Lincoln Electric Synergic 7, Operator'S Manual

Page 1: ...STALL 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 For use with machine Code Nu...

Page 2: ...WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of...

Page 3: ...ical earth ground 3 f Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation 3 g Never dip the electrode in water for co...

Page 4: ...vent 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 Avoid welding near hydraulic...

Page 5: ...appropri s et non inflamma bles 4 Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise pais...

Page 6: ...ion below for future reference This information can be found on your machine nameplate Product _________________________________________________________________________________ Model Number __________...

Page 7: ...s Guard Regulator A 8 Electrical Installation A 9 Optional Features Installation A 10 Operation Section B Safety Precautions B 1 Duty Cycle B 1 Keypad Setup and Operation B 1 Procedure Selector Switch...

Page 8: ...m Model Type Wire Speed Range IPM M M Wire Size Capabilities Solid Electrodes Cored Electrodes Input Power Temperature Rating Operating Storage 40 42 V 10 50 60 Hz 4 0 Amps The following is for both t...

Page 9: ...ge permanent magnet motor and highly efficient two reduction spur gearbox which operates in any position The non fluid lubricant won t leak Quick Release Wire Feed System Provides a completely tool le...

Page 10: ...ossed domes All keys are generously spaced to provide easy selection even if wearing welding gloves 2 Step or 4 Step Trigger Modes Unit operates only when trigger is pressed in 2 Step mode normal oper...

Page 11: ...topped memory ammeter Timer Crater Select key enables operator to choose spot or gas timers or crater speed as indicated by the appro priate light Pressing the key causes lights to sequence left to ri...

Page 12: ...screws The long screw and plain washer go into the top hole WARNING Observe all additional Safety Guidelines detailed throughout this manual ELECTRIC SHOCK can kill Do not touch electrically live part...

Page 13: ...lso requires K489 2 Fast Mate Adapter PROCEDURE TO INSTALL DRIVE ROLL AND GUIDE TUBES Standard 4 Roll Kits KS655 and KS656 1 Turn OFF welding power source 2 Release both quick release levers by slidin...

Page 14: ...26 and K115 gun and cable assemblies are available to allow welding with Innershield elec trodes Gun cable lengths range from 10 ft 3 0 m to 15 ft 4 5 m The 350 ampere K126 with Synergic 7 will feed e...

Page 15: ...to the gas inlet fitting of the Synergic 7 Wire Feed Unit Connect a supply hose from the gas cylinder flow valve outlet to the 5 8 18 female inert gas fitting on the back panel of the Synergic 7 or i...

Page 16: ...rode cable with Twist Mate connector It is rated at 350 amps 60 duty cycle and is available in lengths of 7 ft 2 m 17 ft 5 m 33 ft 10 m and 50 ft 15 m K677 7 Used with Power Wave 350 Similar to K651 b...

Page 17: ...to the front of the platform so the Synergic 7 can be tilted back and wheeled like a two wheel truck Instruction sheet M13424 for assembly installing the K303 K376 K377 or K378 wire stand is provided...

Page 18: ...supply hose Install the 5 8 18 male outlet of the regulator to the 5 8 18 female gas inlet on the back panel of the Synergic 7 Secure fitting with flow adjuster key at top Attach gas supply to 5 8 18...

Page 19: ...low time 2 Trigger release enables 4 step lock leaving the feeder and power source as in step 1 a 4 step with current interlock will only lock if weld current is flowing Breaking weld arc stops wire f...

Page 20: ...age trim may be adjusted using the Volts Trim encoder knob The syn ergic preset voltage trim level may be adjust ed within the range synergically set by the power source for the process and weld Feed...

Page 21: ...tion This number can be adjusted using the arrow keys To exit this function press any other key except the arrow key gas purge or function select key Burnback Time Selection If necessary for higher wi...

Page 22: ...ource for the Procedure Selector switch to function If this overlay is not used only Procedure A will be selected no matter what position the Procedure switch is in If using the optional K683 1 Dual P...

Page 23: ...eeled from the bottom of the coil 6 Set one of the Readi Reel inside cage wires on the slot in the retaining spring tab 7 Lower the Readi Reel to depress the retaining spring and align the other insid...

Page 24: ...retainers fully engage the retaining groove on the spindle ELECTRODE FEEDING AND BRAKE ADJUSTMENT 1 Turn the Readi Reel or spool until the free end of the electrode is accessible 2 While tightly hold...

Page 25: ...the spring loaded arms will not interfere with the later removal of the coil tie wires 5 When loading 0 030 to 0 045 electrode be certain the coil is placed on the reel so the spring loaded arms are...

Page 26: ...through the drive rolls Failure to do this will result in backlash of the coil which may tangle the wire A tangled coil will not feed so it must either be untangled or discarded ______________________...

Page 27: ...ire 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...

Page 28: ...me if used is over 13 If necessary to optimize arc starting adjust wire speed acceleration and or Run In speed See the appropriate sections for adjusting procedures Wire Reel Changing At the end of a...

Page 29: ...on Routine Maintenance Periodic Maintenance and Troubleshooting Guide Problem 24 EP Indicates problem in EPROM assembly See Troubleshooting Guide Problem 24 uP Indicates problem in microprocessor RAM...

Page 30: ...e cable and is available in lengths of 7 ft 2 m 17 ft 5 m 25 ft 7 6 m 33 ft 10 m and 50 ft 15 m K643 Control Cable Extension Consists of an 8 conductor control cable with 14 pin connectors on each end...

Page 31: ...ncludes framework to which is attached a 2 51 mm O D spindle with adjustable brake and 50 60 lb 22 7 27 2 kg K438 Readi Reel adapter Includes a lift bail and cable clamp for fas tening the input cable...

Page 32: ...ted for 400 amps 60 duty cycle Consult sales specifications for appropriate models K556 GMAW process Magnum 400XA X TRAC TOR gun and cable assemblies are rated at 400 amps 60 duty cycle Consult sales...

Page 33: ...ose K1449 1 Dual Procedure Remote Control Includes a remote control box with a 16ft 5m length control cable with 4 pin plug for the mating receptacle on the bottom of the Synergic 7 control box The re...

Page 34: ...d Cable Maintenance See appropriate Operator s Manual MAINTENANCE Safety Precautions Routine Maintenance Drive Rolls and Guide Tubes After feeding every coil of wire inspect the drive roll section Cle...

Page 35: ...Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMP TOMS This column describes possible symptoms that the machine may exhibit F...

Page 36: ...Inspect gun cable and replace if necessary b Remove wire from gun and cable feed in new wire Note any obstructions in gun and cable Replace gun and cable if neces sary c See Wire Feed Drive Roll and G...

Page 37: ...cle welding a See Problem 1 b Defective wire feed motor or gearbox a Defective wire feed motor or con trol PC board a See Gas Metal Arc Welding Guide GS 100 b Clean gas nozzle Make certain that gas di...

Page 38: ...ive control PC board or gun connector a If WFS and preset Volts Trim parame ters on wire feeder display do not match those on power source display see Problem 14 b Measure voltage across pin 2 of J3 a...

Page 39: ...known good input cable see step b to wire feeder 1 receptacle of power source and jumper across sockets C and D of 8 socket input cable plug If no arc voltage is present refer to display on power sou...

Page 40: ...ted to the other input receptacle 1 or 2 of power source then power source is defective b Disconnect input cable from power source and wire feeder Check continuity between socket G of 8 socket plug an...

Page 41: ...e receptacle between pin 2 of J2 and socket A of remote receptacle between pin 3 of J2 and socket D of remote receptacle and between pin 4 of J2 and socket C of remote recepta cle If any of these cont...

Page 42: ...If not refer to Problem 14 c Disconnect harness plug from J2 on Control board Check continuity between plug pins 1 and 12 when local dual procedure switch is in position A but not when in Gun or B No...

Page 43: ...ocal dual procedure switch should be in Gun position if a remote control kit is attached If an optional gun dual procedure switch is attached and both the local dual procedure switch and remote s dual...

Page 44: ...AUSE RECOMMENDED COURSE OF ACTION 23 Display is blank a Power source is OFF b Feeder supply fuse or circuit breaker at power source is blown or tripped c Display or Control PC board is bad a Turn ON p...

Page 45: ...s any key to reset Check all settings before proceeding to weld If this condition persists then ROM assembly X8 on the Control PC board is faulty Replace Control PC board See procedure for replacing P...

Page 46: ...f PC board is visibly damaged electrically before possibly subjecting the new PC board to the same cause of failure check for possible shorts opens or grounds caused by 1 Frayed or pinched lead insula...

Page 47: ...CODER PC BOARD PROCEDURE SWITCH LOCAL DUAL ENCODER PC BOARD 2 1 3 4 5 6 7 2 1 3 4 5 6 7 8 500 505 505 500 A B C D 1112 13 14 15 16 521 520 519 500 505 527 526 517 516 519 520 512B 500 81R 82R 521 520...

Page 48: ...CE TO PROPER POLARITY POWER SOURCE AND SET UP PROCEDURE CHANGE POLARITY TURN POWER OFF REVERSE ELECTRODE AND WORK CABLES AT N B DIAGRAM SHOWS ELECTRODE POSITIVE TO WARNING AND FUTURE DUTY CYCLE OF APP...

Page 49: ...I N T 1 1 6 0 8 0 9 9 7 0 3 8 1 6 H E X H D S C R E W S F O R M T G C O N T R O L B O X T O W I R E R E E L S T A N D 3 P L A C E S 9 4 2 7 7 4 0 3 1 2 8 1 1 1 1 T O L E R A N C E 1 2 5 W I R E D R I...

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: ...electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja da Aislese del trabajo y...

Page 55: ...e Be und Entl ftung des Arbeitsplatzes Mantenha seu rosto da fuma a Use ventila o e exhaust o para remover fumo da zona respirat ria Turn power off before servicing Desconectar el cable de ali mentaci...

Page 56: ...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 Pr...