Lincoln Electric 7H User Manual

Synergic 7 and 7H OPERATOR’S MANUALIM557August, 2005Safety Depends on YouLincoln arc welding and cuttingequipment is designed and builtwith safety in

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

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

FOR ENGINEpowered equipment.1.a. Turn the engine off before troubleshooting and maintenancework unless the maintenance work requires it to be running.

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

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

iiSAFETYiiARC RAYS can burn.4.a. Use a shield with the proper filter and coverplates to protect your eyes from sparks andthe rays of the arc when weld

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

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

FOR ELECTRICALLYpowered equipment.8.a. Turn off input power using the disconnectswitch at the fuse box before working onthe equipment.8.b. Install equ

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

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 & 7HP10PIN 1CONNECTOR CAVITY1(COMPONENT SIDE OF P.C. BOARD)PIN NUMBERING SEQUENCE**J61(COMPONENT SIDE OF P.C. BOARD)CAVIT

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

ivSAFETYivMar. ‘93PRÉCAUTIONS DE SÛRETÉPour votre propre protection lire et observer toutes les instruc-tions et les précautions de sûreté specifiques

NOTESSYNERGIC 7 & 7H

NOTESSYNERGIC 7 & 7H

NOTESSYNERGIC 7 & 7H

NOTESSYNERGIC 7 & 7H

WARNINGAVISO DEPRECAUCIONATTENTIONWARNUNGATENÇÃOSpanishFrenchGermanPortugueseJapaneseChineseKoreanArabicREAD AND UNDERSTAND THE MANUFACTURER’S INSTRUC

WARNINGAVISO DEPRECAUCIONATTENTIONWARNUNGATENÇÃOSpanishFrenchGermanPortugueseJapaneseChineseKoreanArabicLEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE

• Sales and Service through Subsidiaries and Distributors Worldwide •Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB

vvThank Youfor selecting a QUALITY product by Lincoln Electric. We want youto take pride in operating this Lincoln Electric Company product••• as much

viviTABLE OF CONTENTSPageInstallation ...Section A

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