Lincoln Electric IM558 User Manual

IM558

R

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Synergic 7 and 7H Water Cooled

For use with machine Code Numbers 10252 and 10253

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.

January, 1996

World's Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors

NRTL/C

OPERATOR’S MANUAL

Sales and Service through Subsidiaries and Distributors Worldwide

22801 St. Clair Ave. Cleveland, Ohio 44117-1199 U.S.A. Tel. [phone]

i

SAFETY

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

i

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.

____________________________________________________

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

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.

Mar ʻ95

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 manufacturerʼs instructions for this

equipment and the consumables to be used, including the

material safety data sheet (MSDS) and follow your

employerʼs safety practices. MSDS forms are available from

your welding distributor or from the manufacturer.

5.e. Also see item 1.b.

Mar ʻ95

vapors

to

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 manufacturerʼs
recommendations.

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

Mar ʻ95

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 LʼArc

1. Protegez-vous contre la secousse électrique:

a. Les circuits à lʼélectrode 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 sʼisoler 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 lʼeau 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 sʼapplicuent 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 lʼon pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque dʼincendie dû aux étincelles.

7. Quand on ne soud
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque dʼincendie.

8. Sʼassurer que la masse est connectée le plus prés possible
de la zone de travail quʼil est pratique de le faire. Si on place
la masse sur la charpente de la construction ou dʼautres
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 dʼincendie ou dʼechauffement des chaines et des
câbles jusquʼà ce quʼils 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
dʼopérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de lʼarc 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.

e pas, poser la pince à une endroit isolé de

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 nʼimporte quelle
partie du corps.

3. Un coup dʼarc peut être plus sévère quʼun coup de soliel,
donc:

a. Utiliser un bon masque avec un verre filtrant approprié

ainsi quʼun verre blanc afin de se protéger les yeux du
rayonnement de lʼarc et des projections quand on soude
ou quand on regarde lʼarc.

b. Porter des vêtements convenables afin de protéger la

peau de soudeur et des aides contre le rayonnement de
lʻarc.

c. Protéger lʼautre personnel travaillant à proximité au

soudage à lʼaide dʼécrans appropriés et non-inflamma­bles.

4. Des gouttes de laitier en fusion sont émises de lʼarc de
soudage. Se protéger avec des vêtements de protection
libres de lʼhuile, 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 lʼélectricité 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, Iʼinstallation et lʼentretien du poste
seront effectués par un électricien qualifié.

3. Avant de faires des travaux à lʼinterieur de poste, la
debrancher à lʼinterrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leur

Mar. ʻ93

Thank You

for selecting a QUALITY product by Lincoln Electric. We want you
to take pride in operating this Lincoln Electric Company product

••• as much pride as we have in bringing this product to you!

Please Examine Carton and Equipment For 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 Name & Number _____________________________________

Code & Serial Number _____________________________________

Date of Purchase _____________________________________

Whenever you request replacement parts for or information on this equipment always supply the information
you have recorded above.

vv

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:

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.

TABLE OF CONTENTS

Page

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

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

GeneralDescription................................................................................................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 KP656) .......................................................A-6

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

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

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

Gun Cable Connection....................................................................................A-7

Gun and Cable AssembliesWith Fast-Mode Connection.......................................A-7

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

Gun Cable Connections: Wire Feeder to Gun ...............................................A-8

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

vi

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-7

Gas Guard Regulator Setting ................................................................................B-7

Making a Weld.......................................................................................................B-8

Wire Reel Changing...............................................................................................B-8

Wire Feed Overload Protection .............................................................................B-8

Grounding Lead Protector .....................................................................................B-9

Explanation of Prompting and Error Messages .....................................................B-9

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........................................................................................................Appendix

A-1

INSTALLATION

TECHNICAL SPECIFICATIONS – SYNERGIC 7 AND 7H WATER COOLED

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

K685-3

50 - 770

1.25 - 19.5

.025 - 1/16”

0.6 - 1.6mm

.045 - 3/32”

1.2 - 2.4mm

K685-4

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 & Weight Without Wire Stand With K377 Wire Stand

4-Roll Feeder:

Length
Width
Height
Total Weight

(Less Electrode)

292 mm (11.50")

295mm (11.60”)
282mm (11.11”)

13.6 kg (30.0 lbs.)

573 mm (22.56")

295mm (11.60”)
432mm (17.00”)

18.1 kg (40.0 lbs.)

SYNERGIC 7 & 7H

A-2

INSTALLATION

GENERAL DESCRIPTION

The Synergic 7 is a CSA / NRTL/C certified 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 input 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, Euro-style Fast-Mate™ gun connector, and factory
equipped with a water connection kit for water cooled guns.
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.

The Synergic 7 Water Cooled is available in 2 models:

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.)

Fast-Mate™ (European Style) Gun Connector -

Provides for electrode, shielding gas and gun control
leads for connections in a single connector.

Ordering Speed Range Wire Size Range

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

K685-3 Synergic 4-Roll 50 - 770 .025 - 3/32

7 (1.25 - 19.5) (0.6 - 2.4)

K685-4 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:

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

gas-metal-arc processes.

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

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

COLD FEED GAS PURGE

TRIGGER MODE

2-STEP

STD

4-STEP

LOCK

SPOT

PREFLOW POSTFLOW

type with “snap” tactile feel and
embossed domes. Long life
design. Spatter resistant surface.

TRIM

VOLTS

/

V

Display - 3-1/2 digit 7-segment

RUN-IN

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

WFS

tors. .56” (14.2mm) character
height. Displays arc voltage in
volts, wire speed in IPM or m/m and

2

1

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.

VOLTS

V

PREFLOW POSTFLOW

2

1

A-4

Function Select key enables operator to choose which

TRIM

/

function will be displayed as shown by the appropriate
indicator light. Pressing the key causes lights to sequence

RUN-IN

(top to bottom) starting from the current indicated position.
The function displayed will be adjustable with the rotating

WFS

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

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.

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.

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

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.

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) Loosen the molded hand screw on the front of the
wire drive and pull the gun connector out of the
connector block. The guide tube provided in the
gun connector is for .045" (1.2 mm) or smaller wire
sizes (marked with one ring). If larger wire sizes
are used, remove and replace the guide tube with
the larger hole guide tube (marked with four rings)
which is provided in the storage hole of appropriate
capacity wire drive faceplates (near motor). The
guide tube is secured with a set screw on the bot­tom of the brass hex so the guide is flush with the
incoming end of the gun connector.

9) With the gun connector removed, back out the
screws for the incoming and outgoing guide tubes.

10) 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.

11) 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.

ture for descriptions of the 250 to 400 ampere air
cooled gun and cables that are available. Gun cable
lengths range from 10 ft. (3.0 m) to 15 ft. (4.5 m) and
feed electrode sizes .035" (0.9 mm) to 1/16" (1.6 mm).
These guns require the use of either the K173-1 or
K184# vacuum units.

# Requires S14927-8 connector hose and an S20591

hose adapter.

Gun Cable Connection: Wire Feeder to Gun

a. Check that the drive roll(s), feeder guide tubes and

gun connector guide tube are appropriate for the
electrode size being used. If necessary, change
them per Drive Roll Installation Section.

b. Connect gun to gun connector making sure all pins

and gas tube line up with appropriate holes in con­nector. Tighten gun by turning large nut on gun
clockwise.

12) Reinstall the gun connector into the conductor

block and tighten molded handscrew.

13) Re-latch both quick release levers.

14) 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

An expanding line of Magnum Fast-Mate™ air cooled
and water cooled 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 400
ampere air cooled gun and cables that are available
as well as the Magnum Water Cooled 450 ampere
water cooled gun and cable. 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).

An expanding line of Magnum X-Tractor gun and
cable assemblies provides fume extraction capability
for welding with solid and cored electrodes using the
GMAW process. See the appropriate Magnum litera-

SYNERGIC 7 & 7H

A-8

INSTALLATION

A-8

Synergic 7 Water Connections (for Water­Cooled Guns)

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
continituity 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

8-PIN PLUG, FRONT VIEW

INSTALLATION

(5 m), 25 ft (7.6 m), 33 ft (10 m) and 50 ft (15 m).
K676 - (Used with Power Wave 450) Similar to K648 but

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

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 thecon­nection to the work makes tight metal-to-metal electri­cal contact.

Current

60% Duty

Cycle

300 Amps

400 Amps

500 Amps

* For pulse welding applications, the next larger cable

size is recommended.

Copper Work Cable Size, AWG *

Up to 100 ft Length (30m)

00 (67 mm2)

000 (85 mm

000 (85 mm2)

INSTALLATION

2

)

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.

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.

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

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

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.

INSTALLATION

A-11

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.

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 See Installation section “Shielding Gas
Connections”.

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 key energizes the wire
feeder but not the power source or
solenoid valve. This cold feed
speed is digitally displayed and is

COLD FEED

GAS PURGE

adjustable (with “Arrow keys”) only
while pressing the Cold Feed Key.
The last setting is held in memory
for next Cold feeding.

Gas Purge

key energizes the sole­noid valve but not the wire feeder or
power source.

for

2-STEP

STD

4-STEP

LOCK

SPOT

SYNERGIC 7 & 7H

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 wirefeeder 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

V

VOLTS

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 oper-

TRIM

/

ator to choose which function will
be displayed as indicated by the

RUN-IN

appropriate light. Pressing the key
causes lights to sequence (top to

WFS

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

as

- Indicates Weld Feed

SYNERGIC 7 & 7H

B-3

PREFLOW POSTFLOW

2

1

Timer/Crater Select - key enables
operator to choose crater speed, spot
or gas timers as indicated by the appro­priate light. Pressing key causes lights

CRATER

to sequence (left to right, top to bottom)
starting from the current indicated posi-

SPOT

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

Top Left Light

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

Top Right Light

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

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.

OPERATION

GAS PURGE

GAS PURGE

PREFLOW POSTFLOW

GAS PURGE

COLD FEED

B-3

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

TRIM

VOLTS

/

V

RUN-IN

2

1

can be adjusted using the arrow keys. To exit this
function, press any other key except the arrow key,

WFS

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.
Pressing both the Gas Purge Key then the function
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
sec increments. To exit this function press any other
key except the arrow keys, gas purge or function
select key.

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

CRATER

m/m. If the speed display units were m/m,
then they will change to IPM. If the display

SPOT

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 and Cold Feed
keys 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.

As shipped, the Run-In function is off with a
fixed setting of min. rated speed. 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
and the Run-In indicator light will return to
the function key sequence. Re-pressing 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.

SYNERGIC 7 & 7H

B-4

OPERATION

B-4

GAS PURGE

2-STEP

STD

4-STEP

LOCK

SPOT

GAS PURGE

4-Step Trigger Mode
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

Dual Procedure Remote Control (K1449-1)

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.

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.

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

B-5

Brake Holding PinR
(Must engage holeR
in adapter rib)

GROOVES

2" O.D. SPINDLE

PIN

MOLDED ADAPTER

RETAINING SPRING

R

OPERATION

To Mount 10 to 44 lb (4.5 - 20kg) Spool
(12” / 300mm Diameter): For 8” (200mm)

spools, a K468 spindle adapter must be used.)

1) Remove the locking collar on the 2” (51mm) diam­eter spindle.

B-5

Installation of K363-P Readi-Reel Adapter

READI-REEL

INSIDE CAGE WIRES

THREADED LOCKING COLLAR

Wire Reel Loading - Readi-Reels and
Spools (Models equipped with 2” (51mm)
spindle)

TO MOUNT A 30 LB (14 kg) READI-REEL
PACKAGE USING THE MOLDED PLASTIC K363-P
TYPE ADAPTER:

1) Make certain that the threaded locking collar is
tight and securely locks the adapter on the spindle
(see figure above).

2) Rotate the spindle and adapter so the retaining
spring is at the 12 oʼclock position.

3) Position the Readi-Reel so that it will rotate in a
clockwise direction when feeding (wire is to be de­reeled from bottom of the coil).

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

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

6) Slide cage all the way onto the adapter until the
retaining spring “pops up” fully.

2) Place the spool on the spindle making certain the
brake holding pin enters one of the holes in the
back side of the spool. Be certain the wire comes
off the reel in a clockwise direction when de-reeled
from the bottom of the coil.

3) Replace and tighten the locking collar.

Feeding Electrode and Brake Adjustment

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

2) While tightly holding the electrode, cut off the bent
end and straighten the first 6” (150mm). Cut off
the first 1” (25mm). (If the electrode is not properly
straightened, it may not feed or may not go into
the outgoing guide tube causing a “birdnest”.)

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

4) Press the Cold Inch key or the gun trigger and
push the electrode into the drive roll.

WARNING

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

___________________________________________

5) Feed the electrode through the gun.

WARNING

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

___________________________________________

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

SYNERGIC 7 & 7H

6) Adjust the brake tension with the thumbscrew on
the spindle hub, until the reel turns freely but with
little or no overrun when wire feeding is stopped.
Do not overtighten.

B-6

OPERATION

Wire Reel Loading - 50-60lb (22.7-27.2kg)
Coils (K303 or K376 Wire Reel Stand)

Adjustable Wire Reel Brake

The mount for standard 50-60 lb (22.7-27.2 kg) elec­trode coils includes a two-position brake assembly.
Generally the brake should be at the inner position
(nearest to the wire reel shaft) for wire feed speeds
below 400 in/min. (10m/m). It should be at the outer
position for the faster wire speeds often used when
feeding small diameter electrode.

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

To Mount a 50-60lb (22.7-27.2kg) Coil:

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

B-6

4) Tighten the cover as much as possible by hand.

DO NOT hammer on the spinner nut arms.

5) Cut and remove only the tie wire holding the free
end of the coil. Insert the free end into one of the
holes in the cover and secure it by bending it back.
Cut and remove the remaining tie wires.

CAUTION

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

___________________________________________

2) Lay the reel flat on the floor, loosen the spinner nut
and remove the cover plate.

3) Before cutting the tie wires, place the coil of elec­trode on the reel so it unwinds as the reel rotates
clockwise.

a) Be sure the coil is placed so the spring loaded

arms will not interfere with the later removal of
the coil tie wires (see illustration below).

b) When loading .030-.045” (0.8-1.2mm) elec-

trode, be certain the coil is placed on the reel so
the spring loaded arms are at the center of the
slots in the cardboard coil liner. This provides
the positive compression of the coil sides need­ed for trouble-free wire feeding (see illustration).

c) Put the cover plate on the reel so that the four

arms of the cover straddle and are in line with
the spring loaded arm of the reel proper.

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

Feeding Electrode

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

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

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

WARNING

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

___________________________________________

SYNERGIC 7 & 7H

B-7

OPERATION

B-7

Wire Loading of 13-14lb (6kg) Innershield
Coils

The K378 small mounting stand for the 14 pound (6
Kg) Innershield coil does not have an adjustable
brake. It has a fixed drag built into the reel spindle.

To load a 14 pound coil:

1) Remove the snap-on lid from the plastic canister.

2) Remove the center clamping nut and the cover
plate from the wire reel.

3) Unpack the 14 lb. (6 kg) coil of wire. Be sure not
to bend the side tangs of the coil liner and straight­en any tangs that may have been bent.

4) Remove the start end of the coil from its holding
slot in the coil liner, cut off the bent end, straighten
the first six inches, and cut off the first inch.
Thread it through the canister wire feed liner until
about four inches of electrode are exposed.

5) Place the coil onto the disc support.

6) Replace the front reel cover and center clamping
nut, keep the reel from turning and tighten the
clamping nut securely.

7) Thread the exposed end of the electrode into the
wire feeder until it touches the drive rolls. Press
the Cold Inch key or the gun trigger and feed the
electrode through the system.

NOTE: If the electrode is not properly straightened, it

may not feed or may not go into the outgoing
tube causing a "birdnest".

WARNING

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

___________________________________________

Idle Roll Pressure Setting

The idle roll pressure is set at the factory, backed out
three turns from full pressure on 4-roll feeders. This is
an approximate setting. For small wire sizes and
aluminum wire up to 9 or 10 turns out may be required
to minimize “birdnesting”. The optimum idle roll pres­sure varies with type of wire, surface condition, lubri­cation, and hardness. The optimum idle roll setting
can be determined as follows:

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

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

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

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

Gas Guard Regulator Setting

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

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

SYNERGIC 7 & 7H

B-8

OPERATION

Making a Weld

1) Use only Power Wave model “synergic” power
sources.

2) Properly connect the electrode and work leads for
the correct electrode polarity.

B-8

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

13) If necessary to optimize arc starting, adjust wire

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

3) Use Mode Selection key to set desired operating
mode. (Refer to Mode Selection section.)

4) Use Function Select and Arrow keys to set desired
Run-in and encoder knob to set Weld Feed Speed.
(Set for each procedure if using a Dual Procedure
function). (See the appropriate sections for adjust­ing procedures).

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

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

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

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

WARNING

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

____________________________________

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

10) Position electrode over joint. End of electrode

may be lightly touching the work.

11) Lower welding helmet, close gun trigger and start

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

Wire Reel Changing

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

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

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

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

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

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

Wire Feed Overload Protection

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

SYNERGIC 7 & 7H

B-9

OPERATION

B-9

Grounding Lead Protector

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

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

Explanation of Prompting and
Error Messages

Display Prompt or Error

HI Indicates arc voltage is above 80V DC.

--- Indicates selected Run-In speed will be the

same as the weld speed. To enter a different
Run-In speed simply press the increase arrow
key with Run-In selected.

HXX Indicates wire feed overload. XX indicates

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

EP Indicates problem in EPROM assembly. See

Troubleshooting Guide Problem 24.

uP Indicates problem in microprocessor RAM.

See Troubleshooting Guide Problem 24.

EXX Indicates various system problems. XX will

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

Er EEPROM error. Usually occurs at power-up.

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

GLP Indicates that the Grounding Lead Protector

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

SYNERGIC 7 & 7H

C-1

ACCESSORIES

C-1

OPTIONAL FEATURES

DRIVE ROLL AND GUIDE TUBE KITS:

Steel Wire Sizes: 4-Roll

* .068 - 3/32” (1.7 - 2.4mm) Cored KP655-3/32
* 1/16” (1.6mm) Cored or Solid KP655-1/16

.045 - .052” (1.2 - 1.4mm) Solid KP655-052S
.045 - .052” (1.2 - 1.4mm) Cored KP655-052C
.035” (0.9-1.0mm) Cored KP655-035C
.035” (0.9-1.0mm) Solid KP655-035S
.030” (0.8mm) Solid KP655-030S
.023” (0.6mm) Solid KP655-025S

Aluminum Wire Sizes:

1/16” (1.6mm) KP656-1/16A

KP647-1/16A**

3/64” (1.2mm) KP656-3/64A

KP647-3/64A**
.040” (1.0mm) KP647-040A**
.035” (0.9mm) KP656-035A

Drive rolls for only cored electrode sizes are stencilled
with a “C” suffix to the wire sizes.

Drive rolls for only solid electrode sizes are stencilled
with an “S” suffix to the wire sizes.

Drive rolls for aluminum wire sizes are stencilled with an
“A” suffix to the wire sizes.

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

K648 - (Used with Power Wave 450) Consists of an 8­conductor control cable with a 14-pin plug and a 4/0
(107 mm
at 500 amps, 60% duty cycle and is available in lengths
of 7 ft (2 m), 17 ft (5 m), 25 ft (7.6 m), 33 ft (10 m) and
50 ft (15 m).

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

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 8­conductor control cable with a 14-pin plug and 2/0 (67
mm2) electrode cable with Twist-Mate™ connector. It
is rated at 350 amps, 60% duty cycle and is available in
lengths of 7 ft. (2 m), 17 ft. (5 m), 33 ft. (10 m), and 50
ft. (15 m).

2

) electrode cable with stud terminal. It is rated

* Not for Synergic 7H model.

** For use with Binzel European guns. Installation

instructions are included with these kits.

INPUT CABLE ASSEMBLIES:

K649 - (Used with Power Wave 450/500) Consists of an

8-conductor control cable with a 14-pin control cable plug
and a 4/0 (107mm2) electrode cable with Twist-Mate™
connector. It is rated at 500 amps, 60% duty cycle and is
available in lengths of 7 ft (2 m), 17 ft (5 m), 25 ft (7.6 m),
33 ft (10 m) and 50 ft (15 m).

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),

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, with
out electrode cable, and is available in lengths of 7 ft (2
m), 17 ft (5 m), 25 ft (7.6 m), 33 ft (10 m) and 50 ft (15
m).

K643 (Control Cable Extension) - Consists of an 8
conductor control cable with 14-pin connectors on
each end for extending the control cable between the
power source and the control cables. Available in
lengths of 17 ft (5 m), 25 ft (8 m), 33 ft (10 m) and 50 ft
(15 m).

-

SYNERGIC 7 & 7H

C-2

ACCESSORIES

C-2

WIRE REEL ASSEMBLY:

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

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

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

K376 - Same as K303 above but without dust shield.
A dust shield that covers the wire reel and protects the
wire from falling dirt and dust is available for this unit.
Order part number S14543. This unit will also accept
the M11515 door kit (see K303 above) but only if
already equipped with optional dust shield (S14543).

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

READI-REEL ADAPTERS:

K363P - Adapts Lincoln Readi-Reel coils of electrode

30 lb (14 kg) and 22 lb (10 kg) to a 2” (51mm) spindle.
Durable molded plastic one piece construction.
Designed for easy loading; adapter remains on spin­dle for quick changeover. (used with K162H)

K438 - Adapts Lincoln Readi-Reel coils of electrode
50-60 lb (22.7-27.2 kg) to a 2” (51mm) spindle. (used
with K162H).

SPINDLE ADAPTERS:

K162H - Spindle for mounting Readi-Reels and 2”

(51mm) I.D. spools with 60 lb (27.2 kg) capacity. The
shaft for the standard wire coils is removed from the
mounting frame-work and the K162H is installed in its
place. Includes an easily adjustable friction brake for
control of overrun.

When used with Readi-Reels a Readi-Reel adapter is
required.

K435 - Permits 14 lb (6 kg) Innershield coils to be
mounted on 2” (51mm) O.D. spindles. For use with
optional K162H adapter.

K468 - Permits 8” (203mm) O.D. spools to be mount­ed on 2” (51mm) O.D. spindles. For use with optional
K162H adapter.

GUN AND CABLE ASSEMBLIES:

K378 - Small mounting stand for 13-14 lb. (6 kg)

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

K445 - 50-60 lb. (22.7-27.2 kg) Readi-Reel mounting
stand. This assembly includes framework to which is
attached a 2" (51 mm) O.D. spindle with adjustable
brake and 50-60 lb. (22.7-27.2 kg) (K438) Readi-Reel
adapter. Includes a lift bail and cable clamp for fas­tening the input cable assembly. Does not include a
dust shield. A dust shield that covers the wire reel
and protects the wire from falling dirt and dust is avail­able for this unit. Order part number S14543. This
unit will also accept the M11515 door kit (see K303
above) but only if already equipped with optional dust
shield (S14543).

SYNERGIC 7 & 7H

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

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

K498 - Magnum 200 FM GMAW gun and cable
assemblies are rated for 200 amps, 60% duty cycle.
(Consult sales specifications for appropriate models).

K534 - Magnum 250L FM GMAW gun and cable
assemblies are rated for 250 amps, 30% duty cycle.
(Consult sales specifications for appropriate models).

K478 - Magnum 300 FM GMAW gun and cable
assemblies are rated for 300 amps, 60% duty cycle.
(Consult sales specifications for appropriate models).

2

). (Consult sales specifi-

C-3

K479 - Magnum 400 FM GMAW gun and cable

assemblies are rated for 400 amps, 60% duty cycle.
(Consult sales specifications for appropriate models).

K556 * - GMAW process Magnum 400XA X-TRAC­TOR gun and cable assemblies are rated at 400
amps, 60% duty cycle. (Consult sales specifications
for appropriate models).

K566 * - GMAW process Magnum 250XA X-TRAC­TOR gun and cable assemblies are rated 250 amps,
60% duty cycle. (Consult sales specifications for
appropriate models).

* K179 type vacuum unit not recommended for

use with Synergic 7.

ACCESSORIES

MISC. OPTIONS:

K659-1 (Gas Guard Regulator) - Adjustable flow regu-

lator with removable adjustor key for CO2 and Argon
blend gases. Mounts onto wire drive gas inlet, and
reduces gas waste and arc start "blow" by reducing
surge caused by excess pressure in supply hose.

C-3

K1449-1 (Dual Procedure Remote Control) - Includes

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

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

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

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

SYNERGIC 7 & 7H

D-1

MAINTENANCE

Safety Precautions

WARNING

MAINTENANCE

Wire Reel Mounting - 50 (22.7kg) and
60lb (27.2kg) Coils

To prolong the life of the reel shaft, periodically coat it

ith a thin layer of grease.

w

D-1

ELECTRIC SHOCK can kill.

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

•

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

• Turn OFF input power at welding power
source before installation or changing
drive roll and/or guide tubes.

• Welding power source must be connected
to system ground per the National
Electrical Code or any applicable local
codes.

• Only qualified personnel should
perform this installation.

Observe all additional Safety Guidelines detailed
throughout this manual.

Routine Maintenance

Drive Rolls and Guide Tubes

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

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

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

No maintenance of the two-position adjustable brake
is needed. If the brake shoe wears through to the
metal, replace the brake assembly.

Wire Reel Mounting - Readi-Reels and
10 through 30lb (4.5-14kg) Spools

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

Avoiding Wire Feeding Problems

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

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

b) Keep the electrode cable as straight as possible

when welding or loading electrode through cable.

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

cables.

d) Keep cable clean by following maintenance

instructions.

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

electrodes have proper surface lubrication.

f) Replace contact tip when the arc starts to become

unstable or the contact tip end is fused or
deformed.

g) Do not use excessive wire spindle brake settings.

Periodic Maintenance

Wire Drive Motor and Gearbox

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

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

Gun and Cable Maintenance

See appropriate Operatorʼs Manual.

SYNERGIC 7 & 7H

E-1

TROUBLESHOOTING

TROUBLESHOOTING GUIDE

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.

E-1

WARNING

This Troubleshooting Guide is designed to be used by the machine Owner/Operator. Unauthorized repairs per­formed on this equipment may result in danger to the technician and machine operator and will invalidate your
factory warranty. For your safety, please observe all safety notes and precautions detailed in the Safety Section
of this manual to avoid electrical shock or danger while troubleshooting this equipment.

_________________________________________________________________________________________

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact your local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

SYNERGIC 7 & 7H

E-2

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

POSSIBLE AREAS OF

MISADJUSTMENTS(S)

E-2

RECOMMENDED

COURSE OF ACTION

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

a. Gun cable kinked and/or twisted.

b. Wire jammed in gun and cable.

c. Incorrect position of drive rolls with

grooves.

d. Drive rolls loose.

e. Gun cable dirty.

f. Worn drive roll.

g. Electrode rusty and/or dirty.

h. Worn nozzle or cable liner.

i.

Partially flashed or melted contact tip.

a. Inspect gun cable and replace if

necessary.

b. Remove wire from gun and cable

feed in new wire. Note any
obstructions in gun and cable.
Replace gun and cable if neces­sary.

c. See Wire Feed Drive Roll and

Guide Tubs Kits section for proper
installation of drive roll.

d. Remove, clean, install and tighten.

e. Clean cable or replace liner.

f. Replace.

g. Replace.

h. Replace.

i. Replace contact tip.

2. Variable or “hunting” arc.

j. Incorrect idle roll pressure.

k. Improper liner, tip or guide tube.

a. Wrong size, worn and/or melted

contact tip.

b. Worn work cable or poor work

connection.

c. Loose electrode connections.

d. Wrong polarity.

e. Problem with serial communica-

tions in control cable.

j. Set idle roll pressure per section

on Idle Roll Pressure Setting.

k. Install proper equipment.

a. Replace tip - remove any spatter on end of

tip.

b. Inspect - Repair or replace as necessary.

c. Be sure electrode lead is tight in wire feeder

contact block, gun nozzle and gun tip tight.

d. Check connection at output studs for polari-

ty required by welding process.

e. Make sure control cable connections are

tight. Check for consistent WFS. Make sure
parameters on Power Source display, such
as WFS, match those on wire feeder display,
if not, see Problem 14, otherwise try chang­ing Synergic 7 control board. If problem per­sists refer to Power Source trouble shooting
information.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

SYNERGIC 7 & 7H

E-3

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

POSSIBLE AREAS OF

MISADJUSTMENTS(S)

E-3

RECOMMENDED

COURSE OF ACTION

3. Poor arc striking with sticking or
“blast-offs”, weld porosity, narrow
and ropy looking bead, or elec­trode stubbing into plate while
welding.

4. Tip seizes in diffuser.

5. Unit shuts off while welding and
“HXX” appears on display.

a. Improper procedures or tech-

niques.

b. Improper gas shielding.

a. Tip overheating due to prolonged

or excessive high current and/or
duty cycle welding.

a. See Problem 1.

a. See “Gas Metal Arc Welding

Guide” (GS-100).

b. Clean gas nozzle. Make certain that gas

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

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

a. Do not exceed current and duty

cycle rating of gun.

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

a. Correct problems causing motor

overload.

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

b.

Defective wire feed motor or gearbox.

a. Defective wire feed motor or con-

trol PC board.

b. Replace.

a. Set Run-in speed to maximum.

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

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

SYNERGIC 7 & 7H

E-4

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

POSSIBLE AREAS OF

MISADJUSTMENTS(S)

E-4

RECOMMENDED

COURSE OF ACTION

7. No control of wire feed.

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

a.

Problem with serial communications.

b. Defective wire feed motor tach or

control PC Board.

a. Faulty gun or gun trigger switch.

b. Defective control PC board or

gun connector.

a. If WFS and preset Volts/Trim parame-

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

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

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

a. Remove gun. Check continuity

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

b. Remove gun. Check voltage across

trigger sockets on gun connector.

If voltage > ± 11 VDC then gun is
defective.

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

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

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

SYNERGIC 7 & 7H

E-5

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

POSSIBLE AREAS OF

MISADJUSTMENTS(S)

E-5

RECOMMENDED

COURSE OF ACTION

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

a. Power source is defective.

b. Input cable is defective.

c. Wiring harness or Control PC

board is defective.

a. If arc voltage is present when wire feeder is

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

b. Disconnect input cable from power source and

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

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

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

10. Speed does not change when

weld current flows.

11. Voltmeter does not function or

read properly when arc voltage is
present.

a. Run-in and weld speeds are set

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

b. Power Source may be defective

or there may be a problem with
the Serial communications.

a. Electrode sensing lead or connec-

tions may be intermittent.

b. Serial communication problem.

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

tings.

b. Make sure that parameters on power source

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

a. Check continuity from brass block on wire

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

b. Make sure that parameters on power source

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

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

SYNERGIC 7 & 7H

E-6

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

POSSIBLE AREAS OF

MISADJUSTMENTS(S)

E-6

RECOMMENDED

COURSE OF ACTION

12. Arrow keys do not change Weld

speed or volts/trim.

13. WFS knob does not change

Run-in speed.

14. WFS and preset Volts/Trim para-

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

a. This is normal, as only the WFS and

volts/trim knobs will adjust these settings.

a. This is normal, as only the arrow

keys will adjust this setting.

a. Power source is defective.

b. Problem with serial communica-

tions in control cable.

c. Problem with wire feeder harness

or Control PCB.

a. Refer to operation section of this manual

a. Refer to operation section of this manual.

a. If parameters on power source and wire

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

b. Disconnect input cable from power source

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

c. Remove molex plug P1 from J1 on Control

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

15. Display does not change when

WFS and/or Volts/Trim knobs
are turned.

a. A remote control kit is connected.

b. Broken harness wire(s) or harness

disconnected from Encoder
board(s) or Control board.

c. Defective Encoder boards and/or

Control board.

a. When a remote control kit is connected to

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

b. Check for continuity between correspond-

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

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

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

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

SYNERGIC 7 & 7H

E-7

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

POSSIBLE AREAS OF

MISADJUSTMENTS(S)

E-7

RECOMMENDED

COURSE OF ACTION

16. Wire feeder's display does not

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

a. Loose connection to Remote con-

trol receptacle, J16.

b. Faulty Remote PC board.

c. Faulty remote cable.

d. Faulty remote wiring harness.

e. Faulty wire feeder harness or

remote cable receptacle.

f. Faulty Control board or Remote

PC board.

a. Make sure that remote cable connec-

tions are tight.

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

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

c. Remove remote cable from wire feed-

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

d. Remove plug from J1 on Remote PC

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

e. Remove plug from J2 on Control

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

f. Try replacing Remote PC board. If

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

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

SYNERGIC 7 & 7H

E-8

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

POSSIBLE AREAS OF

MISADJUSTMENTS(S)

E-8

RECOMMENDED

COURSE OF ACTION

17. Dual procedure is not functioning

when using the local dual proce­dure switch.

18. Optional gun dual procedure

switch is not functioning properly.

a. Optional gun dual procedure

switch or remote control kit may
be connected.

b. Serial communication problem.

c. Faulty local dual procedure switch,

wiring harness, or Control board.

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

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

b. Faulty remote control kit.

c. Serial communication problem.

d. Faulty optional gun dual proce-

dure switch.

e. Faulty wiring harness or optional

gun dual procedure amphenol.

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

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

b. Make sure that parameters on power source dis-

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

c. Disconnect harness plug from J2 on Control

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

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

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

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

this solves the problem, refer to Problem 19.

c. Make sure parameters on power source display,

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

d. Remove switch. Make sure there is continuity

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

e. Remove optional gun dual procedure switch and

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

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

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

replacing PC boards.)

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

SYNERGIC 7 & 7H

E-9

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

POSSIBLE AREAS OF

MISADJUSTMENTS(S)

E-9

RECOMMENDED

COURSE OF ACTION

19. Dual procedure switch of remote

control kit is not functioning prop­erly.

a. Local dual procedure switch is not

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

b. Faulty communication between

wire feeder and remote control kit.

c. Faulty dual procedure switch,

wiring harness, or PC board in
remote control kit.

a. Local dual procedure switch should be

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

b. If knobs on remote control kit are not

operating properly, refer to Problem

16.

c. Disconnect harness plug from Remote

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

20. Purge key does not turn on sole-

noid but trigger closure does.

21. Cold Feed key does not turn on

wire feed motor but trigger clo­sure does.

22. Display and/or indicator lights do

not change when the arrow or
select keys are pressed.

a. Defective keypad or Display PC

board is defective.

a. Defective keypad or Display PC

board is defective.

a. Defective keypad or Display PC

board.

a. Check continuity between sockets 5

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

a. Check continuity between sockets 4

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

a. Ring out keypad. Replace if defec-

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

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

SYNERGIC 7 & 7H

E-10

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

POSSIBLE AREAS OF

MISADJUSTMENTS(S)

E-10

RECOMMENDED

COURSE OF ACTION

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

b. Feeder supply fuse or circuit

breaker at power source is blown
or tripped.

c. Display or Control PC board is

bad

a. Turn ON power source.

b. Check input cable and feeder unit for

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

c. Observe LED mounted on Control PC

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

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

SYNERGIC 7 & 7H

E-11

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

24. Display shows any of the following:

TROUBLESHOOTING

POSSIBLE AREAS OF

MISADJUSTMENTS(S)

E-11

RECOMMENDED

COURSE OF ACTION

HI

---

HXX

Er

EXX

EP

a. Voltmeter function is selected and arc

voltage is > 80 VDC.

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

abled.

a. See Problem 5 or see Section on

Safety Precautions.

a. EEPROM error.

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

System error.

a. EPROM checksum error.

a. Normal operation. Voltmeter only reads 0-

80 VDC.

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

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

a. XX indicates time in seconds before unit

will automatically reset.

a. Parameter recalled at power-up was out of

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

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

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

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

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

uP

GLP

a. Microprocessor RAM error.

a. Grounding Lead Protector circuit is

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

b. Faulty GLP reed switch, harness, or

Control PCB.

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

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

a. To return to normal operating mode,

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

b. Replace GLP reed switch CR1 if it is

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

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

SYNERGIC 7 & 7H

E-12

TROUBLESHOOTING

Procedure for Replacing PC Boards

WARNING

ELECTRIC SHOCK can kill.

• Have a qualified individual install and
service this equipment.

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

• Do not touch electrically hot parts.

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

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

damage to any of

E-12

a. If there is no

install a new one and see if this remedies the prob­lem. If the problem is remedied, reinstall the old
PC board to see if the problem still exists. If it
does no longer exist with old PC board:

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

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

b. If PC board is visibly damaged electrically

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

1. Frayed or pinched lead insulation.

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

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

visible damage to the PC board,

, before

4. Foreign matter or interference behind the PC
boards.

c. If PC board is visibly damaged mechanically,

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

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

SYNERGIC 7 & 7H

F-1

DIAGRAMS

F-1

519

500

553

552

551

554

521

512A

520

7865

4

3

2

1

PROCEDURE B

DURE A

PROCE

*

DISPLAY

*

J11

PROCEDURE SWITCH

LOCAL DUAL

FEG

B

P.C. BOARD

A

CD

500

500

505

1

2

ENCODER PC BOARD

7865

*
*

4

3

2

1

J10

517

500

505

516

8

5

6

4

7

3

J12**

VOLTS

1

2

3

J13**

ENCODER PC BOARD

527

526

5

6

4

GUN

8

7

ABC

WFS

B

KEYPAD

C

C

B

500

A

A

E

E

D

CABLE

CONTROL

J19

D

D

E

N.B.

E

G

*

2

1

J6

6

*

U

U

542

BRIDGE

W

B

553

551

500

554

512A

552

B

U

R

82R

81R

512B

519

520

527

526

505

500

500

519

520

517

516

521

W

2

4

500M

81

82

W

542

5

J5

234

1

8

76

*

5432

J4

1

*

43

2

J3

1

16

15

14

13

12
11

*

10
9

8

J2

7

6

4253

1

8

7

*

456

J1

23

1

R

500

+

-

AC AC

R

R.F. TOROID ASSEMBLY

J18

67

R.F. TOROID ASSEMBLY

W

B

B

U

U

P.M.

TACH

R

R

B

GAS

SOLENOID

N.A.

INPUT ELECTRODE CABLE

WIRING DIAGRAM SYNERGIC 7

J20

1

2

CASE

GROUNDING

STUD

P20

P20 J20

U

CR1

U

GLP

REED

SWITCH

MAGNETICALLY

COUPLED

F

R

A

(41)

F

(42)

D

L9972

REMOTE CONTROL

OPTIONAL DUAL PROCEDURE

82R

D

1

1

2

J8

*

G

L

W

*

L

*
*

W

P8

CONTROL P.C. BOARD

J16

82R

R.F. TOROID ASSEMBLY

B - BLACK

R - RED

LEAD COLOR CODING

ELECTRICAL SYMBOLS PER E1537.

J12

J13

1

E
NC

E
QU

G SE

8

J11

J10

PONENT SIDE OF P.C. BOARD)

IN NUMBERIN
P

(COM

**

3

2

4

R

67

81

82

GND

B

F

H

E

D

G

C

RECEPTACLE

INPUT CABLE

1

J5

12

UMBERING SEQUENCE

J3

1

J6

CAVITY N

*

COMPONENT SIDE OF P.C. BOARD)
(

OPTIONAL DUAL

PROCEDURE SWITCH

B

A

500

512B

81R

A

REMOTE CABLE

C

B

B

C

A

81R

512B

500

L

L

N.A. JUMPER FOR HIGH SPEED GEARBOX

N.B. TRIGGER LEADS OF WATER COOLED

MODELS CONNECT TO FAST-MATE GUN

W - WHITE

U - BLUE

PIN 1

NUMBERING SEQUENCE

CONNECTOR CAVITY

519

520

L

L

CONNECTOR.

P12

P13

)

P10

P11

R

ECTO
N
N

CO
F
O

E

1

2

D
I
S

P20P8J8

EAD
L

1

2
N
O
N
(

J20

J17

PIN 1

PIN 1

***

L

8

6

4

1

4
3

4

1

2

R.F. CHOKE

16

9

J2

8

5

J1

J4

SYNERGIC 7 & 7H

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

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

F-2

DIAGRAMS

INPUT CONNECTION DIAGRAM

F-2

A

S21041-1

service this machine.

Only qualified persons should install, use or

Power Source before connecting the wire feeder.

Turn OFF the power switch on the Welding

AND FUTURE DUTY CYCLE OF APPLICATION.

N.A. WELDING CABLE MUST BE SIZED FOR CURRENT

SHOCK

ELECTRIC

WARNING

CAN KILL

ON POWER SOURCE TO PROPER POLARITY.

POWER SOURCE AND SET-UP PROCEDURE

CHANGE POLARITY, TURN POWER "OFF",

REVERSE ELECTRODE AND WORK CABLES AT

N.B. DIAGRAM SHOWS ELECTRODE POSITIVE. TO

IN CABLE.

N.C. PINS NOT LISTED ARE NOT CONNECTED

PRESENT IN YOUR EQUIPMENT.

(SEE APPROPRIATE WIRING DIAGRAM)

ONLY AND EACH MAY OR MAY NOT BE

FUNCTIONS ARE LISTED FOR REFERENCE

B=42

C=2

K=42

A=41

D=4

I=41

G=81

E=GND

H=82

N=67

F=67

8-PIN BOX RECEPTACLE, FRONT VIEW

AND 8-SOCKET CABLE PLUG, REAR VIEW

M=81

B=GND

L=82

ELECTRODE CABLE

TO WORK

SYNERGIC 7 & 7H

D=4

C=2

14-SOCKET BOX RECEPTACLE, FRONT VIEW

AND 14-PIN CABLE PLUG, REAR VIEW

8

PIN

14

POWER SOURCE TO WIRE FEEDER CABLE

PIN

PLUG

PLUG

PIN#

FUNCTION

LEAD

PIN#

C

E

GROUNDING LEAD

TRIGGER CIRCUIT

2

GND

C

B

H

DAB

TRIGGER CIRCUIT

4

D

G

-SERIAL COMM LOOP

42V AC

+SERIAL COMM LOOP

42V AC

41

42

81

82

I

L

K

M

F

ELECTRODE

67

N

F-3

DIAGRAMS

DIMENSION PRINT

F-3

9.42

11.60

.77

4.03

1-28-94

8.09

WIRE DRIVE & CONTROL BOX AS’BLY

DIMENSION PRINT

9.70

3/8-16 HEX. HD. SCREWS

FOR MTG. CONTROL BOX

TO WIRE REEL STAND

(3 PLACES)

1.28

TOLERANCE ~.12

.90

11.11

SYNERGIC 7 & 7H

NOTES

SYNERGIC 7 & 7H

LLIINNCCOOLLNN EELLEECCTTRRIICC SSEERRVVIICCEE MMAANNUUAALLSS

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For North America invoiced orders over $50.00 & credit card orders, if UPS is requested, it will be invoiced or charged to you at cost.
Outside U.S.A. Mainland order must be prepaid in U.S. Funds. Please add $2.00 per book for surface mail or $15.00 per book for air parcel post shipment.
METHOD OF PAYMENT: (Sorry, No C.O.D. Orders)

CHECK ONE:

Please Invoice (only if order is over $50.00)
Check or Money Order Enclosed, U.S. Funds only
Credit Card - Telephone: _______________________________________________

Account No.

USE THIS FORM TO ORDER:

BOOKS OR FREE INFORMATIVE CATALOGS Telephone: [phone] or, for fastest service, FAX this completed form to: 216-361-5901.

|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_| Exp Date |_|_| |_|_|

VISA

MasterCard

®

®

Order from: BOOK DIVISION, The Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199

Name: _______________________________________________

Address: _______________________________________________

_______________________________________________

Signature as it appears on Charge Card:

Month Year

______________________

Lincoln Welding School Titles: Price Code Quantity Cost

(ED-80)

Seminar Information Procedure Handbook “Twelfth Edition” $15.00 PH

(ED-45)

Educational Video Information Incentive Management $5.00 IM

(ED-93)

James F. Lincoln Arc Welding The American Century of John C. Lincoln $5.00 AC
Foundation Book Information Welding Preheat Calculator $3.00 WC-8

(JFLF-515)

New Lessons in Arc Welding $5.00 L

How to Read Shop Drawings $4.50 H

A New Approach to Industrial Economics $5.00 NA

Pipe Welding Charts $4.50 ED-89

SUB TOTAL

Additional Shipping Costs if any

TOTAL COST

WARNING

Spanish

AVISO DE

PRECAUCION

● Do not touch electrically live parts or

electrode with skin or wet clothing.

● Insulate yourself from work and

ground.

● No toque las partes o los electrodos

bajo carga con la piel o ropa moja­da.

● Aislese del trabajo y de la tierra.

● Keep flammable materials away.

● Mantenga el material combustible

fuera del área de trabajo.

● Wear eye, ear and body protection.

● Protéjase los ojos, los oídos y el

cuerpo.

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

● Ne laissez ni la peau ni des vête-

ments mouillés entrer en contact
avec des pièces sous tension.

● Isolez-vous du travail et de la terre.

● Berühren Sie keine stromführenden

Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!

● Isolieren Sie sich von den

Elektroden und dem Erdboden!

● Não toque partes elétricas e elec-

trodos com a pele ou roupa molha­da.

● Isole-se da peça e terra.

● Gardez à l’écart de tout matériel

inflammable.

● Entfernen Sie brennbarres Material!

● Mantenha inflamáveis bem guarda-

dos.

● Protégez vos yeux, vos oreilles et

votre corps.

● Tragen Sie Augen-, Ohren- und Kör-

perschutz!

● Use proteção para a vista, ouvido e

corpo.

READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.

SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.

LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.

LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER­STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

● Keep your head out of fumes.

● Use ventilation or exhaust to

remove fumes from breathing zone.

● Turn power off before servicing.

● Do not operate with panel open or

guards off.

WARNING

● Los humos fuera de la zona de res-

piración.

● Mantenga la cabeza fuera de los

humos. Utilice ventilación o
aspiración para gases.

● Gardez la tête à l’écart des fumées.

● Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zones
de travail.

● Vermeiden Sie das Einatmen von

Schweibrauch!

● Sorgen Sie für gute Be- und

Entlüftung des Arbeitsplatzes!

● Mantenha seu rosto da fumaça.

● Use ventilação e exhaustão para

remover fumo da zona respiratória.

● Desconectar el cable de ali-

mentación de poder de la máquina
antes de iniciar cualquier servicio.

● Débranchez le courant avant

l’entretien.

● Strom vor Wartungsarbeiten

abschalten! (Netzstrom völlig öff­nen; Maschine anhalten!)

● Não opere com as tampas removidas.

● Desligue a corrente antes de fazer

serviço.

● Não toque as partes elétricas nuas.

● No operar con panel abierto o

guardas quitadas.

● N’opérez pas avec les panneaux

ouverts ou avec les dispositifs de
protection enlevés.

● Anlage nie ohne Schutzgehäuse

oder Innenschutzverkleidung in
Betrieb setzen!

● Mantenha-se afastado das partes

moventes.

● Não opere com os paineis abertos

ou guardas removidas.

Spanish

AVISO DE

PRECAUCION

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.

P

ERFORMANCE

LUS

R

ROTECTION

P

P

R

3

YEAR

WARRANTY

PARTS &

LABOR

R

LIMITED WARRANTY

STATEMENT OF WARRANTY:

The Lincoln Electric Company (Lincoln) warrants to the
original purchaser (end-user) of new equipment that it will
be free of defects in workmanship and material.

This warranty is void if Lincoln finds that the equipment
has been subjected to improper care or abnormal opera­tion.

WARRANTY PERIOD:

All warranty periods date from the date of shipment to the
original purchaser and are as follows:

Three Years:

Transformer Welders
Motor-generator Welders
Inverter Welders
Automatic Wire Feeders
Semiautomatic Wire Feeders
Plasma-cutting Power Source
Engine Driven Welders (except engine and engine
accessories) with operating speed under 2,000 RPM

Two Years:

Engine Driven Welders (except engine, engine
accessories and Power-Arc generator/welders)

with operating speed over 2,000 RPM

warranty superseded

TO OBTAIN WARRANTY COVERAGE:

You are required to notify Lincoln Electric, your Lincoln
Distributor, Lincoln Service Center or Field Service Shop of
any defect within the warranty period. Written notification is
recommended.

WARRANTY REPAIR:

If Lincoln's inspection of the equipment confirms the exis­tence of a defect covered by this warranty, the defect will
be corrected by repair or replacement at Lincoln's option.

WARRANTY COSTS:

You must bear the cost of shipping the equipment to a
Lincoln Service Center or Field Service Shop as well as

see imws 1

return shipment to you from that location.

IMPORTANT WARRANTY LIMITATIONS:

• Lincoln will not accept responsibility for repairs made
without its authorization.

• Lincoln shall not be liable for consequential damages
(such as loss of business, etc.) caused by the defect or
reasonable delay in correcting the defect.

All engine and engine accessories are warranted by the
engine or engine accessory manufacturer and are not cov­ered by this warranty.

One Year:

Equipment not listed above such as gun and cable assem­blies, water coolers, FAS TRAK or MIG-TRAK equipment,
Power-Arc generator/welders, Wire Feed Module (Factory
Installed) and field-installed optional equipment.

World's Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors

• Sales and Service through Subsidiaries and Distributors Worldwide

22801 St. Clair Ave. Cleveland, Ohio 44117-1199 U.S.A. Tel. [phone]

• Lincoln's liability under this warranty shall not exceed
the cost of correcting the defect.

• This written warranty is the only express warranty
provided by Lincoln with respect to its products.
Warranties implied by law such as the Warranty of
Merchantability are limited to the duration of this
limited warranty for the equipment involved.

August, ʻ94