RETURN TO MAIN MENU IM559 Synergic 7F and Synergic 7FH June, 2003 For use with machine Code Numbers 10190, 10191 & 10254 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 thoughtful operation on your part. DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT.
i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. The Above For Diesel Engines The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS.
ii ii SAFETY 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. Insulate yourself from work and ground using dry insulation. Make certain the insulation is large enough to cover your full area of physical contact with work and ground.
iii iii SAFETY 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. Avoid welding near hydraulic lines. Have a fire extinguisher readily available. 6.b.
iv iv SAFETY PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions 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. Les circuits à l’électrode et à la piéce sont sous tension quand la machine à souder est en marche.
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! Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped, title passes to the purchaser upon receipt by the carrier.
TABLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications ........................................................................................A-1 GeneralDescription ................................................................................................A-2 Recommended Processes and Equipment ...........................................................A-2 Standard Features ..........
A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS – SYNERGIC 7F AND SYNERGIC 7FH WIRE FEED - (4 - ROLL) CONTROL Model SYNERGIC 7F SYNERGIC 7F SYNERGIC 7FH Type K678-2 K679-1 K679-2 50 - 770 1.25 - 19.5 80 - 1200 2.00 - 30.5 .025 - 1/16” 0.6 - 1.6mm .025 - .045” 0.6 - 1.2mm .045 - 3/32” 1.2 - 2.4mm .045” 1.2mm Wire Speed Range: IPM M/M Wire Size Capabilities: Solid Electrodes Cored Electrodes Input Power: 40-42 V ± 10% 50/60 Hz 4.
A-2 INSTALLATION GENERAL DESCRIPTION The Synergic 7F is a CSA / NRTL/C certified semiautomatic constant speed wire feeder designed specifically for use with the Invertec Power Wave type power sources. This boom or fixture mounting wire feeder consists of a Synergic 7F Control Box and the choice of the standard Synergic 7F or High Speed Synergic 7FH wire feed unit and connecting cable assemblies.
A-3 INSTALLATION 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 7F models. Also available, as an option (K659-1), a Gas Guard regulator for flow surge suppression.
A-4 A-4 INSTALLATION K E Y PA D A N D D I S P L AY DESCRIPTION V VOLTS / TRIM RUN-IN WFS COLD FEED Keypad - Seven key, membrane type with “snap” tactile feel and embossed domes. Long life design. Spatter resistant surface. GAS PURGE V VOLTS / TRIM RUN-IN WFS TRIGGER MODE PREFLOW 2-STEP STD 4-STEP POSTFLOW 1 2 CRATER Adjusting either encoder knob automatically transfers display (and indicator light) to the function being adjusted.
A-5 INSTALLATION INSTALLATION OF THE SYNERGIC 7F COMPONENTS Safety Precautions WARNING A-5 door screws. c) Mount the box. d) Tighten the screws. e) Close the control box door and replace the door screws. Connecting Wire Feed Unit to Control Box ELECTRIC SHOCK can kill. • Do not touch electrically live parts such as output terminals or internal wiring.
A-6 A-6 INSTALLATION Wire Feed Drive Roll and Guide Tube Kits NOTE: The maximum sizes the Synergic 7F will feed satisfactorily are the 3/32” (2.4mm) cored and 1/16” (1.6mm) solid electrodes. The maximum sizes the synergic 7FH will feed satisfactorily are the .045 (1.2mm) cored and .045” (1.2mm) solid electrodes. PROCEDURE TO INSTALL DRIVE ROLL AND GUIDE TUBES WARNING ELECTRIC SHOCK can kill. • Do not touch electrically live parts such as output terminals or internal wiring.
A-7 INSTALLATION 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. Be certain that the proper plastic insert is used. Fine wire chisel point tube must have largest radius next to drive roll. Tighten in place. 11) Re-latch both quick release levers. 12) To start new electrode, straighten the first 6” (150mm) and cut off the first 1” (25mm).
A-8 A-8 INSTALLATION Gun Cable Connections: Wire Feeder to Gun a. Check that the drive rolls, feeder guide tubes and gun connector guide tube are appropriate for the electrode size being used. If necessary, change them per the section on “Wire Feed Drive Roll and Guide Tube Kits”. b. Connect gun to gun connector making sure all pins and gas tube line up with appropriate holes in connector. Tighten gun by turning large nut on gun clockwise.
A-9 A-9 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. • Turn OFF input power at welding power source before installation or changing drive roll and/or guide tubes.
A-10 INSTALLATION A-10 OPTIONAL FEATURES INSTALLATION 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 7F Wire Feed Models. The reel for 50 or 60 pound coils is shipped with the needed mounting shaft, hardware, and insulation.
B-1 B-1 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. 2-STEP STD 4-STEP LOCK SPOT 1.
B-2 OPERATION V VOLTS / TRIM RUN-IN WFS 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. Whichever is pressed last is the one that will be displayed since they cannot be displayed simultaneously.
B-3 B-3 OPERATION PREFLOW POSTFLOW 1 2 CRATER SPOT Timer/Crater Select - key enables operator to choose crater speed, spot or gas timers as indicated by the appropriate light. Pressing key causes lights to sequence (left to right, top to bottom) starting from the current indicated position. Any parameter not available in the mode selected is skipped over.
B-4 OPERATION 4-Step Trigger Selection GAS PURGE 2-STEP STD 4-STEP LOCK SPOT Mode Dual Procedure Remote Control (K1449-1) Pressing both the Gas Purge key and then the Trigger mode select key causes the 4-step mode light to turn on and will toggle the 4-step trigger mode between: 4-step with current interlock (as shipped) Crater light will not turn on. and 4-step with crater fill. Crater light will turn on for crater speed setting with arrow keys.
B-5 B-5 OPERATION MOLDED ADAPTER 2" O.D. SPINDLE RETAINING SPRING Brake Holding Pin (Must engage hole in adapter rib) PIN To Mount 10 to 44 lb (4.5-20kg) Spool (12”/300mm Diameter): (Requires installation of 2” (51mm) spindle K162H Kit. For 8” (200mm) spools, a K468 spindle adapter must be used.) 1) Remove the locking collar on the 2” (51mm) diameter spindle.
B-6 B-6 OPERATION Wire Reel Loading - 50-60lb (22.7-27.2kg) Coils (K299 Wire Reel Mounting Kit) Adjustable Wire Reel Brake The mount for standard 50-60 lb (22.7-27.2 kg) 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. (10m/m). It should be at the outer position for the faster wire speeds often used when feeding small diameter electrode.
B-7 OPERATION Wire Loading of 13-14lb (6kg) Innershield Coils Requires use of K162H Spindle Kit and K435 14 Lb. Coil Adapter. B-7 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 pressure varies with type of wire, surface condition, lubrication, and hardness.
B-8 OPERATION 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 Speeds. (Set for each procedure if using any Dual Procedure function). (See the appropriate sections for adjusting procedures).
B-9 OPERATION 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 the same as the weld speed. To enter a different Run-In speed simply press the increase arrow key with Run-In selected. HXX Indicates wire feed overload. XX indicates time remaining in seconds before unit resets automatically. See sections on Routine Maintenance, Periodic Maintenance, and Troubleshooting Guide Problem 25.
C-1 ACCESSORIES 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” (0.9-1.0mm) Solid .030” (0.8mm) Solid .023” (0.6mm) Solid Aluminum Wire Sizes: 1/16” (1.6mm) 3/64” (1.2mm) .040” (1.0mm) .035” (0.
C-2 ACCESSORIES 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 spindle for quick changeover. (used with K162H) C-2 K309* - Innershield Linconditioner gun and cable assemblies are rated 250 amps, 60% duty cycle. Maximum size for Synergic 7F Wire Feed unit is 5/64” (2.0 mm). Not recommended for Synergic 7FH Wire Feed unit.
D-1 MAINTENANCE D-1 Wire Reel Mounting - 50 (22.7kg) and 60lb (27.2kg) Coils MAINTENANCE Safety Precautions To prolong the life of the reel shaft, periodically coat it with a thin layer of grease. 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.
E-1 TROUBLESHOOTING E-1 TROUBLESHOOTING GUIDE 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. • Turn OFF input power at welding power source before installation or changing drive roll and/or guide tubes.
E-2 E-2 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) 1. Rough wire feeding or wire not feeding but drive rolls turning. POSSIBLE AREAS OF MISADJUSTMENTS(S) RECOMMENDED COURSE OF ACTION a. Gun cable kinked and/or twisted. a. Inspect gun cable and replace if necessary. b. Wire jammed in gun and cable. b. Remove wire from gun and cable feed in new wire. Note any obstructions in gun and cable. Replace gun and cable if necessary. c.
E-3 E-3 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENTS(S) 3. Poor arc striking with sticking or a. Improper procedures or tech“blast-offs”, weld porosity, narrow niques. and ropy looking bead, or electrode stubbing into plate while b. Improper gas shielding. welding. RECOMMENDED COURSE OF ACTION a. See “Gas Metal Arc Welding Guide” (GS-100). b. Clean gas nozzle. Make certain that gas diffuser is not restricted.
E-4 E-4 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) 7. No control of wire feed. POSSIBLE AREAS OF MISADJUSTMENTS(S) RECOMMENDED COURSE OF ACTION a. Problem with serial communications. a. If WFS and preset Volts/Trim parameters on wire feeder display do not match those on power source display, see Problem 14. b. Defective Wire Feed Unit to Control box cable or harnessing. b.
E-5 E-5 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENTS(S) 9. Wire feed motor runs and solenoid a. Power source is defective. turns on but no arc voltage present. 10. Speed does not change when weld current flows. RECOMMENDED COURSE OF ACTION a. If arc voltage is present when wire feeder is connected to the other input receptacle (#1 or #2) of power source then power source is defective.
E-6 E-6 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENTS(S) RECOMMENDED COURSE OF ACTION 12. Arrow keys do not change Weld speed or volts/trim. a. This is normal, as only the WFS and volts/trim knobs will adjust these settings. a. Refer to operation section of this manual 13. WFS knob does not change Run-in speed. a. This is normal, as only the arrow keys will adjust this setting. a.
E-7 E-7 TROUBLESHOOTING 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. POSSIBLE AREAS OF MISADJUSTMENTS(S) RECOMMENDED COURSE OF ACTION a. Loose connection to Remote con- a. Make sure that remote cable connectrol receptacle, J22. tions are tight. b. Faulty Remote PC board. b.
E-8 E-8 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENTS(S) RECOMMENDED COURSE OF ACTION 17. Dual procedure is not functioning a. Optional gun dual procedure when using the local dual proceswitch or remote control kit may dure switch. be connected. a.
E-9 E-9 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENTS(S) RECOMMENDED COURSE OF ACTION 19. Dual procedure switch of remote a. Local dual procedure switch is not a. Local dual procedure switch should be control kit is not functioning propin "Gun" position, and/or an in "Gun" position if a remote control kit erly. optional gun dual procedure is attached. If an optional gun dual switch is attached.
E-10 E-10 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) 23. Display is blank. POSSIBLE AREAS OF MISADJUSTMENTS(S) a. Power source is OFF. RECOMMENDED COURSE OF ACTION a. Turn ON power source. b. Feeder supply fuse or circuit b. Check input cable and feeder unit for breaker at power source is blown short in 41 and 42 circuit. Check for or tripped. shorted motor. Replace fuse or reset circuit breaker. c. Display or Control PC board is bad. 24.
E-11 E-11 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENTS(S) RECOMMENDED COURSE OF ACTION 25. Display shows any of the following: HI a. Voltmeter function is selected and a. Normal operation. Voltmeter only arc voltage is > 80 VDC. reads 0-80 VDC. --- a. Run-in speed is selected but is disabled. HXX a. See Problem 5 or see Section on a. XX indicates time in seconds before Safety Precautions.
E-12 E-12 TROUBLESHOOTING Procedure for Replacing PC Boards Gun Cable Connector Requirements to Permit Proper Connection to Wire Feed Units WARNING ELECTRIC SHOCK can kill. • Have a qualified individual install and service this equipment. • Turn the power source input power off at the disconnect switch before working on this equipment. • Do not touch electrically hot parts.
SYNERGIC 7F & FH CAVITY NUMBERING SEQUENCE 7 8 5 6 4 3 527 526 14 7 J5 4 4 8 5 6 1 L R.F. CHOKE 3 4 PIN 1 F D G E 500 553 552 551 1 J14 J12 4 3 2 1 P14 P12 3 4 2 CONTROL CABLE B SHIELDED CABLE 531 U J9 J8 J W E D C W C B A J15 WIRE FEED UNIT ASSEMBLY B A 520 F I K H G M 67 L A B R U B W P.M. N D C E B B R M 519 P12*** I STUD GROUNDING CASE R.F. TOROID ASSEMBLY R.F. TOROID ASSEMBLY E 4 N.A.
SYNERGIC 7F & FH K=42 M=81 N=67 I=41 -SERIAL COMM LOOP 81 67 M N F G H B A D C E PIN# IN CABLE. N.C. PINS NOT LISTED ARE NOT CONNECTED ON POWER SOURCE TO PROPER POLARITY. POWER SOURCE AND SET-UP PROCEDURE REVERSE ELECTRODE AND WORK CABLES AT CHANGE POLARITY, TURN POWER "OFF", (SEE APPROPRIATE WIRING DIAGRAM) N M L K J I H G F M17770-1 ELECTRODE 67 A GUN DUAL PROC.
11.26 1.57 .41 2.38 2.62 10.32 5.24 10.00 FOR MOUNTING) (2 HOLES R .28 R .14 SYNERGIC 7F & FH DIMENSION PRINT SYNERGIC 7F CONTROL BOX 6.16 DIAGRAMS M17740 4-7-95 13.
F-4 F-4 DIAGRAMS WIRE FEED UNIT DIMENSION PRINT GUN CABLE FITTING SWING ARM CLOSED C L OF WIRE 2.90 C L OF WIRE 7.00 11.25 7.69 6.75 4.67 1.00 6.67 6.25 7.16 7.50 C L 8.06 1.00 OF WIRE .281 1.31 (10 HOLES FOR MOUNTING WIRE FEED UNIT) 6.21 3.36 WIRE FEED DIRECTION OUTLET GAS FITTING REMOTE CONNECTOR INLET 3.18 GAS FITTING TRIGGER CONNECTOR 1.44 TYP. INPUT CONNECTOR 1.72 CLEARANCE ENVELOPE OF QUICK RELEASE ARMS TOP VIEW .25 4-7-95 .87 .25 .
NOTES SYNERGIC 7F & FH
NOTES SYNERGIC 7F & FH
● Do not touch electrically live parts or WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENÇÃO ● Keep flammable materials away. ● Wear eye, ear and body protection. ● Mantenga el material combustible ● Protéjase los ojos, los oídos y el 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 mojada. ● Aislese del trabajo y de la tierra.
● Keep your head out of fumes. ● Use ventilation or exhaust to ● Turn power off before servicing. ● Do not operate with panel open or guards off. remove fumes from breathing zone. ● Los humos fuera de la zona de res- piración. ● Mantenga la cabeza fuera de los humos. Utilice ventilación o aspiración para gases. ● Gardez la tête à l’écart des fumées. ● Utilisez un ventilateur ou un aspira- ● Desconectar el cable de ali- mentación de poder de la máquina antes de iniciar cualquier servicio.
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