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IM539
October, 1999
Synergic 7F and Synergic 7FH
Semiautomatic Wire Feeders or Controls with code numbers 10189, 10190 & 10191
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.
OPERATOR’S MANUAL
• World's Leader in Welding and Cutting Products •
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Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
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7.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.
4.f. Sparks and spatter are thrown from the welding arc. Wear oil
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.
4.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.
---------------------------------------------------------------------------------------
7.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.
4.h. Also see item 7c.
7.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.
CYLINDER may explode
if damaged.
5.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.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.
5.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
7.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.
5.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.
5.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
7.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
5.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
5.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
ELECTRIC AND MAGNETIC FIELDS
5.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.
may be dangerous
8.a. Electric current flowing through any
conductor causes localized Electric and
Magnetic Fields (EMF). Welding current
creates EMF fields around welding cables
and welding machines.
FOR ELECTRICALLY
powered equipment.
8.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
6.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.c. Exposure to EMF fields in welding may have other health
effects which are now not known.
6.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.
8d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
8.d.1. Route the electrode and work cables together - Secure
them with tape when possible.
6.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
8.d.2. Never coil the electrode lead around your body.
8.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.
FOR ENGINE
powered equipment.
7.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
---------------------------------------------------------------------------------------
8.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
8.d.5. Do not work next to welding power source.
7.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.
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Mar. ‘93
– 3 –
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zones où l’on pique le laitier.
PRÉCAUTIONS DE SÛRETÉ
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
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:
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
8. S’assurer que la masse est connectée le plus prés possible de
la zone de travail qu’il est pratique de le faire. Si on place la
masse sur la charpente de la construction ou d’autres endroits
éloignés de la zone de travail, on augmente le risque de voir
passer le courant de soudage par les chaines de levage,
câbles de grue, ou autres circuits. Cela peut provoquer des
risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue ou
les vétements mouillés. Porter des gants secs et sans trous
pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble de
soudage et la machine à souder en bon et sûr état
defonctionnement.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le total
de la tension à vide des deux machines.
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.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie du
corps.
3. Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
a. Utiliser un bon masque avec un verre filtrant approprié ainsi
qu’un verre blanc afin de se protéger les yeux du
rayonnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la peau
de soudeur et des aides contre le rayonnement de l‘arc.
1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse,
pantalons sans revers, et chaussures montantes.
3. Avant de faires des travaux à l’interieur de poste, la debrancher
à l’interrupteur à la boite de fusibles.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
4. Garder tous les couvercles et dispositifs de sûreté à leur place.
-4-
Mar. ‘93
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TABLE OF CONTENTS
Page
GENERAL DESCRIPTION..................................................................................................7
RECOMMENDED PROCESSES AND EQUIPMENT .........................................................7
STANDARD FEATURES ....................................................................................................7
Wire Drive Features..........................................................................................................7
Control Features ...............................................................................................................8
KEYPAD AND DISPLAY DESCRIPTION...........................................................................9
OPTIONAL FEATURES ..................................................................................................10-11
Drive Roll and Guide Tube Kits........................................................................................10
Input Cable Assemblies ...................................................................................................10
Wire Reel Assemblies......................................................................................................10
Readi-Reel Adapters........................................................................................................11
Spindle Adapters..............................................................................................................11
Gun and Cable Assemblies .............................................................................................11
Miscellaneous Options.....................................................................................................11
SPECIFICATIONS..............................................................................................................12
INSTALLATION..................................................................................................................13
Installation of Synergic 7F Components ..........................................................................14
Wire Feed Drive Roll and Guide Tube Kits......................................................................14
PROCEDURE TO INSTALL DRIVE ROLL AND GUIDE TUBES......................................14
Standard 4-Roll Kits (KP571 and KP572)........................................................................14
Gun and Cable Assemblies...........................................................................................15-16
Synergic 7F Water Connections (For Water-Cooled Guns).............................................16
GMAW Shielding Gas with Gas Guard Regulator ...........................................................16
Electrical Installation ........................................................................................................17
Input Cable: Synergic 7F Wire Feeder to Invertec Synergic Type Power Sources ...17
Work Cable ......................................................................................................................17
OPTIONAL FEATURES INSTALLATION..........................................................................18
OPERATING INSTRUCTIONS........................................................................................19-26
Keypad Setup and Operation...........................................................................................19
Power-Down Save ......................................................................................................19
Operation Keys ...........................................................................................................19
Mode Selection ...........................................................................................................19
Display Control Keys...................................................................................................20
Timer/Crater Select.....................................................................................................21
Acceleration Selection .....................................................................................................21
Selection of English or Metric Speed Display Units.........................................................21
Run-In Selection ..............................................................................................................21
4-Step Trigger Mode Selection ........................................................................................22
Wire Reel Loading - Readi-Reels and Spools...............................................................22-24
Feeding Electrode and Brake Adjustment .......................................................................22
Adjustable Wire Reel Brake.............................................................................................23
Idle Roll Pressure Setting ................................................................................................24
Gas Guard Regulator Setting...........................................................................................24
Making a Weld .................................................................................................................25
Wire Reel Changing.........................................................................................................25
Wire Feed Overload Protection........................................................................................25
Explanation of Prompting and Error Messages ...............................................................26
MAINTENANCE .................................................................................................................27
Routine Maintenance.......................................................................................................27
Avoiding Wire Feeding Problems.....................................................................................27
Periodic Maintenance ......................................................................................................27
TROUBLESHOOTING GUIDE ........................................................................................28-35
Procedure for Replacing PC Boards................................................................................36
Gun Cable Connector Requirements to Permit Proper Connection to Wire Feed Unit ...36
WIRING DIAGRAM ............................................................................................................37
CONNECTION DIAGRAM..................................................................................................38
DIMENSION PRINTS.......................................................................................................39-40
PARTS MANUAL.......................................................................................................P-266 Series
– 5 –
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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!
Thank 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.
Code Number _____________________________________
Serial Number _____________________________________
Model Name _____________________________________
Date of Purchase __________________________________
Whenever you request replacement parts for or information on this equipment always supply the information you
have recorded above.
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.
– 6 –
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The Synergic 7FH wire feed unit has the following
wire feeding capabilities:
GENERAL DESCRIPTION
The Synergic 7F is a semiautomatic constant speed
wire feeder designed specifically for use with the
Power Wave™ type power sources. This boom or
fixture mounting wire feeder consists of a Synergic 7F
Control Box and the choice of the standard Synergic
7F of High Speed Synergic 7FH wire feed unit and
connecting cable assemblies. A serial communication
link is supplied through the input control cable of the
Synergic 7F enabling information to be shared
between the power source and wire feeder control.
The 4-Roll Synergic 7F wire feed units comes factory
equipped with gas solenoid valve with gas fittings and
standard Lincoln gun connector and connector for an
optional dual procedure gun switch. Control includes a
3-1/2 digit LED display with rotating knob encoder
controls for setting the wire feed speed and voltage. A
tactile-feel keypad provides selection of operating
mode, function selection, timer selection and crater fill
selection and parameter adjustment. Two keys
provide Cold Feed and Gas Purge functions.
a) Feeds .025 - .045” (0.6-1.2mm) solid wire for
gas-metal-arc processes.
b) Feeds .045 - (1.2mm) cored wire for Outershield
GMA or Innershield processes.
Recommended power sources are The Lincoln
Electric Company Synergic type Power Wave power
sources with 42V AC auxiliary power, and a 14-pin
connector receptacle.
STANDARD FEATURES
Wire Feed Features:
Wire Drive Unit - Incorporates low voltage permanent
magnet motor and highly efficient two-reduction spur
gearbox with insulated mounting bracket for mounting
and operation in any position. The non-fluid lubricant
won’t leak.
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.). In
addition, when 4-step trigger mode is selected, crater
fill WFS is also adjustable. 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.
“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.
Drive Rolls and Guide Tubes - Provide long life,
positive feeding and precise alignment of electrode.
Minimizes “birdnest” or mill-thru of wire if properly set.
(Ordered separately.)
The K678-1 Synergic 7F control may be used with
either of the two available 4-roll wire feed units.
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.
Ordering
Speed Range Wire Size Range
Information Model
Drive
IPM (m/m)
IN. (MM)
K679-1
K679-2
Synergic
7F
4-Roll
50 - 770
(1.25 - 19.5)
.025 - 3/32
(0.6 - 2.4)
Run-in Speed Setting - Allows the arc striking speed
“Run-in” to be adjusted independently of the weld feed
speed for starting optimization.
Synergic
7FH
4-Roll
80 - 1200
(2.00 - 30.5)
.025 - .045
(0.6 - 1.2)
The feeder to control cable assemblies are available in two types:
Cold Feed Speed - Provides cold feed speed adjustment
independent of weld, run-in and crater speed.
K680-”L” Includes a control cable with a 14-pin MS style connector on each end, and a 4/0 weld
cable. Available in lengths “L” of 16ft (4.9m) or 25ft (7.6m).
K681-”L” Same as above but does not include weld cable available in lengths “L” of 12ft (3.6m),
16ft (4.9m) or 25ft (7.6m).
Adjustable 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.
RECOMMENDED PROCESSES
AND EQUIPMENT
Solid-State Dynamic Braking - Quickly stops wire
feed motor to minimize wire overrun during weld
termination. Solid-state design requires no
maintenance.
The Synergic 7F 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).
– 7 –
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Crater Fill - Provides crater feed speed adjustment (in
4-step trigger mode) independent of weld, cold feed,
or run-in speeds.
Crater Fill - Allows setting of crater fill WFS (when 4-
step with crater fill trigger mode is selected),
independent of weld, cold feed, and run-in speeds.
Solid-State Overload Protection - No circuit breaker
to reset. Front panel display indicates time remaining
before automatic reset.
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.
Gas Solenoid Valve - Complete with inlet fittings for
easy installation of gas is standard on Synergic 7F
models. Also available as an option (K659-1) a Gas
Guard regulator for flow surge suppression.
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.
English/Metric Speed Display - Provides front panel
selection of speed display in units of IPM or M/M.
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.
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.
Control Features:
Microcomputer Based Control - Provides precise
setting and display of all parameters and precision
timing functions. Optimizes wire drive control for crisp
acceleration and smooth response with precise
repeatability. Allows synergic control of various
welding processes by communicating information over
a serial link to the compatible power source.
Display and Indicator Lights - Wide temperature
range, long life, 3-1/2 digit 7-segment LED display
with .56” (14.2mm) character height permits easy
viewing even from long gun cable distances.
Individual red indicator lights are high intensity LED’s
for viewing at almost any angle.
Encoder Controls - Rotating encoders provide
continuous knob control for setting both Wire Feed
Speed and Volts/Trim procedures.
Keypad - Consists of 7 membrane keys with tactile-
feel embossed domes. All keys are generously
spaced to provide easy selection, even if wearing
welding gloves.
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.
– 8 –
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Function Select key enables operator to
choose which function will be displayed as
shown by the appropriate indicator light.
Pressing the key causes lights to sequence
(top to bottom) starting from the current
indicated position. The function displayed will
be adjustable with the rotating encoders or
arrow keys.
K E Y P A D A N D D I S P L A Y
DESCRIPTION
VOLTS
TRIM
/
V
RUN-IN
WFS
Keypad - Seven key, membrane
type with “snap” tactile feel and
COLD FEED
GAS PURGE
embossed domes.
Long life
design. Spatter resistant surface.
Top Light - Indicates display of preset voltage
or percent trim when not welding and arc
voltage while welding (as indicated by top light
“blinking”). The power source automatically
determines whether preset voltage or percent
trim will be displayed, and adjustable with
Volts/Trim rotating encoder control.
VOLTS
TRIM
RUN-IN
WFS
/
V
Display - 3-1/2 digit 7-segment
LED with (+) or (-) polarity
indicators. .56” (14.2mm) character
height. Displays arc voltage in
volts, wire speed in IPM or m/m and
all timers in seconds.
TRIGGER MODE
PREFLOW
POSTFLOW
2
2-STEP
1
STD
4-STEP
LOCK
CRATER
SPOT
SPOT
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.
Indicator Lights - Extra bright red
LED’s for viewing at almost any
angle. Always indicates the mode
being used and which function or
timer is beiing ddiissppllaayyeedd.. A function
and a timer light will never be on at
the same time since they can only
be displayed one at a time.
Bottom Light - Indicates Weld Feed Speed
(WFS) is being displayed, and is adjustable
with the Wire Feed Speed rotating encoder
control.
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 Inch, and the
last speed selected is stored in
memory for next Cold feeding.
PREFLOW
POSTFLOW
Timer/Crater Select key enables operator to
choose spot or gas timers, or crater speed as
indicated by the appropriate light. Pressing the
key causes lights to sequence (left to right, top
to bottom) starting from the current indicated
selection. Any parameter not available in the
mode selected is skipped over.
2
1
CRATER
SPOT
Top Left Light - indicates preflow time is being
displayed in seconds.
Gas Purge key energizes the
solenoid valve but not the wire
feeder or power source.
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.
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.
2-STEP
STD
Bottom Light - indicates spot on time is being
displayed in seconds.
4-STEP
LOCK
SPOT
Top Light - Indicates 2-step
(standard) trigger mode.
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.
Middle Light - Indicates 4-step
(lock) trigger mode. This mode may
be selected to include crater fill or
weld current interlock.
Decrease arrow key decreases the setting of
the parameter selected to be displayed.
Arrow keys do not function for Wire Feed
Speed or Volts/Trim settings, which are
adjusted using the rotating encoder knobs.
Bottom Light - Indicates spot weld
mode.
– 9 –
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WIRE REEL ASSEMBLY:
OPTIONAL FEATURES
K299 - Wire reel assembly for customer mounting. Includes
50 - 60 lb wire reel spindle shaft, adjustable brake,
insulation and mounting hardware.
DRIVE ROLL AND GUIDE TUBE KITS:
Steel Wire Sizes:
4-Roll
* .068 - 3/32” (1.7 - 2.4mm) Cored
* 1/16” (1.6mm) Cored or Solid
.045 - .052” (1.2 - 1.4mm) Solid
.045 - .052” (1.2 - 1.4mm) Cored
.035” (0.9-1.0mm) Cored
.035” (0.9-1.0mm) Solid
KP655-3/32
KP655-1/16
KP655-052S
KP655-052C
KP655-035C
KP655-035S
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)
.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**
KP656-3/64A
KP647-3/64A**
KP647-040A**
KP656-035A
K438 - Adapts Lincoln Readi-Reel coils of electrode 50-60 lb
(22.7-27.2 kg) to a 2” (51mm) spindle. (used with K162H).
3/64” (1.2mm)
.040” (1.0mm)
.035” (0.9mm)
SPINDLE ADAPTERS:
Drive rolls for only cored electrode sizes are stencilled with a “C” suffix
to the wire sizes.
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.
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.
When used with Readi-Reels a Readi-Reel adapter is
required.
* Not for Synergic 7H model.
** For use with Binzel European guns. Installation instructions are
included with these kits.
K435 - Permits 14 lb (6 kg) Innershield coils to be mounted
on 2” (51mm) O.D. spindles. For use with optional K162H
adapter.
INPUT CABLE ASSEMBLIES:
K649 - (Used with Power Wave 450/500) Consists of an 8-
conductor control cable with 14-pin control cable plug and a
K468 - Permits 8” (203mm) O.D. spools to be mounted on
2” (51mm) O.D. spindles. For use with optional K162H
adapter.
2
4/0 (107 mm ) 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).
GUN AND CABLE ASSEMBLIES:
K648 - (Used with Power Wave 450) Consists of an 8-
conductor control cable with a 14-pin plug and a 4/0 (107
mm2) electrode cable with stud terminal. It is rated at 500
amps, 60% duty cycle and is available in lengths of 7 ft (2
m), 17 ft (5 m), 25 ft (7.6 m), 33 ft (10 m) and 50 ft (15 m).
The following Lincoln gun and cable assemblies are
compatible with both the Synergic 7F and Synergic 7FH
Wire Feed units:
K126 - Innershield® gun and cable assemblies are rated at
350 amps, 60% duty cycle. Maximum wire size for Synergic
7F models is 5/64” (2.0 mm). Not recommended for
Synergic 7FH models. (Consult sales specifications for
appropriate models).
K651 - (Used with Power Wave 350) Consists of an 8-
conductor control cable with 14-pin control cable plug and a
2
2/0 (67 mm ) 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).
K115 - Innershield gun and cable assemblies are rated at
450 amps, 60% duty cycle. Maximum wire size for Synergic
7F models is 5/64” (2.0 mm). Not recommended for
Synergic 7FH models. (Consult sales specifications for
appropriate models).
K642 - (Control Cable only) Consists of an 8-conductor
control cable with 14-pin control cable plug, without
electrode cable, and is available in lengths of 7 ft (2 m), 17 ft
(5 m), 25 ft (7.6 m), 33 ft (10 m) and 50 ft (15 m).
K470 - Magnum 300 GMAW gun and cable assemblies are
rated for 300 amps, 60% duty cycle. (Consult sales
specifications for appropriate models).
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 cable. Available in lengths of 17 ft (5m), 25 ft
(7.6m), 33 ft (10m), and 50 ft (15m).
K471 - Magnum 400 GMAW gun and cable assemblies are
rated for 400 amps, 60% duty cycle. (Consult sales
specifications for appropriate models).
K497 - Magnum 200 GMAW gun and cable assemblies are
rated 200 amps, 60% duty cycle. (Consult sales
specifications for appropriate models).
– 10 –
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K541 - Magnum 400 Short Neck GMAW gun and cable
assemblies are rated 400 amps, 60% duty cycle. (Consult
sales specifications for appropriate models).
MISCELLANEOUS OPTIONS:
K682 Water Connection Kit - Includes water cooled gun
tube fittings and self-sealing outlet and inlet quick-
connectors for mounting onto the Synergic 7F Wire Drive
mounting bracket.
K598 - Magnum 550 GMAW gun and cable assemblies are
rated 550 amps, 60% duty cycle. (Consult sales
specifications for appropriate models).
K659-1 - (Gas Guard Regulator) Adjustable flow regulator
K206* - Innershield Linconditioner gun and cable
assemblies are rated 350 amps, 60% duty cycle. Maximum
size for Synergic 7F Wire Feed unit is 5/64” (2.0 mm). Not
recommended for Synergic 7FH Wire Feed unit. (Consult
sales specifications for appropriate models).
2
with removable adjustor key for CO 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.
K683-1 - (Dual Procedure Switch) Kit includes gun switch
and mountings for Lincoln Innershield and Magnum guns
with 15 ft (4.6 m) control cable and 3-pin plug.
K289* - Innershield Linconditioner gun and cable
assemblies are rated 500 amps, 60% duty cycle. Maximum
size for Synergic 7F Wire Feed unit is 5/64” (2.0 mm). Not
recommended for Synergic 7FH Wire Feed unit. (Consult
sales specifications for appropriate models).
K309* - Innershield Linconditioner gun and cable
assemblies are rated 250 amps, 60% duty cycle. Maximum
size for Synergic 7F Wire Feed unit is 5/64” (2.0 mm). Not
recommended for Synergic 7FH Wire Feed unit. (Consult
sales specifications for appropriate models).
The following Lincoln gun and cable assemblies are
equipped with a Fast-Mate™ connector. They can be
used with Synergic 7F Wire Feed unit by installing a
K489-2 Fast-Mate adapter kit.
K684 - Magnum “Super Cool” FM water cooled
GMAW gun and cable assemblies are rated 450
2
amps, 100% duty cycle (CO ). (Consult sales
specifications for appropriate models).
K498 - Magnum 200 FM GMAW gun and cable
assemblies are rated for 200 amps, 60% duty cycle.
(Consult sales specifications for appropriate models).
K534 - Magnum 250L FM GMAW gun and cable
assemblies are rated for 250 amps, 30% duty cycle.
(Consult sales specifications for appropriate models).
K478 - Magnum 300 FM GMAW gun and cable
assemblies are rated for 300 amps, 60% duty cycle.
(Consult sales specifications for appropriate models).
K479 - Magnum 400 FM GMAW gun and cable
assemblies are rated for 400 amps, 60% duty cycle.
(Consult sales specifications for appropriate models).
K556 * - GMAW process Magnum 400XA X-
TRACTOR gun and cable assemblies are rated at 400
amps, 60% duty cycle. (Consult sales specifications
for appropriate models).
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 7F.
– 11 –
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SPECIFICATIONS FOR SYNERGIC 7F
AND SYNERGIC 7FH
WIRE FEED - (4 - ROLL)
CONTROL
Model
Type
SYNERGIC 7F
SYNERGIC 7F
SYNERGIC 7FH
K678-1
K679-1
K679-2
Wire Speed Range:
IPM
M/M
50 - 770
1.25 - 19.5
80 - 1200
2.00 - 30.5
Wire Size Capabilities:
Solid Electrodes
.025 - 1/16”
0.6 - 1.6mm
.025 - 1/16”
0.6 - 1.6mm
.025 - .045”
0.6 - 1.2mm
Cored Electrodes
Input Power:
.045 - 3/32”
1.2 - 2.4mm
.045 - 3/32”
1.2 - 2.4mm
.045”
1.2mm
40-42 V 10%
50/60 Hz
4.0 Amps
Temperature Rating:
Operating
-20°C to +40°C
-40°C to +40°C
Storage
Dimensions:
Height
11.25” (285.8 mm)
7.16” (181.9 mm)
8.06” (204.7 mm)
13.31” (338.1 mm)
10.32” (262.1 mm)
6.16” (156.5 mm)
Width
Depth
Weight
16.5 lbs (7.5 Kg)
13.25 lbs (6.0 Kg)
– 12 –
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b) Open the control box door by removing the two
INSTALLATION
door screws.
c) Mount the box.
d) Tighten the screws.
Safety Precautions
e) Close the control box door and replace the door
screws.
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts such
as output terminals or internal wiring.
Connecting Wire Feed Unit to Control Box
The Feeder to Control cable assemblies are available
in two types:
• When inching with gun trigger, electrode
and drive mechanism are “hot” to work
and ground.
K680-”L” Includes a control cable with 14-pin MS-
style connectors on each end, and a 4/0
weld cable to route between the Wire
Drive and the Control Box. Available in
lengths “L” of 16ft. (4.9m) and 25ft.
(7.6m).
K681-”L” Same as K680, but does not include
weld cable. Available in lengths “L” of
12ft. (3.6m), 16ft. (4.9m) and 25ft.
(7.6m).
• Turn OFF welding power source before
installing 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.
1. Making certain the cables are protected from any
sharp corners which may damage their jackets,
mount the cable assembly along the boom so the
end with the female MS-style connector pins is at
the wire feed unit.
Observe all additional Safety Guidelines detailed
throughout this manual.
INSTALLATION OF THE SYNERGIC 7F COMPONENTS
Mounting the Wire Feed Unit (K679-1 or -2)
2. Connect the 14-socket cable connector to the
receptacle on the back of the wire feed unit
connection box.
Mount the wire feed unit by means of the insulated
mounting bracket attached to the bottom of the
gearbox. Reference L9777 dimension print at the rear
of this manual to find the size and location of the
mounting holes. The gearbox assembly is electrically
“hot” when the gun trigger is pressed. Therefore,
make certain the gearbox does not come in contact
with the structure on which the unit is mounted.
3. At the same end, connect the electrode lead to the
connection stud of the brass gun connection block
on the front of the wire feed unit.
4. At the control box end, connect the 14-pin
connector of the cable to the mating receptacle on
the bottom of the control box.
The wire feed unit should be mounted so that the
drive rolls are in a vertical plane so dirt will not collect
in the drive roll area. Position the mechanism so it will
point down at about a 45° angle so the wire feed gun
cable will not be bent sharply as it comes from the
unit.
Electrode Routing
The electrode supply may be either from reels, Readi-
Reels, spools or bulk packaged drums or reels.
Observe the following precautions:
1. The electrode must be routed to the wire feed unit
so that the bends in the wire are at a minimum,
and also that the force required to pull the wire
from the reel into the wire feed unit is kept at a
minimum.
Mounting the Control Box (K678-1)
The same control box is used for both the Synergic 7F
and Synergic 7FH wire feed units and contains two
keyhole slots and one slot for mounting. Reference
M17740 dimension print in the rear of this manual for
size and location of these slots. Mount the box at
some convenient location close to the wire feed unit
which will enable the desired control cable assembly
to reach between the control box and the wire feed
unit.
2. The electrode is “hot” when the gun is energized
and must be insulated from the boom and
structure.
3. If more than one wire feed unit shares the same
boom, their wire and reels must be insulated from
each other and insulated from their mounting
structure.
a) Drill the required holes in the mounting surface,
partially install 1/4-20 screws.
– 13 –
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Wire Feed Drive Roll and Guide Tube Kits
PROCEDURE TO INSTALL DRIVE
ROLL AND GUIDE TUBES
NOTE: The maximum sizes the Synergic 7F will feed
satisfactorily are the 3/32” (2.4mm) cored and
WARNING
1/16” (1.6mm) solid electrodes.
The
maximum sizes the synergic 7FH will feed
satisfactorily are the .045 (1.2mm) cored and
.045” (1.2mm) solid electrodes.
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.
The electrode sizes that can be fed with each
roll and guide tube are stencilled on each part.
Check the kit for proper components.
• Turn OFF welding power source before
installing 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.
Steel Wire Sizes:
4-Roll
* .068 - 3/32” (1.7 - 2.4mm) Cored
* 1/16” (1.6mm) Cored or Solid
.045 - .052” (1.2 - 1.4mm) Solid
.045 - .052” (1.2 - 1.4mm) Cored
.035” (0.9-1.0mm) Cored
.035” (0.9-1.0mm) Solid
KP655-3/32
KP655-1/16
KP655-052S
KP655-052C
KP655-035C
KP655-035S
KP655-030S
KP655-025S
• Only qualified personnel should
perform this installation.
Observe all additional Safety Guidelines detailed
throughout this manual.
.030” (0.8mm) Solid
.023” (0.6mm) Solid
Aluminum Wire Sizes:
1/16” (1.6mm)
Standard 4-Roll Kits (KP571 and KP572)
KP656-1/16A
KP647-1/16A**
KP656-3/64A
KP647-3/64A**
KP647-040A**
KP656-035A
1) Turn off welding power source.
3/64” (1.2mm)
2) Release both quick release levers by sliding the
levers sideways into the open positions.
.040” (1.0mm)
.035” (0.9mm)
3) Remove hex screw & clamping collar from the
drive shaft closest to the incoming side of the
feeder.
Drive rolls for only cored electrode sizes are stencilled
with a “C” suffix to the wire sizes.
4) Install drive roll onto keyed shaft. Double grooved
drive rolls are to be installed with side stencilled for
correct wire size facing out and with slotted spacer
on top of roll. Two piece drive rolls use a spacer
between the rolls for .068” (1.7mm) and larger wire
sizes. (Do not exceed the maximum wire size
rating of the wire drive.) Replace collar and
tighten clamping screw.
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.
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.
– 14 –
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8) Back out the screws for the incoming and outgoing
guide tubes.
Gun Cable Connection:
Lay the cable out straight. Insert the connector on the
welding conductor cable into the brass conductor
block on the front of the Synergic 7F gearbox. Make
sure it is all the way in and tighten the hand wheel.
Keep this connection clean and bright. Connect the
trigger control cable polarized plug into the mating 5
cavity receptacle on the front of the Synergic 7F Wire
Feed Unit.
9) Install the longer guide tube in the rear hole near
the incoming drive roll. Slide the tube in until it
almost touches the roll. Tighten in place.
10) Install the remaining guide tube in the front hole.
Be certain that the proper plastic insert is used.
Fine wire chisel point tube must have largest
radius next to drive roll. Tighten in place.
For GMA Gun Cables:
11) Re-latch both quick release levers.
Install the barbed fitting and union nut to the 5/8-18
female inert gas fitting on the front of the Synergic 7F
wire drive. Connect the 3/16” I.D. gas hose from the
gun cable to the barbed fitting. When the gun is to be
removed, this fitting can be easily detached by
loosening the union nut.
12) To start new electrode, straighten the first
6” (150mm) and cut off the first 1” (25mm). Insert
free end through the incoming tube. Press gun
trigger & push wire into the drive roll.
TO SET IDLE ROLL PRESSURE: See Idle Roll
Pressure Setting, in Operating Instructions section.
Gun and Cable Assemblies with Fast-
Mate Connections (Requires K489-2 Fast-Mate
Adapter Kit)
Gun and Cable Assemblies with Standard
L. E. Connections
GMAW Guns
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 “Super Cool” 450
ampere water cooled gun and cable. Gun cable
lengths range from 10 ft (3.0m) to 25 ft (7.6m) and
feed electrode sizes .025” (0.6mm) to 5/64” (2.0mm).
An expanding line of Magnum gun and cable
assemblies are available to allow welding with solid
and cored electrodes using the GMAW process. See
the appropriate Magnum literature for descriptions of
the 200 to 550 ampere air cooled gun and cables that
are available. Gun cable lengths range from 10 ft
(3.0m) to 25 ft (7.6m) and feed electrode sizes .025”
(0.6mm) to 5/64” (2.0mm). The entire line of Magnum
Fast-Mate gun and cable assemblies can also be
used by installing a K489-2 Fast-Mate adapter kit.
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
literature for descriptions of the 250 to 400 ampere air
cooled gun and cables that are available. Gun cable
lengths range from 10 ft (3.0m) to 15 ft (4.5m) and
feed electrode sizes .035” (0.9mm) to 1/16” (1.6mm).
These guns require the use of either the K173-1 or
K184# vacuum units.
INNERSHIELD Guns
K126 and K115 gun and cable assemblies are
available to allow welding with Innershield electrodes.
Gun cable lengths range from 10 ft. (3.0 m) to 15 ft.
(4.5 m). The 350 ampere K126 with Synergic 7F will
feed electrode sizes .062” (1.6 mm) to 5/64” (2.0 mm).
The 450 ampere K115 with Synergic 7F will feed
5/64” (2.0 mm) electrode.
Three smoke extraction gun and cable assemblies
are available, 250 ampere K309, 350 ampere K206
and the 500 ampere K289. All gun and cable lengths
are 15 ft. (4.5 m). Both the K206 and K309 with
Synergic 7F will feed electrode sizes .062” (1.6 mm)
to 5/64’ (2.0 mm). K289 with Synergic 7F will feed
5/64” (2.0 mm) electrode. These guns require the use
of the K184 vacuum unit for use with Synergic 7F.
#
Requires S14927-8 connector hose and an S20591
hose adapter.
– 15 –
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GMAW Shielding Gas
Gun Cable Connections: Wire Feeder
to Gun
WARNING
CYLINDER may explode if damaged.
• Keep cylinder upright and chained to
support.
• Keep cylinder away from areas where
it may be damaged.
a. Check that the drive rolls, feeder guide tubes and
gun connector guide tube are appropriate for the
electrode size being used. If necessary, change
them per section on Wire Feed Drive Roll and
Guide Tube Kits.
• Never lift welder with cylinder attached.
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.
• 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.
Synergic 7F Water Connections (for
Water-Cooled Guns)
The Synergic 7F models must have a K682-2 Water
Connection Kit installed. (see section under Electrical
Installation; Water Connection Kit.
SEE AMERICAN NATIONAL STANDARD Z-49.1,
“SAFETY IN WELDING AND CUTTING” PUBLISHED
BY THE AMERICAN WELDING SOCIETY.
------------------------------------------------------------------------
1) Using hose clamps provided with the K682-2 Kit,
connect appropriate water hoses to the coolant inlet
and outlet fittings on the back of the K682-2 Kit.
Connect the other ends of the hoses to the appropriate
ports on the water cooling units.
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 7F Wire Feed Unit.
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 K682-2 Kit, male quick connects are
provided with the kit for installation on 3/16” I.D. hose
(Customer to provide appropriate clamps). The feeder
connectors self seal when disconnected.
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 7F 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 7F. 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.
95 MAR
– 16 –
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With input power disconnected from the power
source, install the input cable per connection diagram
M17770 in the rear of this manual and follow exactly
the instructions on the diagram or perform the
following:
Electrical Installation
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts such
as output terminals or internal wiring.
1) Connect the end of the control cable with the 14-
pin cable plug to the mating receptacle on the
power source.
• When inching with gun trigger, electrode
and drive mechanism are “hot” to work
and ground.
2) Connect the electrode lead of that same cable end
to the power source output terminal of the desired
polarity.
• Turn OFF welding power source before
installing or changing drive roll and/or
guide tubes.
3) Connect the 14-socket plug of the control cable to
the mating receptacle on the bottom of the control
box.
• Welding power source must be connected
to system ground per the National
Electrical Code or any applicable local
codes.
4) If not using a single continuous electrode cable
from the Power Source to Wire Feed Unit, bolt the
electrode lead from the power source to the
electrode lead to the wire feed unit using the nut
and bolt supplied with the K680 Control to Feed
Unit cable assembly.
• Only qualified personnel should
perform this installation.
Observe all additional Safety Guidelines detailed
throughout this manual.
Input Cable: Synergic 7F Control to Power Wave
Synergic Type Power Sources
Work Cable
Connect a work lead of sufficient size and length (per
the following table) between the proper output
terminal on the power source and the work. Be sure
the connection to the work makes tight metal-to-metal
electrical contact.
K648 - (Used with Power Wave 450) Consists of an 8-
conductor control cable with a 14-pin plug and a 4/0 (107
mm2) electrode cable with stud terminal. It is rated at 500
amps, 60% duty cycle and is available in lengths of 7 ft (2
m), 17 ft (5 m), 25 ft (7.6 m), 33 ft (10 m) and 50 ft (15 m).
Current
60% Duty
Cycle
Copper Work Cable Size, AWG *
K649 - (Used with Power Wave 450/500) Consists of an 8-
conductor control cable with a 14-pin control cable plug and a
Up to 100 ft Length (30m)
2
4/0 (107mm ) electrode cable with Twist-Mate™ connector. It
00 (67 mm2)
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).
300 Amps
400 Amps
500 Amps
000 (85 mm2)
000 (85 mm2)
K642 (Control Cable Only) - Consists of an 8
conductor control cable with a 14-pin control cable
plug, without electrode cable, and is available in
lengths of 7 ft (2 m), 17 ft (5 m), 25 ft (7.6 m), 33 ft (10
m) and 50 ft (15 m).
* For pulse welding applications, the next larger cable
size is recommended.
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).
– 17 –
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OPTIONAL FEATURES
INSTALLATION
K648 or K649 Input Cable Assembly - See Electrical
Installation section for instructions.
K299 50-60 Lb. Wire Reel for Customer Mounting -
The K299 is available for use with the Synergic 7F
Wire Feed Models. The reel for 50 or 60 pound coils is
shipped with the needed mounting shaft, hardware,
and insulation. Shaft mounting hole requirements are
shown below:
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
7F Wire Feed Unit.
K682-2 Water Connection Kit - Install to either side
of Wire Feed Unit mounting bracket per instructions
shipped with kit.
K659-1 Gas Guard Regulator - Adjustable flow
2
regulator with removable adjustor key for CO and
Argon blend gases. Mounts onto Wire Feed Unit inlet
and reduces gas waste and arc start “blow” by reducing
surge caused by excess pressure in supply hose.( See
Shielding Gas Connections for instructions).
– 18 –
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Mode Selection
OPERATING INSTRUCTIONS
Safety Precautions
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 position.
2-STEP
STD
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts such
as output terminals or internal wiring.
4-STEP
LOCK
SPOT
• When inching with gun trigger, electrode
and drive mechanism are “hot” to work
and ground.
Top Light - Indicates 2-Step
(Standard) Trigger Mode.
• Turn OFF welding power source before
installing or changing drive roll and/or
guide tubes.
1. Trigger closure energizes the
solenoid valve, then the wire feeder
and the power source after Preflow
time (See Timer/ Crater Section).
• Welding power source must be connected
to system ground per the National
Electrical Code or any applicable local
codes.
2. Releasing the trigger turns off the
wire feeder and power source and
then the solenoid valve after
Postflow time.
• Only qualified personnel should
perform this installation.
Observe all additional Safety Guidelines detailed
throughout this manual.
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).
Duty Cycle
The Synergic 7F models are rated at 60% duty cycle
* for a maximum current of 600 amps.
The 4-step modes function as follows:
* Based on a 10 minute time period (6 minutes on, and 4 minutes off).
1. Trigger closure energizes the power
source and wirefeeder after the
preflow time.
KEYPAD SETUP AND OPERATION
Power-Down Save
Power to the Synergic 7F is supplied and controlled
2. Trigger release enables 4-step lock,
leaving the feeder and power source
from the power source.
The Synergic 7F
automatically senses the loss of power when the
power source is turned off.
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.
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.
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
continues welding without changing
the settings from step 2.
b) 4-step with crater fill continues
welding but changes to the crater
settings.
4. Releasing the trigger turns off
wirefeeder and power source and
then gas solenoid after postflow
time.
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
adjustable (with “Arrow keys”) only
while pressing the Cold Feed Key.
The last setting is held in memory
for next Cold Inch feeding.
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.
COLD FEED
Gas Purge key energizes the
solenoid valve but not the wire
feeder or power source.
GAS PURGE
– 19 –
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synergically set by the power source for
the process and weld Feed Speed being
used.
The power source automatically
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.
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.
VOLTS
TRIM
/
V
RUN-IN
WFS
Middle Light - Indicates Run-In
Speed 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 min. 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 Run-In speed).
Function Select key enables
operator to choose which function
will be displayed as indicated by the
appropriate light. Pressing the key
causes lights to sequence (top to
bottom) starting from the current
indicated position. If a timer or
crater speed is being displayed
when the Function Select key is
pressed, then the indicator light of
the last function selected before the
timer/crater key was chosen will
come on and become the starting
point for the sequencing.
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 as the weld speed
setting. You can reset a different Run-
In speed simply by pressing the up
arrow key.
The Run-In speed will also be the
same as 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.
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 terminated, will
continue to be displayed for 5
seconds after welding to permit
operator monitoring.
Bottom Light - Indicates Weld Feed
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 7F Control.
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
95 MAR
– 20 –
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Timer/Crater Select - key enables
operator to choose crater speed, spot
or gas timers as indicated by the
appropriate light. Pressing key causes
lights to sequence (left to right, top to
bottom) starting from the current
indicated position. Any parameter not
available in the mode selected is
skipped over. If a function is being
displayed when the Timer/Crater Select
key is pressed, then the light of the last
parameter selected before the function
was chosen will come on and become
the starting point for the sequencing.
Acceleration Selection
PREFLOW
POSTFLOW
2
1
Pressing both the Gas Purge key
and then function select key at the
same time causes the acceleration
setting to be displayed. The display
will indicate “A-X” where X will be
a number from 1 through 5 with 5
being the fastest acceleration. This
number can be adjusted using the
arrow keys. To exit this function,
press both these keys again or
press any other key except the
arrow keys.
CRATER
SPOT
GAS PURGE
VOLTS
TRIM
/
V
RUN-IN
WFS
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.
Selection of English or
Metric Speed Display Units
Pressing both the Gas Purge key
and then timer select key at the
same time causes the speed
display units to toggle between IPM
(no decimal point displayed) and
m/m (a decimal point displayed). If
the speed display units were IPM,
then they will change to m/m. If the
speed display units were m/m, then
they will change to IPM. If the
display is showing the volts/trim or
one of the timers when the keys are
pressed, the display will be
changed to weld speed to indicate
the selected speed display units.
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.
GAS PURGE
PREFLOW
POSTFLOW
2
1
CRATER
SPOT
Middle Light - indicates that crater feed
speed is being displayed. Crater speed
is only available when 4-step trigger
with crater fill is selected. It is activated
by Step 3 and deactivated by Step 4 of
the 4-step sequence. (See 4-step
trigger mode selection section).
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.
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.
Increase Arrow - key increases the
setting of the parameter selected to be
displayed, except Wire Feed Speed and
Volts/Trim which are controlled by the
encoder knobs.
GAS PURGE
COLD FEED
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.
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.
Arrow key adjustments 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.
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 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.
95 MAR
– 21 –
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4-Step
Selection
Trigger
Mode
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.
Pressing both the Gas Purge key
and then the Trigger mode select
key while the 4-step mode light is on
will toggle the 4-step trigger mode
between:
GAS PURGE
2-STEP
STD
___________________________________________
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.
4-STEP
LOCK
4-step with current interlock (as shipped)
and
4-step with crater fill.
SPOT
(See Mode Selection and Display
Control Keys sections).
To Mount 10 to 44 lb (4.5-20kg) Spool
(12”/300mm Diameter): (Requires installation
of 2” (51mm) spindle K162H Kit. For 8” (200mm)
spools, a K468 spindle adapter must be used.)
MOLDED ADAPTER
2" O.D. SPINDLE
RETAINING SPRING
1) Remove the locking collar on the 2” (51mm)
diameter spindle.
Brake Holding Pin
(Must engage hole
in adapter rib)
PIN
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.
GROOVES
Installation of K363-P Readi-Reel Adapter
READI-REEL
INSIDE CAGE WIRES
THREADED LOCKING COLLAR
3) Replace and tighten the locking collar.
Wire Reel Loading - Readi-Reels and
Spools (Using K162H Spindle Kit with 2”
(51mm) spindle)
Feeding Electrode and Brake Adjustment
1) Turn the Readi-Reel or spool until the free end of
the electrode is accessible.
TO MOUNT A 30 LB (14 KG) READI-REEL
PACKAGE USING THE MOLDED PLASTIC K363-P
TYPE ADAPTER:
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.
1) Make certain that the threaded locking collar is
tight and securely locks the adapter on the spindle
(see figure above).
___________________________________________
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”.)
2) Rotate the spindle and adapter so the retaining
spring is at the 12 o’clock position.
3) Position the Readi-Reel so that it will rotate in a
clockwise direction when feeding (wire is to be de-
reeled from bottom of the coil).
3) Insert the free end through the incoming guide
tube.
4) Set one of the Readi-Reel inside cage wires on the
slot in the retaining spring tab.
4) Press the Cold Inch key or the gun trigger and
push the electrode into the drive roll.
5) Lower the Readi-Reel to depress the retaining
spring and align the other inside cage wires with
the grooves in the molded adapter.
5) Feed the electrode through the gun.
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.
6) Slide cage all the way onto the adapter until the
retaining spring “pops up” fully.
– 22 –
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4) Tighten the cover as much as possible by hand.
Wire Reel Loading - 50-60lb (22.7-27.2kg)
Coils (K299 Wire Reel Mounting Kit)
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.
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.
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.
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.
___________________________________________
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.
To Mount a 50-60lb (22.7-27.2kg) Coil:
Feeding Electrode
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.
1) Turn the reel until the free end of the electrode is
accessible. While tightly holding the electrode, cut
off the bent end.
2) Lay the reel flat on the floor, loosen the spinner nut
and remove the cover plate.
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”.)
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).
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.
b) When loading .030-.045” (0.8-1.2mm)
electrode, be certain the coil is placed on the
reel so the spring loaded arms are at the center
of the slots in the cardboard coil liner. This
provides the positive compression of the coil
sides needed for 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.
– 23 –
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Idle Roll Pressure Setting
Wire Loading of 13-14lb (6kg) Innershield
Coils
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:
Requires use of K162H Spindle Kit and K435 14 Lb.
Coil Adapter.
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 (Optional
K659-1)
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.
– 24 –
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13) If necessary to optimize arc starting, adjust wire
speed acceleration, and/or Run-In speed. (See the
appropriate sections for adjusting procedures).
Making a Weld
1) Use only Power Wave model “synergic” power
sources.
Wire Reel Changing
2) Properly connect the electrode and work leads for
the correct electrode polarity.
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:
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
Speeds. (Set for each procedure if using optional
Dual Procedure Switch).
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.
5) Adjust the voltage or percent trim, if desired, (for
each procedure if using the optional Dual
Procedure Switch) 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.
2) Disconnect the gun cable from the gun connector
on the Synergic 7F 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.
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).
4) After the electrode has been removed, reconnect
the gun cable to the Synergic 7F.
Load a new reel of electrode per the instructions in
the Wire Reel Loading sections.
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.
Wire Feed Overload Protection
The Synergic 7F 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.)
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.
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.
– 25 –
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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 17.
EP
Indicates problem in EPROM assembly. See
Troubleshooting Guide Problem 17.
uP
Indicates problem in microprocessor RAM.
See Troubleshooting Guide Problem 17.
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 section on
Troubleshooting Guide Problem 17. 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.
– 26 –
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MAINTENANCE
Wire Reel Mounting - 50 (22.7kg) and
60lb (27.2kg) Coils
Safety Precautions
To prolong the life of the reel shaft, periodically coat it
with a thin layer of grease.
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts such
as output terminals or internal wiring.
No maintenance of the two-position adjustable brake
is needed. If the brake shoe wears through to the
metal, replace the brake assembly.
• When inching with gun trigger, electrode
and drive mechanism are “hot” to work
and ground.
Wire Reel Mounting - Readi-Reels and
10 through 30lb (4.5-14kg) Spools
• Turn OFF welding power source before
installing or changing drive roll and/or
guide tubes.
No routine maintenance required. Do not lubricate 2”
(51mm) spindle.
• Welding power source must be connected
to system ground per the National
Electrical Code or any applicable local
codes.
Avoiding Wire Feeding Problems
• Only qualified personnel should do
maintenance or troubleshooting work.
Wire feeding problems can be avoided by observing
the following gun handling procedures:
Observe all additional Safety Guidelines detailed
throughout this manual.
a) Do not kink or pull cable around sharp corners.
Routine Maintenance
b) Keep the electrode cable as straight as possible
when welding or loading electrode through cable.
Drive Rolls and Guide Tubes
c) Do not allow dolly wheels or trucks to run over
cables.
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.
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.
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.
g) Do not use excessive wire spindle brake settings.
Periodic Maintenance
Wire Drive Motor and Gearbox
See section on Wire Feed Drive Roll and Guide Tube
Kits for roll changing instructions.
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 Operator’s Manual.
– 27 –
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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.
• Turn OFF welding power source before
installing 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 do
maintenance or troubleshooting work.
Observe all additional Safety Guidelines detailed
throughout this manual.
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.
– 28 –
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PROBLEMS
WHAT TO DO
PROBLEM
POSSIBLE CAUSE
a. Inspect gun cable and replace if
necessary.
1. Rough wire feeding or wire not
feeding but drive rolls turning.
a. Gun cable kinked and/or twisted.
b. Remove wire from gun and cable
feed in new wire. Note any
obstructions in gun and cable.
Replace gun and cable if
necessary.
b. Wire jammed in gun and cable.
c. See Wire Feed Drive Roll and
Guide Tubs Kits section for
c. Incorrect position of drive rolls
with grooves.
proper installation of drive roll.
d. Remove, clean, install and
tighten.
d. Drive rolls loose.
e. Clean cable or replace liner.
f. Replace.
e. Gun cable dirty.
f. Worn drive roll.
g. Replace.
g. Electrode rusty and/or dirty.
h. Worn nozzle or cable liner.
h. Replace.
i. Replace contact tip.
i. Partially flashed or melted
contact tip.
j. Set idle roll pressure per section
on Idle Roll Pressure Setting.
j. Incorrect idle roll pressure.
k. Install proper equipment.
k. Improper liner, tip or guide tube.
a. Replace tip - remove any spatter
on end of tip.
2. Variable or “hunting” arc.
a. Wrong size, worn and/or melted
contact tip.
b. Inspect - Repair or replace as
necessary.
b. Worn work cable or poor work
connection.
c. Be sure electrode lead is tight in
wire feeder contact block, gun
nozzle and gun tip tight.
c. Loose electrode connections.
d. Check connection at output studs
for polarity required by welding
process.
d. Wrong polarity.
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
e. Problem with serial
communications in control cable.
display, if not, try changing Synergic 7F
control board. If problem persists refer to
Power Source trouble shooting information.
– 29 –
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PROBLEMS
WHAT TO DO
PROBLEM
POSSIBLE CAUSE
a. See “Gas Metal Arc Welding
Guide” (GS-100).
3. Poor arc striking with sticking or
“blast-offs”, weld porosity,
narrow and ropy looking bead,
or electrode stubbing into plate
while welding.
a. Improper procedures or
techniques.
b. Clean gas nozzle. Make certain
that gas diffuser is not empty or
turned off. Make certain gas flow
rate is proper.
b. Improper gas shielding.
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.
4. Tip seizes in diffuser.
a. Tip overheating due to prolonged
or excessive high current and/or
duty cycle welding.
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.
5. Unit shuts off while welding and
“HXX” appears on display.
a. See Problem 1.
b. Replace.
b. Defective wire feed motor or
gearbox.
a. Remove Wire Feed Unit to
Control Box Cable and Check A
to A and B to B for continuity. If
there is no continuity in either or
both cases, replace cable.
6. Drive roll does not turn although a. Defective Wire Feed Unit to
arc voltage is present and
solenoid is on.
Control box cable or harnessing.
Otherwise, check Harnessing
from A and B of MS connector on
control box to control board and
A and B at Wire Feed Unit MS
connector to Motor leads for
continuity. If harnessing is O.K.
proceed to b.
b. 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 > 24V DC,
then replace motor assembly. If
< 24V DC, replace Control PC
board (see Procedure for
b. Defective wire feed motor or
control PC board.
Replacing PC Boards).
– 30 –
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PROBLEMS
WHAT TO DO
PROBLEM
POSSIBLE CAUSE
a. Remove Control Box to Wire Feed
Unit Cable and Check F to F, G to G
and H to H for continuity. If any of the
continuity tests fail, replace cable.
Otherwise check related harnesses
for continuity (Refer to Wiring
7. No control of wire feed.
a. Defective Wire Feed Unit to
Control box cable or harnessing.
Diagram). If continuity checks O.K.
on harnessing, proceed to b.
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
b. Defective wire feed motor tach or
control PC Board.
tachometer.
c. See 2e.
c. Problem with serial
communications in input control
cable.
a. Remove gun. Check continuity
between trigger pins with trigger
closed. If no continuity repair or
replace gun.
8. No wire feed, solenoid, or arc
voltage. LED display indicated
Synergic 7F has input power.
a. Faulty gun or gun trigger switch.
b. Replace gun. Remove plug from J1
on control board. Check that there is
continuity between plug pins 2 and 8
when trigger is closed and no
b. Defective Control Box to Wire
Feed Unit Cable or harness
wiring & connections.
continuity when trigger is open. If the
continuity tests pass proceed to c. If
not, check I to I and J to J in cable. If
this continuity test fails, replace
cable. Otherwise check wiring
harnesses and proceed to c. if no
harness problem is encountered.
c. Remove gun. Check voltage across
trigger sockets on gun connector.
c. Defective control PC board or
gun connector.
If voltage is > 11V DC, then gun is
defective.
If voltage is < 11V DC, then check
the voltage across pin 2 (+) and pin 8
(-) of connector J1 on control PC
board.
If the voltage is still < 11V DC, then
replace control PC board, otherwise,
replace gun connector. (See
Procedure for Replacing PC boards.)
– 31 –
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PROBLEMS
POSSIBLE CAUSE
WHAT TO DO
PROBLEM
a. Disconnect input cable from
power source and place a jumper
across sockets C & D of 14-
socket receptacle at power
source. If no arc voltage is
present then power source is
defective.
9. Wire feed motor runs and
solenoid turns on but no arc
voltage is present.
a. Power source is defective.
b. Disconnect input cable from
power source and check
b. Input cable is defective.
continuity between socket C of
8-socket plug and pin C of 14-pin
plug of the input cable and socket
D of 8-socket plug and pin D of
14-pin plug of the input cable.
Replace cable if no continuity.
c. Replace Control PC board. (See
Procedure for Replacing PC
boards).
c. Control PC Board is defective.
a. Set Run-In and weld speeds to
desired settings.
10. Speed does not change when
weld current flows.
a. Run-In and weld speeds are set
to the same value or Run-In is
set to - - -.
b. Check input control cable per
problem 2e. If this is O.K. then
replace Control PC board. (See
Procedure for Replacing PC
boards.)
b. Power source may be defective
or there may be a control cable
problem with the serial
communications - see problem
2e.
a. Check continuity from brass
block on wire feed unit to pin-F
on input connector at control box.
Otherwise, replace Control PC
board. (See Procedure for
Replacing PC Boards.)
11. Voltmeter does not function or
read properly when arc voltage
is present.
a. See problem 2e, also 67
electrode sensing lead or
connections may be intermittent.
a. Refer to Operations Section of
this manual.
12. Arrow keys do not change
WFS or Volts/Trim.
a. This is normal as only WFS and
Volts/Trim knobs will adjust these
settings.
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.)
13. Purge key does not turn on
solenoid but trigger closure
does.
a. Defective keypad or Display PC
Board is defective.
– 32 –
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PROBLEMS
WHAT TO DO
PROBLEM
POSSIBLE CAUSE
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).
14. Cold Feed key does not turn
on wire feed motor but trigger
closure does.
a. Defective keypad or Display PC
board is defective.
a. Ring out keypad. Replace if
defective. If not, then replace
Display PC board. (See Procedure
for Replacing PC boards.)
15. Display and/or indicator lights
do not change when the arrow
or select keys are pressed.
\a. Defective keypad or Display PC
board.
a. Press the function key to light the
LED next to the display function that
corresponds with the knob to be
adjusted.
16. Display does not change when a. Make sure that the function
WFS and/or Volts/Trim knobs
are turned.
select key has been pressed to
light the LED corresponding to
the Volts/Trim or WFS display
depending on which knob you
are attempting to adjust.
b. Check harness connections to
encoder and control boards and
continuity between corresponding
harness leads in P2 and P17.
(Refer to wiring diagram).
b. Broken harness wire(s) or
harness disconnected from
encoder boards(s) or control
board.
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 two
c. Defective Encoder boards and/or
control board.
knobs are properly adjusting, plug
the P17 harness from the working
board into the nonfunctional board.
If the previously nonfunctional board
is now working, replace the control
board. Otherwise replace the
nonfunctional encoder board. (See
procedure for replacing PC boards).
a. Turn ON power source.
17. Display is blank.
a. Power source is OFF.
b. Check input cable and feeder unit
for short in 41 and 42 circuit. Check
for shorted motor. Replace fuse or
reset circuit breaker.
b. Feeder supply fuse or circuit
breaker at power source is blown
or tripped.
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.)
c. Display or Control PC board is
bad.
– 33 –
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PROBLEMS
WHAT TO DO
PROBLEM
POSSIBLE CAUSE
a. Set dual procedure switch at control
box to the gun position. Refer to
operating instructions.
18. Dual Procedure is not
functioning when using the
remote dual procedure switch.
a. Gun has not been selected at the
control box.
b. Remove switch. Check continuity
between switch pins with switch closed
and no continuity with switch open. If it
fails a continuity test, repair or replace
switch.
b. Faulty Remote Dual Procedure
Switch.
c. Refer to Problem 19, Local Dual
Procedure Switch.
c. Faulty Local Dual Procedure
Switch.
d. With switch installed disconnect J2 plug
from control board. Check continuity
between P2 pins 4 and 6 with the
remote switch closed, and no continuity
with the remote switch open. If a
d. Defective Control Box to Wire
Feed Unit cable, associated
harness wiring, or control board.
continuity test fails, replace or repair the
damaged harness or cable. Otherwise
replace control board. (See procedure
for replacing PC boards).
e. Make sure input cable connections are
tight. Make sure parameters on Power
Source display, such as WFS match
those on wire feeder display, if not, try
changing Synergic 7F control board. If
problem persists, refer to Power Source
Troubleshooting information. (See
e. Problems with serial
communications.
procedure for replacing PC boards).
a. Disconnect harness plug from J2 on the
control board. Check that there is
continuity between plug pins 7 and 11
when local DPS is in position “A” but not
when in “Gun” or “B”. Now check that
there is continuity between plug pins 11
and 12 when local DPS 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 the
problem, Otherwise, replace control
board. (See procedure for replacing PC
boards).
19. Dual Procedure is not
functioning when using the
local dual procedure switch.
a. Faulty Local Dual Procedure
Switch or control board.
b. Make sure input cable connections are
tight. Make sure parameters on Power
Source display, such as WFS match those
on wire feeder display, if not, try changing
Synergic 7F control board. If problem
persists, refer to Power Source
e. Problems with serial
communications.
Troubleshooting information. (See
procedure for replacing PC boards).
– 34 –
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PROBLEMS
POSSIBLE CAUSE
WHAT TO DO
PROBLEM
a. Remove control board plug from
J5. Check that if you have a high
speed Wire Feed Unit that you have
continuity between plug P5 pins 4
and 6. Likewise if you have a
20. Wire feed speed is consistent
and adjustable, but operates at the or control board.
wrong speed.
a.Defective gearbox ratio sensing
standard speed Wire Feed Unit you
should not have continuity between
P5 pins 4 and 6. If the continuity test
fails, refer to wiring diagram and
correct the problem in the J13 to J5
jumper sensing system. Otherwise
replace control board.
21. Display shows any of the
following:
a. Normal operation. Voltmeter only
reads 0-80V DC.
HI
a. Voltmeter function is selected
and arc voltage is > 80V DC.
a. Run-In speed is now = weld
speed. To re-enable Run-In speed
simply press the increase arrow key.
- - -
a. Run-In speed is selected but is
disabled.
a. XX indicates time in seconds
HXX
Er
a. See problem 5 or see section on
Safety Precautions.
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
a. EEPROM error.
condition persists then replace
control PC board. (See Procedure
for Replacing PC boards.)
a. Turn off power to feeder. Wait 5
seconds. Turn power back on. If
EXX is displayed again then
replace control PC board. (See
Procedure for Replacing PC
boards.)
EXX
EP
a. Where XX is a number from
1-10. System error.
a. Turn off power to feeder. Wait
5
a. EPROM checksum error.
seconds. Turn power back on. If
EP is displayed again then replace
EPROM assembly. If problem still
persists then replace Control PC
board . (See Procedure for
Replacing PC boards.)
a. Turn off power to feeder. Wait 5
seconds. Turn power back on. If
uP is displayed again, then
replace control PC board. (See
Procedure for Replacing PC
boards.)
uP
a. Microprocessor RAM error.
– 35 –
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Gun Cable Connector Requirements to Permit
Proper Connection to Wire Feed Units
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 damage to
any of its components and conductors on the back of
the board.
Connector for 1/16 - 5/64” (1.6 - 2.0 mm) Wire
a. If there is no visible damage to the PC board,
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:
Connector for .023 - .052” (19.0 / 18.9 mm) Wire
(For all other dimensions, See Diagram above).
1. Check the PC board harness connector pins for
corrosion, contamination, or looseness.
NOTE: Connector part with .749/.747 (19.0/18,9 mm)
diameter should be made from brass if it is to be part
of the welding current carrying circuit.
2. Check leads in the plug harness for loose or
intermittent connection.
“A” Diameter Hole
to be Concentric to
Wire Size
in. (mm)
.749/.747 (19.0/18.9 mm)
Diameter Within .008 (.20) F.I.M.
b. If PC board is visibly damaged electrically, before
possibly subjecting the new PC board to the same
cause of failure, check for possible shorts, opens,
or grounds caused by:
.068- 5/64
(1.7-2.0)
.125 [1/8 (3.2 mm) Drill]
1. Frayed or pinched lead insulation.
1/16 (1.6)
.078 [5/64 (2.0 mm) Drill]
.062 [1/16 (1.6 mm) Drill]
.055 [(1.4 mm) #54 Drill]
2. Poor lead termination, such as a poor contact
or a short to adjacent connection or surface.
.045 & .052 (1.1 & 1.3)
.023-.035 (0.6-0.9)
3. Shorted or open motor leads, or other external
leads.
All dimensions in inches and (millimeters)
Switch Requirements
4. Foreign matter or interference behind the PC
boards.
1/2 Amp AC 24 Volts - Inductive
1/2 Amp DC 24 Volts - Inductive
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.
– 36 –
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5 0 0
5 1 2 A
*
*
5 5 3
5 5 2
5 5 1
5 5 4
*
*
*
*
5 1 2
5 2 2
5 3 1
5 3 0
*
5 3 9
5 4 1
E N C O D E R P C B O A R D
E N C O D E R P C B O R D
* *
* *
5 0 0
J 1 7
J 1 7
5 5 3
5 5 1
*
*
5 5 4
5 1 2 A
5 5 2
T A C H
5 1 9
5 2 0
5 2 4
5 2 5
*
5 2 1
5 2 0
5 1 5
5 1 9
5 1 8
5 1 7
5 1 6
W
2
*
4
5 0 0 M
8 1
8 2
W
5 4 2
– 37 –
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INPUT CONNECTION DIAGRAM
– 38 –
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CONTROL BOX DIMENSION PRINT
– 39 –
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WIRE FEED UNIT DIMENSION PRINT
GUN CABLE FITTING
SWING ARM
CLOSED
C
L
OF WIRE
2.90
C
L
OF WIRE
7.00
11.25
7.69
6.75
4.67
6.67
1.00
6.25
8.06
7.16
7.50
C
L
OF WIRE
3.36
.281
(10 HOLES FOR
MOUNTING WIRE FEED UNIT)
1.00
6.21
1.31
WIRE FEED
DIRECTION
OUTLET
GAS FITTING
REMOTE
CONNECTOR
INLET
GAS FITTING
3.18
TRIGGER
CONNECTOR
1.44 TYP.
INPUT
CONNECTOR
1.72
CLEARANCE ENVELOPE OF QUICK RELEASE ARMS
TOP VIEW
.25
A
.87
.25
L9777
.81
– 40 –
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Now Available...12th Edition
New Lessons in Arc Welding
The Procedure Handbook of Arc Welding
Lessons, simply written, cover manipulatory techniques;
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● Do not touch electrically live parts or
electrode with skin or wet clothing.
● Insulate yourself from work and
ground.
● Keep flammable materials away.
● Wear eye, ear and body protection.
WARNING
Spanish
● No toque las partes o los electrodos ● Mantenga el material combustible
● Protéjase los ojos, los oídos y el
bajo carga con la piel o ropa
mojada.
● Aislese del trabajo y de la tierra.
fuera del área de trabajo.
cuerpo.
AVISO DE
PRECAUCION
French
● Ne laissez ni la peau ni des
● Gardez à l’écart de tout matériel
inflammable.
● Protégez vos yeux, vos oreilles et
votre corps.
vêtements mouillés entrer en contact
avec des pièces sous tension.
ATTENTION
● Isolez-vous du travail et de la terre.
German
● Berühren Sie keine stromführenden
Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!
● Isolieren Sie sich von den
● Entfernen Sie brennbarres Material! ● Tragen Sie Augen-, Ohren- und Kör-
perschutz!
WARNUNG
Elektroden und dem Erdboden!
Portuguese
● Não toque partes elétricas e
electrodos com a pele ou roupa
molhada.
● Mantenha inflamáveis bem
guardados.
● Use proteção para a vista, ouvido e
corpo.
ATENÇÃO
● Isole-se da peça e terra.
Japanese
Chinese
Korean
Arabic
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.
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● 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
Spanish
● Los humos fuera de la zona de
respiración.
● Mantenga la cabeza fuera de los
humos. Utilice ventilación o
aspiración para gases.
● Desconectar el cable de
alimentación de poder de la
máquina antes de iniciar cualquier
servicio.
● No operar con panel abierto o
guardas quitadas.
AVISO DE
PRECAUCION
French
● N’opérez pas avec les panneaux
ouverts ou avec les dispositifs de
protection enlevés.
● Gardez la tête à l’écart des fumées.
● Utilisez un ventilateur ou un
aspirateur pour ôter les fumées des
zones de travail.
● Débranchez le courant avant
l’entretien.
ATTENTION
German
● Anlage nie ohne Schutzgehäuse
oder Innenschutzverkleidung in
Betrieb setzen!
● Vermeiden Sie das Einatmen von
Schweibrauch!
● Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
● Strom vor Wartungsarbeiten
abschalten! (Netzstrom völlig
öffnen; Maschine anhalten!)
WARNUNG
Portuguese
● Mantenha-se afastado das partes
moventes.
● Não opere com os paineis abertos
ou guardas removidas.
● Mantenha seu rosto da fumaça.
● Use ventilação e exhaustão para
remover fumo da zona respiratória.
● Não opere com as tampas removidas.
● Desligue a corrente antes de fazer
serviço.
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.
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• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
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