Lincoln Electric SYNERGIC 7 AND 7H IM557 User manual

Synergic 7 and 7H
OPERATOR’S MANUAL
IM557
August, 2005
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.
For use with machine Code Numbers 10250 and 10251
R
NRTL/C
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com
• World's Leader in Welding and Cutting Products •
Copyright © 2005 Lincoln Global Inc.

FOR ENGINE
powered equipment.
1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
1.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.
____________________________________________________
1.c. Do not add the fuel near an open flame
welding arc or when the engine is running.
Stop the engine and allow it to cool before
refueling to prevent spilled fuel from vaporiz-
ing on contact with hot engine parts and
igniting. Do not spill fuel when filling tank. If
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated.
____________________________________________________
1.d. Keep all equipment safety guards, covers and devices in
position and in good repair.Keep hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving
parts when starting, operating or repairing equipment.
____________________________________________________
1.e. In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.
___________________________________________________
1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or
idler by pushing on the throttle control rods
while the engine is running.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
i
SAFETY
i
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER 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 “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box
351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available
from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
WARNING
Mar ‘95
ELECTRIC AND
MAGNETIC FIELDS
may be dangerous
2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines
2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
2.d.1.
Route the electrode and work cables together - Secure
them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
2.d.5. Do not work next to welding power source.
1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents
are known to the State of California to cause can-
cer, birth defects, and other reproductive harm.
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 Diesel Engines The Above For Gasoline Engines

ii
SAFETY
ii
ARC RAYS can burn.
4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
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.
In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical
(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 cooling.
3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
FUMES AND GASES
can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases.When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.
5.b.
Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors to
form phosgene, a highly toxic gas, and other irritating
products.
5.c. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
5.d. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.e. Also see item 1.b.
Mar ‘95

FOR ELECTRICALLY
powered equipment.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
CYLINDER may explode
if damaged.
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
7.c. Cylinders should be located:
• Away from areas where they may be struck or subjected to
physical damage.
• A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
iii
SAFETY
iii
Mar ‘95
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. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact
can cause overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even though they have
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.f.
Sparks and spatter are thrown from the welding arc. Wear oil
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.
6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate cir-
cuits. This can create fire hazards or overheat lifting chains
or cables until they fail.
6.h. Also see item 1.c.

iv
SAFETY
iv
Mar. ‘93
PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les instruc-
tions 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. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une
grande partie du corps peut être en contact avec la
masse.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état
defonctionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à soud-
er parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
2. Dans le cas de travail au dessus du niveau du sol, se pro-
téger contre les chutes dans le cas ou on recoit un choc. Ne
jamais enrouler le câble-électrode autour de n’importe quelle
partie du corps.
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du
rayonnement de l’arc et des projections quand on soude
ou quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
l‘arc.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflamma-
bles.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection
libres de l’huile, tels que les gants en cuir, chemise épaisse,
pantalons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
8. S’assurer que la masse est connectée le plus prés possible
de la zone de travail qu’il est pratique de le faire. Si on place
la masse sur la charpente de la construction ou d’autres
endroits éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de lev-
age, câbles de grue, ou autres circuits. Cela peut provoquer
des risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les
vapeurs du solvant pour produire du phosgéne (gas forte-
ment toxique) ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code
de l’électricité et aux recommendations du fabricant. Le dis-
positif de montage ou la piece à souder doit être branché à
une bonne mise à la terre.
2. Autant que possible, I’installation et l’entretien du poste
seront effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la
debrancher à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.

vv
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!
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or
loss of life.
This statement appears where the information must be followed to avoid minor personal injury or damage to
this equipment.
CAUTION
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 is received.
Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.
Product _________________________________________________________________________________
Model Number ___________________________________________________________________________
Code Number or Date Code_________________________________________________________________
Serial Number____________________________________________________________________________
Date Purchased___________________________________________________________________________
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially important when identifying the correct replacement parts.
On-Line Product Registration
- Register your machine with Lincoln Electric either via fax or over the Internet.
• For faxing: Complete the form on the back of the warranty statement included in the literature packet
accompanying this machine and fax the form per the instructions printed on it.
• For On-Line Registration: Go to our
WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then
“Product Registration”. Please complete the form and submit your registration.

vi
vi TABLE OF CONTENTS
Page
Installation .......................................................................................................Section A
Technical Specifications ........................................................................................A-1
General Description...............................................................................................A-2
Recommended Processes and Equipment ...........................................................A-2
Standard Features.................................................................................................A-2
Keypad and Display Description............................................................................A-4
Safety Precautions ................................................................................................A-5
Installation of the Synergic 7 Components ............................................................A-5
Attaching Wire Reel Stand ..............................................................................A-5
Wire Feed Drive Roll and Guide Tube Kits............................................................A-6
Standard 4-Roll Kits (KS655 and KS656) .......................................................A-6
Procedure to Install Drive Roll and Guide Tubes...................................................A-6
Gun and Cable Assemblies ...................................................................................A-7
GMAW Guns ...................................................................................................A-7
Innershield Guns .............................................................................................A-7
Gun and Cable Connections..................................................................................A-7
Wire Feeder to Gun.........................................................................................A-7
For GMA Gun Cables......................................................................................A-7
Synergic 7 Water Connections ..............................................................................A-8
GMAW Shielding Gas............................................................................................A-8
Gas 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 ....................................................................................B-4
Dual Procedure Remote Control (K1449-1)...........................................................B-4
Wire Reel Loading .................................................................................................B-5
Idle Roll Pressure Setting ......................................................................................B-9
Gas Guard Regulator Setting ................................................................................B-9
Making a Weld.....................................................................................................B-10
Wire Reel Changing.............................................................................................B-10
Wire Feed Overload Protection ...........................................................................B-10
Grounding Lead Protector ...................................................................................B-11
Explanation of Prompting and Error Messages ...................................................B-11
Accessories.....................................................................................................Section C
Optional Features..................................................................................................C-1
Maintenance ....................................................................................................Section D
Safety Precautions ................................................................................................D-1
Routine Maintenance.............................................................................................D-1
Periodic Maintenance............................................................................................D-1
Troubleshooting..............................................................................................Section E
Safety Precautions.................................................................................................E-1
Troubleshooting Guide ..........................................................................................E-2
Procedure for Replacing PC Boards....................................................................E-12
Diagrams ..........................................................................................................Section F
Wiring.....................................................................................................................F-1
Input Connection....................................................................................................F-2
Dimension Print......................................................................................................F-3
Parts Lists...................................................................................................P-278 Series

A-1
INSTALLATION
SYNERGIC 7 & 7H
A-1
TECHNICAL SPECIFICATIONS – SYNERGIC 7 AND 7H
SYNERGIC 7 SYNERGIC 7H
WIRE FEEDER - (4 - ROLL)
K631-3
50 - 770
1.25 - 19.5
.025 - 1/16”
0.6 - 1.6mm
.045 - 3/32”
1.2 - 2.4mm
-20°C to +40°C
-40°C to +40°C
K631-4
80 - 1200
2.00 - 30.5
.025 - .045”
0.6 - 1.2mm
.045”
1.2mm
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 the Synergic 7 and
Synergic 7H models:
Size & Weight Without Wire Stand With K377 Wire Stand
4-Roll Feeder:
Length
Width
Height
Total Weight
(Less Electrode)
269 mm (10.60")
295mm (11.60”)
282mm (11.11”)
12.9 kg (28.5 lbs.)
550 mm (21.66")
295mm (11.60”)
432mm (17.00”)
17.5 kg (38.5 lbs.)

A-2
INSTALLATION
SYNERGIC 7 & 7H
A-2
GENERAL DESCRIPTION
The Synergic 7 is a semiautomatic constant speed wire
feeder designed specifically for use with the Invertec Power
Wave type power sources. A serial communication link is
supplied through the control cable of the Synergic 7
enabling information to be shared between the power
source and wire feeder. The Synergic 7 comes factory
equipped with a gas solenoid valve with gas fittings and
standard Lincoln gun connector. These models includes a
3-1/2 digit LED display with rotating knob encoder controls
for setting the wire feed speed and voltage and a dual pro-
cedure selector switch. A tactile-feel keypad provides
selection of operating mode, function selection, timer and
crater fill selection and parameter adjustment. Two keys
provide Cold Feed and Gas Purge functions, and connector
receptacles are provided for an optional dual procedure
remote control and dual procedure switch.
The unit has 3 operating modes: 2-step trigger, 4-step trig-
ger and spot. Three functions can be selected: Volts or
Trim Preset/arc (memory) voltmeter, Run-in speed and weld
speed (IPM or m/min.) or (memory) ammeter. In addition,
when 4-step trigger mode is selected, crater fill WFS is also
adjustable. Up to three timers are available depending on
the mode: preflow, postflow and spot, and 5 acceleration
rates are selectable, as well as 6 Burnback settings.
The Synergic 7 is available in 2 models:
b) Feeds .045 - (1.2mm) cored wire for Outershield
GMA or Innershield processes.
Recommended power sources are The Lincoln
Electric Company Synergic type Invertec® Power
Wave power sources with 42VAC auxiliary power, and
a 14-pin connector receptacle.
STANDARD FEATURES
Wire Drive Features:
Wire Drive Unit - Incorporates low voltage 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-less means for releasing and opening
the idle roll pressure arm, precisely adjusting the idle
roll pressure and changing the incoming and outgoing
guide tubes and drive rolls.
Drive Rolls and Guide Tubes - Provide long life,
positive feeding and precise alignment of electrode.
Minimizes “birdnest” or mill-thru of wire if properly set.
(Ordered separately.)
Tachometer Feedback - Provides proper wire feed
acceleration and speed accuracy, independent of fluc-
tuations in line voltage and wire loading, for reliable
arc starting and weld consistency.
Run-in Speed Setting - Allows the arc striking speed
“Run-in” to be adjusted independently of the weld feed
speed for starting optimization.
Cold Feed Speed - Provides cold feed speed adjustment
independent of weld, run-in and crater speeds.
Selectable Acceleration - Provides front panel selec-
tion of 5 acceleration rates. This feature in combina-
tion with Run-in Speed provides the ability to easily
optimize starting on any process or procedure.
Solid-State Dynamic Braking - Quickly stops wire feed
motor to minimize wire overrun during weld termina-
tion. Solid-state design requires no maintenance.
Ordering Speed Range Wire Size Range
Information Model Drive IPM (m/m) IN. (MM)
K631-3 Synergic 4-Roll 50 - 770 .025 - 3/32
7 (1.25 - 19.5) (0.6 - 2.4)
K631-4 Synergic 4-Roll 80 - 1200 .025 - .045
7H (2.00 - 30.5) (0.6 - 1.2)
RECOMMENDED PROCESSES
AND EQUIPMENT
The Synergic 7 wire feed unit has the following wire
feeding capabilities:
a) Feeds .025 - 1/16” (0.6-1.6mm) solid wire for
gas-metal-arc processes.
b) Feeds .045 - 3/32” (1.2-2.4mm) cored wire for Outershield
GMA or Innershield processes up to 5/64” (2.0 mm).
The Synergic 7H wire feed unit has the following wire
feeding capabilities:
a) Feeds .025 - .045” (0.6-1.2mm) solid wire for
gas-metal-arc processes.

A-3
INSTALLATION
SYNERGIC 7 & 7H
A-3
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 7
models. Also available as an option (K659-1) a Gas
Guard regulator for flow surge suppression.
English/Metric Speed Display - Provides front panel
selection of speed display in units of IPM or M/M.
4-Roll Drive - Both models employ 4-Roll Drive, with
2 driven rolls, providing optimal feeding force for prob-
lem feeding situations, with low wire deformation for
improved feeding of soft wires.
Control Features:
Microcomputer Based Control - Provides precise
setting and display of all parameters and precision
timing functions. Optimizes wire drive control for crisp
acceleration and smooth response with precise
repeatability. Allows synergic control of various weld-
ing processes by communicating information over a
serial link to the compatible power source.
Display and Indicator Lights - Wide temperature
range, long life, 3-1/2 digit 7-segment LED display
with .56” (14.2mm) character height permits easy
viewing even from long gun cable distances.
Individual red indicator lights are high intensity LED’s
for viewing at almost any angle. Mode and Timer func-
tion keys and indicator lights are concealed behind a
hinged “drop-door” cover.
Encoder Controls - Rotating encoders provide con-
tinuous knob control for setting both Wire Feed Speed
and Volts/Trim procedures.
Procedure Switch - Permits selection of A or B pro-
cedures, as set by the procedure controls and memo-
ry pair selected at the Power Wave power source.
Setting switch to center “Gun Switch” position allows
selection of A or B procedures with the optional Dual
Procedure Switch.
Keypad - Consists of 7 membrane keys with tactile-
feel embossed 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-
ation. 4-Step Trigger Mode eliminates the need to
hold the gun trigger closed while welding. Both mod-
els have user selectable 4-step with crater fill, or as
shipped, 4-step with current interlock.
Gas Preflow and Postflow Timers - Allows setting of
shielding gas preflow time (0-2.5 seconds) before
welding arc starts, and gas postflow time
(0-9.9 seconds), after welding arc stops.
Crater Fill - Allows setting of crater fill WFS (when 4-
step with crater fill trigger mode is selected), indepen-
dent of weld, cold feed, and run-in speeds.
Selectable Burnback Time - Provides front panel
selection of 6 Burnback times. This feature provides
selectable Burnback time (default = 0ms) if required to
prevent electrode from sticking in weld puddle at finish
of weld.
Spot Mode - Allows a single timed weld cycle each
time the gun trigger is held closed. Duration (0.2-9.9
seconds) is set by the Spot ON timer.
Digital “Memory” Voltmeter - Displays arc voltage
from 0 to 80V DC, when welding gun trigger is activat-
ed, with automatic polarity indication for positive or
negative electrode. The last welding voltage moni-
tored at end of weld is displayed for 5 seconds after
weld has stopped. This allows checking actual volt-
age after weld has stopped.
Digital “Memory” Ammeter - Weld Feed Speed
(WFS) display may be selectable to display welding
amps only while welding and the last welding amps
monitored at the end of the weld will be displayed for
5 seconds after the weld has stopped. This allows
checking actual weld current after the weld has
stopped.
Power-down Save - All settings, including mode,
Run-in speed, cold feed speed, crater speed, weld
speed, timers, English-Metric units and acceleration
are automatically saved when power is removed. This
feature does not require batteries and when power is
restored it will automatically return all settings to the
state they were in when power was removed.
However, the power source may overwrite any or all
of these parameters after Power-Up Recall is com-
plete.

A-4
INSTALLATION
SYNERGIC 7 & 7H
A-4
Keypad - Seven key, membrane
type with “snap” tactile feel and
embossed domes. Long life
design. Spatter resistant surface.
Display - 3-1/2 digit 7-segment
LED with (+) or (-) polarity indica-
tors. .56” (14.2mm) character
height. Displays arc voltage in
volts, wire speed in IPM or m/m and
all timers in seconds.
Indicator Lights - Extra bright red
LED’s for viewing at almost any
angle. Always indicates the mode
being used and which function or
timer is being displayed.
Function Select key enables operator to choose which
function will be displayed as shown by the appropriate
indicator light. Pressing the key causes lights to sequence
(top to bottom) starting from the current indicated position.
The function displayed will be adjustable with the rotating
encoder controls or arrow keys:
Adjusting either encoder knob automatically transfers dis-
play (and indicator light) to the function being adjusted.
Top Light - Indicates display of preset voltage or percent
trim when not welding and arc voltage while welding (as
indicated by top light “blinking”), and continues for 5 sec-
onds after the weld has stopped (memory vpltmeter). The
power source automatically determines whether preset
voltage or percent trim will be displayed, and adjustable
with Volts/Trim rotating encoder control.
Middle Light - Indicates Run-in speed is being displayed.
As shipped, these models are setup for a 50 IPM
(1.27m/min) fixed run-in speed with display function deac-
tivated. They may be user-selected to activate or deacti-
vate adjustable Run-in display, and setting with arrow
keys.
Bottom Light - Indicates Weld Feed Speed (WFS) is being
displayed, and is adjustable with the Wire Feed Speed
rotating encoder control. If selected, this light will “blink”
while welding, indicating that the display has been select-
ed to display welding amps, and continues for 5 seconds
after the weld is stopped (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 right, top to bottom) starting from the current indi-
cated selection. Any parameter not available in the mode
selected is skipped over.
Top Left Light - indicates preflow time is being displayed in
seconds.
Top Right Light - indicates postflow time is being dis-
played in seconds.
Middle Light - indicates Crater Feed Speed is being dis-
played. This display will only occur if 4-step mode with
crater fill is selected.
Bottom Light - indicates spot on time is being displayed in
seconds.
Increase arrow key increases the setting of the para-
meter selected to be displayed. Arrow keys do not
function for Wire Feed Speed or Volts/Trim settings,
which are adjusted using the rotating encoder knobs.
Decrease arrow key decreases the setting of the para-
meter selected to be displayed. Arrow keys do not
function for Wire Feed Speed or Volts/Trim settings,
which are adjusted using the rotating encoder knobs.
Cold Feed key energizes the wire
feeder but not the power source or
solenoid valve. Cold feed speed is
adjustable and is displayed only
while pressing Cold Feed, and the
last speed selected is stored in
memory for the next Cold feeding.
Gas Purge key energizes the sole-
noid valve but not the wire feeder or
power source.
Mode Select key enables operator
to choose mode of operation shown
by the indicator lights. Pressing key
causes mode lights to sequence
(top to bottom) starting from the
current indicated selection.
Top Light - Indicates 2-step (stan-
dard) trigger mode.
Middle Light - Indicates 4-step
(lock) trigger mode. This mode may
be selected to include crater fill or
weld current interlock.
Bottom Light - Indicates spot weld
mode.
V
12
COLD FEED GAS PURGE
WFS
PREFLOW POSTFLOW
SPOT
STD
LOCK
SPOT
RUN-IN
2-STEP
4-STEP
CRATER
TRIM
/
VOLTS
L9571-1
V
WFS
RUN-IN
TRIM
/
VOLTS
12
SPOT
CRATER
STD
LOCK
SPOT
2-STEP
4-STEP
COLD FEED
GAS PURGE
KEYPAD AND DISPLAY
DESCRIPTION

A-5
INSTALLATION
SYNERGIC 7 & 7H
A-5
INSTALLATION OF THE SYNERGIC 7 COMPONENTS
Safety Precautions
Attaching Wire Reel Stand
The mounting hardware for mounting the wire reel
stand is included with the wire feeder. (Screws and
washers are inserted in their respective mounting
holes.) To connect:
1) Remove the three 3/8" (9.5 mm) hex head screws
from the back of the wire feed unit.
2) Place the wire reel stand mounting bracket in posi-
tion against the back of the wire feed unit.
3) Replace and tighten the 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 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 source must be connected
to system ground per the National
Electrical Code or any applicable local
codes.
•Only qualified personnel should
perform this installation.

A-6
INSTALLATION
SYNERGIC 7 & 7H
A-6
Wire Feed Drive Roll and Guide Tube Kits
NOTE: The maximum sizes the Synergic 7 will feed
satisfactorily are the 3/32” (2.4mm) cored and
1/16” (1.6mm) solid electrodes. The maximum
sizes the Synergic 7H will feed satisfactorily are
the .045 (1.2mm) cored and .045” (1.2mm) solid
electrodes.
The electrode sizes that can be fed with each
roll and guide tube are stencilled on each part.
Check the kit for proper components.
Steel Wire Sizes: 4-Roll
* .068 - 3/32” (1.7 - 2.4mm) Cored KS655-3/32
* 1/16” (1.6mm) Cored or Solid KS655-1/16
.045 - .052” (1.2 - 1.4mm) Solid KS655-052S
.045 - .052” (1.2 - 1.4mm) Cored KS655-052C
.035” (0.9-1.0mm) Cored KS655-035C
.035” (0.9-1.0mm) Solid KS655-035S
.030” (0.8mm) Solid KS655-030S
.023” (0.6mm) Solid KS655-025S
Aluminum Wire Sizes:
1/16” (1.6mm) KS656-1/16A
KS647-1/16A**
3/64” (1.2mm) KS656-3/64A
KS647-3/64A**
.040” (1.0mm) KS647-040A**
.035” (0.9mm) KS656-035A
Drive rolls for only cored electrode sizes are stencilled
with a “C” suffix to the wire sizes.
Drive rolls for only solid electrode sizes are stencilled
with an “S” suffix to the wire sizes.
Drive rolls for aluminum wire sizes are stencilled with an
“A” suffix to the wire sizes.
* Not for Synergic 7H model.
** For use with Binzel European guns. Installation
instructions are included with these kits. Also
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 sliding the
levers sideways into the open positions.
3) Remove clamping screw & clamping collar from the
drive shaft closest to the incoming side of the feed-
er.
4) Install drive roll onto keyed shaft. (Do not exceed
the maximum wire size rating of the wire drive.)
Replace collar and tighten clamping screw.
5) Back out the set screw for the middle guide tube.
Install the middle guide tube and slide it up against
the drive roll. DO NOT TIGHTEN THE MIDDLE
GUIDE AT THIS TIME.
6) Install the outgoing drive roll following the same
procedure as steps 3 & 4.
7) Center the middle guide between the two drive rolls
and tighten in place.
WARNING
Observe all additional Safety Guidelines detailed
throughout this manual.
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 source must be connected
to system ground per the National
Electrical Code or any applicable local
codes.
•Only qualified personnel should
perform this installation.

A-7
INSTALLATION
SYNERGIC 7 & 7H
A-7
8) Back out the screws for the incoming and outgoing
guide tubes.
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" (25 mm). Insert
free end through the incoming tube. Press gun
trigger and push wire into the drive roll.
TO SET IDLE ROLL PRESSURE, see Idle Roll
Pressure Setting.
Gun and Cable Assemblies
GMAW Guns
An expanding line of Magnum gun and cable assem-
blies are available to allow welding with solid and
cored electrodes using the GMAW process. See the
appropriate Magnum literature for descriptions of the
200 to 550 ampere air cooled gun and cables that are
available. Gun cable lengths range from 10 ft. (3.0 m)
to 25 ft. (7.6 m) and feed electrode sizes .025" (0.6
mm) to 5/64" (2.0 mm). The entire line of Magnum
Fast-Mate gun and cable assemblies can also be
used by installing a K489-1 Fast-Mate adapter kit.
Innershield Guns
K126 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 electrode sizes .062" (1.6 mm)
to 5/64" (2.0 mm). The 450 ampere K115 with
Synergic 7 will feed 5/64" (2.0 mm) electrode.
Three smoke extraction gun and cable assemblies
are available, 250 ampere K309, 350 ampere K206
and the 500 ampere K289. All gun cable lengths
are 15 ft. (4.5 m). Both the K206 and K309 with
Synergic 7 will feed electrode sizes .062" (1.6 mm)
to 5/64" (2.0 mm). K289 with Synergic 7 will feed
5/64" (2.0 mm) electrode. These guns require the
use of the K184 vacuum unit for use with Synergic
7.
Gun Cable Connection: Wire Feeder to Gun
Lay the cable out straight. Insert the connector on the
welding conductor cable through the large hole in the
front panel of the Synergic 7 and into the brass con-
ductor block on the front of the gearbox. Make sure it
is all the way in and tighten the hand wheel. Keep this
connection clean and bright. Connect the control
cable polarized plug into the mating 5 cavity recepta-
cle on the front of the control section below the key-
pad.
For GMA Gun Cables:
Install the barbed fitting and union nut to the 5/8-18
female inert gas fitting on the front of the Synergic 7
wire drive. Connect the 3/16" I.D. gas hose from the
gun cable to the barbed fitting. When the gun is to be
removed, this fitting can be easily detached by loosen-
ing the union nut.

A-8
INSTALLATION
SYNERGIC 7 & 7H
A-8
Synergic 7 Water Connections (for Water-
Cooled Guns)
These Synergic 7 models must have a K590-4 Water
Connection Kit installed. See Options Installation section.
1) Using male quick-connect fittings (included with
appropriate Synergic 7 input cable assemblies), con-
nect the water hoses to the coolant inlet and outlet on
the back of the Synergic 7. Connect the other ends of
these hoses to the appropriate ports on the water
cooling units.
2) In the event the water line fittings on your water
cooled gun are incompatible with the female quick
connects on the front of the Synergic 7, male quick-
connects are provided for installation on 3/16 (5 mm)
I.D. hose (Customer to provide appropriate clamps).
The feeder connectors self seal when disconnected.
GMAW Shielding Gas
Customer must provide a cylinder of shielding gas, a
pressure regulator, a flow control valve, and a hose
from the flow valve 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, if used, on the inlet of
the Gas Guard regulator. (See Below).
Gas Guard Regulator - The Gas Guard Regulator is
an optional accessory (K659-1) on these models.
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 female inlet of regulator
per instructions in the “Gas Connections” Section.
CYLINDER may explode if damaged.
• Keep cylinder upright and chained to
support.
• Keep cylinder away from areas where
it may be damaged.
• Never lift welder with cylinder attached.
• Never allow welding electrode to touch cylinder.
• Keep cylinder away from welding or other live elec-
trical circuits.
BUILDUP OF SHIELDING GAS may
harm health or kill.
•Shut off shielding gas supply when not
in use.
SEE AMERICAN NATIONAL STANDARD Z-49.1,
“SAFETY IN WELDING AND CUTTING” PUBLISHED
BY THE AMERICAN WELDING SOCIETY.
------------------------------------------------------------------------
WARNING

A-9
INSTALLATION
SYNERGIC 7 & 7H
A-9
ELECTRICAL INSTALLATION
Input Cable: Synergic 7 Wire Feeder to Power
Wave Synergic Type Power Sources
NOTE: CSAnrtl certification of the Synergic 7 models is with
input cable assemblies identified by carton date codes
010161, or above. These assemblies have grounding lead
continuity between the 14-pin plug pin B and the 8-socket
plug pin E per diagram below.
K649 - (Used with Power Wave 450/500) Consists of an 8-con-
ductor control cable with a 14-pin control cable plug and a 4/0
(107mm2) electrode cable with Twist-Mate™ connector. It is
rated at 500 amps, 60% duty cycle 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).
K675 - (Used with Power Wave 450/500) Similar to K649
but 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
and is available in lengths of 7 ft. ( 2 m), 25 ft. (7.6 m) and
50 ft. (15 m).
K641- (Used with Power Wave 450/500 and Synergic 7/7H
with water quick connection) Similar to K649 but includes a
gas hose with a 5/8-18 male fitting for the Synergic 7 inlet
and water hoses with quick-connect male fittings to connect
between the water cooler and the Synergic 7 water connec-
tions. It is rated at 500 amps, 60% duty cycle and is avail-
able 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).
K648 - (Used with Power Wave 450) Consists of an 8-con-
ductor control cable with a 14-pin plug and a 4/0 (107 mm2)
electrode cable with stud terminal. It is rated at 500 amps,
60% duty cycle 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).
K676 - (Used with Power Wave 450) Similar to K648 but
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
and is available in lengths of 7 ft. (2 m), 25 ft. (7.6 m) and 50
ft. (15 m).
K640 - (Used with Power Wave 450 and Synergic 7/7H with
water quick-connection) Similar to K648 but includes a gas
hose with a 5/8-18 male fitting for the Synergic 7 inlet and
water hoses with quick-connect male fittings to connect
between the water cooler and Synergic 7 water connections.
It is rated at 500 amps, 60% duty cycle and is available in
lengths of 7 ft. (2 m), 25 ft. (7.6 m) and 50 ft. (15 m).
K651 - (Used with Power Wave 350) Consists of an 8-con-
ductor control cable with a 14-pin plug and 2/0 (67 mm2)
electrode 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 but
includes a gas hose with a 5/8-18 male fitting for the
Synergic 7 inlet. It is rated at 350 amps, 60% duty cycle
and is available in 7 ft. (2 m) length.
K650 - (Used with Power Wave 350 and Synergic 7/7H with
water quick connection) Similar to K651 but includes a gas
hose with a 5/8-18 male fitting for the Synergic 7 inlet and
water hoses with quick-connect male fittings to connect
between the water cooler and the Synergic 7 water connec-
tions. It is rated at 350 amps, 60% duty cycle and is avail-
able in lengths of 7 ft. (2 m), 17 ft. (5 m), 33 ft. (10 m) and
50 ft. (15 m).
K642 (Control Cable Only) - Consists of an 8 conductor
control cable with a 14-pin control cable plug, without elec-
trode 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 con-
ductor control cable with 14-pin connectors on each end for
extending the control cable between the power source and
the control cables. Available in lengths of 17 ft (5 m), 25 ft
(8 m), 33 ft (10 m) and 50 ft (15 m).
With input power disconnected from the power
source, install the input cable per connection diagram
S21041 in the rear of this manual and follow exactly
the instructions on the diagram or perform the follow-
ing:
1) Connect the end of the control cable with the 14-
pin cable plug to the mating receptacle on the
power source.
2) Connect the electrode lead of that same cable end
to the power source output terminal of the desired
polarity.
3) Route the other end of the electrode cable through
the large oval hole in the rear panel of the Synergic
7 case. Connect to the brass block on the side of
the gearbox using the bolt provided.
WARNING
Observe all additional Safety Guidelines detailed throughout this manual.
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 source must be connected
to system ground per the National
Electrical Code or any applicable local
codes.
•Only qualified personnel should
perform this installation.
E=GND
8-PIN PLUG, FRONT VIEW
14-PIN PLUG, FRONT VIEW
B=GND

A-10
INSTALLATION
SYNERGIC 7 & 7H
A-10
4) Connect the remaining end of the control cable
with the 8-socket cable plug to the mating recepta-
cle on the Synergic 7.
5) Install the input cable under the wire reel mounting
stand strain relief clamp. Remove the screws hold-
ing the clamp to the base of the wire reel mounting
assembly, put the input cable assembly under the
clamp and reinstall the screws.
Work Cable
Connect a work lead of sufficient size and length (per
the following table) between the proper output terminal
on the power source and the work. Be sure the con-
nection to the work makes tight metal-to-metal electri-
cal contact.
* For pulse welding applications, the next larger cable
size is recommended.
OPTIONAL FEATURES
INSTALLATION
K178-1 Mounting Platform - Synergic 7 Models on
Synergic Power Sources (Requires a K303, K376,
K377, K378 or K445 Wire Reel Assembly) This is a
turntable type platform for mounting the Synergic 7 on
the top of Synergic power sources. Bolt the platform to
the lift bail per instructions (M16260) supplied with the
platform.
K162-H Spindle for Mounting Readi-Reels and 2" (51
mm) I.D. Spools (60 lb/27 kg Capacity) (For use with
K303 and K376 Wire Reel Stand) To mount the 2" spin-
dle kit for Readi-Reels and 10 through 60 pound
spools, remove the shaft for the standard 50-60 pound
wire coils from the mounting framework. Install the
spindle per the instructions shipped with the kit.
When used with Readi-Reels, a Readi-Reel Adapter is
required.
For 8" O.D. (200 mm) spools, a K468 Spindle Adapter
is available.
K163 Undercarriage (Requires K303, K376, K377, or
K378) The undercarriage includes casters, wheels, a
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
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 with the undercarriage.
K683-1 - Dual Procedure Switch Dual Procedure
Switch mounts to gun with appropriate bracket, provid-
ed, per the installation instructions included with the
kit. 3-pin switch cord plug connects to 3-pin remote
receptacle on the front panel of the Synergic 7 Wire
Feed Unit.
K1449-1 - Dual Procedure Remote Control Provides
remote rotating knob encoder control of Wire Feed
Speed and Volts/Trim, along with a dual procedure
selector switch, which disables comparable front panel
controls when the remote control is connected.
The 4-pin plug of the remote control connects to the
mating receptacle on the bottom of the Synergic 7
Control box.
K590-4 - Water Connection Kit Install per the instruc-
tions shipped with the kit.
K648, K649, K651 or K642 Input Cable Assembly
See Electrical Installation section for instructions
K675, K676 or K677 Input Cable Assembly (Gas)
See Electrical Installation and Shielding Gas
Connections sections for instructions.
K640, K641 or K650 Input Cable Assembly (Water &
Gas) See Electrical Installation, Water Connections
and Shielding gas connections sections for instruc-
tions.
K376 50-60 Lb. Wire Reel Mounting Stand (without
dust shield) and
K303 50-60 Lb. Wire Reel Mounting Stand (with dust
shield) The assembly includes a framework to which is
attached the 50-60 lb. wire reel, a mounting spindle, a
lift bail, and a cable clamp for fastening the input cable
assembly. It is easily mounted to the basic wire feed
unit by three bolts. The reel mounting spindle is the
pull knob type with a built-in brake.
The brake pad is adjustable for proper braking at low
or high wire feed speeds.
Copper Work Cable Size, AWG *
Up to 100 ft Length (30m)
Current
60% Duty
Cycle
300 Amps
400 Amps
500 Amps
00 (67 mm2)
000 (85 mm2)
000 (85 mm2)

A-11
INSTALLATION
SYNERGIC 7 & 7H
A-11
Wire Reel Dust Shield for K376 50-60 Lb. Wire Reel
Mounting Stand - If the user desires to protect the
wire from falling dirt and dust, there is a shield avail-
able to cover the wire reel. Order part number
S14543. Instructions are included with the kit.
Wire Reel Dust Shield Door for K303 and K376
(when equipped with an S14543 shield) - In
extremely dusty and dirty locations, this door kit can
be added to those units having the shield kit
(S14543). This door kit includes a hinged door and
sliding bottom seal. When these parts are attached to
the reel support per the instructions included, the unit
becomes a completely enclosed housing. Order part
number M11514.
K377 - Small Mounting Stand for Readi-Reel Coils or
10-44 Pound (4.5-20 kg) Spools with 2" I.D. - This
assembly includes a small frame to which is attached
a wire reel spindle similar to the K162 Spindle. The
unit is supplied with the K363 Readi-Reel Adapter for
using the Lincoln "Readi-Reel Electrode Coils".
Without the adapter, the unit is capable of handling
spools with a 2" (51mm) I.D., a 12" (30mm) maximum
O.D., and a 4" (101mm) width. For spools with an 8"
(200mm) O.D., a K468 spindle adapter is available.
The spindle has an adjustable braking system. See
Installation section “Attaching the Wire Reel Stand”
for mounting to wire feed unit.
K378 - Small Mounting Stand for 13-14 Pound
Innershield Coils - This assembly includes the same
smaller frame as used in the K377 and a fully
enclosed canister system for de reeling of the 14
pound (6 kg) coil. This system has a fixed brake for
this coil. See Installation section “Attaching the Wire
Reel Stand” for mounting to wire feed unit.
K659-1 - Gas Guard Regulator - Adjustable flow regu-
lator with removable adjustor key for CO2 and Argon
blend gases. Mounts onto feeder inlet, and reduces
gas waste and arc start "blow" by reducing surge
caused by excess pressure in 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 female inlet of regu-
lator per See Installation section “Shielding Gas
Connections”.
K1524-1 Universal Wire Reel Stand - The assembly
includes a reel stand, a 2" (51 mm) O.D. spindle with
adjustable brake, rubber mounting feet, and a cable
clamp for fastening the input cable. It is easily mount-
ed to the wire feed unit by three bolts. The wire feed-
er reel stand assembly fits on top of the power source
and is correctly positioned by using a hole in the base
that accommodates the power source lift bale. The 2"
(51mm) O.D. spindle can be set on one of two mount-
ing locations on the stand, depending on what coil of
wire and spindle adapter is being used. The upper
hole mounts 50-60 lb coils, the lower hole mounts 10-
30 lb, 13-14 lb, and 8" O.D. coils. Installation instruc-
tions are included with the kit.
K1555-1 Insulated Lift Bale Kit for K1524-1 - A lift
bale can be added to the K1524-1 Universal Wire
Reel Stand. The K1555-1 provides electrical insula-
tion between the wire stand assembly and the lift
hook. It is easily mounted to the wire stand with three
bolts and a threaded plate. Installation instructions are
included with the kit.
K1556-1 Caster Kit for K1524-1 - A light duty caster
kit can be added to the K1524-1 Universal Wire Reel
Stand. The K1556-1 includes 4 2" O.D. light duty
casters that mount in place of the rubber feet on the
wire stand base. Installation instructions are included
with the kit.
K1557-1 Swivel Platform for K1524-1 - A swivel plat-
form can be added to the K1524-1 Universal Wire
Reel Stand. The K1557-1 includes a pivot top plate
and a base assembly. The pivot top plate mounts to
the underside of the base of the wire stand assembly
using four screws. The swivel base mounts to the
power source lift bale with hardware provided or it can
be mounted to a surface of choice with four customer
provided bolts. Installation instructions are provided
with the kit.

B-1
OPERATION
B-1
SYNERGIC 7 & 7H
OPERATING INSTRUCTIONS
Safety Precautions
Duty Cycle
The Synergic 7 models are rated at 60% duty cycle * for
a maximum current of 600 amps.
* Based on a 10 minute time period (6 minutes on, and 4 minutes off).
KEYPAD SETUP AND OPERATION
Power-Down Save
Power to the Synergic 7 is supplied and controlled
from the power source. The Synergic 7 automatically
senses the loss of power when the power source is
turned off.
Procedure settings, including mode, crater speed,
cold feed speed , run-in speed, weld speed, timers
and acceleration are automatically saved when power
is removed. Arc Voltage setting is retained by the
synergic power source. This feature does not require
batteries and when power is restored it will automati-
cally return all settings to the state they were in when
power was removed. The power source may auto-
matically overwrite any or all of these settings follow-
ing power-up recall.
Mode Selection
Mode Select key ( behind “drop-
door” cover) enables operator to
choose mode of operation shown
by the indicator lights. Pressing key
causes mode lights to sequence
(top to bottom) starting from the
current indicated position.
Top Light - Indicates 2-Step
(Standard) Trigger Mode.
1. Trigger closure energizes the
solenoid valve, then the wire feeder
and the power source after Preflow
time (See Timer/ Crater Section).
2. Releasing the trigger turns off the
wire feeder and power source and
then the solenoid valve after
Postflow time.
Middle Light - Indicates 4-Step (Lock)
Trigger Mode. These models have selectable
4-step with crater fill or, as shipped, 4-step
with current interlock. (See 4-step trigger
mode selection for method of switching).
The 4-step modes function as follows:
1. Trigger closure energizes the power
source and wire feeder after the pre-
flow 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 feed
and power source output.
b) 4-step with crater fill will lock without
welding.
3. Closing the trigger a second time
continues welding.
a) 4-step with current interlock contin-
ues welding without changing the
settings from step 2.
b) 4-step with crater fill continues weld-
ing but changes to the crater set-
tings.
4. Releasing the trigger turns off wire
feeder and power source and then
gas solenoid after postflow time.
Bottom Light - Indicates Spot Weld
Mode. Trigger closure energizes the
solenoid valve, then wire feeder and
the power source. The spot on timer
starts when current flows. The wire
feeder and power source then sole-
noid valve are all turned off when the
spot on timer times out even through
the trigger is still closed.
COLD FEED
GAS PURGE
Operation Keys
Cold Feed key energizes the wire
feeder but not the power source or
solenoid valve. This cold feed
speed is digitally displayed and is
adjustable (with “Arrow keys”) only
while pressing the Cold Feed Key.
The last setting is held in memory
for next Cold feeding.
Gas Purge key energizes the sole-
noid valve but not the wire feeder or
power source.
STD
LOCK
SPOT
2-STEP
4-STEP
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 source must be connected
to system ground per the National
Electrical Code or any applicable local
codes.
•Only qualified personnel should
perform this installation.
WARNING
Observe all additional Safety Guidelines detailed
throughout this manual.

B-2
OPERATION
B-2
SYNERGIC 7 & 7H
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. Only
one function or timer indicator light
can be on at one time and therefore
it always indicates what is being
displayed. The arrow keys allow
you to adjust the Run-in speed
timer or crater speed being dis-
played. The encoder knobs allow
rotational adjustment of weld wire
feed speed and Arc Volts/Trim.
Note: If an indicator light is skipped, that
parameter may not be enabled. Refer to
section covering that parameter.
Function Select key enables oper-
ator to choose which function will
be displayed as indicated by the
appropriate light. Pressing the key
causes lights to sequence (top to
bottom) starting from the current
indicated position. If a timer or
crater speed is being displayed
when the Function Select key is
pressed, then the indicator light of
the last function selected before the
timer/crater key was chosen will
come on and become the starting
point for the sequencing.
Adjusting either encoder knob automati-
cally transfers display (and indicator light)
to the function being adjusted (Volts/Trim
or Wire Feed Speed).
Top Light - indicates Voltmeter
Function has been selected and arc
voltage (in volts) will be displayed along
with electrode polarity when the trigger
has been pressed. When the trigger is
not pressed, this will serve as a preset
voltage/trim function and the preset
voltage/trim will be displayed. The top
light “blinks” when arc voltage is being
displayed and stays lit when preset volt-
age/trim is displayed. The last welding
voltage displayed before the weld is
stopped, will continue to be displayed
for 5 seconds after welding to permit
operator monitoring.
The preset voltage/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
Speed being used.
The power source auto-
matically determines whether preset volt-
age or percent trim will be displayed.
Preset voltage is indicated by one digit only
to the right of the decimal point, while per-
cent trim always displays two digits to the
right of the decimal point.
Middle Light - Indicates Run-In Speed
Function has been selected and the Run-In
speed setting is being displayed in IPM or
m/m (see section for English or Metric dis-
play).
As shipped these models are setup for
minimum rated fixed Run-In speed with dis-
play function deactivated. They may be
user-selected to activate or deactivate
adjustable Run-In display. (See section for
selection of Run-In and resetting fixed Run-
In speed).
Wire will be fed at the Run-In speed rate
until arc current begins to flow. Once arc
current flows, wire will be fed at the Weld
speed rate. Decreasing Run-In speed
below its lower limit (using the down arrow
key) causes the display to read “- - -”. This
indicates that the Run-In speed will be kept
the same as the weld speed setting. You
can reset a different Run-In speed simply
by pressing the up arrow key.
The Run-In speed will also be the same as
the weld speed setting if rapid restrike
welding applications are used, where the
arc is restruck in a fraction of a second
after the previous welding arc was stopped.
Bottom Light - Indicates Weld Feed
Speed (WFS) Function has been selected
and the weld speed setting is being dis-
played in IPM or m/m (see section for
English or Metric speed display). The
range of Weld Feed Speed is synergically
set by the power source for the process
being used, and is adjustable using the
Wire Feed Speed encoder knob on the
front of the Synergic 7 Control.
If selected (see Memory Ammeter
Selection section), the bottom light will
“blink” while welding, indicating that the dis-
play has been selected to display welding
amps. The last welding current displayed
before the weld is stopped will continue to
be displayed for 5 seconds after welding to
permit operator monitoring.
V
WFS
RUN-IN
TRIM
/
VOLTS