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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