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 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 Soudage A L...
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 TABLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications ........................................................................................A-1GeneralDescription ................
Page 8 - INSTALLATION; TECHNICAL SPECIFICATIONS – SYNERGIC 7F AND SYNERGIC 7FH; SYNERGIC 7F
A-1 SYNERGIC 7F & FH A-1 INSTALLATION TECHNICAL SPECIFICATIONS – SYNERGIC 7F AND SYNERGIC 7FH SYNERGIC 7F SYNERGIC 7F SYNERGIC 7FH CONTROL WIRE FEED - (4 - ROLL) K678-2 40-42 V ± 10% 50/60 Hz 4.0 Amps K679-1 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...
Page 9 - GENERAL DESCRIPTION; “Quick Release” Wire Feed System -
A-2 INSTALLATION SYNERGIC 7F & FH A-2 GENERAL DESCRIPTION The Synergic 7F is a CSA / NRTL/C certified semiautomaticconstant speed wire feeder designed specifically for usewith the Invertec Power Wave type power sources. Thisboom or fixture mounting wire feeder consists of a Synergic7F Control Bo...
Page 11 - Extra bright red; K E Y P A D
A-4 INSTALLATION SYNERGIC 7F & FH 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 ...
Page 12 - INSTALLATION OF THE SYNERGIC 7F COMPONENTS; Connecting Wire Feed Unit to Control Box; ELECTRIC SHOCK can kill.
A-5 INSTALLATION SYNERGIC 7F & FH A-5 INSTALLATION OF THE SYNERGIC 7F COMPONENTS Safety Precautions Mounting the Wire Feed Unit (K679-1 or -2) Mount the wire feed unit by means of the insulatedmounting bracket attached to the bottom of the gear-box. Reference L9777 dimension print at the rear of...
Page 13 - Wire Feed Drive Roll and Guide Tube Kits
A-6 INSTALLATION SYNERGIC 7F & FH A-6 Wire Feed Drive Roll and Guide Tube Kits NOTE: The maximum sizes the Synergic 7F will feedsatisfactorily are the 3/32” (2.4mm) cored and1/16” (1.6mm) solid electrodes. The maximumsizes the synergic 7FH will feed satisfactorilyare the .045 (1.2mm) cored and ....
Page 14 - ) Install the longer guide tube in the rear hole near; Gun Cable Connection:; GMAW Guns
A-7 INSTALLATION SYNERGIC 7F & FH A-7 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 proper plastic insert is used.Fin...
Page 15 - GMAW Shielding Gas; Gas Guard Regulator -
A-8 INSTALLATION SYNERGIC 7F & FH A-8 G u n C a b l e C o n n e c t i o n s : Wi r e F e e d e rto Gun a. Check that the drive rolls, feeder guide tubes and gun connector guide tube are appropriate for theelectrode size being used. If necessary, changethem per the section on “Wire Feed Drive Rol...
Page 16 - ELECTRICAL INSTALLATION; Work Cable; * For pulse welding applications, the next larger cable; Current
A-9 INSTALLATION SYNERGIC 7F & FH A-9 ELECTRICAL INSTALLATION Input Cable: Synergic 7F Control to Power WaveSynergic 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 groun...
Page 17 - See; Dual Procedure; tor with removable adjustor key for CO
A-10 INSTALLATION SYNERGIC 7F & FH A-10 OPTIONAL FEATURESINSTALLATION K648, K649 or K642 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 ...
Page 18 - OPERATION; OPERATING INSTRUCTIONS; Safety Precautions; - Indicates Spot Weld
B-1 OPERATION B-1 SYNERGIC 7F & FH 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...
Page 19 - 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 operator monitoring.; 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 7F & FH 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/crat...
Page 21 - 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 22 - (Requires installation; Feeding Electrode and Brake Adjustment
B-5 OPERATION B-5 SYNERGIC 7F & FH 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 locki...
Page 23 - DO NOT; Feeding Electrode; CAUTION
B-6 OPERATION B-6 SYNERGIC 7F & FH 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 ...
Page 24 - Idle Roll Pressure Setting
B-7 OPERATION B-7 SYNERGIC 7F & FH 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 “ birdne...
Page 25 - Making a Weld
B-8 OPERATION B-8 SYNERGIC 7F & FH 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 Functi...
Page 26 - Display
B-9 OPERATION B-9 SYNERGIC 7F & FH Explanation of Prompting and Error Messages Display Prompt or Error HI Indicates arc voltage is above 80V DC. --- Indicates selected Run-In speed will be thesame as the weld speed. To enter a differentRun-In speed simply press the increase arrowkey with Run-In ...
Page 27 - ACCESSORIES; OPTIONAL FEATURES; DRIVE ROLL AND GUIDE TUBE KITS:; suffix to the wire sizes.; INPUT CABLE ASSEMBLIES:
C-1 ACCESSORIES C-1 K643 (Control Cable Extension) Consists of an 8-conductorc o n t r o l c a b l e w i t h 1 4 - p i n c o n n e c t o r s o n e a c h e n d f o rextending the control cable between the power source andthe control cable. Available in lengths of 17 ft (5m), 25 ft(7.6m), 33 ft (10m),...
Page 28 - GUN AND CABLE ASSEMBLIES:; connector. They can be; * K179 type vacuum unit not recommended for use with
C-2 ACCESSORIES C-2 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 easyloading; adapter remains on spindle for quick changeover.(used with K162H) K438 - Adap...
Page 29 - Avoiding Wire Feeding Problems; Wire Drive Motor and Gearbox; MAINTENANCE; Drive Rolls and Guide Tubes
D-1 MAINTENANCE D-1 SYNERGIC 7F & FH 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 throug...
Page 30 - TROUBLESHOOTING; TROUBLESHOOTING GUIDE
E-1 TROUBLESHOOTING E-1 SYNERGIC 7F & FH TROUBLESHOOTING GUIDE This Troubleshooting Guide is designed to be used by the machine Owner/Operator. Unauthorized repairs per-formed on this equipment may result in danger to the technician and machine operator and will invalidate yourfactory warranty. ...
Page 31 - Local Lincoln Authorized Field Service Facility; PROBLEMS
E-2 TROUBLESHOOTING E-2 SYNERGIC 7F & FH 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 trouble...
Page 41 - Procedure for Replacing PC Boards; Switch Requirements
E-12 TROUBLESHOOTING E-12 SYNERGIC 7F & FH 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 ...
Page 42 - DIAGRAMS; WIRING DIAGRAM SYNERGIC 7F; ram for a particular code is pasted inside
F-1 DIAGRAMS F-1 SYNERGIC 7F & FH ELECTRODE INPUT CABLE GAS SOLENOID W 539 ASSEMBLY W GUN TRIGGER 541 CONNECTION SWITCH P.M. DUAL PROCEDURE OPTIONAL GUN R R U U B B TA CH B 67 GAS F G H K L I A N E D C B A C B A J M E B A C D J15 J8 UNIT WIRE FEED 1 2 CABLE SHIELDED CABLE SHIELDED 3 1 2 B R 67 U...
Page 43 - INPUT CONNECTION DIAGRAM
F-2 DIAGRAMS F-2 SYNERGIC 7F & FH service this machine. Power Source before connecting the wire feeder. H=TACH ELECTRIC Only qualified persons should install, use or G=TACH E=519 14 PIN L=82 K=42 CAN KILL SHOCK IN CABLE. 14 PIN G PLUG F PIN# I K ELECTRODE L 67 M N 14-SOCKET BOX RECEPTACLE, FRONT...
Page 44 - CONTROL BOX DIMENSION PRINT
F-3 DIAGRAMS F-3 SYNERGIC 7F & FH DIMENSION PRINT 10.00 2.38 10.32 .41 1.57 11.26 M17740 SYNERGIC 7F CONTROL BOX 13.31 (2 HOLES FOR MOUNTING) 6.16 R .14 5.24 2.62 R .28 4-7-95 CONTROL BOX DIMENSION PRINT
Page 45 - WIRE FEED UNIT DIMENSION PRINT
F-4 DIAGRAMS F-4 SYNERGIC 7F & FH 1 . 0 0 6 . 2 5 6 . 7 5 4 . 6 7 R E M O T E 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 ...
Page 46 - NOTES