Lincoln Electric IM558 User Manual
IM558
R
RETURN TO MAIN MENU
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. (216) 481-8100
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
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