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B-9
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". The optimum idle roll pres-
sure varies with type of wire, surface condition, lubri-
cation, and hardness. The optimum idle roll setting
can be determined as follows:
1) Release the incoming idle roll pressure arm, then
press end of gun against a solid object that is elec-
trically isolated from the welder output and press
the gun trigger for several seconds.
2) If the wire "birdnests", jams, or breaks at the drive
roll, the idle roll pressure is too great. Back the
pressure setting out 1/2 turn, run new wire through
gun, and repeat above steps.
3) If the only result is drive roll slippage, disengage
the gun locking nut, and pull the gun cable forward
about 6" (150mm). There should be a slight wavi-
ness in the exposed wire. If there is no waviness,
the pressure is too low. Increase the pressure set-
ting 1/4 turn, reconnect the gun, tighten the locking
nut, and repeat the above steps.
4) After the outgoing pressure is set, determine how
many turns away from full pressure the setting is.
Set both idle roll tensions to this setting. Engage
both idle rolls before welding. In most applications,
best wire feeding will occur when both idle roll
pressures are set the same.
Gas Guard Regulator Setting
1) With the gas supply shut off, the Gas Guard regu-
lator flow adjusting key should be set to maximum
(full clockwise) which is rated to be 60 SCFH (28
lts/ min).
2) Adjust gas supply flow rate for a level higher than
will be required, then adjust Gas Guard flow
adjusting key counterclockwise to the desired gas
flow rate.
OPERATION
SYNERGIC 7 & 7H
B-9
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