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IM557
August, 2005
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. 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.
R
N
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i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can- chemicals known to the State of California to cause cer, birth defects, and other reproductive harm. cancer, birth defects, or other reproductive harm. The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY
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ii ii SAFETY ELECTRIC SHOCK can ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover kill. plates to protect your eyes from sparks and 3.a. The electrode and work (or ground) circuits the rays of the arc when welding or observing are electrically “hot” when the welder is on. open arc welding. Headshield and filter lens Do not touch these “hot” parts with your bare should conform to ANSI Z87. I standards. skin or wet clothing. Wear dry, hole-free gloves to insulate hands. 4.b. Us
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iii iii SAFETY WELDING SPARKS can CYLINDER may explode cause fire or explosion. if damaged. 6.a. Remove fire hazards from the welding area. 7.a.Use only compressed gas cylinders If this is not possible, cover them to prevent containing the correct shielding gas for the the welding sparks from starting a fire. process used and properly operating Remember that welding sparks and hot regulators designed for the gas and materials from welding can easily go through small cracks pressure used. All hos
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iv iv SAFETY 5. Toujours porter des lunettes de sécurité dans la zone de PRÉCAUTIONS DE SÛRETÉ soudage. Utiliser des lunettes avec écrans lateraux dans les zones où l’on pique le laitier. Pour votre propre protection lire et observer toutes les instruc- tions et les précautions de sûreté specifiques qui parraissent 6. Eloigner les matériaux inflammables ou les recouvrir afin de dans ce manuel aussi bien que les précautions de sûreté prévenir tout risque d’incendie dû aux étincelles. générales su
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v v for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product Thank You ��� 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. Consequently, Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment
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vi vi TABLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications ........................................................................................A-1 General Description...............................................................................................A-2 Recommended Processes and Equipment ...........................................................A-2 Standard Fe
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A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS – SYNERGIC 7 AND 7H WIRE FEEDER - (4 - ROLL) Model SYNERGIC 7 SYNERGIC 7H Type K631-3 K631-4 Wire Speed Range: IPM 50 - 770 80 - 1200 M/M 1.25 - 19.5 2.00 - 30.5 Wire Size Capabilities: Solid Electrodes .025 - 1/16” .025 - .045” 0.6 - 1.6mm 0.6 - 1.2mm Cored Electrodes .045 - 3/32” .045” 1.2 - 2.4mm 1.2mm Input Power: 40-42 V ± 10% 50/60 Hz 4.0 Amps Temperature Rating: Operating -20°C to +40°C Storage -40°C to +40°C The follow
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A-2 A-2 INSTALLATION b) Feeds .045 - (1.2mm) cored wire for Outershield GENERAL DESCRIPTION GMA or Innershield processes. The Synergic 7 is a semiautomatic constant speed wire Recommended power sources are The Lincoln feeder designed specifically for use with the Invertec Power Electric Company Synergic type Invertec® Power Wave type power sources. A serial communication link is Wave power sources with 42VAC auxiliary power, and supplied through the control cable of the Synergic 7 a 14-pin c
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A-3 A-3 INSTALLATION Crater Fill - Provides crater feed speed adjustment (in 2-Step or 4-Step Trigger Modes - Unit operates only 4-step trigger mode) independent of weld, cold inch, when trigger is pressed in 2-Step mode (normal) oper- or run-in speeds. ation. 4-Step Trigger Mode eliminates the need to hold the gun trigger closed while welding. Both mod- Solid-State Overload Protection - No circuit breaker els have user selectable 4-step with crater fill, or as to reset. Front panel display
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A-4 A-4 INSTALLATION Function Select key enables operator to choose which KEYPAD AND DISPLAY function will be displayed as shown by the appropriate VOLTS/ TRIM V DESCRIPTION indicator light. Pressing the key causes lights to sequence RUN-IN (top to bottom) starting from the current indicated position. The function displayed will be adjustable with the rotating WFS encoder controls or arrow keys: Keypad - Seven key, membrane L9571-1 type with “snap” tactile feel and Adjusting either encoder k
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A-5 A-5 INSTALLATION 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. � Turn OFF input power at welding power source before installation or changing drive roll and/or guide tubes. � Welding power so
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A-6 A-6 INSTALLATION Wire Feed Drive Roll and Guide Tube Kits PROCEDURE TO INSTALL DRIVE ROLL AND GUIDE TUBES NOTE: The maximum sizes the Synergic 7 will feed satisfactorily are the 3/32” (2.4mm) cored and WARNING 1/16” (1.6mm) solid electrodes. The maximum sizes the Synergic 7H will feed satisfactorily are ELECTRIC SHOCK can kill. the .045 (1.2mm) cored and .045” (1.2mm) solid � Do not touch electrically live parts such as output terminals or internal wiring. electrodes. � When inching with
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A-7 A-7 INSTALLATION 8) Back out the screws for the incoming and outgoing Gun Cable Connection: Wire Feeder to Gun guide tubes. Lay the cable out straight. Insert the connector on the 9) Install the longer guide tube in the rear hole near welding conductor cable through the large hole in the the incoming drive roll. Slide the tube in until it front panel of the Synergic 7 and into the brass con- almost touches the roll. Tighten in place. ductor block on the front of the gearbox. Make su
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A-8 A-8 INSTALLATION Synergic 7 Water Connections (for Water- GMAW Shielding Gas Cooled Guns) WARNING These Synergic 7 models must have a K590-4 Water CYLINDER may explode if damaged. Connection Kit installed. See Options Installation section. � Keep cylinder upright and chained to support. 1) Using male quick-connect fittings (included with � Keep cylinder away from areas where appropriate Synergic 7 input cable assemblies), con- it may be damaged. nect the water hoses to the coolant inlet
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A-9 A-9 INSTALLATION K676 - (Used with Power Wave 450) Similar to K648 but ELECTRICAL INSTALLATION includes a gas hose with a 5/8-18 male fitting for the Synergic 7 inlet. It is rated at 500 amps, 60% duty cycle WARNING and is available in lengths of 7 ft. (2 m), 25 ft. (7.6 m) and 50 ft. (15 m). ELECTRIC SHOCK can kill. � Do not touch electrically live parts such K640 - (Used with Power Wave 450 and Synergic 7/7H with as output terminals or internal wiring. water quick-connection) Similar t
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A-10 A-10 INSTALLATION 4) Connect the remaining end of the control cable K163 Undercarriage (Requires K303, K376, K377, or with the 8-socket cable plug to the mating recepta- K378) The undercarriage includes casters, wheels, a cle on the Synergic 7. handle and related hardware. Casters are mounted at the front and the wheels to the rear of the platform. The handle is bolted to the front of the platform so the 5) Install the input cable under the wire reel mounting Synergic 7 can be tilted
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A-11 A-11 INSTALLATION Wire Reel Dust Shield for K376 50-60 Lb. Wire Reel K1524-1 Universal Wire Reel Stand - The assembly Mounting Stand - If the user desires to protect the includes a reel stand, a 2" (51 mm) O.D. spindle with wire from falling dirt and dust, there is a shield avail- adjustable brake, rubber mounting feet, and a cable able to cover the wire reel. Order part number clamp for fastening the input cable. It is easily mount- S14543. Instructions are included with the kit. ed
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B-1 B-1 OPERATION OPERATING INSTRUCTIONS Mode Selection 2-STEP Mode Select key ( behind “drop- Safety Precautions STD door” cover) enables operator to WARNING choose mode of operation shown 4-STEP by the indicator lights. Pressing key LOCK ELECTRIC SHOCK can kill. causes mode lights to sequence � Do not touch electrically live parts such (top to bottom) starting from the as output terminals or internal wiring. SPOT current indicated position. � When inching with gun trigger, electrode and driv
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B-2 B-2 OPERATION The preset voltage/trim may be adjusted, Display Control Keys using the Volts/Trim encoder knob. The syn- The function select, timer/crater ergic preset voltage/trim level may be adjust- select, arrow keys and rotational ed within the range synergically set by the encoders all effect the display. power source for the process and weld Feed Pressing the function select key will Speed being used. The power source auto- cause a function to be displayed. matically determines whethe
