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Miller Electric SYNCROWAVE 250 - User Manual

Miller Electric SYNCROWAVE 250
84 pages
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Processes
TM-353E January 2001
Eff. w/Serial Number JJ339876
Description
TIG (GTAW) Welding
Stick (SMAW) Welding
Arc Welding Power Source
Syncrowave 250
60 Hz, 50 Hz
R
Visit our website at
www.MillerWelds.com

Table of Contents

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Summary

Section 1 - Safety Precautions

1-1. Symbol Usage

Explains symbols indicating possible hazards in procedures.

1-2. Servicing Hazards

Details potential electric shock, burn, and injury hazards during servicing.

1-3. EMF Information

Discusses low-frequency electric and magnetic fields and their effects.

Section 2 - Definitions

2-1. Warning Label Definitions

Explains hazard symbols and their meanings on the unit.

2-2. Rating Label For CE Products

Details the information found on the CE rating label.

2-3. Symbols And Definitions

Provides a comprehensive list of symbols used in the manual and their meanings.

Section 3 - Installation

3-1. Specifications

Lists technical specifications of the welding power source.

3-2. Volt-Ampere Curves

Shows voltage and amperage output capabilities for DC and AC modes.

3-3. Duty Cycle And Overheating

Explains duty cycle percentages and overheating protection measures.

3-4. Selecting A Location

Guides on choosing a suitable location for the welding unit, considering airflow.

3-5. Dimensions And Weights

Provides physical dimensions and weight specifications of the unit.

3-6. Tipping

Advises on safe handling and movement to prevent tipping hazards.

3-7. Weld Output Terminals And Selecting Cable Sizes

Details weld output connections and guidance on selecting appropriate cable sizes.

3-8. Remote 14 Receptacle

Describes the function and pinout of the Remote 14 receptacle.

3-9. 115 Volts AC Duplex Receptacle And Shielding Gas Connections

Explains the 115V AC receptacle and shielding gas connection setup.

3-10. Electrical Service Guide

Provides recommendations for input voltage, amperage, and conductor sizing.

3-11. Placing Jumper Links And Connecting Input Power

Instructions on setting jumper links and connecting input power for correct voltage.

Section 4 - Operation

4-1. Controls

Identifies and describes the function of each control on the front panel.

4-2. Output Selector Switch

Explains how to use the output selector for DCEN, AC, and DCEP modes.

4-3. Meters

Describes the Ammeter and Voltmeter functions and readings.

4-4. Crater Time Controls

Details the controls for reducing current at the end of a weld cycle.

4-5. Spot Time Controls

Explains the controls for setting duration for spot welding operations.

4-6. AC Balance Control

Describes how the AC balance control affects cleaning and penetration.

4-7. Amperage Adjustment Controls

Explains how to adjust and set the welding amperage.

4-8. Output (Contactor) Control Switch

Details the switch for selecting unit output control method.

4-9. Arc Controls

Explains how arc control (dig) affects welding characteristics.

4-10. Postflow Time Control

Describes setting the duration for gas flow after welding stops.

4-11. High Frequency Controls

Explains the high frequency start and continuous modes.

4-12. Preflow Time Control (Optional)

Details setting gas flow duration before arc initiation.

Section 5 - Theory Of Operation

Section 6 - Troubleshooting

6-1. Troubleshooting Table

Lists common troubles and their recommended remedies.

6-2. Troubleshooting Circuit Diagram For Welding Power Source

Provides a circuit diagram for troubleshooting power source issues.

6-3. Waveforms For Section 6-2

Displays waveforms related to troubleshooting circuit diagrams.

6-4. Control Board PC1 Testing Information (Use With Section 6-5)

Provides guidance for testing the control board PC1.

6-5. Control Board PC1 Test Point Values

Lists voltage readings and test points for control board PC1.

6-6. Remote Board PC2 Testing Information (Use With Section 6-7)

Offers testing information for the remote board PC2.

6-7. Remote 14 Filter Board PC2 Test Point Values (Use With Section 6-2 And Section 6-6)

Lists test point values for the remote 14 filter board PC2.

6-8. Meter Calibration

Instructions for calibrating the unit's ammeter and voltmeter.

6-9. Input Voltage Labels And Connections

Diagrams showing input voltage labels and connection points.

Section 7 - Maintenance

7-1. Routine Maintenance

Outlines recommended maintenance tasks and schedules.

7-2. Circuit Breaker CB1

Describes the function and reset procedure for circuit breaker CB1.

7-3. Fuses F1 And F2

Details the location and function of fuses F1 and F2.

7-4. Adjusting Spark Gaps

Provides instructions for adjusting the spark gap settings.

Section 8 - High Frequency (HF)

8-1. Welding Processes Using HF

Explains the use of HF in GTAW and SAW welding processes.

8-2. Sources Of HF Radiation From Incorrect Installation

Identifies sources of HF radiation and potential interference issues.

8-3. Correct Installation

Provides guidelines for proper installation to minimize HF interference.

Section 9 - Electrical Diagrams

Section 10 - Parts List

Figure 10-1. Main Assembly

Lists parts for the main assembly of the Syncrowave 250.

Figure 10-2. Panel, Front w;Components

Lists components for the front panel assembly.

Figure 10-3. Rectifier, Si Diode

Lists parts for the Si diode rectifier assembly.

Figure 10-4. Panel, Rear w;Components

Lists components for the rear panel assembly.

Figure 10-5. Panel, Mtg Components

Lists components for the mounting panel.

Figure 10-6. Control Panel, Lower Front

Lists parts for the lower front control panel.

Optional Equipment

Lists parts for optional equipment available for the unit.

Miller Electric SYNCROWAVE 250 Specifications

General IconGeneral
Input Frequency60 Hz
Welding ProcessesTIG, Stick
TIG Welding CapabilityYes
Stick Welding CapabilityYes
High Frequency StartYes
Pulse WeldingYes
Input Voltage208/230/460 V
Input Phase1 or 3
Output Voltage Range10 - 30 V
Rated Output250 A at 30 V
Duty Cycle60%
AC/DC OutputAC/DC

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