ESAB ESAB Syntronic 3 User manual

ESAB Syntronic 3

Synchronization control for push-pull drives

Instruction Manual

DOKP4M4080 2021 01 11 1.02

DOKP4M4080 1.02 -2- © ESAB/TBi 2021

 
DOKP4M4080   1.02                                                                                -3-                                                                 © ESAB/TBi 2021 
Contents 
 
 
Important basic information ............................................................................................................. 4 
1  Safety instructions .................................................................................................................................. 4 
2  Symbols and signal words...................................................................................................................... 5 
3  Notes on intended use ........................................................................................................................... 5 
3.1  Field of application, transport and storage ......................................................................................... 5 
3.2  Scope of delivery (standard) .............................................................................................................. 5 
3.3  Disposal and recycling ....................................................................................................................... 5 
4  Warranty ................................................................................................................................................. 6 
Product description, technical data .................................................................................................. 6 
1  Product description and function ............................................................................................................ 6 
2  Specifications ......................................................................................................................................... 7 
Operation of the product .................................................................................................................. 7 
1  Connection ............................................................................................................................................. 8 
2  Mounting points ...................................................................................................................................... 8 
3  Commissioning & adjustment ................................................................................................................. 9 
4  Display / control elements .................................................................................................................... 10 
Cleaning and Maintenance ............................................................................................................ 10 
1  Regular checks ..................................................................................................................................... 10 
2  Repairs to the device ............................................................................................................................ 10 
Troubleshooting ............................................................................................................................. 11 
 
 
 

DOKP4M4080 1.02 -4- © ESAB/TBi 2021

1 Important basic information

1.1 Safety instructions

Danger!

Failure to observe the information and instructions in this manual may result in

injury or death and / or damage to equipment, components and the product. All

persons who work on the product or with the product must read this operating

manual in its entirety before beginning this work and observe all instructions.

▪ Please keep this operating manual for future reference and pass it on with the product.

▪ The accident prevention regulations and the safety-relevant regulations of the relevant company and

country must be strictly adhered to.

▪ Before installation and maintenance work, the power supply to the system must be disconnected.

▪ It must be ensured that the entire system remains switched OFF for the duration of the work. There is

a risk of fatal electric shock. There is also a risk of other system parts being destroyed through a short-

circuit.

▪ A welding system poses a variety of dangers for people. The product may only be used by qualified

personnel, this also applies to initial start-up and maintenance. In doing so, observe the instructions in

this operating manual as well as the operating instructions of any connected devices, such as welding

torch, power source, or wire feeder.

▪ The ESAB Syntronic 3 is only to be connected and operated within the bounds of its technical

specifications.

▪ The device may only be connected to electrical outlets which have been installed correctly.

▪ The specified voltage supply and the control voltage must be strictly adhered to. By applying too high a

supply voltage or through incorrect handling, the device can be destroyed, and life-threatening

situations can arise. Electrical short circuits must be avoided.

▪ The ESAB Syntronic 3 must be firmly fixed in suitable place by means of the screw connection option

provided.

▪ All electrical wiring must be protected from damage. The condition of the device must be checked

regularly by a specialist. Damage must be properly repaired before further use.

▪ Operation in potentially explosive areas is prohibited.

▪ The device should be protected from welding spatter, wetness and moisture.

▪ The device may only be operated within closed rooms.

▪ The accident prevention regulations and the safety-relevant regulations of the relevant company and

country must be strictly adhered to.

▪ Liability for the function of the device is in any case transferred to the owner or operator, as far as the

device is improperly maintained, repaired or changed or if the device is handled in a manner which

does not correspond to the intended use.

DOKP4M4080 1.02 -5- © ESAB/TBi 2021

1.2 Symbols and signal words

Symbol

Signal word

Meaning

Danger!

Description of a hazard with a high degree of risk, which can lead

to death or serious injuries if it is not avoided.

Warning!

Description of a hazard with a medium degree of risk, which can

lead to death or serious injuries if it is not avoided.

Caution!

Description of a hazard with a low degree of risk, which can lead

to minor or moderate injuries if it is not avoided

Note!

Important note!

Indication of a note that contributes to intended use, or to

information on the product.

1.3 Notes on intended use

1.3.1 Field of application, transport and storage

▪ The ESAB Syntronic 3 is only to be used within the specifications and for the purpose intended by

the manufacturer.

▪ The ESAB Syntronic 3 is intended exclusively for commercial and industrial use by qualified

specialists. For accidents and damage due to improper use of the product, the manufacturer

declines all liability.

▪ The installation, operation and maintenance provisions specified in these instructions must be

adhered to.

▪ The product must be protected against humidity and moisture during transport, storage, and use.

▪ The device is designed for use at ambient temperatures between 0°C and + 40°C. Beyond these

limits, special measures may need to be taken.

1.3.2 Scope of delivery (standard)

▪ ESAB Syntronic 3 including associated connection cable and power supply unit

▪ operating manual

1.3.3 Disposal and recycling

▪ Please do not dispose of the product in the household waste.

▪ The product must be disposed of in accordance with country-specific requirements

(directives, provisions, laws, regulations, standards, ...).

DOKP4M4080 1.02 -6- © ESAB/TBi 2021

1.4 Warranty

Our products are carefully checked before delivery. We guarantee that the product is free of material and

processing defects at the time of delivery, and functions as intended.

ESAB offers warranty for material and processing defects according to the requirements of the law. Wear

parts are always excluded from the warranty.

The warranty does not cover damage or functional defects which result from

▪ overloading, misuse, or using the product for a purpose for which it was not intended

▪ accidents

▪ failure to follow instructions in the manual

▪ improper installation or assembly

▪ lack of maintenance

▪ modification of the product compared to its original condition

▪ normal wear and tear

ESAB assumes no liability except for the replacement or repair of the defective parts. In the event of a

complaint, the ESAB Syntronic 3 must be returned to the manufacturer for inspection and repair.

2 Product description, technical data

2.1 Product description and function

The ESAB Syntronic 3 is needed for synchronization control between a ESAB MXH PP MIG torch and the

main drive of the wire feeder.

The Syntronic 3 ensures precise speed adjustment between both drives at every selected wire feed speed,

so that the wire can be conveyed without interference.

The Syntronic 3 is compatible with all common main feed devices.

The ESAB Syntronic 3 is used for the precise synchronization of two electric drives on the basis of their

motor voltages. Both wire feeds run in what is called sequential operation, meaning that the main wire feed

(master) specifies the required speed, and the subsequent wire feed (slave) is brought to the same speed.

For this purpose, the motor voltage of the main wire feed (master) is continuously measured, the appropriate

output value for the push-pull drive (slave) is calculated and provided at the output by the power amplifier,

which is included in the Syntronic 3.

The measuring input of the Syntronic 3 is electrically isolated and has a high resistance, so that feedback

effects on the main drive by the Syntronic 3 can be prevented. The main drive and its control thus continue to

work as if no other wire drive were connected. The characteristics of the welding machines are thus retained.

After the installation of a new system and following significant changes to the wire feed system (change of

wire diameter or wire material, change of conveyor length or use of a wire guide liner with different sliding

properties), the control characteristics of the Syntronic 3 may have to be adapted to the system. This

operation is performed at two operating points, one at low wire speed and one at high wire feed speed. All

other values are calculated by the Syntronic 3 itself.

The Syntronic 3 uses integrated circuits to protect the motor connected to the output from damage caused by

excessively high motor current, for example when the drive is mechanically locked. Activation of the

protection circuit briefly switched OFF the motor.

DOKP4M4080 1.02 -7- © ESAB/TBi 2021

2.2 Specifications

ESAB Syntronic 3

Item No.:

Supply voltage:

0700 025 311

100-240 V/AC 50/60 Hz

Power supply board

24V / DC

Control input

0 - 42 V DC, high impedance

Output

0-24V DC, max. 1.0 A

Power input

max. 25 W

Fuse protection

1A mT fuse 5x20mm

Temperature range for operation

0 - 40 °C

Display

current conveying force (at the motor output)

Wire feed speed

2 - 15 m/min

Please check the technical data which applies to your device before commissioning. You will find this on

the type plate which is attached to the device. If you have any questions about your device, please have

the serial number ready.

The ESAB Syntronic 3 has been constructed in accordance with the current state of the art and is operates

reliably providing that it is used as intended. The device bears the CE marking.

3 Operation of the product

The Syntronic 3 must be connected to the main drive of the feed unit and to the PP MIG torch. We

recommended mounting the Syntronic 3 firmly in or on the main feeder. For this purpose, four screw

connections with M5 threads are provided on the rear.

Danger!

The supply voltage to the welding machine must be disconnected before starting

installation work. It must be ensured that the entire system remains switched OFF

for the duration of the work. There is a risk of fatal electric shock.

DOKP4M4080 1.02 -8- © ESAB/TBi 2021

3.1 Connection

NOTE!

Connection to an excessively high supply voltage can destroy the ESAB Syntronic 3.

The correct supply voltage can be found on the rating plate.

Connection to other country-specific sockets is possible, for example by means of an

approved socket adapter.

3.2 Mounting points

View from below

4x M5 - 6mm deep

DOKP4M4080 1.02 -9- © ESAB/TBi 2021

3.3 Commissioning & adjustment

1. Connection: Generate main feeder motor "signal input" line;

2. Connection: Connect PP MIG torch motor;

3. Connection: Establish functional earth (FE);

4. Provide power supply unit with voltage (plug it in).

5. Open the pressure lever of the PP MIG torch;

6. Straighten out cable assembly;

7. Allow the welding wire to run in slowly;

8. After the wire has passed through the PP MIG torch, close the pressure lever;

9. set the wire feed of the welding machine to approx. 4 m/min;

10. start the wire transport;

11. Open cover on device if necessary;

12. use the potentiometer "Offset", set the required delivery force so that the green LED of the

delivery indicator lights up; stop the wire feed again;

13. next, set the wire feed on the welding machine to approx. 12 m/min;

14. start the wire transport again;

15. use the potentiometer "Scaling" to set the required delivery force so that the green LED of

the delivery indicator lights up;

16. Stop the wire feed again;

17. for fine adjustments, repeat steps 9 to 16 several times if necessary, until the correct value

(green LED) is shown on the display for both speeds;

Following successful adjustment, the display of the conveying force is no longer needed for

further operation, as it serves only for the purposes of comparison. Therefore, while

operating at different wire feed speeds, values other than "green LED" can be displayed as

the system now regulates the delivery force.

18. Close the device by screwing the lid on.

3.4 Display / control elements

4 Cleaning and Maintenance

4.1 Regular checks

In order to ensure trouble-free operation of the device, the following checks should be carried out regularly:

• Check that all connections have been screwed on / connected properly and check for damaged areas;

• Check the device operation for faults. For fault analysis and troubleshooting see section 5.

• Clean the housing with a soft cloth. Do not use strong cleaning agents!

Defective parts must be replaced immediately if the safe functioning can no longer be guaranteed.

4.2 Repairs to the device

Repairs to the ESAB Syntronic 3 may only be carried out by the manufacturer or an authorized agent. In

the event of a complaint, the ESAB Syntronic 3 must be returned to the manufacturer for inspection and

repair.

5 Troubleshooting

Fault

Possible causes

Measures

No wire feed at the

beginning of a

welding process

Wire feed at the welding power source

does not start

Check whether the torch is properly connected to

the power source. Consider tesing the functioning

of the torch button and the control line with a

continuity tester.

Wire feed of the welding power source

set incorrectly

Check that the drive inside the wire feeder case

has been set in accordance with the

manufacturer’s instructions.

Power supply of the ESAB Syntronic 3

absent or wrong

Check the power supply and associated

connecting cables.

Wire splatter is stuck to the contact tip

or the contact tip has been affected by

abrasion

Replace the contact tip.

Has the drive been equipped

appropriately with respect to the

welding wire used?

For ESAB MXH drive: Check that the right drive

rolls have been installed in accordance with the

operating instructions.

Other drives: Check with reference to

manufacturer's instructions.

Has the torch been equipped with wire

of an appropriate diameter and

material?

Check wire conduit (cable assembly and torch

neck) and contact tip.

Is contact pressure of the rolls set

correctly on the wire feeder?

Adjust contact pressure in accordance with wire

material and diameter

PP MXH motor does not start

Check whether "Signal Input" is connected and

has the right polarity

PP MXH motor is running / turning the

wrong way

Reverse the polarity of the motor cable

Wire feed stops

during the welding

process

Wire spool is empty

Check how much welding wire there is on the coil

in the wire feeder.

Wire splatter is stuck to the contact tip

or the contact tip has been affected by

abrasion

Renew contact tip, if necessary blow compressed

air through the burner neck, wire conduit channel

and wire conduit.

Is there a wire jam in the cable

assembly?

Open the PP MXH and gently pull on the end of

the welding wire.

If you can pull more than about 2 cm of wire from

the cable assembly before the wire is stretched

again, the Syntronic 3 needs to be readjusted.

The overload protection of the

Syntronic 3 has switched the motor off

Check wire conduit in cable assembly, torch neck

and contact tip

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