Page 2 - Free; copy of “Arc Welding Safety” booklet E205 is available from the; WARNING; ARC WELDING can be hazardous.
– 2 – PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDRENAWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING. Read and understand the following safety highlights. For additional safety information it is strongly recommended that youpurchase a copy o...
Page 3 - ELECTRIC AND MAGNETIC FIELDS
– 3 – FOR ENGINEpowered equipment. 7.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. --------------------------------------------------------------------------------------- 7.b. Operate engines in open, well-ventilated areas o...
Page 4 - PRÉCAUTIONS DE SÛRETÉ
-4- PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce 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 g é n é r a l e s suivantes: Sûreté Pour Soudage A L’Arc 1....
Page 5 - TABLE OF CONTENTS
– 5 – TABLE OF CONTENTS Page GENERAL DESCRIPTION ..................................................................................................7 RECOMMENDED PROCESSES AND EQUIPMENT .........................................................7 STANDARD FEATURES .........................................
Page 6 - Thank You; for selecting a; QUALITY; product by Lincoln Electric.; Please Examine Carton and Equipment For Damage Immediately
– 6 – Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this LincolnElectric Company product ••• as much pride as wehave in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save this manua...
Page 7 - “Quick Release” Wire Feed System -
GENERAL DESCRIPTION The Synergic 7F is a semiautomatic constant speedwire feeder designed specifically for use with thePower Wave™ type power sources. This boom orfixture mounting wire feeder consists of a Synergic 7FControl Box and the choice of the standard Synergic7F of High Speed Synergic 7FH wi...
Page 9 - K E Y P A D; Extra bright red
– 9 – 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 L E D w i t h ( + ) o r ( - ) p o l a r i t yindicators. .56” (14.2mm) charact...
Page 10 - OPTIONAL FEATURES; DRIVE ROLL AND GUIDE TUBE KITS:; INPUT CABLE ASSEMBLIES:; ) electrode cable with stud terminal. It is rated at 500; GUN AND CABLE ASSEMBLIES:
– 10 – OPTIONAL FEATURES DRIVE ROLL AND GUIDE TUBE KITS: Steel Wire Sizes: 4-Roll * .068 - 3/32” (1.7 - 2.4mm) Cored KP655-3/32 * 1/16” (1.6mm) Cored or Solid KP655-1/16 .045 - .052” (1.2 - 1.4mm) Solid KP655-052S .045 - .052” (1.2 - 1.4mm) Cored KP655-052C .035” (0.9-1.0mm) Cored KP655-035C .035” (...
Page 11 - MISCELLANEOUS OPTIONS:; and Argon blend gases.; - G M A W p r o c e s s M a g n u m 4 0 0 X A X -; * K179 type vacuum unit not recommended for use with
– 11 – MISCELLANEOUS OPTIONS: K682 Water Connection Kit - Includes water cooled gunt u b e f i t t i n g s a n d s e l f - s e a l i n g o u t l e t a n d i n l e t q u i c k -connectors for mounting onto the Synergic 7F Wire Drivemounting bracket. K659-1 - (Gas Guard Regulator) Adjustable flow regu...
Page 13 - INSTALLATION; Safety Precautions; Connecting Wire Feed Unit to Control Box
– 13 – INSTALLATION Safety Precautions INSTALLATION OF THE SYNERGIC 7F COMPONENTS Mounting the Wire Feed Unit (K679-1 or -2) Mount the wire feed unit by means of the insulatedm o u n t i n g b r a c k e t a t t a c h e d t o t h e b o t t o m o f t h egearbox. Reference L9777 dimension print at the ...
Page 14 - ELECTRIC SHOCK can kill.; Wire Feed Drive Roll and Guide Tube Kits
PROCEDURE TO INSTALL DRIVEROLL AND GUIDE TUBES Standard 4-Roll Kits (KP571 and KP572) 1) Turn off welding power source. 2) Release both quick release levers by sliding the levers sideways into the open positions. 3) Remove hex screw & clamping collar from the drive shaft closest to the incoming ...
Page 15 - Gun Cable Connection:; GMAW Guns
– 15 – 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 front hole. Be certain that the pr...
Page 16 - GMAW Shielding Gas; Gas Guard Regulator -
– 16 – GMAW Shielding Gas Customer must provide a cylinder of shielding gas, apressure regulator, a flow control valve, and a hosef r o m t h e f l o w v a l v e t o t h e g a s i n l e t f i t t i n g o f t h eSynergic 7F Wire Feed Unit. Connect a supply hose from the gas cylinder flowvalve outlet ...
Page 17 - Electrical Installation; Work Cable; * For pulse welding applications, the next larger cable; Current
– 17 – Electrical Installation Input Cable: Synergic 7F Control to Power WaveSynergic Type Power Sources K648 - (Used with Power Wave 450) Consists of an 8- conductor control cable with a 14-pin plug and a 4/0 (107mm 2 ) electrode cable with stud terminal. It is rated at 500 amps, 60% duty cycle and...
Page 18 - Dual Procedure; - A d j u s t a b l e f l o w
– 18 – OPTIONAL FEATURESINSTALLATION K648 or K649 Input Cable Assembly - See Electrical Installation section for instructions. K299 50-60 Lb. Wire Reel for Customer Mounting - The K299 is available for use with the Synergic 7FWire Feed Models. The reel for 50 or 60 pound coils isshipped with the nee...
Page 19 - OPERATING INSTRUCTIONS; T r i g g e r c l o s u r e e n e r g i z e s t h e; Closing the trigger a second time; R e l e a s i n g t h e t r i g g e r t u r n s o f f; - Indicates Spot Weld
– 19 – OPERATING INSTRUCTIONS Safety Precautions Duty Cycle The Synergic 7F models are rated at 60% duty cycle* for a maximum current of 600 amps. * Based on a 10 minute time period (6 minutes on, and 4 minutes off). KEYPAD SETUP AND OPERATION Power-Down Save Power to the Synergic 7F is supplied and...
Page 20 - - i n d i c a t e s V o l t m e t e r; - Indicates Weld Feed
– 20 – 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/crater select keyw i l l c a u s e a...
Page 21 - Acceleration Selection
– 21 – 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, spoto r g a s t i m e r s a s i n d i c a t e d b y t h eappropriate light. Pressing key causeslights to sequence (left to right, top tob o t t o m ) s t a r t i n g f r o m t h e c u r r e n tindicated...
Page 22 - (Requires installation; Feeding Electrode and Brake Adjustment
– 22 – W i r e R e e l L o a d i n g - R e a d i - R e e l s a n dSpools (Using K162H Spindle Kit with 2”(51mm) spindle) T O M O U N T A 3 0 L B ( 1 4 K G ) R E A D I - R E E LPACKAGE USING THE MOLDED PLASTIC K363-PTYPE ADAPTER: 1) Make certain that the threaded locking collar is tight and securely ...
Page 23 - DO NOT; Feeding Electrode; CAUTION
– 23 – 4) Tighten the cover as much as possible by hand. DO NOT hammer on the spinner nut arms. 5) Cut and remove only the tie wire holding the free end of the coil. Insert the free end into one of theholes in the cover and secure it by bending it back.Cut and remove the remaining tie wires. Always ...
Page 24 - Idle Roll Pressure Setting; ) Release the incoming idle roll pressure arm, then
– 24 – 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 requiredt o m i n i m i z e “ b i r d n e s t i n g ” . T h ...
Page 27 - Wire Drive Motor and Gearbox; MAINTENANCE; Drive Rolls and Guide Tubes
– 27 – 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 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 shoe wears through to themetal, replace the brake a...
Page 29 - PROBLEMS
– 29 – PROBLEM 1. Rough wire feeding or wire not feeding but drive rolls turning. 2. Variable or “hunting” arc. POSSIBLE CAUSE a. Gun cable kinked and/or twisted. b. Wire jammed in gun and cable. c. Incorrect position of drive rolls with grooves. d. Drive rolls loose. e. Gun cable dirty. f. Worn dri...
Page 30 - PROBLEM
PROBLEMS PROBLEM 3. Poor arc striking with sticking or “blast-offs”, weld porosity,narrow and ropy looking bead,or electrode stubbing into platewhile welding. 4. Tip seizes in diffuser. 5. Unit shuts off while welding and “HXX” appears on display. 6. Drive roll does not turn although arc voltage is ...
Page 35 - HXX; POSSIBLE CAUSE
– 35 – PROBLEM 20. Wire feed speed is consistentand adjustable, but operates at thewrong speed. 21. Display shows any of the following: HI - - - HXX Er EXX EP uP POSSIBLE CAUSE a.Defective gearbox ratio sensingor control board. a. Voltmeter function is selected and arc voltage is > 80V DC. a. Run...
Page 36 - All dimensions in inches and (millimeters); Switch Requirements
– 36 – Procedure for Replacing PC Boards Before replacing a PC board which is suspected ofbeing defective, visually inspect the PC board inquestion for any electrical or mechanical damage toany of its components and conductors on the back ofthe board. a. If there is no visible damage to the PC board...
Page 37 - WIRING DIAGRAM SYNERGIC 7F; ram for a particular code is pasted inside
– 37 – 6 4 1 5 1 4 J13 J4 12 J1 10 L 6 8 PIN 1 R.F. CHOKE P10 P11 5 1 CLEVELAND, OHIO U.S.A. L9778 A 1 7 WIRING DIAGRAM SYNERGIC 7F J2 P.C. BOARD J10 3 J11 1 21 1 J6 J5 J3 J7 DPTT CONTROL P.C. BOARD INPUT CABLE RECEPTACLE A 2 B 4 C D R.F. TOROID ASSEMBLY ELECTRODE INPUT CABLE * * * J1 7 * J3 * * J14...
Page 38 - INPUT CONNECTION DIAGRAM
– 38 – service this machine. Power Source before connecting the wire feeder. H=TACH ELECTRIC Only qualified persons should install, use or G=TACH D=522 E=519 14 PIN L=82 K=42 CAN KILL SHOCK IN CABLE. 14 PIN G PLUG F PIN# C D H I K ELECTRODE L 67 M N 14-SOCKET BOX RECEPTACLE, FRONT VIEW C=2 I=TRIG. A...
Page 39 - CONTROL BOX DIMENSION PRINT
– 39 – DIMENSION PRINT 10.00 2.38 10.32 .41 1.57 11.26 M17740 SYNERGIC 7F CONTROL BOX A 13.31 (2 HOLES FOR MOUNTING) 6.16 R .14 5.24 2.62 R .28 CONTROL BOX DIMENSION PRINT
Page 40 - WIRE FEED UNIT DIMENSION PRINT
– 40 – 1 . 0 0 6 . 2 5 6 . 7 5 4 . 6 7 R E M O T E A 6 . 6 7 7 . 1 6 7 . 5 0 1 . 7 2 3 . 1 8 . 2 5 . 2 5 . 2 8 1 7 . 0 0 1 1 . 2 5 1 . 4 4 T Y P . O U T L E T 1 . 3 1 . 8 1 1 . 0 0 8 . 0 6 . 8 7 I N L E T I N P U T 3 . 3 6 6 . 2 1 G A S F I T T I N G M O U N T I N G W I R E F E E D U N I T ) ( 1 0 H...
Page 41 - Lincoln Welding School; BASIC COURSE; weeks of fundamentals
Now Available...12th EditionThe Procedure Handbook of Arc Welding With over 500,000 copies of previous editions published since 1933, the Procedure Handbook is considered by many to be the “Bible” of the arc welding industry. T h i s p r i n t i n g w i l l g o f a s t s o d o n ’ t d e l a y . P l ...
Page 44 - • 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 • World's Leader in Welding and Cutting Products •
