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Synergic 7 and 7H OPERA TOR’S MANUAL IM557 August, 2005 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.
FOR ENGINE powered 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.
ii SAFETY ii ARC RA YS can burn. 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.
FOR ELECTRICALL Y powered equipment. 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.
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 dans ce manuel aussi bien que les précautions de sûreté générales suivantes: Sûreté Pour Soudage A L’Arc 1.
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.
vi vi T ABLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications ......................................................................
A-1 INST ALLA TION SYNERGIC 7 & 7H A-1 TECHNICAL SPECIFICA TIONS – 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.
A-2 INST ALLA TION SYNERGIC 7 & 7H A-2 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-3 INST ALLA TION SYNERGIC 7 & 7H A-3 Crater Fill - Provides crater feed speed adjustment (in 4-step trigger mode) independent of weld, cold inch, or run-in speeds. Solid-State Overload Protection - No circuit breaker to reset. Front panel display indicates time remaining before automatic reset.
A-4 INST ALLA TION SYNERGIC 7 & 7H A-4 Keypad - Seven key, membrane type with “snap” tactile feel and embossed domes. Long life design. Spatter resistant surface. Display - 3-1/2 digit 7-segment LED with (+) or (-) polarity indica- tors. .56” (14.
A-5 INST ALLA TION SYNERGIC 7 & 7H A-5 INST ALLA TION OF THE SYNERGIC 7 COMPONENTS Safety Precautions 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.
A-6 INST ALLA TION SYNERGIC 7 & 7H A-6 Wire Feed Drive Roll and Guide T ube Kits 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 .
A-7 INST ALLA TION 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 it almost touches the roll. Tighten in place.
A-8 INST ALLA TION SYNERGIC 7 & 7H A-8 Synergic 7 W ater Connections (for W ater- Cooled Guns) These Synergic 7 models must have a K590-4 Water Connection Kit installed.
A-9 INST ALLA TION SYNERGIC 7 & 7H A-9 ELECTRICAL INST ALLA TION 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.
A-10 INST ALLA TION 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.
A-1 1 INST ALLA TION SYNERGIC 7 & 7H A-1 1 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.
B-1 OPERA TION B-1 SYNERGIC 7 & 7H OPERA TING INSTRUCTIONS Safety Precautions Duty Cycle The Synergic 7 models are rated at 60% duty cycle * for a maximum current of 600 amps.
B-2 OPERA TION B-2 SYNERGIC 7 & 7H 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.
B-3 OPERA TION B-3 SYNERGIC 7 & 7H Timer/Crater Select - key enables 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.
B-4 OPERA TION B-4 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.
B-5 OPERA TION B-5 SYNERGIC 7 & 7H WIRE LOADING Loading a 22 to 30 Lb. (10 to 14 kg) Readi-Reel Package Using the Molded Plastic K363-P Readi-Reel Adapter: The Spindle should be located in the LOWER mounting hole of the K1524-1 Universal Stand if used.
B-6 OPERA TION B-6 SYNERGIC 7 & 7H 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: The spindle should be located in the lower mounting hole of the K1524-1 Universal Stand if used. [For 8 in.
B-7 OPERA TION B-7 SYNERGIC 7 & 7H WIRE REEL LOADING – 50 AND 60 LB COILS (K303 OR K376 WIRE REEL ST AND) ADJUSTABLE WIRE REEL BRAKE The mount for standard 50 and 60 pound electrode coils includes a two-position brake assembly.
B-8 OPERA TION B-8 SYNERGIC 7 & 7H WIRE REEL LOADING – 50 AND 60 LB COILS (K1524-1 UNIVERSAL WIRE REEL ST AND) 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.
B-9 OPERA TION B-9 SYNERGIC 7 & 7H 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”.
B-10 OPERA TION 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.
B-1 1 OPERA TION B-1 1 SYNERGIC 7 & 7H Grounding Lead Protector 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.
C-1 ACCESSORIES C-1 17 ft. (5 m), 25 ft. (7.6 m), 33 ft. (10 m) and 50 ft. (15 m). 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 lengths of 7 ft (2 m), 17 ft (5 m), 25 ft (7.
C-2 ACCESSORIES C-2 WIRE REEL ASSEMBL Y : 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.
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.
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 for appropriate models). * K179 type vacuum unit not recommended for use with Synergic 7.
D-1 MAINTENANCE D-1 SYNERGIC 7 & 7H Wire Reel Mounting - 50 (22.7kg) and 60lb (27.2kg) Coils with 1 ” Spindle To prolong the life of the reel shaft, periodically coat it with a thin layer of grease. No maintenance of the two-position adjustable brake is needed.
E-1 TROUBLESHOOTING E-1 SYNERGIC 7 & 7H W ARNING Observe all additional Safety Guidelines detailed throughout this manual. ELECTRIC SHOCK can kill.
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.
E-3 TROUBLESHOOTING E-3 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 troubleshooting assistance before you proceed.
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 troubleshooting assistance before you proceed.
E-5 TROUBLESHOOTING E-5 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 troubleshooting assistance before you proceed.
E-6 TROUBLESHOOTING E-6 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 troubleshooting assistance before you proceed.
E-7 TROUBLESHOOTING E-7 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 troubleshooting assistance before you proceed.
E-8 TROUBLESHOOTING E-8 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 troubleshooting assistance before you proceed.
E-9 TROUBLESHOOTING E-9 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 troubleshooting assistance before you proceed.
E-10 TROUBLESHOOTING E-10 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 troubleshooting assistance before you proceed.
E-1 1 TROUBLESHOOTING E-1 1 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.
E-12 TROUBLESHOOTING E-12 SYNERGIC 7 & 7H Procedure for Replacing PC Boards 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.
F-1 DIAGRAMS F-1 SYNERGIC 7 & 7H P10 PIN 1 CONNECTOR CAVITY 1 ( C O M P O N E N T S I D 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 I D E O F P . C . B O A R D ) C A V I T Y N U M B E R I N G S E Q U E N C E * R.
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 CI.
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.
NOTES SYNERGIC 7 & 7H.
NOTES SYNERGIC 7 & 7H.
NOTES SYNERGIC 7 & 7H.
NOTES SYNERGIC 7 & 7H.
W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE PARA ESTE EQUIP AMENTO E AS P ARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
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