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IM557
August, 2005
Synergic 7 and 7H
For use with machine Code Numbers 10250 and 10251
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 thought-
ful 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.
R
NRTL/C
OPERATOR’S MANUAL
Copyright © 2005 Lincoln Global Inc.
• 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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SAFETY
ARC RAYS can burn.
ELECTRIC SHOCK can
4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.
kill.
3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:
FUMES AND GASES
can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
fumes and gases.When welding, keep
your head out of the fume. Use enough
• AC Welder with Reduced Voltage Control.
ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
5.b. Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors to
form phosgene, a highly toxic gas, and other irritating
products.
3.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
3.g. Never dip the electrode in water for cooling.
5.c. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.
5.d. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
5.e. Also see item 1.b.
Mar ‘95
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SAFETY
WELDING SPARKS can
cause fire or explosion.
CYLINDER may explode
if damaged.
6.a. Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
the welding sparks from starting a fire.
Remember that welding sparks and hot
materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.
process used and properly operating
regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.
7.c. Cylinders should be located:
•Away from areas where they may be struck or subjected to
physical damage.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact
can cause overheating and create a fire hazard.
•A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even though they have
been “cleaned”. For information, purchase “Recommended
Safe Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.
FOR ELECTRICALLY
powered equipment.
6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate cir-
cuits. This can create fire hazards or overheat lifting chains
or cables until they fail.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.
6.h. Also see item 1.c.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Mar ‘95
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SAFETY
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.
PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les instruc-
tions et les précautions de sûreté specifiques qui parraissent
dans ce manuel aussi bien que les précautions de sûreté
générales suivantes:
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une
grande partie du corps peut être en contact avec la
masse.
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 lev-
age, câbles de grue, ou autres circuits. Cela peut provoquer
des risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état
defonctionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
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 forte-
ment toxique) ou autres produits irritants.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à soud-
er parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.
2. Dans le cas de travail au dessus du niveau du sol, se pro-
téger 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.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du
rayonnement de l’arc et des projections quand on soude
ou quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
l‘arc.
1. Relier à la terre le chassis du poste conformement au code
de l’électricité et aux recommendations du fabricant. Le dis-
positif 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-inflamma-
bles.
2. Autant que possible, I’installation et l’entretien du poste
seront effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la
debrancher à l’interrupteur à la boite de fusibles.
4. 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.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
Mar. ‘93
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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.
Product _________________________________________________________________________________
Model Number ___________________________________________________________________________
Code Number or Date Code_________________________________________________________________
Serial Number____________________________________________________________________________
Date Purchased___________________________________________________________________________
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially important when identifying the correct replacement parts.
On-Line Product Registration
- Register your machine with Lincoln Electric either via fax or over the Internet.
• For faxing: Complete the form on the back of the warranty statement included in the literature packet
accompanying this machine and fax the form per the instructions printed on it.
• For On-Line Registration: Go to our WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then
“Product Registration”. Please complete the form and submit your registration.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
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.
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TABLE OF CONTENTS
Page
Installation .......................................................................................................Section A
Technical Specifications ........................................................................................A-1
General Description...............................................................................................A-2
Recommended Processes and Equipment ...........................................................A-2
Standard Features.................................................................................................A-2
Keypad and Display Description............................................................................A-4
Safety Precautions ................................................................................................A-5
Installation of the Synergic 7 Components ............................................................A-5
Attaching Wire Reel Stand..............................................................................A-5
Wire Feed Drive Roll and Guide Tube Kits............................................................A-6
Standard 4-Roll Kits (KS655 and KS656) .......................................................A-6
Procedure to Install Drive Roll and Guide Tubes...................................................A-6
Gun and Cable Assemblies ...................................................................................A-7
GMAW Guns...................................................................................................A-7
Innershield Guns.............................................................................................A-7
Gun and Cable Connections..................................................................................A-7
Wire Feeder to Gun.........................................................................................A-7
For GMA Gun Cables......................................................................................A-7
Synergic 7 Water Connections ..............................................................................A-8
GMAW Shielding Gas............................................................................................A-8
Gas Guard Regulator......................................................................................A-8
Electrical Installation..............................................................................................A-9
Optional Features Installation..............................................................................A-10
Operation ............................................................................................................Section B
Safety Precautions ................................................................................................B-1
Duty Cycle .............................................................................................................B-1
Keypad Setup and Operation ................................................................................B-1
Procedure Selector Switch ....................................................................................B-4
Dual Procedure Remote Control (K1449-1)...........................................................B-4
Wire Reel Loading .................................................................................................B-5
Idle Roll Pressure Setting ......................................................................................B-9
Gas Guard Regulator Setting ................................................................................B-9
Making a Weld.....................................................................................................B-10
Wire Reel Changing.............................................................................................B-10
Wire Feed Overload Protection ...........................................................................B-10
Grounding Lead Protector ...................................................................................B-11
Explanation of Prompting and Error Messages ...................................................B-11
Accessories.....................................................................................................Section C
Optional Features..................................................................................................C-1
Maintenance ....................................................................................................Section D
Safety Precautions ................................................................................................D-1
Routine Maintenance.............................................................................................D-1
Periodic Maintenance............................................................................................D-1
Troubleshooting..............................................................................................Section E
Safety Precautions.................................................................................................E-1
Troubleshooting Guide ..........................................................................................E-2
Procedure for Replacing PC Boards....................................................................E-12
Diagrams ..........................................................................................................Section F
Wiring.....................................................................................................................F-1
Input Connection....................................................................................................F-2
Dimension Print......................................................................................................F-3
Parts Lists...................................................................................................P-278 Series
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A-1
A-1
INSTALLATION
TECHNICAL SPECIFICATIONS – SYNERGIC 7 AND 7H
WIRE FEEDER - (4 - ROLL)
Model
Type
SYNERGIC 7
SYNERGIC 7H
K631-3
K631-4
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 - .045”
0.6 - 1.2mm
Cored Electrodes
Input Power:
.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
The following is for both the Synergic 7 and
Synergic 7H models:
Size & Weight
4-Roll Feeder:
Without Wire Stand With K377 Wire Stand
Length
Width
Height
Total Weight
(Less Electrode)
269 mm (10.60")
295mm (11.60”)
282mm (11.11”)
12.9 kg (28.5 lbs.)
550 mm (21.66")
295mm (11.60”)
432mm (17.00”)
17.5 kg (38.5 lbs.)
SYNERGIC 7 & 7H
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A-2
A-2
INSTALLATION
b) Feeds .045 - (1.2mm) cored wire for Outershield
GMA or Innershield processes.
GENERAL DESCRIPTION
The Synergic 7 is a semiautomatic constant speed wire
feeder designed specifically for use with the Invertec Power
Wave type power sources. A serial communication link is
supplied through the control cable of the Synergic 7
enabling information to be shared between the power
source and wire feeder. The Synergic 7 comes factory
equipped with a gas solenoid valve with gas fittings and
standard Lincoln gun connector. These models includes a
3-1/2 digit LED display with rotating knob encoder controls
for setting the wire feed speed and voltage and a dual pro-
cedure selector switch. A tactile-feel keypad provides
selection of operating mode, function selection, timer and
crater fill selection and parameter adjustment. Two keys
provide Cold Feed and Gas Purge functions, and connector
receptacles are provided for an optional dual procedure
remote control and dual procedure switch.
Recommended power sources are The Lincoln
Electric Company Synergic type Invertec® Power
Wave power sources with 42VAC auxiliary power, and
a 14-pin connector receptacle.
STANDARD FEATURES
Wire Drive Features:
Wire Drive Unit - Incorporates low voltage permanent
magnet motor and highly efficient two-reduction spur
gearbox which operates in any position. The non-fluid
lubricant won’t leak.
“Quick Release” Wire Feed System - Provides a
completely tool-less means for releasing and opening
the idle roll pressure arm, precisely adjusting the idle
roll pressure and changing the incoming and outgoing
guide tubes and drive rolls.
The unit has 3 operating modes: 2-step trigger, 4-step trig-
ger and spot. Three functions can be selected: Volts or
Trim Preset/arc (memory) voltmeter, Run-in speed and weld
speed (IPM or m/min.) or (memory) ammeter. In addition,
when 4-step trigger mode is selected, crater fill WFS is also
adjustable. Up to three timers are available depending on
the mode: preflow, postflow and spot, and 5 acceleration
rates are selectable, as well as 6 Burnback settings.
Drive Rolls and Guide Tubes - Provide long life,
positive feeding and precise alignment of electrode.
Minimizes “birdnest” or mill-thru of wire if properly set.
(Ordered separately.)
The Synergic 7 is available in 2 models:
Tachometer Feedback - Provides proper wire feed
acceleration and speed accuracy, independent of fluc-
tuations in line voltage and wire loading, for reliable
arc starting and weld consistency.
Ordering
Information Model
Speed Range Wire Size Range
IPM (m/m)
Drive
IN. (MM)
K631-3
K631-4
Synergic
7
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
7H
4-Roll
80 - 1200
(2.00 - 30.5)
.025 - .045
(0.6 - 1.2)
Cold Feed Speed - Provides cold feed speed adjustment
independent of weld, run-in and crater speeds.
RECOMMENDED PROCESSES
AND EQUIPMENT
Selectable Acceleration - Provides front panel selec-
tion of 5 acceleration rates. This feature in combina-
tion with Run-in Speed provides the ability to easily
optimize starting on any process or procedure.
The Synergic 7 wire feed unit has the following wire
feeding capabilities:
Solid-State Dynamic Braking - Quickly stops wire feed
motor to minimize wire overrun during weld termina-
tion. Solid-state design requires no maintenance.
a) Feeds .025 - 1/16” (0.6-1.6mm) solid wire for
gas-metal-arc processes.
b) Feeds .045 - 3/32” (1.2-2.4mm) cored wire for Outershield
GMA or Innershield processes up to 5/64” (2.0 mm).
The Synergic 7H wire feed unit has the following wire
feeding capabilities:
a) Feeds .025 - .045” (0.6-1.2mm) solid wire for
gas-metal-arc processes.
SYNERGIC 7 & 7H
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A-3
A-3
INSTALLATION
Crater Fill - Provides crater feed speed adjustment (in
4-step trigger mode) independent of weld, cold inch,
or run-in speeds.
2-Step or 4-Step Trigger Modes - Unit operates only
when trigger is pressed in 2-Step mode (normal) oper-
ation. 4-Step Trigger Mode eliminates the need to
hold the gun trigger closed while welding. Both mod-
els have user selectable 4-step with crater fill, or as
shipped, 4-step with current interlock.
Solid-State Overload Protection - No circuit breaker
to reset. Front panel display indicates time remaining
before automatic reset.
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.
Gas Solenoid Valve - Complete with inlet fittings for
easy installation of gas is standard on Synergic 7
models. Also available as an option (K659-1) a Gas
Guard regulator for flow surge suppression.
Crater Fill - Allows setting of crater fill WFS (when 4-
step with crater fill trigger mode is selected), indepen-
dent of weld, cold feed, and run-in speeds.
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 prob-
lem feeding situations, with low wire deformation for
improved feeding of soft wires.
Selectable Burnback Time - Provides front panel
selection of 6 Burnback times. This feature provides
selectable Burnback time (default = 0ms) if required to
prevent electrode from sticking in weld puddle at finish
of weld.
Control Features:
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.
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 weld-
ing processes by communicating information over a
serial link to the compatible power source.
Digital “Memory” Voltmeter - Displays arc voltage
from 0 to 80V DC, when welding gun trigger is activat-
ed, with automatic polarity indication for positive or
negative electrode. The last welding voltage moni-
tored at end of weld is displayed for 5 seconds after
weld has stopped. This allows checking actual volt-
age after weld has stopped.
Display and Indicator Lights - Wide temperature
range, long life, 3-1/2 digit 7-segment LED display
with .56” (14.2mm) character height permits easy
viewing even from long gun cable distances.
Individual red indicator lights are high intensity LED’s
for viewing at almost any angle. Mode and Timer func-
tion keys and indicator lights are concealed behind a
hinged “drop-door” cover.
Digital “Memory” Ammeter - Weld Feed Speed
(WFS) display may be selectable to display welding
amps only while welding and the last welding amps
monitored at the end of the weld will be displayed for
5 seconds after the weld has stopped. This allows
checking actual weld current after the weld has
stopped.
Encoder Controls - Rotating encoders provide con-
tinuous knob control for setting both Wire Feed Speed
and Volts/Trim procedures.
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 com-
plete.
Procedure Switch - Permits selection of A or B pro-
cedures, as set by the procedure controls and memo-
ry pair selected at the Power Wave power source.
Setting switch to center “Gun Switch” position allows
selection of A or B procedures with the optional Dual
Procedure Switch.
Keypad - Consists of 7 membrane keys with tactile-
feel embossed domes. All keys are generously
spaced to provide easy selection, even if wearing
welding gloves.
SYNERGIC 7 & 7H
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A-4
A-4
INSTALLATION
Function Select key enables operator to choose which
function will be displayed as shown by the appropriate
indicator light. Pressing the key causes lights to sequence
(top to bottom) starting from the current indicated position.
The function displayed will be adjustable with the rotating
encoder controls or arrow keys:
K E Y P A D A N D D I S P L A Y
DESCRIPTION
VOLTS/ TRIM
RUN-IN
V
WFS
Keypad - Seven key, membrane
type with “snap” tactile feel and
L9571-1
Adjusting either encoder knob automatically transfers dis-
play (and indicator light) to the function being adjusted.
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”), and continues for 5 sec-
onds after the weld has stopped (memory vpltmeter). The
power source automatically determines whether preset
voltage or percent trim will be displayed, and adjustable
with Volts/Trim rotating encoder control.
VOLTS/ TRIM
V
Display - 3-1/2 digit 7-segment
LED with (+) or (-) polarity indica-
tors. .56” (14.2mm) character
height. Displays arc voltage in
volts, wire speed in IPM or m/m and
all timers in seconds.
RUN-IN
WFS
POSTFLOW
PREFLOW
2-STEP
STD
2
1
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 deac-
tivated. They may be user-selected to activate or deacti-
vate adjustable Run-in display, and setting with arrow
keys.
Indicator Lights - Extra bright red
LED’s for viewing at almost any
angle. Always indicates the mode
being used and which function or
timer is being displayed.
Bottom Light - Indicates Weld Feed Speed (WFS) is being
displayed, and is adjustable with the Wire Feed Speed
rotating encoder control. If selected, this light will “blink”
while welding, indicating that the display has been select-
ed to display welding amps, and continues for 5 seconds
after the weld is stopped (memory ammeter).
Cold Feed key energizes the wire
feeder but not the power source or
solenoid valve. Cold feed speed is
adjustable and is displayed only
while pressing Cold Feed, and the
last speed selected is stored in
memory for the next Cold feeding.
Timer/Crater Select key enables operator to choose spot
or gas timers, or crater speed as indicated by the appro-
priate light. Pressing the key causes lights to sequence
(left to right, top to bottom) starting from the current indi-
cated selection. Any parameter not available in the mode
selected is skipped over.
2
1
COLD FEED
GAS PURGE
CRATER
SPOT
Top Left Light - indicates preflow time is being displayed in
seconds.
Gas Purge key energizes the sole-
noid valve but not the wire feeder or
power source.
Top Right Light - indicates postflow time is being dis-
played in seconds.
Middle Light - indicates Crater Feed Speed is being dis-
played. 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
Increase arrow key increases the setting of the para-
meter 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.
SPOT
Top Light - Indicates 2-step (stan-
dard) trigger mode.
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 para-
meter selected to be displayed. Arrow keys do not
function for Wire Feed Speed or Volts/Trim settings,
which are adjusted using the rotating encoder knobs.
Bottom Light - Indicates spot weld
mode.
SYNERGIC 7 & 7H
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A-5
A-5
INSTALLATION
INSTALLATION OF THE SYNERGIC 7 COMPONENTS
Safety Precautions
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts such
as output terminals or internal wiring.
•
When inching with gun trigger, electrode and
drive mechanism are “hot” to work and
ground and could remain energized several
seconds after the gun trigger is released.
• Turn OFF input power at welding power
source before installation or changing
drive roll and/or guide tubes.
• Welding power source must be connected
to system ground per the National
Electrical Code or any applicable local
codes.
• Only qualified personnel should
perform this installation.
Observe all additional Safety Guidelines detailed
throughout this manual.
Attaching Wire Reel Stand
The mounting hardware for mounting the wire reel
stand is included with the wire feeder. (Screws and
washers are inserted in their respective mounting
holes.) To connect:
1) Remove the three 3/8" (9.5 mm) hex head screws
from the back of the wire feed unit.
2) Place the wire reel stand mounting bracket in posi-
tion against the back of the wire feed unit.
3) Replace and tighten the screws. The long screw
and plain washer go into the top hole.
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A-6
A-6
INSTALLATION
Wire Feed Drive Roll and Guide Tube Kits
PROCEDURE TO INSTALL DRIVE
ROLL AND GUIDE TUBES
NOTE: The maximum sizes the Synergic 7 will feed
satisfactorily are the 3/32” (2.4mm) cored and
1/16” (1.6mm) solid electrodes. The maximum
sizes the Synergic 7H will feed satisfactorily are
the .045 (1.2mm) cored and .045” (1.2mm) solid
electrodes.
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts such
as output terminals or internal wiring.
When inching with gun trigger, electrode and
drive mechanism are “hot” to work and
ground and could remain energized several
seconds after the gun trigger is released.
• Turn OFF input power at welding power
source before installation or changing
drive roll and/or guide tubes.
•
The electrode sizes that can be fed with each
roll and guide tube are stencilled on each part.
Check the kit for proper components.
• 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.
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
KS655-3/32
KS655-1/16
KS655-052S
KS655-052C
KS655-035C
KS655-035S
KS655-030S
KS655-025S
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 (KS655 and KS656)
KS656-1/16A
KS647-1/16A**
KS656-3/64A
KS647-3/64A**
KS647-040A**
KS656-035A
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 clamping screw & clamping collar from the
drive shaft closest to the incoming side of the feed-
er.
Drive rolls for only cored electrode sizes are stencilled
with a “C” suffix to the wire sizes.
4) Install drive roll onto keyed shaft. (Do not exceed
the maximum wire size rating of the wire drive.)
Replace collar and tighten clamping screw.
Drive rolls for only solid electrode sizes are stencilled
with an “S” suffix to the wire sizes.
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.
Drive rolls for aluminum wire sizes are stencilled with an
“A” suffix to the wire sizes.
* Not for Synergic 7H model.
** For use with Binzel European guns. Installation
instructions are included with these kits. Also
requires K489-2 Fast-Mate Adapter.
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.
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A-7
A-7
Gun Cable Connection: Wire Feeder to Gun
INSTALLATION
8) Back out the screws for the incoming and outgoing
guide tubes.
Lay the cable out straight. Insert the connector on the
welding conductor cable through the large hole in the
front panel of the Synergic 7 and into the brass con-
ductor block on the front of the gearbox. Make sure it
is all the way in and tighten the hand wheel. Keep this
connection clean and bright. Connect the control
cable polarized plug into the mating 5 cavity recepta-
cle on the front of the control section below the key-
pad.
9) Install the longer guide tube in the rear hole near
the incoming drive roll. Slide the tube in until it
almost touches the roll. Tighten in place.
10) Install the remaining guide tube in the front hole.
Be certain that the proper plastic insert is used.
Fine wire chisel point tube must have largest
radius next to drive roll. Tighten in place.
11) Re-latch both quick release levers.
For GMA Gun Cables:
12) To start new electrode, straighten the first 6"
(150mm) and cut off the first 1" (25 mm). Insert
free end through the incoming tube. Press gun
trigger and push wire into the drive roll.
Install the barbed fitting and union nut to the 5/8-18
female inert gas fitting on the front of the Synergic 7
wire drive. Connect the 3/16" I.D. gas hose from the
gun cable to the barbed fitting. When the gun is to be
removed, this fitting can be easily detached by loosen-
ing the union nut.
TO SET IDLE ROLL PRESSURE, see Idle Roll
Pressure Setting.
Gun and Cable Assemblies
GMAW Guns
An expanding line of Magnum gun and cable assem-
blies are available to allow welding with solid and
cored electrodes using the GMAW process. See the
appropriate Magnum literature for descriptions of the
200 to 550 ampere air cooled gun and cables that are
available. Gun cable lengths range from 10 ft. (3.0 m)
to 25 ft. (7.6 m) and feed electrode sizes .025" (0.6
mm) to 5/64" (2.0 mm). The entire line of Magnum
Fast-Mate gun and cable assemblies can also be
used by installing a K489-1 Fast-Mate adapter kit.
Innershield Guns
K126 and K115 gun and cable assemblies are
available to allow welding with Innershield elec-
trodes. Gun cable lengths range from 10 ft. (3.0
m) to 15 ft. (4.5 m). The 350 ampere K126 with
Synergic 7 will feed electrode sizes .062" (1.6 mm)
to 5/64" (2.0 mm). The 450 ampere K115 with
Synergic 7 will feed 5/64" (2.0 mm) electrode.
Three smoke extraction gun and cable assemblies
are available, 250 ampere K309, 350 ampere K206
and the 500 ampere K289. All gun cable lengths
are 15 ft. (4.5 m). Both the K206 and K309 with
Synergic 7 will feed electrode sizes .062" (1.6 mm)
to 5/64" (2.0 mm). K289 with Synergic 7 will feed
5/64" (2.0 mm) electrode. These guns require the
use of the K184 vacuum unit for use with Synergic
7.
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A-8
A-8
INSTALLATION
Synergic 7 Water Connections (for Water-
Cooled Guns)
GMAW Shielding Gas
WARNING
These Synergic 7 models must have a K590-4 Water
Connection Kit installed. See Options Installation section.
CYLINDER may explode if damaged.
• Keep cylinder upright and chained to
support.
• Keep cylinder away from areas where
it may be damaged.
1) Using male quick-connect fittings (included with
appropriate Synergic 7 input cable assemblies), con-
nect the water hoses to the coolant inlet and outlet on
the back of the Synergic 7. Connect the other ends of
these hoses to the appropriate ports on the water
cooling units.
• Never lift welder with cylinder attached.
• Never allow welding electrode to touch cylinder.
• Keep cylinder away from welding or other live elec-
trical circuits.
BUILDUP OF SHIELDING GAS may
2) In the event the water line fittings on your water
cooled gun are incompatible with the female quick
connects on the front of the Synergic 7, male quick-
connects are provided for installation on 3/16 (5 mm)
I.D. hose (Customer to provide appropriate clamps).
The feeder connectors self seal when disconnected.
harm health or kill.
• Shut off shielding gas supply when not
in use.
SEE AMERICAN NATIONAL STANDARD Z-49.1,
“SAFETY IN WELDING AND CUTTING” PUBLISHED
BY THE AMERICAN WELDING SOCIETY.
------------------------------------------------------------------------
Customer must provide a cylinder of shielding gas, a
pressure regulator, a flow control valve, and a hose
from the flow valve to the gas inlet fitting of the
Synergic 7 Wire Feed Unit.
Connect a supply hose from the gas cylinder flow
valve outlet to the 5/8-18 female inert gas fitting on the
back panel of the Synergic 7 or, if used, on the inlet of
the Gas Guard regulator. (See Below).
Gas Guard Regulator - The Gas Guard Regulator is
an optional accessory (K659-1) on these models.
Install the 5/8-18 male outlet of the regulator to the
5/8-18 female gas inlet on the back panel of the
Synergic 7. Secure fitting with flow adjuster key at top.
Attach gas supply to 5/8-18 female inlet of regulator
per instructions in the “Gas Connections” Section.
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A-9
A-9
INSTALLATION
K676 - (Used with Power Wave 450) Similar to K648 but
includes a gas hose with a 5/8-18 male fitting for the
Synergic 7 inlet. It is rated at 500 amps, 60% duty cycle
and is available in lengths of 7 ft. (2 m), 25 ft. (7.6 m) and 50
ft. (15 m).
ELECTRICAL INSTALLATION
WARNING
ELECTRIC SHOCK can kill.
K640 - (Used with Power Wave 450 and Synergic 7/7H with
water quick-connection) Similar to K648 but includes a gas
hose with a 5/8-18 male fitting for the Synergic 7 inlet and
water hoses with quick-connect male fittings to connect
between the water cooler and Synergic 7 water connections.
It is rated at 500 amps, 60% duty cycle and is available in
lengths of 7 ft. (2 m), 25 ft. (7.6 m) and 50 ft. (15 m).
• Do not touch electrically live parts such
as output terminals or internal wiring.
•
When inching with gun trigger, electrode and
drive mechanism are “hot” to work and
ground and could remain energized several
seconds after the gun trigger is released.
• Turn OFF input power at welding power
source before installation or changing
drive roll and/or guide tubes.
• Welding power source must be connected
to system ground per the National
Electrical Code or any applicable local
codes.
K651 - (Used with Power Wave 350) Consists of an 8-con-
ductor control cable with a 14-pin plug and 2/0 (67 mm2)
electrode cable with Twist-Mate™ connector. It is rated at
350 amps, 60% duty cycle and is available in lengths of 7 ft.
(2 m), 17 ft. (5 m), 33 ft. (10 m), and 50 ft. (15 m).
• Only qualified personnel should
perform this installation.
K677-7 - (Used with Power Wave 350) Similar to K651 but
includes a gas hose with a 5/8-18 male fitting for the
Synergic 7 inlet. It is rated at 350 amps, 60% duty cycle
and is available in 7 ft. (2 m) length.
Observe all additional Safety Guidelines detailed throughout this manual.
K650 - (Used with Power Wave 350 and Synergic 7/7H with
water quick connection) Similar to K651 but includes a gas
hose with a 5/8-18 male fitting for the Synergic 7 inlet and
water hoses with quick-connect male fittings to connect
between the water cooler and the Synergic 7 water connec-
tions. It is rated at 350 amps, 60% duty cycle and is avail-
able in lengths of 7 ft. (2 m), 17 ft. (5 m), 33 ft. (10 m) and
50 ft. (15 m).
Input Cable: Synergic 7 Wire Feeder to Power
Wave Synergic Type Power Sources
NOTE: CSAnrtl certification of the Synergic 7 models is with
input cable assemblies identified by carton date codes
010161, or above. These assemblies have grounding lead
continuity between the 14-pin plug pin B and the 8-socket
plug pin E per diagram below.
K642 (Control Cable Only) - Consists of an 8 conductor
control cable with a 14-pin control cable plug, without elec-
trode cable, and is available in lengths of 7 ft (2 m), 17 ft (5
m), 25 ft (7.6 m), 33 ft (10 m) and 50 ft (15 m).
B=GND
K643 (Control Cable Extension) - Consists of an 8 con-
ductor 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).
E=GND
14-PIN PLUG, FRONT VIEW
8-PIN PLUG, FRONT VIEW
K649 - (Used with Power Wave 450/500) Consists of an 8-con-
ductor control cable with a 14-pin control cable plug and a 4/0
(107mm ) electrode cable with Twist-Mate™ connector. It is
2
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).
With input power disconnected from the power
source, install the input cable per connection diagram
S21041 in the rear of this manual and follow exactly
the instructions on the diagram or perform the follow-
ing:
K675 - (Used with Power Wave 450/500) Similar to K649
but includes a gas hose with a 5/8-18 male fitting for the
Synergic 7 inlet. It is rated at 500 amps, 60% duty cycle
and is available in lengths of 7 ft. ( 2 m), 25 ft. (7.6 m) and
50 ft. (15 m).
1) Connect the end of the control cable with the 14-
pin cable plug to the mating receptacle on the
power source.
K641- (Used with Power Wave 450/500 and Synergic 7/7H
with water quick connection) Similar to K649 but includes a
gas hose with a 5/8-18 male fitting for the Synergic 7 inlet
and water hoses with quick-connect male fittings to connect
between the water cooler and the Synergic 7 water connec-
tions. It is rated at 500 amps, 60% duty cycle and is avail-
able 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).
2) Connect the electrode lead of that same cable end
to the power source output terminal of the desired
polarity.
K648 - (Used with Power Wave 450) Consists of an 8-con-
3) Route the other end of the electrode cable through
the large oval hole in the rear panel of the Synergic
7 case. Connect to the brass block on the side of
the gearbox using the bolt provided.
2
ductor control cable with a 14-pin plug and a 4/0 (107 mm )
electrode cable with stud terminal. It is rated at 500 amps,
60% duty cycle and is available in lengths of 7 ft (2 m), 17 ft
(5 m), 25 ft (7.6 m), 33 ft (10 m) and 50 ft (15 m).
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A-10
A-10
INSTALLATION
4) Connect the remaining end of the control cable
with the 8-socket cable plug to the mating recepta-
cle on the Synergic 7.
K163 Undercarriage (Requires K303, K376, K377, or
K378) The undercarriage includes casters, wheels, a
handle and related hardware. Casters are mounted at
the front and the wheels to the rear of the platform.
The handle is bolted to the front of the platform so the
Synergic 7 can be tilted back and wheeled like a two-
wheel truck. Instruction sheet M13424 for assembly
installing the K303, K376, K377, or K378 wire stand is
provided with the undercarriage.
5) Install the input cable under the wire reel mounting
stand strain relief clamp. Remove the screws hold-
ing the clamp to the base of the wire reel mounting
assembly, put the input cable assembly under the
clamp and reinstall the screws.
Work Cable
K683-1 - Dual Procedure Switch Dual Procedure
Switch mounts to gun with appropriate bracket, provid-
ed, per the installation instructions included with the
kit. 3-pin switch cord plug connects to 3-pin remote
receptacle on the front panel of the Synergic 7 Wire
Feed Unit.
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 con-
nection to the work makes tight metal-to-metal electri-
cal contact.
Current
Copper Work Cable Size, AWG *
60% Duty
K1449-1 - Dual Procedure Remote Control Provides
remote rotating knob encoder control of Wire Feed
Speed and Volts/Trim, along with a dual procedure
selector switch, which disables comparable front panel
controls when the remote control is connected.
Up to 100 ft Length (30m)
Cycle
300 Amps
00 (67 mm2)
400 Amps
500 Amps
000 (85 mm2)
000 (85 mm2)
The 4-pin plug of the remote control connects to the
mating receptacle on the bottom of the Synergic 7
Control box.
* For pulse welding applications, the next larger cable
size is recommended.
K590-4 - Water Connection Kit Install per the instruc-
tions shipped with the kit.
OPTIONAL FEATURES
INSTALLATION
K648, K649, K651 or K642 Input Cable Assembly
See Electrical Installation section for instructions
K178-1 Mounting Platform - Synergic 7 Models on
Synergic Power Sources (Requires a K303, K376,
K377, K378 or K445 Wire Reel Assembly) This is a
turntable type platform for mounting the Synergic 7 on
the top of Synergic power sources. Bolt the platform to
the lift bail per instructions (M16260) supplied with the
platform.
K675, K676 or K677 Input Cable Assembly (Gas)
See Electrical Installation and Shielding Gas
Connections sections for instructions.
K640, K641 or K650 Input Cable Assembly (Water &
Gas) See Electrical Installation, Water Connections
and Shielding gas connections sections for instruc-
tions.
K162-H Spindle for Mounting Readi-Reels and 2" (51
mm) I.D. Spools (60 lb/27 kg Capacity) (For use with
K303 and K376 Wire Reel Stand) To mount the 2" spin-
dle kit for Readi-Reels and 10 through 60 pound
spools, remove the shaft for the standard 50-60 pound
wire coils from the mounting framework. Install the
spindle per the instructions shipped with the kit.
K376 50-60 Lb. Wire Reel Mounting Stand (without
dust shield) and
K303 50-60 Lb. Wire Reel Mounting Stand (with dust
shield) The assembly includes a framework to which is
attached the 50-60 lb. wire reel, a mounting spindle, a
lift bail, and a cable clamp for fastening the input cable
assembly. It is easily mounted to the basic wire feed
unit by three bolts. The reel mounting spindle is the
pull knob type with a built-in brake.
When used with Readi-Reels, a Readi-Reel Adapter is
required.
For 8" O.D. (200 mm) spools, a K468 Spindle Adapter
is available.
The brake pad is adjustable for proper braking at low
or high wire feed speeds.
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A-11
A-11
INSTALLATION
Wire Reel Dust Shield for K376 50-60 Lb. Wire Reel
Mounting Stand - If the user desires to protect the
wire from falling dirt and dust, there is a shield avail-
able to cover the wire reel. Order part number
S14543. Instructions are included with the kit.
K1524-1 Universal Wire Reel Stand - The assembly
includes a reel stand, a 2" (51 mm) O.D. spindle with
adjustable brake, rubber mounting feet, and a cable
clamp for fastening the input cable. It is easily mount-
ed to the wire feed unit by three bolts. The wire feed-
er reel stand assembly fits on top of the power source
and is correctly positioned by using a hole in the base
that accommodates the power source lift bale. The 2"
(51mm) O.D. spindle can be set on one of two mount-
ing locations on the stand, depending on what coil of
wire and spindle adapter is being used. The upper
hole mounts 50-60 lb coils, the lower hole mounts 10-
30 lb, 13-14 lb, and 8" O.D. coils. Installation instruc-
tions are included with the kit.
Wire Reel Dust Shield Door for K303 and K376
(when equipped with an S14543 shield) - In
extremely dusty and dirty locations, this door kit can
be added to those units having the shield kit
(S14543). This door kit includes a hinged door and
sliding bottom seal. When these parts are attached to
the reel support per the instructions included, the unit
becomes a completely enclosed housing. Order part
number M11514.
K1555-1 Insulated Lift Bale Kit for K1524-1 - A lift
bale can be added to the K1524-1 Universal Wire
Reel Stand. The K1555-1 provides electrical insula-
tion between the wire stand assembly and the lift
hook. It is easily mounted to the wire stand with three
bolts and a threaded plate. Installation instructions are
included with the kit.
K377 - Small Mounting Stand for Readi-Reel Coils or
10-44 Pound (4.5-20 kg) Spools with 2" I.D. - This
assembly includes a small frame to which is attached
a wire reel spindle similar to the K162 Spindle. The
unit is supplied with the K363 Readi-Reel Adapter for
using the Lincoln "Readi-Reel Electrode Coils".
Without the adapter, the unit is capable of handling
spools with a 2" (51mm) I.D., a 12" (30mm) maximum
O.D., and a 4" (101mm) width. For spools with an 8"
(200mm) O.D., a K468 spindle adapter is available.
The spindle has an adjustable braking system. See
Installation section “Attaching the Wire Reel Stand”
for mounting to wire feed unit.
K1556-1 Caster Kit for K1524-1 - A light duty caster
kit can be added to the K1524-1 Universal Wire Reel
Stand. The K1556-1 includes 4 2" O.D. light duty
casters that mount in place of the rubber feet on the
wire stand base. Installation instructions are included
with the kit.
K378 - Small Mounting Stand for 13-14 Pound
Innershield Coils - This assembly includes the same
smaller frame as used in the K377 and a fully
enclosed canister system for de reeling of the 14
pound (6 kg) coil. This system has a fixed brake for
this coil. See Installation section “Attaching the Wire
Reel Stand” for mounting to wire feed unit.
K1557-1 Swivel Platform for K1524-1 - A swivel plat-
form can be added to the K1524-1 Universal Wire
Reel Stand. The K1557-1 includes a pivot top plate
and a base assembly. The pivot top plate mounts to
the underside of the base of the wire stand assembly
using four screws. The swivel base mounts to the
power source lift bale with hardware provided or it can
be mounted to a surface of choice with four customer
provided bolts. Installation instructions are provided
with the kit.
K659-1 - Gas Guard Regulator - Adjustable flow regu-
lator with removable adjustor key for CO2 and Argon
blend gases. Mounts onto feeder inlet, and reduces
gas waste and arc start "blow" by reducing surge
caused by excess pressure in supply hose.
Install the 5/8-18 male outlet of the regulator to the
5/8-18 female gas inlet on the back panel of the
Synergic 7. Secure fitting with flow adjuster key at
top. Attach gas supply to 5/8-18 female inlet of regu-
lator per See Installation section “Shielding Gas
Connections”.
SYNERGIC 7 & 7H
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B-1
B-1
OPERATION
OPERATING INSTRUCTIONS
Safety Precautions
Mode Selection
2-STEP
STD
Mode Select key ( behind “drop-
door” cover) enables operator to
choose mode of operation shown
by the indicator lights. Pressing key
causes mode lights to sequence
(top to bottom) starting from the
current indicated position.
Top Light - Indicates 2-Step
(Standard) Trigger Mode.
1. Trigger closure energizes the
solenoid valve, then the wire feeder
and the power source after Preflow
time (See Timer/ Crater Section).
WARNING
ELECTRIC SHOCK can kill.
4-STEP
LOCK
• Do not touch electrically live parts such
as output terminals or internal wiring.
When inching with gun trigger, electrode and
drive mechanism are “hot” to work and
ground and could remain energized several
seconds after the gun trigger is released.
SPOT
•
• Turn OFF input power at welding power
source before installation or changing
drive roll and/or guide tubes.
• Welding power source must be connected
to system ground per the National
Electrical Code or any applicable local
codes.
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.
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).
Observe all additional Safety Guidelines detailed
throughout this manual.
Duty Cycle
The 4-step modes function as follows:
The Synergic 7 models are rated at 60% duty cycle * for
a maximum current of 600 amps.
1. Trigger closure energizes the power
source and wire feeder after the pre-
flow time.
* Based on a 10 minute time period (6 minutes on, and 4 minutes off).
KEYPAD SETUP AND OPERATION
Power-Down Save
Power to the Synergic 7 is supplied and controlled
from the power source. The Synergic 7 automatically
senses the loss of power when the power source is
turned off.
2. Trigger release enables 4-step lock,
leaving the feeder and power source
as in step 1.
a) 4-step with current interlock will only
lock if weld current is flowing.
Breaking weld arc stops wire feed
and power source output.
b) 4-step with crater fill will lock without
welding.
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 automati-
cally return all settings to the state they were in when
power was removed. The power source may auto-
matically overwrite any or all of these settings follow-
ing power-up recall.
3. Closing the trigger a second time
continues welding.
a) 4-step with current interlock contin-
ues welding without changing the
settings from step 2.
b) 4-step with crater fill continues weld-
ing but changes to the crater set-
tings.
4. Releasing the trigger turns off wire
feeder 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
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 sole-
noid valve are all turned off when the
spot on timer times out even through
the trigger is still closed.
COLD FEED
adjustable (with “Arrow keys”) only
while pressing the Cold Feed Key.
The last setting is held in memory
for next Cold feeding.
Gas Purge key energizes the sole-
noid valve but not the wire feeder or
GAS PURGE power source.
SYNERGIC 7 & 7H
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B-2
B-2
OPERATION
The preset voltage/trim may be adjusted,
using the Volts/Trim encoder knob. The syn-
ergic preset voltage/trim level may be adjust-
ed within the range synergically set by the
power source for the process and weld Feed
Speed being used. The power source auto-
matically determines whether preset volt-
age or percent trim will be displayed.
Preset voltage is indicated by one digit only
to the right of the decimal point, while per-
cent 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 dis-
played. The encoder knobs allow
rotational adjustment of weld wire
feed speed and Arc Volts/Trim.
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 dis-
play).
As shipped these models are setup for
minimum rated fixed Run-In speed with dis-
play 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).
Note: If an indicator light is skipped, that
parameter may not be enabled. Refer to
section covering that parameter.
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.
Function Select key enables oper-
VOLTS/ TRIM ator to choose which function will
be displayed as indicated by the
V
RUN-IN
appropriate light. Pressing the key
causes lights to sequence (top to
bottom) starting from the current
WFS
indicated position. If a timer or
crater speed is being displayed
when the Function Select key is
pressed, then the indicator light of
the last function selected before the
timer/crater key was chosen will
come on and become the starting
point for the sequencing.
Adjusting either encoder knob automati-
cally transfers display (and indicator light)
to the function being adjusted (Volts/Trim
or Wire Feed Speed).
Bottom Light - Indicates Weld Feed
Speed (WFS) Function has been selected
and the weld speed setting is being dis-
played in IPM or m/m (see section for
English or Metric speed display). The
range of Weld Feed Speed is synergically
set by the power source for the process
being used, and is adjustable using the
Wire Feed Speed encoder knob on the
front of the Synergic 7 Control.
If selected (see Memory Ammeter
Selection section), the bottom light will
“blink” while welding, indicating that the dis-
play has been selected to display welding
amps. The last welding current displayed
before the weld is stopped will continue to
be displayed for 5 seconds after welding to
permit operator monitoring.
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 volt-
age/trim is displayed. The last welding
voltage displayed before the weld is
stopped, will continue to be displayed
for 5 seconds after welding to permit
operator monitoring.
SYNERGIC 7 & 7H
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B-3
B-3
OPERATION
Timer/Crater Select - key enables
Acceleration Selection
operator to choose crater speed, spot
or gas timers as indicated by the appro-
priate light. Pressing key causes lights
to sequence (left to right, top to bottom)
starting from the current indicated posi-
tion. Any parameter not available in the
mode selected is skipped over. If a
function is being displayed when the
Timer/Crater Select key is pressed,
then the light of the last parameter
selected before the function was cho-
sen will come on and become the start-
ing point for the sequencing.
Pressing both the “Gas Purge” key and then the func-
tion select key at the same time causes the accelera-
tion setting to be displayed. The display will indi-
cate “A-X” where X will be a number from 1 through 5
with 5 being the fastest acceleration. This number
can be adjusted using the arrow keys. To exit this
function, press any other key except the arrow key,
gas purge or function select key.
2
1
CRATER
SPOT
GAS PURGE
VOLTS/ TRIM
V
RUN-IN
WFS
Burnback Time Selection
If necessary, for higher wire feed speeds, burnback
time maybe selected to prevent the electrode from
sticking in the weld puddle a the end of the weld.
Pressing both the Gas Purge Key then the function
select key at the same time, displaying acceleration
setting per above, then pressing the function key a
second time, while holding gas purge pressed, dis-
plays the burnback time selection. Default is “b0"
which is zero delay. Selecting “b1" through “b5"
increases delay from 10 m sec to 50 m sec in 10 m
sec increments. To exit this function press any other
key except the arrow keys, gas purge or function
select key.
Top Left Light - indicates preflow time
is being displayed in seconds. This is
the time the shielding gas flows before
the wire feed and power source are
activated.
Top Right Light - indicates postflow
time is being displayed in seconds.
This is the time the shielding gas flows
after the wire feed and power source
are deactivated.
Selection of English or Metric Speed
Display Units
Middle Light - indicates that crater feed
speed is being displayed. Crater speed
is only available when 4-step trigger
with crater fill is selected. (See 4-step
trigger mode selection section). It is
activated by Step 3 and deactivated by
Step 4 of the 4-step sequence.
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 dis-
play 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.
GAS PURGE
2
1
CRATER
SPOT
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 key then the Cold
Feed key at the same time causes Run-In
function to toggle on or off, as indicated by the
Run-In indicator light turning on or remaining
off in the function select sequence.
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
As shipped, the Run-In function is off with a
fixed setting of 50 IPM (1.27 m/min.).
Therefore, the Run-In indicator light will not
sequence with the function select key, but the
fixed setting will still be used for actual Run-In
speed.
Decrease Arrow - key decreases the
setting of the parameter selected to be
displayed, except Wire Feed Speed and
Volts/Trim which are controlled by the
encoder knobs.
Arrow Keys use the “Accelerating
Digit” method for setting changes,
where holding the arrow key causes
setting change rate to accelerate from
slow to fast. Releasing arrow key resets
to slow setting change.
Activation of adjustable Run-In speed using the
above dual key press will permit Run-In speed
to be adjusted with the arrow keys, (See
Section 3.3.4), and the Run-In indicator light
will return to the function key sequence. Re-
pressing the above dual key again removes
the Run-In light from the function key
sequence, but replaces the fixed Run-In speed
with the adjusted Run-In speed setting, until
readjusted.
SYNERGIC 7 & 7H
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B-4
B-4
OPERATION
4-Step
Selection
Trigger
Mode
Dual Procedure Remote Control (K1449-1)
When this option is connected to the feeder control
receptacle the front panel knob controls are disabled
and procedure control is transferred to the knob
encoder controls of the remote, which function in the
exact same manner.
Pressing both the Gas Purge key
and then the Trigger mode select
key causes the 4-step mode light to
turn on and will toggle the 4-step
trigger mode between:
4-step with current interlock (as shipped)
Crater light will not turn on.
and
4-step with crater fill.
Crater light will turn on for crater speed set-
ting with arrow keys.
(See Mode Selection and Display
Control Keys sections).
GAS PURGE
2-STEP
STD
NOTE: The dual procedure overlay must be pre-
sent on the Power Wave power source for the
Procedure Selector switch to function. If this
overlay is not used, only Procedure A will be
selected no matter what position the Procedure
switch is in.
4-STEP
LOCK
SPOT
If using the optional K683-1 Dual Procedure Switch to
select A or B along with the remote, both the front
panel and remote Procedure selector switches must
be set to “Gun Switch” (center) position.
Memory Ammeter Selection
Pressing both the Gas Purge key
then the Up Arrow key at the same
time causes the WFS light to “blink”
for about 3 seconds while display
GAS PURGE shows weld amps reading with elec-
trode polarity symbol. This indicates
that while welding, the display will
show welding amps, indicated by
“blinking” WFS indicator light, which
continues for 5 seconds after the
weld is stopped (memory ammeter)
before returning to displaying WFS
(light not “blinking”.)
Pressing both the Gas
Purge and Up Arrow key again,
returns WFS display to wire speed
while welding.
Procedure Selector Switch
The toggle switch on the front panel provides selection
of Procedure A or Procedure B, as set with the front
panel knob controls. Rotating the knob encoder
changes only the procedure selected by this switch.
Also, this switch selects the A or B memory pair select-
ed at the Power Wave power source.
NOTE: The dual procedure overlay must be present
on the Power Wave power source for the Procedure
Selector switch to function. If this overlay is not
used, only Procedure A will be selected no matter
what position the Procedure switch is in.
Setting the toggle switch to the center “Gun Switch”
position permits the Procedure A or Procedure B to be
selected by the optional K683-1 Dual Procedure
Switch. The K1449-1 Dual Procedure Remote Control
can be used with this panel Procedure Switch in any
position.
SYNERGIC 7 & 7H
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B-5
B-5
OPERATION
6) Set one of the Readi-Reel inside cage wires on the
slot in the retaining spring tab.
WIRE LOADING
Loading a 22 to 30 Lb. (10 to 14 kg) Readi-Reel
Package Using the Molded Plastic K363-P
Readi-Reel Adapter:
7) Lower the Readi-Reel to depress the retaining
spring and align the other inside cage wires with
the grooves in the molded adapter.
The Spindle should be located in the LOWER mounting hole
of the K1524-1 Universal Stand if used.
8) Slide the cage all the way onto the adapter until
the retaining spring "pops up" fully.
1) Depress the Release Bar on the Retaining Collar and
remove it from the spindle. NOTE: Earlier spindles
used a threaded collar. See Figure B.1a or B.1b.
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 elec-
trode.
2) Place the Adapter on the spindle.
3) Re-install the Retaining Collar. Make sure that the
Release Bar “pops up” and that the collar retainers
fully engage the retaining groove on the spindle.
___________________________________________
9) 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 spindle.
4) Rotate the spindle and adapter so the retaining
spring is at the 12 o'clock position.
5) Position the Readi-Reel so that it will rotate in a
direction when feeding so as to be de-reeled from
the bottom of the coil.
FIGURE B.1b (Retaining Collar)
FIGURE B.1a (Threaded Locking Collar)
2
IN. O.D. SPINDLE
ADAPTER
RETAINING SPRING
BRAKE
HOLDING
PIN
GROOVES
READI-REEL
INSIDE CAGE WIRES
THREADED
LOCKING
COLLAR
SYNERGIC 7 & 7H
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B-6
B-6
OPERATION
TO MOUNT 10 TO 44 lb (4.5 to 20 kg) SPOOLS
(12 in./300 mm DIAMETER) OR 13-14 lb (6 kg)
INNERSHIELD COILS:
2. While tightly holding the electrode, cut off the bent
end and straighten the first six inches. Cut off the
first inch. (If the electrode is not properly
straightened, it may not feed or may not go into
the outgoing guide tube, causing a “birdnest”.)
The spindle should be located in the lower mounting
hole of the K1524-1 Universal Stand if used.
3. Insert the free end through the incoming guide
tube.
[For 8 in. (200 mm) spools, a K468 spindle adapter
must first be slipped onto the spindle.]
4. Press the cold inch key or gun trigger and push
the electrode into the drive roll.
[For 13 to 14 lb (6 kg) Innershield coils, a K435 Coil
Adapter must be used.]
WARNING
1. Depress the Release Bar on the Retaining Collar
and remove it from the spindle. NOTE: Earlier
spindles used a threaded collar. See Figure B.5a or
B.5b.
ELECTRIC SHOCK
can kill.
• Do not touch electrically live parts
such as output terminals or
internal wiring.
2. Place the spool on the spindle, making certain
the spindle brake pin enters one of the holes in
the backside of the spool. Be certain the wire
comes off the reel in a direction so as to de-reel
from the bottom of the coil.
• When inching with the gun
trigger, electrode and drive
mechanism are “hot” to work and
ground and could remain “hot” for
several seconds after the gun
trigger is released.
3. Re-install the Retaining Collar. Make sure that
the Release Bar “pops up” and that the collar
retainers fully engage the retaining groove on the
spindle.
------------------------------------------------------------------------
5. Inch the electrode through the gun.
ELECTRODE
ADJUSTMENT
FEEDING
AND
BRAKE
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.
1. Turn the Readi-Reel or spool until the free end of
the electrode is accessible.
SYNERGIC 7 & 7H
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B-7
B-7
OPERATION
WIRE REEL LOADING – 50 AND 60 LB
COILS (K303 OR K376 WIRE REEL STAND)
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 “back lashing” of the coil, which may tangle the
wire. A tangled coil will not feed. It must be untangled
or discarded.
ADJUSTABLE WIRE REEL BRAKE
The mount for standard 50 and 60 pound 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 (10 m/min). It should be at the outer
position for the faster wire speeds often used when
feeding smaller diameter electrode.
------------------------------------------------------------------------
8. 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.
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.
9. 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 OR 60 LB COIL:
FIGURE B.2 – LOADING A 50 OR 60 LB COIL.
1. To remove the wire reel from its shaft, grasp the
spring loaded knob and pull out. This straightens
the knob so it seats into the shaft when released.
Remove the reel.
SPINNER
NUT
COVER
PLATE
2. Lay the reel flat on the floor. Loosen the spinner
nut and remove the cover plate. See Figure B.2.
3. Place the coil of electrode on the reel so it
unwinds as the reel rotates clockwise. DO NOT
cut the tie wires at this time.
SLOTS
4. Be sure the coil is placed so the spring loaded
arms will not interfere with the later removal of the
coil tie wires.
CARDBOARD
COIL
LINER
5. When loading 0.030 to 0.045” 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.
COIL
TIE WIRE
6. Put the cover plate on the reel so the four arms of
the cover plate straddle and are in line with the
spring loaded arms of the reel.
REEL
SPRING
LOADED
ARM
7. Tighten the cover as much as possible by hand.
DO NOT hammer on the spinner nut arms.
SYNERGIC 7 & 7H
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B-8
B-8
OPERATION
FIGURE B.3 – K1504-1 COIL REEL.
WIRE REEL LOADING – 50 AND 60 LB
COILS (K1524-1 UNIVERSAL WIRE REEL
STAND)
SPINNER NUT
TO MOUNT A 50 to 60 lb (22.7 to 27.2 kg) COIL:
(USING K1504-1 COIL REEL) (FOR 50 to 60 lb
READI-REELS A K438 READI-REEL ADAPTER
MUST BE USED.)
COVER
PLATE
The spindle should be located in the UPPER mount-
ing hole.
SLOTS
1. With the K-1504-1 Coil Reel mounted on the 2 in.
(51 mm) spindle (or with reel laying flat on the
floor) loosen the spinner nut and remove the reel
cover. See Figure B.3.
CARDBOARD
COIL LINER
2. Before cutting the tie wires, place the coil of elec-
trode on the reel so it unwinds from the bottom
as the reel rotates.
COIL
3. Tighten the spinner nut against the reel cover as
much as possible by hand, using the reel cover
spokes for leverage. DO NOT hammer on the
spinner nut arms.
TIE WIRE
SPRING
LOADED ARM
4. Cut and remove only the tie wire holding the free
end of the coil. Hook the free end around the rim
of the reel cover and wrap it around to secure.
Cut and remove the retaining tie wires.
REEL
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 “backlash” of the coil, which may tangle the
wire. A tangled coil will not feed, so it must either be
untangled or discarded.
Feeding Electrode
1) Turn the reel until the free end of the electrode is
accessible. While tightly holding the electrode, cut
off the bent end.
____________________________________
2) Straighten the first 6” (150mm) and cut off the first
1” (25mm). Insert the free end through the incoming
guide tube. Press the Cold Inch key or the gun trigger
and push the electrode into the drive roll. Feed the
electrode through the gun. (If the electrode is not
properly straightened, it may not feed or may not go
into the outgoing guide tube causing a “birdnest”.)
5. Be sure the coil is engaged with the spindle
brake pin and the Release Bar and Retaining
Collar “pops up” and that the collar retainers fully
engage the retaining groove on the spindle.
WARNING
When feeding with the gun trigger, the electrode and
drive mechanism are always “HOT” to work and
ground and could remain “HOT” several seconds after
the gun trigger is released.
___________________________________________
SYNERGIC 7 & 7H
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B-9
B-9
OPERATION
Idle Roll Pressure Setting
The idle roll pressure is set at the factory, backed out
three turns from full pressure on 4-roll feeders. This is
an approximate setting. For small wire sizes and
aluminum wire up to 9 or 10 turns out may be required
to minimize “birdnesting”. The optimum idle roll pres-
sure varies with type of wire, surface condition, lubri-
cation, and hardness. The optimum idle roll setting
can be determined as follows:
1) Release the incoming idle roll pressure arm, then
press end of gun against a solid object that is elec-
trically 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 wavi-
ness in the exposed wire. If there is no waviness,
the pressure is too low. Increase the pressure set-
ting 1/4 turn, reconnect the gun, tighten the locking
nut, and repeat the above steps.
4) After the outgoing pressure is set, determine how
many turns away from full pressure the setting is.
Set both idle roll tensions to this setting. Engage
both idle rolls before welding. In most applications,
best wire feeding will occur when both idle roll
pressures are set the same.
Gas Guard Regulator Setting
1) With the gas supply shut off, the Gas Guard regu-
lator flow adjusting key should be set to maximum
(full clockwise) which is rated to be 60 SCFH (28
lts/ min).
2) Adjust gas supply flow rate for a level higher than
will be required, then adjust Gas Guard flow
adjusting key counterclockwise to the desired gas
flow rate.
SYNERGIC 7 & 7H
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B-10
B-10
OPERATION
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.
Making a Weld
1) Use only Power Wave model “synergic” power
sources.
13) If necessary to optimize arc starting, adjust wire
speed acceleration, and/or Run-In speed. (See
the appropriate sections for adjusting procedures).
2) Properly connect the electrode and work leads for
the correct electrode polarity.
Wire Reel Changing
3) Use Mode Selection key to set desired operating
mode. (Refer to Mode Selection section.)
At the end of a coil, remove the last of the old elec-
trode coil from the conductor cable by either pulling it
out at the nozzle end of the gun or by using the follow-
ing procedure:
4) Use Function Select and Arrow keys to set desired
Run-in and encoder knob to set Weld Feed Speed.
(Set for each procedure if using a Dual Procedure
function). (See the appropriate sections for adjust-
ing procedures).
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 a Dual Procedure function)
using the encoder knob in “Volts/Trim” function
(refer to Volts/Trim section). The final setting can
be adjusted according to the desired arc voltage
while welding.
2) Disconnect the gun cable from the gun connector
on the Synergic 7 Wire Feed Unit and lay the gun
and cable out straight.
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).
3) Using pliers to grip the wire, pull it out of the cable
from the connector end.
4) After the electrode has been removed, reconnect
the gun cable to the Synergic 7.
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.
Load a new reel of electrode per the instructions in
the Wire Reel Loading sections.
Wire Feed Overload Protection
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”.
The Synergic 7 has solid-state overload protection of
the wire drive motor. If the wire drive motor becomes
overloaded for an extended period of time, the protec-
tion 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 indi-
cates 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 oper-
ate 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.)
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.
SYNERGIC 7 & 7H
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B-11
B-11
OPERATION
Grounding Lead Protector
Explanation of Prompting and
The frame of the Synergic 7 wire feeder is grounded
to the frame of the power source by a lead in the con-
trol cable. An overload protector prevents welding
current from damaging this lead if the electrode circuit
touches the wire feeder frame while the electrode is
electrically hot.
Error Messages
Display
Prompt or Error
HI
---
Indicates arc voltage is above 80V DC.
If such a grounding lead fault occurs, the wire feeder
display will show "GLP", and the trigger circuit will be
disabled. To reset the circuit, release the trigger,
make sure that the electrode is not touching the wire
feeder frame, and then either press any key on the
keypad or close the trigger. When the GLP circuit is
reset, the "GLP" display is removed and the wire feed-
er is returned to normal operating mode.
Indicates selected Run-In speed will be the
same as the weld speed. To enter a different
Run-In speed simply press the increase arrow
key with Run-In selected.
HXX
Indicates wire feed overload. XX indicates
time remaining in seconds before unit resets
automatically. See sections on Routine
Maintenance, Periodic Maintenance, and
Troubleshooting Guide Problem 24.
EP
Indicates problem in EPROM assembly. See
Troubleshooting Guide Problem 24.
uP
Indicates problem in microprocessor RAM.
See Troubleshooting Guide Problem 24.
EXX
Indicates various system problems. XX will
be a number from 01 to 10. Turn off power to
feeder. Wait 5 seconds. Turn power back on.
If error persists, see Troubleshooting Guide
Problem 24. If error does not reoccur, be
sure to check all wire feed speed, accelera-
tion, and timer settings before you proceed.
Er
EEPROM error. Usually occurs at power-up.
Indicates one or more of the recalled settings
is out of acceptable limits. Press any key to
return to normal operation. Be sure to check
all wire feed speed, acceleration, and timer
settings before you proceed.
GLP
Indicates that the Grounding Lead Protector
circuit was activated due to excessive current
flow into the wire feeder frame. When the
Grounding Lead Protector circuit is activated
the wire feeder is disabled, i.e. the trigger out-
put to the power source is opened up, the
motor is stopped, and the gas solenoid is
turned off. To resume normal operation,
release the trigger, make sure that the elec-
trode is not touching the wire feeder frame,
and then either press a key on the keypad or
close the trigger. See Problem 24 in the
Troubleshooting Guide.
SYNERGIC 7 & 7H
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C-1
C-1
ACCESSORIES
17 ft. (5 m), 25 ft. (7.6 m), 33 ft. (10 m) and 50 ft. (15
m).
OPTIONAL FEATURES
DRIVE ROLL AND GUIDE TUBE KITS:
K648 - (Used with Power Wave 450) Consists of an 8-
Steel Wire Sizes:
4-Roll
conductor control cable with a 14-pin plug and a 4/0
2
(107 mm ) electrode cable with stud terminal. It is rated
* .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
KS655-3/32
KS655-1/16
KS655-052S
KS655-052C
KS655-035C
KS655-035S
KS655-030S
KS655-025S
at 500 amps, 60% duty cycle and is available in lengths
of 7 ft (2 m), 17 ft (5 m), 25 ft (7.6 m), 33 ft (10 m) and
50 ft (15 m).
K676 - (Used with Power Wave 450) Similar to K648
but includes a gas hose with a 5/8-18 male fitting for
the Synergic 7 inlet. It is rated at 500 amps, 60% duty
cycle and is available in lengths of 7 ft. (2 m), 25 ft. (7.6
m) and 50 ft. (15 m).
.030” (0.8mm) Solid
.023” (0.6mm) Solid
Aluminum Wire Sizes:
1/16” (1.6mm)
KS656-1/16A
KS647-1/16A**
KS656-3/64A
KS647-3/64A**
KS647-040A**
KS656-035A
K640 - (Used with Power Wave 450 and Synergic 7/7H
with water quick-connection) Similar to K648 but
includes a gas hose with a 5/8-18 male fitting for the
Synergic 7 inlet and water hoses with quick-connect
male fittings to connect between the water cooler and
Synergic 7 water connections. It is rated at 500 amps,
60% duty cycle and is available in lengths of 7 ft. (2 m),
3/64” (1.2mm)
.040” (1.0mm)
.035” (0.9mm)
Drive rolls for only cored electrode sizes are stencilled 25 ft. (7.6 m) and 50 ft. (15 m).
with a “C” suffix to the wire sizes.
K651 - (Used with Power Wave 350) Consists of an 8-
conductor control cable with a 14-pin plug and 2/0 (67
mm2) electrode cable with Twist-Mate™ connector. It
is rated at 350 amps, 60% duty cycle and is available in
lengths of 7 ft. (2 m), 17 ft. (5 m), 33 ft. (10 m), and 50
ft. (15 m).
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.
K677-7 - (Used with Power Wave 350) Similar to K651
but includes a gas hose with a 5/8-18 male fitting for
the Synergic 7 inlet. It is rated at 350 amps, 60% duty
cycle and is available in 7 ft. (2 m) length.
* Not for Synergic 7H model.
** For use with Binzel European guns. Installation
instructions are included with these kits.
INPUT CABLE ASSEMBLIES:
K650 - (Used with Power Wave 350 and Synergic 7/7H
with water quick connection) Similar to K651 but
includes a gas hose with a 5/8-18 male fitting for the
Synergic 7 inlet and water hoses with quick-connect
male fittings to connect between the water cooler and
the Synergic 7 water connections. It is rated at 350
amps, 60% duty cycle and is available in lengths of 7 ft.
(2 m), 17 ft. (5 m), 33 ft. (10 m) and 50 ft. (15 m).
K649 - (Used with Power Wave 450/500) Consists of an
8-conductor control cable with a 14-pin control cable plug
2
and a 4/0 (107mm ) electrode cable with Twist-Mate™
connector. It is rated at 500 amps, 60% duty cycle and is
available in lengths of 7 ft (2 m), 17 ft (5 m), 25 ft (7.6 m),
33 ft (10 m) and 50 ft (15 m).
K675 - (Used with Power Wave 450/500) Similar to K649
but includes a gas hose with a 5/8-18 male fitting for the
Synergic 7 inlet. It is rated at 500 amps, 60% duty cycle
and is available in lengths of 7 ft. ( 2 m), 25 ft. (7.6 m)
and 50 ft. (15 m).
K642 (Control Cable Only) - Consists of an 8 conduc-
tor control cable with a 14-pin control cable plug, with-
out electrode cable, and is available in lengths of 7 ft (2
m), 17 ft (5 m), 25 ft (7.6 m), 33 ft (10 m) and 50 ft (15
m).
K641- (Used with Power Wave 450/500 and Synergic
7/7H with water quick connection) Similar to K649 but
includes a gas hose with a 5/8-18 male fitting for the
Synergic 7 inlet and water hoses with quick-connect male
fittings to connect between the water cooler and the
Synergic 7 water connections. It is rated at 500 amps,
60% duty cycle and is available in lengths of 7 ft. (2 m),
K643 (Control Cable Extension) - Consists of an 8
conductor control cable with 14-pin connectors on
each end for extending the control cable between the
power source and the control cables. Available in
lengths of 17 ft (5 m), 25 ft (8 m), 33 ft (10 m) and 50 ft
(15 m).
SYNERGIC 7 & 7H
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C-2
C-2
ACCESSORIES
UNIVERSAL WIRE REEL STAND (K1524-1)
WIRE REEL ASSEMBLY:
Includes a 2" (51mm) O.D. Spindle with adjustable
brake and two locations for mounting the spindle to
allow for the mounting of 50 - 60lb, 10 - 30 lb, 13 -
14lb, and 8" O.D. coils with proper spindle adapters.
(See OPERATION section) Capable of being mount-
ed on the top of a suitable power source or surface
without the need for any other mounting kit. Optional
features available for this stand include:
K303 - 50-60 lb. (22.7-27.2 kg) Wire reel mounting
stand. Assembly includes a framework to which is
attached the 50-60 lb. (22.7-27.2 kg) wire reel, a
mounting spindle, a dust shield, a lift bail, and a cable
clamp for fastening the input cable assembly. The
reel mounting spindle is the pull knob type with a built-
in brake. The brake pad is adjustable for proper brak-
ing at low or high wire feed speeds. In extremely
dusty and dirty locations a wire reel dust shield door
kit can be added to this unit.
• K1555-1 insulated lift bale
• K1556-1 caster kit
• K1557-1 swivel platform.
This door kit, which includes a hinged door and sliding
bottom seal, makes the housing completely enclosed.
Order part number M11514.
60 LB. (27.2 KG) COIL ADAPTER (K1504-1)
Permits 50-60 lb. (22.7-27.2 Kg) coils to be mounted
to a 2" (51mm) spindle.
K376 - Same as K303 above but without dust shield.
A dust shield that covers the wire reel and protects the
wire from falling dirt and dust is available for this unit.
Order part number S14543. This unit will also accept
the M11514 door kit (see K303 above) but only if
already equipped with optional dust shield (S14543).
K1551-1 INSULATED LIFT BALE: Provides a
bolt on lift bale with an electrically insulated lift hook.
K377 - Small mounting stand for Readi-Reel coils or
10-30 lb. (4.5-14 kg) spools with 2" (51 mm) I.D. This
assembly includes a small frame to which is attached
a 2" (51 mm) O.D. wire reel spindle and a K363P
Readi Reel adapter for using the Lincoln "Readi-Reel
Electrode Coils". Without the adapter, the unit is
capable of handling spools with a 2" (51 mm) I.D., a
12" (305 mm) maximum O.D., and a 4" (101 mm)
width.
K1556-1 CASTER KIT: Comes with 4 light duty
2" O.D. casters which mount in place of the rubber
feet on the wire stand. Use in light duty applications
where portability is required. Can be used in combi-
nation with the K1557-1 swivel platform.
K1557-1 SWIVEL PLATFORM: Allows for the
mounting of the wire feeder reel stand assembly on
top of a suitable power source if the need for the wire
feeder reel stand assembly to swivel is desired. Also
has mounting holes in the base feet for mounting to
any surface that it can be fastened to. Comes with a
rotating tool tray to hold gun tips, guide tubes, drive
rolls, etc. Will work in combination with the K1556-1
caster kit.
K378 - Small mounting stand for 13-14 lb. (6 kg)
Innershield coils. This assembly includes the same
smaller frame as used in the K377 and a fully
enclosed canister system for de-reeling of the 14 lb. (6
kg) coil. This system has a fixed brake for this coil.
K445 - 50-60 lb. (22.7-27.2 kg) Readi-Reel mounting
stand. This assembly includes framework to which is
attached a 2" (51 mm) O.D. spindle with adjustable
brake and 50-60 lb. (22.7-27.2 kg) (K438) Readi-Reel
adapter. Includes a lift bail and cable clamp for fas-
tening the input cable assembly. Does not include a
dust shield. A dust shield that covers the wire reel
and protects the wire from falling dirt and dust is avail-
able for this unit. Order part number S14543. This
unit will also accept the M11514 door kit (see K303
above) but only if already equipped with optional dust
shield (S14543).
SYNERGIC 7 & 7H
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C-3
C-3
ACCESSORIES
K541 Magnum 400 Short Neck GMAW gun and cable
assemblies are rated 400 amps, 60% duty cycle.
(Consult sales specifications for appropriate models)
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 spin-
dle for quick changeover. (used with K162H)
K598 Magnum 550 GMAW gun and cable assemblies
are rated 550 amps, 60% duty cycle. (Consult sales
specifications for appropriate models)
K206• Innershield Linconditioner gun and cable
assemblies are rated 350 amps, 60% duty cycle.
Maximum size for Synergic 7 models is 5/64" (2.0
mm). Not recommended for Synergic 7H models.
(Consult sales specifications for appropriate models)
K438 - Adapts Lincoln Readi-Reel coils of electrode
50-60 lb (22.7-27.2 kg) to a 2” (51mm) spindle. (used
with K162H).
SPINDLE ADAPTERS:
K289• Innershield Linconditioner gun and cable
assemblies are rated 500 amps, 60% duty cycle.
Maximum size for Synergic 7 models is 5/64" (2.0
mm). Not recommended for Synergic 7H models.
(Consult sales specifications for appropriate models)
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.
K309• Innershield Linconditioner gun and cable
assemblies are rated 250 amps, 60% duty cycle.
Maximum size for Synergic 7 models is 5/64" (2.0
mm). Not recommended for Synergic 7H models.
(Consult sales specifications for appropriate models)
When used with Readi-Reels a Readi-Reel adapter is
required.
K435 - Permits 14 lb (6 kg) Innershield coils to be
mounted on 2” (51mm) O.D. spindles. For use with
optional K162H adapter.
• K179 type vacuum unit not recommended for use with Synergic 7.
The following Lincoln gun and cable assemblies are
equipped with a Fast-Mate™ connector. They can be
used with these Synergic 7 models by installing a
K489-1 Fast-Mate™ adapter kit.
K468 - Permits 8” (203mm) O.D. spools to be mount-
ed on 2” (51mm) O.D. spindles. For use with optional
K162H adapter.
K684 - Magnum “Water Cooled” FM water cooled
GUN AND CABLE ASSEMBLIES:
GMAW gun and cable assemblies are rated 450
2
amps, 100% duty cycle (CO ). (Consult sales specifi-
K126 Innershield gun and cable assemblies are rated
at 350 amps, 60% duty cycle. Maximum wire size for
Synergic 7 models is 5/64" (2.0 mm). Not recom-
mended for Synergic 7H models. (Consult sales spec-
ifications for appropriate models)
cations for appropriate models).
K498 - Magnum 200 FM GMAW gun and cable
assemblies are rated for 200 amps, 60% duty cycle.
(Consult sales specifications for appropriate models).
K115 Innershield gun and cable assemblies are rated
at 450 amps, 60% duty cycle. Maximum wire size for
Synergic 7 models is 5/64" (2.0 mm). Not recom-
mended for Synergic 7H models. (Consult sales spec-
ifications 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).
K470 Magnum 300 GMAW gun and cable assemblies
are rated 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).
K471 Magnum 400 GMAW gun and cable assemblies
are rated 400 amps, 60% duty cycle. (Consult sales
specifications for appropriate models)
K556 * - GMAW process Magnum 400XA X-TRAC-
TOR gun and cable assemblies are rated at 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)
SYNERGIC 7 & 7H
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C-4
C-4
ACCESSORIES
K566 * - GMAW process Magnum 250XA X-TRAC-
TOR gun and cable assemblies are rated 250 amps,
60% duty cycle. (Consult sales specifications for
appropriate models).
* K179 type vacuum unit not recommended for
use with Synergic 7.
MISC. OPTIONS:
K590-4 (Water Connection Kit) - Includes water sup-
ply quick-connectors already attached to mounting
insulators and internal connection hoses for easy
installation on the front and rear panels of the
Synergic 7 case. Also includes water cooled gun tube
fittings and self-sealing outlet and inlet quick-connec-
tors for mounting to the front of the Synergic 7 case.
K659-1 (Gas Guard Regulator) - Adjustable flow regu-
lator with removable adjustor key for CO2 and Argon
blend gases. Mounts onto wire drive gas inlet, and
reduces gas waste and arc start "blow" by reducing
surge caused by excess pressure in supply hose.
K1449-1 (Dual Procedure Remote Control) - Includes
a remote control box with a 16ft. (5m) length control
cable with 4-pin plug for the mating receptacle on the
bottom of the Synergic 7 control box. The remote
control box contains 2 rotating knob encoders, one
controls arc voltage and the other controls weld wire
feed speed, and a procedure selector switch which
function the same as comparable controls on the front
panel, which are disabled when the remote is con-
nected.
K683-1 (Dual Procedure Switch) - Kit includes gun
switch, and mountings for Lincoln Innershield and
Magnum guns, with 15 ft. (4.5 m) control cable and 3-
pin plug.
K163 Undercarriage - For all Synergic 7 wire reel
stand combinations. Includes mounting frame, front
casters, 10" (254 mm) O.D. rear wheels, and handle.
Use when portability is required.
K178-1 Swivel Platform - For all Synergic 7 wire reel
stand combinations. For mounting wire feeder wire
reel stand assembly on top of suitable Lincoln Idealarc
power sources. Recommended input cable length is 7
ft. (2 m) when using the K178-1 on the Invertec power
sources.
SYNERGIC 7 & 7H
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D-1
D-1
MAINTENANCE
Wire Reel Mounting - 50 (22.7kg) and
MAINTENANCE
60lb (27.2kg) Coils with 1” Spindle
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 and could remain energized several
seconds after the gun trigger is released.
Wire Reel Mounting - Readi-Reels, 10
through 44lb (4.5-20kg) Spools and 50-
60lb Coils with K1504-1 Adapter
• Turn OFF input power at welding power
source before installation or changing
drive roll and/or guide tubes.
• Welding power source must be connected
to system ground per the National
Electrical Code or any applicable local
codes.
No routine maintenance required. Do not lubricate 2”
(51mm) spindle.
Avoiding Wire Feeding Problems
• Only qualified personnel should
perform this installation.
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.
b) Keep the electrode cable as straight as possible
when welding or loading electrode through cable.
Routine Maintenance
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 elec-
trodes 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
Every year inspect the gearbox and coat the gear
teeth with a moly-disulfide filled grease. Do not use
graphite grease.
See section on Wire Feed Drive Roll and Guide Tube
Kits for roll changing instructions.
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.
SYNERGIC 7 & 7H
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E-1
E-1
TROUBLESHOOTING
WARNING
Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.
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 and to avoid Electrical
Shock, please observe all safety notes and precautions detailed throughout this manual.
__________________________________________________________________________
This Troubleshooting Guide is provided to help you
locate and repair possible machine malfunctions.
Simply follow the three-step procedure listed below.
Step 3. RECOMMENDED COURSE OF ACTION
This column provides a course of action for the
Possible Cause, generally it states to contact your
local Lincoln Authorized Field Service Facility.
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled “PROBLEM (SYMP-
TOMS)”. This column describes possible symptoms
that the machine may exhibit. Find the listing that
best describes the symptom that the machine is
exhibiting.
If you do not understand or are unable to perform the
Recommended Course of Action safely, contact your
local Lincoln Authorized Field Service Facility.
Step 2. POSSIBLE CAUSE.
The second column labeled “POSSIBLE CAUSE” lists
the obvious external possibilities that may contribute
to the machine symptom.
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts such
as output terminals or internal wiring.
•
When inching with gun trigger, electrode and
drive mechanism are “hot” to work and
ground and could remain energized several
seconds after the gun trigger is released.
• Turn OFF input power at welding power
source before installation or changing
drive roll and/or guide tubes.
• Welding power source must be connected
to system ground per the National
Electrical Code or any applicable local
codes.
• Only qualified personnel should
perform this installation.
Observe all additional Safety Guidelines detailed
throughout this manual.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
SYNERGIC 7 & 7H
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E-2
E-2
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE
CAUSE
RECOMMENDED
COURSE OF ACTION
1. Rough wire feeding or wire not
feeding but drive rolls turning.
a. Gun cable kinked and/or twisted. a. Inspect gun cable and replace if
necessary.
b. Wire jammed in gun and cable.
b. Remove wire from gun and cable
feed in new wire. Note any
obstructions in gun and cable.
Replace gun and cable if neces-
sary.
c. Incorrect position of drive rolls with c. See Wire Feed Drive Roll and
grooves.
Guide Tubs Kits section for proper
installation of drive roll.
d. Drive rolls loose.
d. Remove, clean, install and tighten.
e. Clean cable or replace liner.
f. Replace.
e. Gun cable dirty.
f. Worn drive roll.
g. Electrode rusty and/or dirty.
h. Worn nozzle or cable liner.
g. Replace.
h. Replace.
i. Partially flashed or melted contact tip. i. Replace contact tip.
j. Incorrect idle roll pressure.
j. Set idle roll pressure per section
on Idle Roll Pressure Setting.
k. Improper liner, tip or guide tube.
k. Install proper equipment.
2. Variable or “hunting” arc.
a. Wrong size, worn and/or melted
contact tip.
a. Replace tip - remove any spatter on end of
tip.
b. Worn work cable or poor work
connection.
c. Loose electrode connections.
b. Inspect - Repair or replace as necessary.
c. Be sure electrode lead is tight in wire feeder
contact block, gun nozzle and gun tip tight.
d. Wrong polarity.
d. Check connection at output studs for polari-
ty required by welding process.
e. Make sure control cable connections are
tight. Check for consistent WFS. Make sure
parameters on Power Source display, such
as WFS, match those on wire feeder display,
if not, see Problem 14, otherwise try chang-
ing Synergic 7 control board. If problem per-
sists refer to Power Source trouble shooting
information.
e. Problem with serial communica-
tions in control cable.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
SYNERGIC 7 & 7H
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E-3
E-3
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE
CAUSE
RECOMMENDED
COURSE OF ACTION
3. Poor arc striking with sticking or
“blast-offs”, weld porosity, narrow
and ropy looking bead, or elec-
trode stubbing into plate while
welding.
a. Improper procedures or tech-
niques.
a. See “Gas Metal Arc Welding
Guide” (GS-100).
b. Improper gas shielding.
b. Clean gas nozzle. Make certain that gas
diffuser is not restricted. Make certain that
gas cylinder is not empty or turned off.
Make certain gas solenoid valve is operat-
ing and gas flow rate is proper.
Remove gun liner and check rubber seal
for any sign of deterioration or damage. Be
sure set screw in brass connector is in
place and tightened against the liner bush-
ing.
4. Tip seizes in diffuser.
a. Tip overheating due to prolonged a. Do not exceed current and duty
or excessive high current and/or
duty cycle welding.
cycle rating of gun.
A light application of high temper-
ature antiseize lubricant (such as
Lincoln E2607 Graphite Grease)
may be applied to tip threads.
5. Unit shuts off while welding and
“HXX” appears on display.
a. See Problem 1.
a. Correct problems causing motor
overload.
b. Defective wire feed motor or gearbox.
b. Replace.
6. Drive roll does not turn although
arc voltage is present and sole-
noid is on.
a. Defective wire feed motor or con- a. Set Run-in speed to maximum.
trol PC board.
Disconnect wire drive plug P5
from PC board. Measure voltage
across pin 1 (+) of J5 and pin 2 (-)
of J5 on PC board with trigger
closed. If voltage is ≥24 VDC,
then replace motor assembly. If
≤24 VDC, replace Control PC
board (see Procedure for
replacing PC boards).
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
SYNERGIC 7 & 7H
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E-4
E-4
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE
CAUSE
RECOMMENDED
COURSE OF ACTION
7. No control of wire feed.
a. Problem with serial communications. a. If WFS and preset Volts/Trim parame-
ters on wire feeder display do not
match those on power source display,
see Problem 14.
b. Defective wire feed motor tach or b. Measure voltage across pin 2 (+) of J3
control PC Board.
and pin 3 (-) of J3 on PC board with
motor running. If voltage is 1.5-3.5V
then replace control PC board (see
Procedure for Replacing PC Boards).
If not, then replace tachometer.
8. No wire feed, solenoid, or arc volt- a. Faulty gun or gun trigger switch.
age. LED display indicated
a. Remove gun. Check continuity
between trigger pins with trigger
closed. If no continuity repair or
replace gun.
Synergic 7 has input power.
b. Defective control PC board or
gun connector.
b. Remove gun. Check voltage across
trigger sockets on gun connector.
If voltage > 11 VDC then gun is
defective.
If voltage is < 11 VDC then check
the voltage across pin 2 (+) and pin 8
(-) of connector J1 on control PC
board.
If the voltage is still < 11 VDC then
replace control PC board. (See
Procedure for replacing PC boards).
Otherwise, either the gun connector or
wiring harness is faulty.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
SYNERGIC 7 & 7H
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E-5
E-5
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE
CAUSE
RECOMMENDED
COURSE OF ACTION
9. Wire feed motor runs and solenoid a. Power source is defective.
a. If arc voltage is present when wire feeder is
connected to the other input receptacle (#1 or
#2) of power source then power source is
defective. Otherwise, select a stick procedure
on power source, connect a known good input
cable (see step b) to wire feeder #1 receptacle
of power source, and jumper across sockets C
and D of 8-socket input cable plug. If no arc
voltage is present (refer to display on power
source) then power source is defective.
turns on but no arc voltage pre-
sent.
b. Input cable is defective.
b. Disconnect input cable from power source and
wire feeder. Check continuity between socket
C of 8-socket plug and pin C of 14-pin plug of
the input cable, and between socket D of 8-
socket plug and pin D of 14-pin plug of the
input cable. Replace cable if no continuity.
c. Wiring harness or Control PC
board is defective.
c. Check continuity between pin C of 8-pin recep-
tacle and pin 7 of plug P1, and between pin D
of 8-pin receptacle and pin 6 of plug P1. If no
continuity then harness is faulty, otherwise
replace Control PC board. (See procedure for
replacing PC boards.)
10. Speed does not change when
weld current flows.
a. Run-in and weld speeds are set
to the same value or run-in is set
to ---.
a. Set run-in and weld speeds to desired set-
tings.
b. Power Source may be defective
or there may be a problem with
the Serial communications.
b. Make sure that parameters on power source
display, such as WFS, match those on wire
feeder display. If not, refer to Problem 14.
Otherwise, replace control PC board. (See
procedure for replacing PC boards.)
11. Voltmeter does not function or
read properly when arc voltage is
present.
a. Electrode sensing lead or connec- a. Check continuity from brass block on wire
tions may be intermittent.
feeder to pin F of 8-pin control cable recepta-
cle on wire feeder. If there is no continuity,
repair faulty connection.
b. Serial communication problem.
b. Make sure that parameters on power source
display, such as WFS, match those on wire
feeder display. If not, refer to Problem 14.
Otherwise, replace Control PC board. (See
procedure for replacing PC boards.)
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
SYNERGIC 7 & 7H
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E-6
E-6
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE
CAUSE
RECOMMENDED
COURSE OF ACTION
12. Arrow keys do not change Weld a. This is normal, as only the WFS and
a. Refer to operation section of this manual
speed or volts/trim.
volts/trim knobs will adjust these settings.
13. WFS knob does not change
Run-in speed.
a. This is normal, as only the arrow a. Refer to operation section of this manual.
keys will adjust this setting.
14. WFS and preset Volts/Trim para- a. Power source is defective.
meters on wire feeder display do
not match those on power
a. If parameters on power source and wire
feeder display match when wire feeder is
connected to the other input receptacle (#1
or #2) of power source then power source
is defective.
source display.
b. Problem with serial communica-
tions in control cable.
b. Disconnect input cable from power source
and wire feeder. Check continuity between
socket G of 8-socket plug and pin G of 14
pin plug of the input cable. Check continu-
ity between socket H of 8-socket plug and
pin H of 14-pin plug of the input cable.
Replace cable if no continuity.
c. Problem with wire feeder harness c. Remove molex plug P1 from J1 on Control
or Control PCB.
PCB. Check continuity from pin G of 8-pin
receptacle on wire feeder to pin 4 of plug
P1, and from pin H of 8-pin receptacle to
pin 3 of plug P1. If no continuity then repair
harness, otherwise replace Control PCB.
(See procedure for replacing PC boards.)
15. Display does not change when
WFS and/or Volts/Trim knobs
are turned.
a. A remote control kit is connected. a. When a remote control kit is connected to
the Wire Feeder, the WFS and Volts/Trim
knobs of the Wire Feeder become inactive
and the WFS and Volts/Trim knobs of the
remote control kit must be used.
b. Broken harness wire(s) or harness b. Check for continuity between correspond-
disconnected from Encoder
board(s) or Control board.
ing harness leads of molex plug P2 on
Control board and molex plugs P12 and
P13 on Encoder boards (refer to wiring dia-
gram). If any of these continuity tests fail,
repair or replace harness.
c. Defective Encoder boards and/or c. If b. is not the problem and neither the WFS
Control board.
or Volts/Trim knobs are properly adjusting
then replace the Control board. If one of
the knobs is properly adjusting, plug the
harness, P12 or P13, from the working
board into the nonfunctional board. If the
previously nonfunctional board is now work-
ing then replace the Control board, other-
wise replace the nonfunctional Encoder
board. (See procedure for replacing PC
boards.)
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
SYNERGIC 7 & 7H
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E-7
E-7
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE
CAUSE
RECOMMENDED
COURSE OF ACTION
16. Wire feeder's display does not
change when WFS and/or
Volts/Trim knobs of the remote
control kit are turned.
a. Loose connection to Remote con- a. Make sure that remote cable connec-
trol receptacle, J16.
tions are tight.
b. Faulty Remote PC board.
b. If either the WFS knob, the Volts/Trim
knob, or the dual procedure switch of
the remote control kit is operating
properly then replace the Remote PC
board.
c. Faulty remote cable.
c. Remove remote cable from wire feed-
er and unplug connector P2 from J2 in
remote control kit. Check continuity
between pin 1 of J2 and socket B of
remote receptacle, between pin 2 of
J2 and socket A of remote receptacle,
between pin 3 of J2 and socket D of
remote receptacle, and between pin 4
of J2 and socket C of remote recepta-
cle. If any of these continuity tests fail
then repair or replace remote cable.
d. Remove plug from J1 on Remote PC
board and unplug connector P2 from
J2 in remote control kit. Check conti-
nuity between pin 1 of P2 and pin 2 of
P1, between pin 2 of P2 and pin 3 of
P1, between pin 3 of P2 and pin 4 of
P1, and between pin 4 of P2 and pin 5
of P1. If any of these tests failed,
repair or replace remote wiring har-
ness.
d. Faulty remote wiring harness.
e. Faulty wire feeder harness or
remote cable receptacle.
e. Remove plug from J2 on Control
board of wire feeder and remove
remote cable from wire feeder. Check
continuity between socket A of remote
receptacle J16 and pin 14 of plug P2,
between socket B of remote recepta-
cle and pin 7 of plug P2, between
socket C of remote receptacle and pin
15 of plug P2, and between socket D
of remote receptacle and pin 16 of
plug P2. If any of these tests failed
then repair or replace wiring harness.
Check continuity between either of the
four pins of receptacle J16. If there is
continuity between either of the pins
then receptacle is faulty.
f. Faulty Control board or Remote
PC board.
f. Try replacing Remote PC board. If
this does not solve the problem then
replace Control board of wire feeder.
(See procedure for replacing PC
boards.)
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
SYNERGIC 7 & 7H
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E-8
E-8
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE
CAUSE
RECOMMENDED
COURSE OF ACTION
17. Dual procedure is not functioning a. Optional gun dual procedure
a. When the dual procedure switch is in the “Gun”
position then either the remote or the optional gun
dual procedure switch must be used to select
between procedures “A” and “B”.
when using the local dual proce-
dure switch.
switch or remote control kit may
be connected.
b. Serial communication problem.
b. Make sure that parameters on power source dis-
play, such as WFS, match those on wire feeder
display. If not, refer to Problem 14.
c. Faulty local dual procedure switch, c. Disconnect harness plug from J2 on Control
wiring harness, or Control board.
board. Check continuity between plug pins 1 and
12 when local dual procedure switch is in position
"A", but not when in "Gun" or "B". Now check con-
tinuity between plug pins 5 and 12 when local dual
procedure switch is in position "B", but not when in
"Gun" or "A". If any of these continuity tests fail,
repair or replace switch or switch harness to cor-
rect problem. Otherwise, replace Control board.
(See procedure for replacing PC boards.)
18. Optional gun dual procedure
a. Local dual procedure switch is not in "Gun" a. Place local dual procedure switch in "Gun" posi-
switch is not functioning properly. position, and/or remote control kit's dual
procedure switch is not in "Gun" position.
tion and, if a remote control kit is attached, place
its dual procedure switch in "Gun" position also.
b. If a remote control kit is attached, remove it. If
this solves the problem, refer to Problem 19.
c. Make sure parameters on power source display,
such as WFS, match those on wire feeder display.
If not, refer to Problem 14.
b. Faulty remote control kit.
c. Serial communication problem.
d. Faulty optional gun dual proce-
dure switch.
d. Remove switch. Make sure there is continuity
between switch pins with switch closed, and no
continuity with switch open. If either of these tests
failed, repair or replace switch.
e. Faulty wiring harness or optional
gun dual procedure amphenol.
e. Remove optional gun dual procedure switch and
disconnect harness plug from J2 on Control
board. Check that there is continuity between pin
A of receptacle J17 and pin 13 of plug P2. Check
that there is continuity between pin C of recepta-
cle J17 and pin 4 of plug P2. Check no continuity
between pins A and C of receptacle J17. If any of
these continuity tests fail, repair or replace switch
amphenol J17 or switch harness.
f. Faulty local dual procedure switch. f. Perform step c. of Problem 17.
g. Faulty Control board.
g. Replace Control PC board. (See procedure for
replacing PC boards.)
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
SYNERGIC 7 & 7H
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E-9
E-9
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE
CAUSE
RECOMMENDED
COURSE OF ACTION
19. Dual procedure switch of remote a. Local dual procedure switch is not a. Local dual procedure switch should be
control kit is not functioning prop-
erly.
in "Gun" position, and/or an
optional gun dual procedure
switch is attached.
in "Gun" position if a remote control kit
is attached. If an optional gun dual
procedure switch is attached and both
the local dual procedure switch and
remote's dual procedure switch are in
"Gun" position then the optional gun
dual procedure switch is used to
switch between procedures "A" and
"B".
b. Faulty communication between
wire feeder and remote control kit.
b. If knobs on remote control kit are not
operating properly, refer to Problem
16.
c. Faulty dual procedure switch,
wiring harness, or PC board in
remote control kit.
c. Disconnect harness plug from Remote
PC board. Check that there is conti-
nuity between plug pins 7 and 8 when
dual procedure switch is in position
"A", but not when in "Gun" or "B".
Now check that there is continuity
between plug pins 6 and 7 when dual
procedure switch is in position "B", but
not when in "Gun" or "A". If any of
these tests failed, repair or replace
switch or switch harness. Otherwise
replace Remote PC board.
20. Purge key does not turn on sole- a. Defective keypad or Display PC
noid but trigger closure does. board is defective.
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).
21. Cold Feed key does not turn on a. Defective keypad or Display PC
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).
wire feed motor but trigger clo-
sure does.
board is defective.
22. Display and/or indicator lights do a. Defective keypad or Display PC
a. Ring out keypad. Replace if defec-
tive. If not, then replace Display PC
board. (See Procedure for Replacing
PC boards).
not change when the arrow or
select keys are pressed.
board.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
SYNERGIC 7 & 7H
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E-10
E-10
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE
CAUSE
RECOMMENDED
COURSE OF ACTION
23. Display is blank
a. Power source is OFF.
a. Turn ON power source.
b. Feeder supply fuse or circuit
breaker at power source is blown
or tripped.
b. Check input cable and feeder unit for
short in 41 and 42 circuit. Check for
shorted motor. Replace fuse or reset
circuit breaker.
c. Display or Control PC board is
bad
c. Observe LED mounted on Control PC
board. It should blink on and off at a
controlled rate of 1 second ON and 1
second OFF. If so, then replace
Display PC board. If not, replace
Control PC board. (See Procedure
for Replacing PC boards)
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
SYNERGIC 7 & 7H
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E-11
E-11
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE
CAUSE
RECOMMENDED
COURSE OF ACTION
24. Display shows any of the following:
HI
a. Voltmeter function is selected and arc a. Normal operation. Voltmeter only reads 0-
voltage is > 80 VDC.
80 VDC.
---
a. Run-in speed is selected but is dis-
abled.
a. Run-in speed is now = weld speed. To re
enable Run-in speed simply press the
increase arrow key.
HXX
Er
a. See Problem 5 or see Section on
Safety Precautions.
a. XX indicates time in seconds before unit
will automatically reset.
a. EEPROM error.
a. Parameter recalled at power-up was out of
range. Press any key to reset. Check all
settings before proceeding to weld. If this
condition persists then ROM assembly X8
on the Control PC board is faulty. Replace
Control PC board. (See procedure for
replacing PC boards.)
EXX
EP
a. Where XX is a number from 1 to 10.
System error.
a. Turn off power to feeder. Wait for 5 sec-
onds. Turn power back on. If EXX is dis-
played again then ROM assembly X8 on
the Control board is faulty. Replace
Control PC board. (See procedure for
replacing PC boards.)
a. EPROM checksum error.
a. Microprocessor RAM error.
a. Turn off power to feeder. Wait 5 seconds.
Turn power back on. If EP is displayed
again then ROM assembly X8 on Control
PC board is faulty. Replace Control PC
board. (See procedure for replacing PC
boards.)
uP
a. Turn off power to feeder. Wait 5 seconds.
Turn power back on. If uP is displayed
again then ROM assembly X8 on the
Control PC board is faulty. Replace
Control PC board. (See procedure for
replacing PC boards.
GLP
a. Grounding Lead Protector circuit is
activated, due to excessive current
flow into the wire feeder frame.
a. To return to normal operating mode,
release the trigger, and press any key on
the keypad. If "GLP" is still displayed or if
it appears again before the trigger is
closed then proceed to step b. Otherwise,
before proceeding to weld make sure that
the electrode is not touching the wire feed-
er frame.
b. Faulty GLP reed switch, harness, or
Control PCB.
b. Replace GLP reed switch CR1 if it is
shorted. Check the wiring harness
between GLP reed switch CR1 and the
Control board. Repair or replace faulty
harness. If the reed switch and the wiring
harness are both OK then replace the
Control board.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
SYNERGIC 7 & 7H
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E-12
E-12
TROUBLESHOOTING
Procedure for Replacing PC Boards
WARNING
ELECTRIC SHOCK can kill.
• Have a qualified individual install and
service this equipment.
• Turn the power source input power off
at the disconnect switch before work-
ing 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 ques-
tion for any electrical or mechanical damage to any of
its components and conductors on the back of the
board.
a. If there is no visible damage to the PC board,
install a new one and see if this remedies the prob-
lem. If the problem is remedied, reinstall the old
PC board to see if the problem still exists. If it
does no longer exist with old PC board:
1. Check the PC board harness connector pins for
corrosion, contamination, or looseness.
2. Check leads in the plug harness for loose or
intermittent connection.
b. If PC board is visibly damaged electrically, before
possibly subjecting the new PC board to the same
cause of failure, check for possible shorts, opens,
or grounds caused by:
1. Frayed or pinched lead insulation.
2. Poor lead termination, such as a poor contact
or a short to adjacent connection or surface.
3. Shorted or open motor leads, or other external
leads.
4. Foreign matter or interference behind the PC
boards.
c. If PC board is visibly damaged mechanically,
inspect for cause, then remedy before installing a
replacement PC board.
If there is damage to the PC board or if replacing
PC board corrects problem, return it to the local
Lincoln Electric Field Service Shop.
SYNERGIC 7 & 7H
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F-1
F-1
DIAGRAMS
5 1 9
5 2 0
5 2 1
ENCODER PC BOARD
ENCODER PC BOARD
5 0 0
5 1 2 A
5 5 3
5 5 2
5 5 1
5 5 4
*
*
*
*
*
*
5 5 3
5 5 1
5 0 0
U
*
*
5 5 4
U
5 1 2 A
5 5 2
8 2 R
8 1 R
5 1 2 B
5 1 9
5 2 0
5 2 7
5 2 6
*
5 0 5
5 0 0
5 0 0
5 1 9
5 2 0
5 1 7
5 1 6
5 2 1
W
2
*
4
5 0 0 M
8 1
8 2
W
5 4 2
R . F . T O R O I D A S S E M B L Y
R E C E P T A C L E
I N P U T C A B L E
SYNERGIC 7 & 7H
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F-2
F-2
DIAGRAMS
INPUT CONNECTION DIAGRAM
SYNERGIC 7 & 7H
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F-3
F-3
DIAGRAMS
DIMENSION PRINT
SYNERGIC 7 & 7H
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NOTES
SYNERGIC 7 & 7H
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NOTES
SYNERGIC 7 & 7H
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NOTES
SYNERGIC 7 & 7H
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NOTES
SYNERGIC 7 & 7H
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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 moja-
da.
● Aislese del trabajo y de la tierra.
fuera del área de trabajo.
cuerpo.
AVISO DE
PRECAUCION
French
● Ne laissez ni la peau ni des vête-
ments mouillés entrer en contact
avec des pièces sous tension.
● Gardez à l’écart de tout matériel
inflammable.
● Protégez vos yeux, vos oreilles et
votre corps.
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 elec-
trodos com a pele ou roupa molha-
da.
● Mantenha inflamáveis bem guarda- ● Use proteção para a vista, ouvido e
dos.
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 HER-
STELLERS. 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 res-
piración.
● Mantenga la cabeza fuera de los
humos. Utilice ventilación o
aspiración para gases.
● Desconectar el cable de ali-
mentación de poder de la máquina
antes de iniciar cualquier servicio.
● No operar con panel abierto o
guardas quitadas.
AVISO DE
PRECAUCION
French
● Débranchez le courant avant l’entre- ● N’opérez pas avec les panneaux
tien.
● Gardez la tête à l’écart des fumées.
● Utilisez un ventilateur ou un aspira-
teur pour ôter les fumées des zones
de travail.
ouverts ou avec les dispositifs de
protection enlevés.
ATTENTION
German
● Strom vor Wartungsarbeiten
abschalten! (Netzstrom völlig öff-
nen; Maschine anhalten!)
● Anlage nie ohne Schutzgehäuse
oder Innenschutzverkleidung in
Betrieb setzen!
● Vermeiden Sie das Einatmen von
Schweibrauch!
● Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
WARNUNG
Portuguese
● Não opere com as tampas removidas.
● Desligue a corrente antes de fazer
serviço.
● 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.
ATENÇÃO
● Não toque as partes elétricas nuas.
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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