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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.
• 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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Synergic 7 and 7H
For use with machine Code Numbers 10250 and 10251
OPERATOR'S MANUAL
• World's Leader in Welding and Cutting Products •
R
NRTL/C
Copyright © 2005 Lincoln Global Inc.
IM557
August, 2005
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Troubleshooting
Related Manuals for Lincoln Electric SYNERGIC 7 AND 7H IM557
Summary of Contents for Lincoln Electric SYNERGIC 7 AND 7H IM557
- Page 1 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.
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Page 2: California Proposition 65 Warnings
351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS. -
Page 3: Electric Shock Can Kill
ELECTRIC SHOCK can 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. 3.b. - Page 4 WELDING SPARKS can cause fire or explosion. 6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent 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.
- Page 5 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. Protegez-vous contre la secousse électrique: a.
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Page 6: On-Line Product Registration
The code number is especially important when identifying the correct replacement parts. - 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. -
Page 7: Table Of Contents
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... -
Page 8: Installation
TECHNICAL SPECIFICATIONS – SYNERGIC 7 AND 7H Model Type Wire Speed Range: Wire Size Capabilities: Solid Electrodes Cored Electrodes Input Power: Temperature Rating: Operating Storage The following is for both the Synergic 7 and Synergic 7H models: Size & Weight 4-Roll Feeder: INSTALLATION SYNERGIC 7... -
Page 9: General Description
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. -
Page 10: Control Features
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. Gas Solenoid Valve - Complete with inlet fittings for easy installation of gas is standard on Synergic 7 models. -
Page 11: Keypad And Display Description
K E Y P A D A N D D I S P L A Y DESCRIPTION Keypad - Seven key, membrane L9571-1 type with “snap” tactile feel and embossed domes. COLD FEED GAS PURGE design. Spatter resistant surface. Display - 3-1/2 digit 7-segment VOLTS TRIM RUN-IN... -
Page 12: Safety Precautions
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. -
Page 13: Wire Feed Drive Roll And Guide Tube Kits
Wire Feed Drive Roll and Guide Tube 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 .045 (1.2mm) cored and .045” (1.2mm) solid electrodes. -
Page 14: Gun And Cable Assemblies
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. 10) Install the remaining guide tube in the front hole. -
Page 15: Synergic 7 Water Connections
Synergic 7 Water Connections (for Water- Cooled Guns) These Synergic 7 models must have a K590-4 Water Connection Kit installed. See Options Installation section. 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. -
Page 16: Electrical Installation
ELECTRICAL INSTALLATION 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. -
Page 17: Optional Features Installation
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 of the wire reel mounting assembly, put the input cable assembly under the clamp and reinstall the screws. - Page 18 A-11 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.
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Page 19: Operation
OPERATING INSTRUCTIONS 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. - Page 20 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.
- Page 21 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 CRATER to sequence (left to right, top to bottom) starting from the current indicated posi- SPOT tion.
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Page 22: Procedure Selector Switch
4-Step Trigger Selection Pressing both the Gas Purge key and then the Trigger mode select key causes the 4-step mode light to GAS PURGE turn on and will toggle the 4-step 2-STEP trigger mode between: 4-step with current interlock (as shipped) 4-STEP Crater light will not turn on. -
Page 23: Wire Reel Loading
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. 1) Depress the Release Bar on the Retaining Collar and remove it from the spindle. - Page 24 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. (200 mm) spools, a K468 spindle adapter must first be slipped onto the spindle.] [For 13 to 14 lb (6 kg) Innershield coils, a K435 Coil Adapter must be used.]...
- Page 25 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 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).
- Page 26 WIRE REEL LOADING – 50 AND 60 LB COILS (K1524-1 UNIVERSAL WIRE REEL STAND) 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.) The spindle should be located in the UPPER mount- ing hole.
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Page 27: Idle Roll Pressure Setting
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”. -
Page 28: Making A Weld
B-10 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 Function Select and Arrow keys to set desired Run-in and encoder knob to set Weld Feed Speed. -
Page 29: Grounding Lead Protector
B-11 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. 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. -
Page 30: Optional Features
OPTIONAL FEATURES DRIVE ROLL AND GUIDE TUBE KITS: Steel Wire Sizes: * .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”... - Page 31 UNIVERSAL WIRE REEL STAND (K1524-1) 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.
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Page 32: Readi-Reel Adapters
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) K438 - Adapts Lincoln Readi-Reel coils of electrode 50-60 lb (22.7-27.2 kg) to a 2”... -
Page 33: Misc. Options
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... -
Page 34: Maintenance
MAINTENANCE 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. -
Page 35: Troubleshooting
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. - Page 36 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) 1. Rough wire feeding or wire not feeding but drive rolls turning. 2. Variable or “hunting” arc. 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.
- Page 37 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) 3. Poor arc striking with sticking or “blast-offs”, weld porosity, narrow and ropy looking bead, or elec- trode stubbing into plate while welding. 4. Tip seizes in diffuser. 5. Unit shuts off while welding and “HXX”...
- Page 38 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) 7. No control of wire feed. 8. No wire feed, solenoid, or arc volt- age. LED display indicated Synergic 7 has input power. 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.
- Page 39 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) 9. Wire feed motor runs and solenoid turns on but no arc voltage pre- sent. 10. Speed does not change when weld current flows. 11. Voltmeter does not function or read properly when arc voltage is present.
- Page 40 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) 12. Arrow keys do not change Weld speed or volts/trim. 13. WFS knob does not change Run-in speed. 14. WFS and preset Volts/Trim para- meters on wire feeder display do not match those on power source display.
- Page 41 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) 16. Wire feeder's display does not change when WFS and/or Volts/Trim knobs of the remote control kit are turned. 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.
- Page 42 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) 17. Dual procedure is not functioning when using the local dual proce- dure switch. 18. Optional gun dual procedure switch is not functioning properly. 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.
- Page 43 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) 19. Dual procedure switch of remote control kit is not functioning prop- erly. 20. Purge key does not turn on sole- noid but trigger closure does. 21. Cold Feed key does not turn on wire feed motor but trigger clo- sure does.
- Page 44 E-10 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) 23. Display is blank 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. TROUBLESHOOTING POSSIBLE CAUSE...
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Page 45: Safety Precautions
E-11 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) 24. Display shows any of the following: 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. TROUBLESHOOTING POSSIBLE CAUSE... -
Page 46: Troubleshooting E
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. TROUBLESHOOTING can kill. SYNERGIC 7 & 7H... -
Page 47: Diagrams
ENCODER PC BOARD 512A 512A 512B 500M DIAGRAMS ENCODER PC BOARD ASSEMBLY TOROID R.F. SYNERGIC 7 & 7H RECEPTACLE CABLE INPUT... -
Page 48: Input Connection
DIAGRAMS INPUT CONNECTION DIAGRAM SYNERGIC 7 & 7H... -
Page 49: Dimension Print
DIAGRAMS DIMENSION PRINT SYNERGIC 7 & 7H... - Page 50 NOTES SYNERGIC 7 & 7H...
- Page 51 NOTES SYNERGIC 7 & 7H...
- Page 52 NOTES SYNERGIC 7 & 7H...
- Page 53 NOTES SYNERGIC 7 & 7H...
- Page 54 ● WARNING ● Spanish ● AVISO DE PRECAUCION ● French ● ATTENTION ● ● German WARNUNG ● Portuguese ● ATENÇÃO ● Japanese Chinese Korean Arabic ● ● ● ● ● ● ● ● ● ●...
- Page 55 ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● Spanish ● PRECAUCION French ● ATTENTION ● German WARNUNG Portuguese ● ● Japanese Chinese Korean Arabic WARNING AVISO DE ATENÇÃO...
- Page 56 • 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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