ELECTRICAL INSTALLATION 
WARNING
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.
Observe all additional Safety Guidelines detailed throughout this manual.
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.
B=GND
E=GND
14-PIN PLUG, FRONT VIEW | 8-PIN PLUG, FRONT VIEW |
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.
