld
mode.
SYNERGIC 7 & 7H
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.
A-5
Observe all additional Safety Guidelines detailed
throughout this manual.
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
A-6
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.
• 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.
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 (KS655 and KS656)
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
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.
GMAW Guns
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
7.
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
E=GND
8-PIN PLUG, FRONT VIEW
14-PIN PLUG, FRONT VIEW
B=GND
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.
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).
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
2
)
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
2
)
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 mm2)
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
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