Page 2 - SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines
FOR ENGINEpowered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors....
Page 3 - ii
ii SAFETY ii ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable...
Page 4 - iii
FOR ELECTRICALLYpowered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working onthe equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’srecommendations. 8.c. Ground the equipment in ac...
Page 5 - iv; PRÉCAUTIONS DE SÛRETÉ
iv SAFETY iv Mar. ‘93 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instruc- tions et les précautions de sûreté specifiques qui parraissent d a n s c e m a n u e l a u s s i b i e n q u e l e s p r é c a u t i o n s d e s û r e t é générales suivantes: Sûreté Pour So...
Page 6 - Thank You; Please Examine Carton and Equipment For Damage Immediately
v v Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save this manual...
Page 7 - TABLE OF CONTENTS; Page
vi vi TABLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications ........................................................................................A-1General Description ............
Page 8 - INSTALLATION; TECHNICAL SPECIFICATIONS – SYNERGIC 7 AND 7H; SYNERGIC 7; Model; Without Wire Stand
A-1 INSTALLATION SYNERGIC 7 & 7H A-1 TECHNICAL SPECIFICATIONS – SYNERGIC 7 AND 7H SYNERGIC 7 SYNERGIC 7H WIRE FEEDER - (4 - ROLL) K631-3 50 - 770 1.25 - 19.5 .025 - 1/16” 0.6 - 1.6mm .045 - 3/32” 1.2 - 2.4mm -20°C to +40°C-40°C to +40°C K631-4 80 - 1200 2.00 - 30.5 .025 - .045” 0.6 - 1.2mm .045”...
Page 9 - GENERAL DESCRIPTION; “Quick Release” Wire Feed System -
A-2 INSTALLATION SYNERGIC 7 & 7H A-2 GENERAL DESCRIPTION The Synergic 7 is a semiautomatic constant speed wirefeeder designed specifically for use with the Invertec PowerWave type power sources. A serial communication link iss u p p l i e d t h r o u g h t h e c o n t r o l c a b l e o f t h e S...
Page 11 - Extra bright red; STD; COLD FEED; K E Y P A D
A-4 INSTALLATION SYNERGIC 7 & 7H A-4 Keypad - Seven key, membrane t y p e w i t h “ s n a p ” t a c t i l e f e e l a n de m b o s s e d d o m e s . L o n g l i f edesign. Spatter resistant surface. D i s p l a y - 3 - 1 / 2 d i g i t 7 - s e g m e n t LED with (+) or (-) polarity indica-t o r s...
Page 12 - INSTALLATION OF THE SYNERGIC 7 COMPONENTS; Attaching Wire Reel Stand; from the back of the wire feed unit.; ELECTRIC SHOCK can kill.
A-5 INSTALLATION SYNERGIC 7 & 7H A-5 INSTALLATION OF THE SYNERGIC 7 COMPONENTS Safety Precautions Attaching Wire Reel Stand The mounting hardware for mounting the wire reelstand is included with the wire feeder. (Screws andwashers are inserted in their respective mountingholes.) To connect: 1) R...
Page 13 - Wire Feed Drive Roll and Guide Tube Kits
A-6 INSTALLATION SYNERGIC 7 & 7H A-6 Wire Feed Drive Roll and Guide Tube Kits NOTE: The maximum sizes the Synergic 7 will feedsatisfactorily are the 3/32” (2.4mm) cored and1/16” (1.6mm) solid electrodes. The maximumsizes the Synergic 7H will feed satisfactorily arethe .045 (1.2mm) cored and .045...
Page 14 - ) Back out the screws for the incoming and outgoing; Gun and Cable Assemblies; GMAW Guns; Gun Cable Connection: Wire Feeder to Gun
A-7 INSTALLATION SYNERGIC 7 & 7H A-7 8) Back out the screws for the incoming and outgoing guide tubes. 9) Install the longer guide tube in the rear hole near the incoming drive roll. Slide the tube in until italmost touches the roll. Tighten in place. 10) Install the remaining guide tube in the ...
Page 15 - ) U s i n g m a l e q u i c k - c o n n e c t f i t t i n g s ( i n c l u d e d w i t h; GMAW Shielding Gas; Gas Guard Regulator -; The Gas Guard Regulator is; CYLINDER may explode if damaged.; • Keep cylinder upright and chained to
A-8 INSTALLATION SYNERGIC 7 & 7H A-8 Synergic 7 Water Connections (for Water-Cooled Guns) These Synergic 7 models must have a K590-4 WaterConnection Kit installed. See Options Installation section. 1) U s i n g m a l e q u i c k - c o n n e c t f i t t i n g s ( i n c l u d e d w i t h appropria...
Page 16 - ELECTRICAL INSTALLATION; install the input cable per connection diagram
A-9 INSTALLATION SYNERGIC 7 & 7H A-9 ELECTRICAL INSTALLATION Input Cable: Synergic 7 Wire Feeder to PowerWave Synergic Type Power Sources NOTE: CSAnrtl certification of the Synergic 7 models is with input cable assemblies identified by carton date codes010161, or above. These assemblies have gro...
Page 17 - Work Cable; * For pulse welding applications, the next larger cable; Current
A-10 INSTALLATION SYNERGIC 7 & 7H A-10 4) Connect the remaining end of the control cable with the 8-socket cable plug to the mating recepta-cle on the Synergic 7. 5) Install the input cable under the wire reel mounting stand strain relief clamp. Remove the screws hold-ing the clamp to the base o...
Page 18 - - If the user desires to protect the
A-11 INSTALLATION SYNERGIC 7 & 7H A-11 Wire Reel Dust Shield for K376 50-60 Lb. Wire ReelMounting Stand - If the user desires to protect the wire from falling dirt and dust, there is a shield avail-a b l e t o c o v e r t h e w i r e r e e l . O r d e r p a r t n u m b e rS14543. Instructions ar...
Page 19 - OPERATION; OPERATING INSTRUCTIONS; Safety Precautions; - Indicates Spot Weld
B-1 OPERATION B-1 SYNERGIC 7 & 7H OPERATING INSTRUCTIONS Safety Precautions Duty Cycle The Synergic 7 models are rated at 60% duty cycle * fora maximum current of 600 amps. * Based on a 10 minute time period (6 minutes on, and 4 minutes off). KEYPAD SETUP AND OPERATION Power-Down Save Power to t...
Page 20 - Display Control Keys; - i n d i c a t e s V o l t m e t e r; after welding to permit; Middle Light; - I n d i c a t e s W e l d F e e d
B-2 OPERATION B-2 SYNERGIC 7 & 7H Display Control Keys T h e f u n c t i o n s e l e c t , t i m e r / c r a t e rselect, arrow keys and rotationale n c o d e r s a l l e f f e c t t h e d i s p l a y .Pressing the function select key willcause a function to be displayed.Pressing the timer/crate...
Page 21 - GAS PURGE
B-3 OPERATION B-3 SYNERGIC 7 & 7H T i m e r / C r a t e r S e l e c t - k e y e n a b l e s operator to choose crater speed, spotor gas timers as indicated by the appro-priate light. Pressing key causes lightsto sequence (left to right, top to bottom)starting from the current indicated posi-tion...
Page 22 - Procedure Selector Switch; Crater light will not turn on.; Memory Ammeter Selection; P r e s s i n g b o t h t h e G a s
B-4 OPERATION B-4 Procedure Selector Switch The toggle switch on the front panel provides selectionof Procedure A or Procedure B, as set with the frontp a n e l k n o b c o n t r o l s . R o t a t i n g t h e k n o b e n c o d e rchanges only the procedure selected by this switch.Also, this switch s...
Page 23 - WIRE LOADING; LOWER
B-5 OPERATION B-5 SYNERGIC 7 & 7H WIRE LOADING Loading a 22 to 30 Lb. (10 to 14 kg) Readi-ReelP a c k a g e U s i n g t h e M o l d e d P l a s t i c K 3 6 3 - PReadi-Reel Adapter: The Spindle should be located in the LOWER mounting hole of the K1524-1 Universal Stand if used. 1) Depress the Rel...
Page 25 - WIRE REEL LOADING; CAUTION
B-7 OPERATION B-7 SYNERGIC 7 & 7H WIRE REEL LOADING – 50 AND 60 LB COILS (K303 OR K376 WIRE REEL STAND) ADJUSTABLE WIRE REEL BRAKE The mount for standard 50 and 60 pound electrodecoils includes a two-position brake assembly.Generally the brake should be at the inner position(nearest to the wire ...
Page 26 - Tighten the spinner nut against the reel cover as; Feeding Electrode; ) Turn the reel until the free end of the electrode is
B-8 OPERATION B-8 SYNERGIC 7 & 7H WIRE REEL LOADING – 50 AND 60 LB COILS (K1524-1 UNIVERSAL WIRE REELSTAND) TO MOUNT A 50 to 60 lb (22.7 to 27.2 kg) COIL:( U S I N G K 1 5 0 4 - 1 C O I L R E E L ) ( F O R 5 0 t o 6 0 l bR E A D I - R E E L S A K 4 3 8 R E A D I - R E E L A D A P T E RMUST BE US...
Page 27 - Idle Roll Pressure Setting; ) Release the incoming idle roll pressure arm, then; Gas Guard Regulator Setting; ) Adjust gas supply flow rate for a level higher than
B-9 OPERATION B-9 SYNERGIC 7 & 7H Idle Roll Pressure Setting The idle roll pressure is set at the factory, backed outthree turns from full pressure on 4-roll feeders. This isan approximate setting. For small wire sizes andaluminum wire up to 9 or 10 turns out may be requiredto minimize “birdnest...
Page 28 - Making a Weld
B-10 OPERATION B-10 SYNERGIC 7 & 7H Making a Weld 1) Use only Power Wave model “synergic” power sources. 2) Properly connect the electrode and work leads for the correct electrode polarity. 3) Use Mode Selection key to set desired operating mode. (Refer to Mode Selection section.) 4) Use Functio...
Page 29 - Grounding Lead Protector; Display
B-11 OPERATION B-11 SYNERGIC 7 & 7H Grounding Lead Protector The frame of the Synergic 7 wire feeder is groundedto the frame of the power source by a lead in the con-trol cable. An overload protector prevents weldingcurrent from damaging this lead if the electrode circuittouches the wire feeder ...
Page 30 - ACCESSORIES; ) electrode cable with stud terminal. It is rated; OPTIONAL FEATURES; DRIVE ROLL AND GUIDE TUBE KITS:; ** F o r u s e w i t h B i n z e l E u r o p e a n g u n s . I n s t a l l a t i o n; INPUT CABLE ASSEMBLIES:
C-1 ACCESSORIES C-1 17 ft. (5 m), 25 ft. (7.6 m), 33 ft. (10 m) and 50 ft. (15m). K648 - (Used with Power Wave 450) Consists of an 8- conductor control cable with a 14-pin plug and a 4/0(107 mm 2 ) electrode cable with stud terminal. It is rated at 500 amps, 60% duty cycle and is available in length...
Page 32 - GUN AND CABLE ASSEMBLIES:
C-3 ACCESSORIES C-3 K541 Magnum 400 Short Neck GMAW gun and cable assemblies are rated 400 amps, 60% duty cycle.(Consult sales specifications for appropriate models) K598 Magnum 550 GMAW gun and cable assemblies are rated 550 amps, 60% duty cycle. (Consult salesspecifications for appropriate models)...
Page 33 - * K179 type vacuum unit not recommended for; Undercarriage - For all Synergic 7 wire reel
C-4 ACCESSORIES C-4 SYNERGIC 7 & 7H K566 * - GMAW process Magnum 250XA X-TRAC- TOR gun and cable assemblies are rated 250 amps,60% duty cycle. (Consult sales specifications forappropriate models). * K179 type vacuum unit not recommended for use with Synergic 7. MISC. OPTIONS: K590-4 ( Water Conn...
Page 34 - Spindle; Wire Drive Motor and Gearbox; MAINTENANCE; Drive Rolls and Guide Tubes
D-1 MAINTENANCE D-1 SYNERGIC 7 & 7H W i r e R e e l M o u n t i n g - 5 0 ( 2 2 . 7 k g ) a n d60lb (27.2kg) Coils with 1 ” Spindle To prolong the life of the reel shaft, periodically coat itwith a thin layer of grease. No maintenance of the two-position adjustable brakeis needed. If the brake s...
Page 35 - TROUBLESHOOTING; Local Lincoln Authorized Field Service Facility; for technical troubleshooting assistance before you proceed.; Step 3. RECOMMENDED COURSE OF ACTION
E-1 TROUBLESHOOTING E-1 SYNERGIC 7 & 7H WARNING Observe all additional Safety Guidelines detailedthroughout this manual. ELECTRIC SHOCK can kill. • Do not touch electrically live parts suchas output terminals or internal wiring. • When inching with gun trigger, electrode anddrive mechanism are “...
Page 36 - PROBLEMS
E-2 TROUBLESHOOTING E-2 SYNERGIC 7 & 7H 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. CAUTION Observe all Saf...
Page 38 - Observe all Safety Guidelines detailed throughout this manual; b. Defective wire feed motor tach or
E-4 TROUBLESHOOTING E-4 SYNERGIC 7 & 7H Observe all Safety Guidelines detailed throughout this manual 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 troubles...
Page 46 - Procedure for Replacing PC Boards
E-12 TROUBLESHOOTING E-12 SYNERGIC 7 & 7H Procedure for Replacing PC Boards Before replacing a PC board which is suspected ofbeing defective, visually inspect the PC board in ques-tion for any electrical or mechanical damage to any ofits components and conductors on the back of theboard. a. If t...
Page 47 - DIAGRAMS; WIRING DIAGRAM SYNERGIC 7; ram for a particular code is pasted inside
F-1 DIAGRAMS F-1 SYNERGIC 7 & 7H P10 PIN 1 CONNECTOR CAVITY 1 (C O M P O N E N T S ID E O F P .C . B O A R D ) PIN NUMBERING SEQUENCE ** J6 1 (C O M P O N E N T S ID E O F P .C . B O A R D ) C A V IT Y N U M B E R IN G S E Q U E N C E * R.F. CHOKE L 82 81 H 67 G F 4 2 D R C B A * J2 P11 2 4 1 J2...
Page 48 - INPUT CONNECTION DIAGRAM
F-2 DIAGRAMS F-2 SYNERGIC 7 & 7H E=GND F=67 8-PIN BOX RECEPTACLE, FRONT VIEW M=81 C=2 N=67 H=82 D=4 14-SOCKET BOX RECEPTACLE, FRONT VIEW G=81 AND 14-PIN CABLE PLUG, REAR VIEW B=GND I=41 TRIGGER CIRCUIT 2 GND L 4 N I PIN ELECTRODE CABLE 42 D PLUG PIN# TRIGGER CIRCUIT 41 C FUNCTION 42V AC +SERIAL ...
Page 49 - TO WIRE REEL STAND; DIMENSION PRINT
F-3 DIAGRAMS F-3 SYNERGIC 7 & 7H 20102 3-13-92 DIMENSION PRINT 11.60 8.09 9.70 3/8-16 HEX. HD. SCREWS FOR MTG. CONTROL BOX TO WIRE REEL STAND (3 PLACES) 9.42 .77 4.03 1.28 11.11 TOLERANCE ~.125 WIRE DRIVE & CONTROL BOX AS'BLY LN-7GMA 4 ROLL DIMENSION PRINT
Page 50 - NOTES
Page 54 - ÇÃ
WARNING AVISO DE PRECAUCION ATTENTION WARNUNG ATEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BEUSED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS I...