REHM SYNERGIC.PRO 251 How to use

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REHM SCHWEISSTECHNIKREHM SCHWEISSTECHNIK
SHORT MANUAL
SYNERGIC.PRO
251, 311, 351, 352, 402, 304, 404, 504
This short manual does not substitute the original operator manual.
Please read this document carefully before your start operating the welding power source.

This models of welding power sources have been developed according to the generally
recognized rules of technology. Nevertheless, their use can lead to a risk for life and limb
of the user or third pares or might lead to damages of the system or other property.
You should therefore read this document completely and thoroughly before starng up
the welding machine.
• Safety and warning noces are used for occupaonal safety and accident prevenon.
They must be observed. Not only the general safety instrucons listed here must be
observed but also the safety and warning informaon in the original manual.
• In addion to the informaon in these brief instrucons, the general safety and
accident prevenon regulaons have to be considered. They dier from country to
country (German: UVV BGV A3, TRBS 2131, BGR 500 Chapter 2.26 „Welding, cung
and allied processes“). In addion the specic regulaons for welding are relevant.
• Please nofy also the safety informaon signs in this document.
• As a maer of principle, no safety devices may be dismantled or put out of operaon,
as this poses a risk and the intended use of the system is no longer guaranteed.
Dismantling of safety devices when seng up, repairing and maintaining is specially
described. The safety devices must be reassembled immediately aer this work has
been completed.
• Changes to the system, the aachment or installaon of addional equipment and
external the use of safety devices is not permied. This invalidates the guarantee and
the reliability claim.
• If external agents are used (e.g. solvents for cleaning), the operator of the system must
guarantee the safety of the system during use.
• Except when this is expressly stated in wring by REHM, REHM welding systems are
only intended for sale to commercial / industrial users and only for their use.
The MIG/MAG welding systems are designed according to EN 60974-1 arc welding
equipment - welding power sources for overvoltage category III and polluon degree 3
and according to EN 60974-10 arc welding equipment - electromagnec compability
(EMC) for group 2 class A and are suitable for use in all areas , except residenal areas
that are directly connected to a public low-voltage supply system. Both conducted and
radiated interference can make it dicult to ensure electromagnec compability in
these areas. For this purpose, the observance of suitable measures to meet the require-
ments (lters for mains connecon, shielding such as the use of shielded lines, welding
lines that are as short as possible, earthing of the workpiece, equipotenal bonding) as
well as the assessment of the environment (such as computers, control equipment,
sound and television broadcast transmiers, neighboring Persons, e.g. when using a
pacemaker). The user is responsible for faults.
Qualicaon of the operang personnel
REHM welding systems may only be used by persons who are trained in the use,
operang and maintenance of the welding systems.
Only qualied, authorized and instructed personnel may work on and with the systems.
1 Safety Instructions

Symbols and sign at the welding machine or system
Aenon - danger or damage
Aenon - high voltage
Disregarding might cause injure or dead.
Personal protective equipment (PPE)
Personal protecve equipment (PPE) is mandatory when working with a welding system:
• Welding protecon lter, protecon level 10-15
• Protecve shield, screen or hood
• Welding gloves
• Leather apron
The company is obliged to provide the operator with the necessary PPE.
Intended Use
The MIG / MAG welding systems are only to be used
• for MIG / MAG or manual electrode welding for hand-guided and machine-guided
operaon (see original operang instrucons)
• for welding metallic materials (such as steels, copper, tanium and aluminum)
• in a perfectly safe condion
Environmental condions
• Temperature range of the ambient air:
- In operaon: -10 ° C to + 40 ° C (14 ° F to 104 ° F)
- During transport and storage: -20 ° C to + 55 ° C (-4 ° F to 131 ° F)
• Relave humidity
- up to 50% at 40 ° C (104 ° F)
- up to 90% at 20 ° C (68 ° F)
• Ambient air:
Free of unusual amounts of dust, acids, corrosive gases or substances, etc.
as long as these do not arise during welding.

2 Design and Connecons
Compact welding machine 251, 311, 351 Compact machine 352, 402
Compact machine 304, 404, 504 Welding machine with separate wire feeder unit
304S, 404S, 504S

No. Detail
1Main switch
2 Central torch adapter (ZA)
3 Welding ground socket (-)
Aenon: Take care that there is a as short as possible and reliable connec-
on between machine and material. Otherwise current ow is uncontrolled
and is searching a path to potenal earth. Damages are possible.
4 Cooling water connecons (blue = Cold water; red = hot water)
5 Air entrance area for air cooling. Air exit area is on the rear side.
6HMI
7Access door to wire feeder unit
8 Place for the gas bole
9 Chain to secure the gas bole
1
2
3
4
5
6
7
8
9

3 HMI
Controls Funcons
1
2
3
4
5
6
7
89
11
12
10
13
1
Operaon
Boot 1.)
2.)
Inicaon of arc voltage
Indicaon of soware version e.g. P2.4
Indicaon of product version e.g. 404
2
Operaon
Boot 1.)
2.)
Indicaon of welding current or material thickness
Version of welding characterisc e.g.1.2
„on“ shows power source ready
3
Control LED „Operaon“ (grün)
Standby voltage is connected to the torch.
Arc ingnion will be acvated if wire touches material.
4
Control LED „Temperature“ (gelb)
If temperature gets too high the machine switches o the power to
protect internal power components. Cooling stays acve.
If temperature comes under a certain level, machine is reacvated
and LED switched o.
5
Control LED „7-Segment indicates material thickness“ (grün)
If switch (posion 7) is placed on the symbol the HMI on
7-segment indicator 2 shows material thickness. The value is related
to the machine adjustments you did. In that mode no welding is
possible.

Controls Funcon
6
Correkon of wire speed
Fine adjustment for wire speed in addion to the machine calculated
speed by adjustments of you did with the rotary cam switches 11 and
12. The correcon value stays acve even if you change steps.
Negave correcon = reduces wire speed => arc gets longer
Posive correcon = increases wire speed => arc gets shorter
If arc energie gets too low and welding result isn‘t convinient you
need to change output voltage by the rotary switches.
7
Mode switch
Auxiliary funcon to nd the right adjustment for a
certein material thickness. 7-Segment indicator 2.
For control reason value of calculated material thickness
is show shortly when acvang the torch buon.
If arc is astablished indicator show welding current.
2-Step mode
4-Step mode
Spot welding - me adjust with potenometer 8
Pulse welding - Interval welding
Pulse me can be adjusted with regulator 8,
the pause me is half the pulse me.
8Time seng
for funcons spot and pulse welding [0.1 ... 5.0 sec]
9
Material selecon switch
Selecon of material like aluminium, copper (CuSi3), steel and stain-
less steel (CrNi) and wire thickness like 0.8, 1.0, 1.2 mm
10
SDI adjustment
Stepless adjustable DC choke to allow hard or so welding arc.
If potenometer is in the le stop posion Automac SDI is switched
on. Now applicaon controller is calculang adjustment according to
posion of rotary switches.
11
Rotary cam switch - coarse adjustment
Not available in all products. Big increase of output voltage and
welding current.
12 Rotary cam switch - ne adjustment
Stepwise increase of voltage and current.
13
FOCUS switch
Arc will be focussed. Available only at products 304, 404 und 504 and
only for steel and stainless steel welding.

4 Automac Funcons
Funcon Descripon, Details
Creep automac Without acve arc, the control unit reduces wire speed
unl wire end touches material. With touch, ignion
starts automacally. Aer ignion, the automac system
accelerates the wire speed to setpoint.
Wire speed automac The synergic control unit calculates wire speed based on
the welding power set by the rotary switches 11, 12.
Fine adjustment is done with regulator 6.
Burn back
automac /
Free burn
automac
Intense of this automac funcon is to prevent wire
scks to material when welding is stopped.
The welding control unit calculates the me required to
avoid the wire scking in relaon to the actual wire
speed and braking phase.
Gas post-ow me The default value is 0,2 sec aer releasing torch trigger
buon.
Thread in automac With press and hold torch buon in 2 step mode, the
automac phase to thread the wire startes if system
detects no arc aer 3 sec.
Speed is set with regulator 6.
Welding stop automac The output voltage is automacally switched o in 4 step
mode if there is no current for 3 seconds.
Data hold automac Aer welding stop, the last current is stored and shown
in 7 segment display 2 (data hold).
SDI automac Steplessly controllable choke.
Acve if regulator 10 is in stop posion on the le side.
Water cooling All products with extension W are water cooled.
The cooling starts automacally with the welding and
stops with a delay me aer welding stop.
Gas ow test With the torch buon pressed and without an arc for 3
seconds, the gas valve opens automacally for maximum
25 seconds. It stops when the buon is released.

5 Special sengs (Specialists only)
Funcon Descripon, details
Specialists can use the
R59, R60 and R61 trim
resistors to change the
sengs for the following
funcons:
- Burn wire free me
- Creep speed
- Gas post-ow me

6 Wire feeder unit
Separate
feeder unit
for S Types
altern.
wire drive
unit is part
of the
compact
machine
Wire drive
unit
4/2
Wire feeder with 4 rolls. The rolls under the wire are driven, the rolls
on top of the wire are free running pinch rollers
1
Adjust contact pressure to the wire: Use the red screws.
- Unlock and lt pinch roller to the side of the door for threading wire
- Turn the screws le and right to ghten or loosen pinch roller.
Aenon:
When opening locks of pressure roller there is a risk of squeezing!
1
4
2
3
56

2Pressure unit - arm with free running pressure rolls.
The rolls are smooth and free running.
3
Geared rolls
The geared rolls can be unlocked by turning the plasc ring so that the
cams t with the ring. Each roller has two grooves for dierent wire
diameter e.g. 0.8/1.0 mm. Quick release system.
In mounted posion a label with acve diameter in dierent colors is
visible. To use the other groove please turn the roller.t Standard from
manufacturer side is 0.8/1.0 with grooves for steel.
Rollers are sold by Rehm.
4Entrance of drive train. Mechanical wire guid into the wire drive unit.
5Plasc wire guide in the middle
6Brass wire guide between feeder and cantral adapter

7 Maintennance
Step Acvity Cycle
Check cool water level For products with water cooling, please
check level of cooling liquid Daily
Check damages Please check if hoses are damaged or if
hoses are kinked. Daily
Check noise of pump When you press torch buon at systems
with water cooling you should hear the
noise of the pump.
Daily
Check cooling air
channel
The air must circulate freely for cooling.
Do not place obstacles in the air ow. Daily
Blow out lters Clean air paths and lters with compres-
sed air. every 6 month
Check Electric and
Isolaon
Checkup of electric system and protec-
ve insolaon at an authorized repair
facility.
The checkup must be done according to
the naonal regulaons.
once per year
Maintenance Recommended maintenance in an
authorized repair facility.
once per year

8 Error Handling
Safety Instructions
If an error occurs, causing danger to human or machine or ambient
around the machine, switch o main switch immediate.
Take care that no one is able to switch on again.
• Only authorized personnel is allowed to eliminate mal funcons.
Safety instrucons must be observed!
• Do not restart device before reason for mal funcon is eliminated.
There should be no more danger to human or machine.
• Before restart of device a release by authorized personnel is required.
Error No. Type of error Reason Measure
Control light „Grid On“
is off. A line is missing
Check fuse F1 and F2 on
power supply and lter
board
Control light „temperature
too high“ is on Thermal protection is actice Let it cool down
Control light „Operation“ is
off
Operation is blocked by
temperature too high or
torch is not proper
connected
Let it cool down or check
connection
001 Internal error Wrong machine type Service
002 Internal error Storage error Service
003 Internal error Selfcheck control board Service
004 Internal error EEPROM not recognized Service
005 --- --- ---
006 Internal error Wrong data set Service
007 Water ow control --- ---
008 --- --- ---
009 Water ow control --- ---
noP No programm No program on that position
of switch
There should be no empty
program position.
Ask service for further
information.

EC-Declaraon of Conformity
for following listed products
Synergic.Pro 251 1031125 Synergic.Pro 304 1122200
Synergic.Pro 311 1031126 Synergic.Pro 304 S 1122201
Synergic.Pro 351 1031127 Synergic.Pro 304 W 1122202
Synergic.Pro 352 W 1031130 Synergic.Pro 304 WS 1122203
Synergic.Pro 402 W 1031131 Synergic.Pro 404 1122210
Synergic.Pro 404 S 1122211
Synergic.Pro 404 W 1122212
Synergic.Pro 404 WS 1122213
Synergic.Pro 504 1122220
Synergic.Pro 504 S 1122221
Synergic.Pro 504 W 1122222
Synergic.Pro 504 WS 1122223

EC-Declaraon of Conformity
It is hereby conrmed that this welding power sources comply with the essenal pro-
tecon requirements which are laid down in the Direcve 2014/30/EU (EMC Direc-
ve) of the council on the approximaon of the laws of the Member States relang to
electromagnec compability and in the Direcve 2014/35/EU relang to electrical
equipment designed for use within certain voltage limits.
The above products comply with the requirements of this direcve and comply with
the safety requirements for arc welding units in accordance with the following pro-
duct standards:
EN 60 974-1: 2018-12
Arc welding equipment – Part 1: Welding power sources
EN 60 974-2: 2013-11
Arc welding equipment – Part 2: Liquid cooling systems
EN 60 974-5: 2014-9
Arc welding equipment – Part 5: Wire feeders
EN 60974-10: 2016-10
Arc welding equipment – Part 10: Electromagnec compability (EMC) requirements
This declaraon is given for the manufacturer:
REHM GmbH u. Co. KG Schweißtechnik
Oostr. 2
73066 Uhingen
Uhingen, 2020/12/04
submied by R. Stumpp

Stand 01/2021 · Artikel-Nr. 7302731
REHM GmbH u. Co. KG Schweißtechnik
Ottostraße 2 I 73066 Uhingen I Germany
Tel.: [phone]
Fax: [phone]
E-Mail: [email protected]
Internet: www.rehm-online.de
REHM – The benchmark for modern welding and cutting
REHM-product range
- MIG/MAG inverter up to 450A
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one
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