Lincoln-electric IM557 Synergic 7 and 7H User Manual

Operator’s ManualSynergic 7 and 7HRegister your machine: www.lincolnelectric.com/registerAuthorized Service and Distributor Locator: www.lincolnelec

A-4INSTALLATION SYNERGIC 7 & 7HA-4Keypad - Seven key, membranetype with “snap” tactile feel andembossed domes. Long lifedesign. Spatter resist

A-5INSTALLATION SYNERGIC 7 & 7HA-5INSTALLATION OF THE SYNERGIC 7 COMPONENTSSafety PrecautionsAttaching Wire Reel StandThe mounting hardware for

A-6INSTALLATION SYNERGIC 7 & 7HA-6Wire Feed Drive Roll and Guide Tube KitsNOTE: The maximum sizes the Synergic 7 will feedsatisfactorily are the

A-7INSTALLATION SYNERGIC 7 & 7HA-78) Back out the screws for the incoming and outgoingguide tubes.9) Install the longer guide tube in the rear

A-8INSTALLATION SYNERGIC 7 & 7HA-8Synergic 7 Water Connections (for Water-Cooled Guns)These Synergic 7 models must have a K590-4 WaterConnection

A-9INSTALLATION SYNERGIC 7 & 7HA-9ELECTRICAL INSTALLATIONInput Cable: Synergic 7 Wire Feeder to PowerWave Synergic Type Power SourcesNOTE: CSAn

A-10INSTALLATION SYNERGIC 7 & 7HA-104) Connect the remaining end of the control cablewith the 8-socket cable plug to the mating recepta-cle on

A-11INSTALLATION SYNERGIC 7 & 7HA-11Wire Reel Dust Shield for K376 50-60 Lb. Wire ReelMounting Stand - If the user desires to protect thewire fr

B-1OPERATIONB-1SYNERGIC 7 & 7HOPERATING INSTRUCTIONSSafety PrecautionsDuty CycleThe Synergic 7 models are rated at 60% duty cycle *fora maximum cu

B-2OPERATIONB-2SYNERGIC 7 & 7HDisplay Control KeysThe function select, timer/craterselect, arrow keys and rotationalencoders all effect the displa

THANK YOU FOR SELECTING A QUALITY PRODUCT BY LINCOLN ELEC TRIC. PLEASE EXAMINE CARTON AND EQUIPMENT FORDAMAGE IMMEDIATELYWhen this equipment is ship

B-3OPERATIONB-3SYNERGIC 7 & 7HTimer/Crater Select - key enablesoperator to choose crater speed, spotor gas timers as indicated by the appro-priate

B-4OPERATIONB-4Procedure Selector SwitchThe toggle switch on the front panel provides selectionof Procedure A or Procedure B, as set with the frontpan

B-5OPERATIONB-5SYNERGIC 7 & 7HWIRE LOADINGLoading a 22 to 30 Lb. (10 to 14 kg) Readi-ReelPackage Using the Molded Plastic K363-PReadi-Reel Adapter

B-6OPERATIONB-6SYNERGIC 7 & 7HTO 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

B-7OPERATIONB-7SYNERGIC 7 & 7HWIRE REEL LOADING – 50 AND 60 LBCOILS (K303 OR K376 WIRE REEL STAND)ADJUSTABLE WIRE REEL BRAKEThe mount for standard

B-8OPERATIONB-8SYNERGIC 7 & 7HWIRE REEL LOADING – 50 AND 60 LBCOILS (K1524-1 UNIVERSAL WIRE REELSTAND)TO MOUNT A 50 to 60 lb (22.7 to 27.2 kg) COI

B-9OPERATIONB-9SYNERGIC 7 & 7HIdle Roll Pressure SettingThe idle roll pressure is set at the factory, backed outthree turns from full pressure on

B-10OPERATIONB-10SYNERGIC 7 & 7HMaking a Weld1) Use only Power Wave model “synergic” powersources.2) Properly connect the electrode and work lea

B-11OPERATIONB-11SYNERGIC 7 & 7HGrounding Lead ProtectorThe frame of the Synergic 7 wire feeder is groundedto the frame of the power source by a l

C-1ACCESSORIESC-117 ft. (5 m), 25 ft. (7.6 m), 33 ft. (10 m) and 50 ft. (15m).K648 - (Used with Power Wave 450) Consists of an 8-conductor control cab

SECTION A:WARNINGS CALIFORNIA PROPOSITION 65 WARNINGSDiesel EnginesDiesel engine exhaust and some of its constituents are known to the State of Calif

C-2ACCESSORIESC-2WIRE REEL ASSEMBLY:K303 - 50-60 lb. (22.7-27.2 kg) Wire reel mountingstand. Assembly includes a framework to which isattached the 50

C-3ACCESSORIESC-3K541 Magnum 400 Short Neck GMAW gun and cableassemblies are rated 400 amps, 60% duty cycle.(Consult sales specifications for appropri

C-4ACCESSORIESC-4SYNERGIC 7 & 7HK566 * - GMAW process Magnum 250XA X-TRAC-TOR gun and cable assemblies are rated 250 amps,60% duty cycle. (Consul

D-1MAINTENANCED-1SYNERGIC 7 & 7HWire Reel Mounting - 50 (22.7kg) and60lb (27.2kg) Coils with 1” SpindleTo prolong the life of the reel shaft, peri

E-1TROUBLESHOOTINGE-1SYNERGIC 7 & 7HWARNINGObserve all additional Safety Guidelines detailedthroughout this manual.ELECTRIC SHOCK can kill.• Do no

E-2TROUBLESHOOTINGE-2SYNERGIC 7 & 7HIf for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,

E-3TROUBLESHOOTINGE-3SYNERGIC 7 & 7HObserve all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test

E-4TROUBLESHOOTINGE-4SYNERGIC 7 & 7HObserve all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test

E-5TROUBLESHOOTINGE-5SYNERGIC 7 & 7HObserve all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test

E-6TROUBLESHOOTINGE-6SYNERGIC 7 & 7HObserve all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test

ELECTRIC SHOCK CAN KILL.3.a. The electrode and work (or ground) circuits areelectrically “hot” when the welder is on. Donot touch these “hot” parts wi

E-7TROUBLESHOOTINGE-7SYNERGIC 7 & 7HObserve all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test

E-8TROUBLESHOOTINGE-8SYNERGIC 7 & 7HObserve all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test

E-9TROUBLESHOOTINGE-9SYNERGIC 7 & 7HObserve all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test

E-10TROUBLESHOOTINGE-10SYNERGIC 7 & 7HObserve all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the tes

E-11TROUBLESHOOTINGE-11SYNERGIC 7 & 7HIf for any reason you do not understand the test procedures or are unable to perform the tests/repairs safel

E-12TROUBLESHOOTINGE-12SYNERGIC 7 & 7HProcedure for Replacing PC BoardsBefore replacing a PC board which is suspected ofbeing defective, visually

F-1DIAGRAMSF-1SYNERGIC 7 & 7HNOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The spe

F-2DIAGRAMSF-2SYNERGIC 7 & 7HE=GNDF=678-PIN BOX RECEPTACLE, FRONT VIEWM=81C=2N=67H=82D=414-SOCKET BOX RECEPTACLE, FRONT VIEW G=81AND 14-PIN CABLE

F-3DIMENSION PRINTF-3SYNERGIC 7 & 7H20102 3-13-92 DIMENSION PRINT 11.608.099.703/8-16 HEX. HD. SCREWSFOR MTG. CONTROL

SYNERGIC 7 & 7HP-278P-278PARTS LIST FORSYNERGIC 7 & 7HThis parts list is provided as an informative guide only.It was accurate at the time of

WELDING AND CUTTINGSPARKS CAN CAUSEFIRE OR EXPLOSION.6.a. Remove fire hazards from the welding area. Ifthis is not possible, cover them to prevent the

SYNERGIC 7 & 7H02-19-2007P-278-AP-278-AMAIN ASSEMBLY1234

02-19-2007SYNERGIC 7 & 7HDo Not use this Parts List for a machine if its code number is not listed. Contact the Service Department for anycode num

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MISCELLANEOUS ITEMS (THESE ITEMS ARE NOT ILLUSTRATED)Warranty Decal S22127-1 1Warning Label M16196 1Drive Roll Decal (Not Water Cooled) S20101 1Drive

02-19-2007SYNERGIC 7 & 7HP-278-CP-278-CControl Box Assembly74A3E3D3C3A6Part of 2A13B2A2B10A4B51B811

1 Control Box Side Assembly L9912 1 X2A Harness, Includes: M18044 1 XRemote Connection Assembly (J18)Plug and Lead Assembly (P1)Toroid (P8)2B Self Tap

SYNERGIC 7 & 7H02-19-2007P-278-DP-278-DRear & Side Panels8B8A3C3B2D2B2C7A9A56B6A42A3A19

1 Cover & Hinge Assembly M17144 1 X •1 Cover & Hinge Assembly M17134 1 • X2A 3/8-16 x 1.25 HHCS CF000105 1 X X2B Lock Washer E106A-16 1 X X2C

02-19-2007SYNERGIC 7 & 7HP-278-EP-278-ECase Front (Not Water Cooled)Part of 3A3APart of 1212Part of 125B5A43C3B21A11B91011A11A11B138B8C8A63D7A

1A Case Front M17932 1 X1B Self Tapping Screw (Not Shown) S8025-91 2 X1C Self Tapping Screw (Not Shown) S8025-92 1 X2 Nameplate M17993 1 X2 Nameplate

vi vi TABLE OF CONTENTSPageInstallation ...Section

02-19-2007SYNERGIC 7 & 7HP-278-FP-278-FCase Front (Water Cooled)Part of 3A10Part of 7Part of 78893A3B3C276B6A1A3D3D45A5C5B8996A7Part of 7Part of

1A Case Front M17931 1 X1B Self Tapping Screw (Not Shown) S8025-91 1 X1C Self Tapping Screw (Not Shown) S8025-92 1 X2 Nameplate M17995 ø1X2 Nameplate

02-19-2007SYNERGIC 7 & 7HP-278-GP-278-GWire Drive Assembly523A3B3C3D3F3C3B3G43E6A6C6B78109A9B9C13121122C1A242322A22B1415161719A19B20181D1C1C21G21

1A Wire Drive Assembly (Synergic 7) L9348-3 1 X1A Wire Drive Assembly (Synergic 7F) L9348-4 1 X1B 1/4-20x.625 HHCS CF000013 3 X1C Lock Washer E106A-2

21F Plain Washer S9262-3 2 X21G Socket Head Screw T9447-21 2 X21H Release Lever Assembly S19965 1 X21J Knob S19922 1 X21K Swing Arm M16446 1 X21L Pivo

NOTES SYNERGIC 7 & 7H

NOTES SYNERGIC 7 & 7H

NOTES SYNERGIC 7 & 7H

CUSTOMER ASSISTANCE POLICYThe business of The Lincoln Electric Company is manufacturing andselling high quality welding equipment, consumables, and cu

A-1INSTALLATION SYNERGIC 7 & 7HA-1TECHNICAL SPECIFICATIONS – SYNERGIC 7 AND 7HSYNERGIC 7 SYNERGIC 7HWIRE FEEDER - (4 - ROLL)K631-350 - 7701

A-2INSTALLATION SYNERGIC 7 & 7HA-2GENERAL DESCRIPTIONThe Synergic 7 is a semiautomatic constant speed wirefeeder designed specifically for use w

A-3INSTALLATION SYNERGIC 7 & 7HA-3Crater Fill - Provides crater feed speed adjustment (in4-step trigger mode) independent of weld, cold inch,or