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TABLE OF CONTENTS
Page
Installation .......................................................................................................Section A
Technical Specifications ........................................................................................A-1
GeneralDescription................................................................................................A-2
Recommended Processes and Equipment ...........................................................A-2
Standard Features .........................................................................................A-2, A-3
Keypad and Display Description............................................................................A-4
Safety Precautions ................................................................................................A-5
Installation of the Synergic 7F Components..........................................................A-5
Mounting the Wire Feed Unit (K679-1 or -2)...................................................A-5
Mounting the Control Box (K678-2).................................................................A-5
Connecting Wire Feed Unit to Control Box .....................................................A-5
Electrode Routing............................................................................................A-5
Wire Feed Drive Roll and Guide Tube Kits............................................................A-6
Standard 4-Roll Kits (KP655 and KP656) .......................................................A-6
Gun and Cable Assemblies With Standard L.E. Connection.................................A-7
GMAW Guns...................................................................................................A-7
Innershield Guns.............................................................................................A-7
Gun Cable Connection....................................................................................A-7
Gun and Cable AssembliesWith Fast-Mode Connection.......................................A-7
GMAW Guns...................................................................................................A-7
Gun Cable Connections: Wire Feeder to Gun ...............................................A-8
Synergic 7F 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. B-2, B-3
Procedure Selection Switch...................................................................................B-4
Dual Procedure Remote Control (K1449-1)...........................................................B-4
Wire Reel Loading..........................................................................................B-5, B-6
Idle Roll Pressure Setting ......................................................................................B-7
Gas Guard Regulator Setting ................................................................................B-7
Making a Weld.......................................................................................................B-8
Wire Reel Changing...............................................................................................B-8
Wire Feed Overload Protection .............................................................................B-8
Explanation of Prompting and Error Messages .....................................................B-9
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 thru E-11
Procedure for Replacing PC Boards....................................................................E-12
Gun Cable Connector Requirements to Permit Proper Connection to Synergic 7F Wire Feed Units...........
E-12
Diagrams ..........................................................................................................Section F
Wiring.....................................................................................................................F-1
Input Connection....................................................................................................F-2
Dimension Prints ...........................................................................................F-3 - F-4
Parts Lists...............................................................................................................P-266