Miller Electric Syncrowave 500 User Manual

Syncrowave 500
Processes
Description
R
TIG (GTAW) Welding
Stick (SMAW) Welding
Arc Welding Power Source
OM-350 000 739AB
December 2001
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www.MillerWelds.com

Miller Electric Syncrowave 500 Specifications

General

Frequency	50 / 60 Hz
Rated Output	500 A at 40 V
Duty Cycle	60%
Processes	TIG, Stick
Max. Open-Circuit Voltage	80 V
Cooling System	Fan-Cooled
Phase	1-Phase or 3-Phase

Summary

Safety Precautions

Symbol Usage

Explains the meaning of warning symbols used throughout the manual to indicate potential hazards.

Arc Welding Hazards

Details general hazards associated with arc welding, including electric shock, fumes, gases, and moving parts.

Additional Symbols For Installation, Operation, And Maintenance

Explains additional safety symbols and associated hazards related to installation, operation, and maintenance.

Principal Safety Standards

Lists key safety standards and codes applicable to welding and cutting operations.

EMF Information

Discusses the effects of electromagnetic fields during welding and provides procedures to minimize exposure.

Installation

Specifications

Provides key technical specifications of the welding power source, including amperage range and input power requirements.

Duty Cycle

Explains the concept of duty cycle and its importance for preventing equipment overheating and damage.

Volt-Ampere Curves

Illustrates the minimum and maximum voltage and amperage output capabilities of the welding power source.

Typical Process Connections

Shows diagrammatic connections for SMAW and GTAW welding processes.

Selecting A Location And Moving Welding Power Source

Provides guidance on choosing a suitable location and safely moving the welding equipment.

Overall Dimensions And Base Mounting Hole Layout

Details the physical dimensions and base mounting hole specifications for the unit.

Selecting And Preparing Weld Output Cables

Guides on choosing and preparing appropriate weld output cables for the welding circuit.

Weld Cable Size*

Provides a chart to select the correct weld cable size based on amperage and cable length.

Lower Front Panel

Identifies and describes the components located on the lower front panel of the unit.

Installing Gas Supply

Explains the procedure for connecting the shielding gas supply cylinder and components.

115 Volts AC Duplex Receptacle And Circuit Breaker

Describes the 115V AC receptacle and its associated circuit breaker protection.

Connecting To Weld Output Terminals

Details the process of safely connecting cables to the unit's weld output terminals.

Remote 14 Receptacle Information And Connections

Provides information and connection instructions for the 14-pin remote receptacle.

Remote 14 Socket Information

Lists the functions and purposes of each socket within the remote 14 receptacle.

Positioning Jumper Links

Explains how to set jumper links to configure the unit for different input voltages.

Electrical Service Guide

Provides guidance on electrical service requirements, including fuse ratings and conductor sizes.

Connecting Input Power

Details the procedure for safely connecting the main input power to the welding unit.

Operation

Controls

Identifies and describes the various controls and their functions on the welding unit's front panel.

Work Clamp

Explains the correct procedure for connecting the work clamp to the workpiece.

AC/DC And Polarity Switches

Describes how to use the switches to select AC/DC output and weld polarity.

Amperage Controls

Details how to adjust the welding amperage using front panel or remote controls.

Start Amperage Controls

Explains how to use the start amperage feature for improved arc initiation.

Output (Contactor) Switch

Explains the function of the output contactor switch for controlling weld output.

AC Balance Control

Describes how to adjust the AC balance for optimizing cleaning or penetration.

Postflow Time Control

Explains how to set the duration for postflow gas after welding stops.

High Frequency Controls

Details how to adjust high frequency settings for arc starting and stability.

Crater Fill Switch

Explains how to use the crater fill feature to taper weld output at the end of a weld.

Ammeter And Voltmeter

Describes the function of the ammeter and voltmeter displays for monitoring weld output.

Power Switch

Explains how to use the main power switch to turn the unit on and off.

Shielding Gas

Details the proper use of shielding gas cylinders and associated components during welding.

Sequence Of Gas Tungsten Arc Welding (GTAW)

Outlines the step-by-step procedure for performing Gas Tungsten Arc Welding (GTAW).

Sequence Of Shielded Metal Arc Welding (SMAW)

Outlines the step-by-step procedure for performing Shielded Metal Arc Welding (SMAW).

Maintenance & Troubleshooting

Routine Maintenance

Lists recommended maintenance tasks and their frequencies for keeping the unit in good condition.

Adjusting Spark Gaps

Provides instructions on how to properly adjust the spark gaps for optimal performance.

Troubleshooting

Lists common operational problems and their corresponding solutions for quick diagnosis and repair.

Electrical Diagram

High Frequency

Welding Processes Requiring High Frequency

Identifies specific welding processes that require the use of high frequency.

Incorrect Installation

Illustrates common mistakes in installing high-frequency equipment that can cause interference.

Correct Installation

Shows proper installation procedures for high-frequency equipment to prevent interference and ensure safety.

Selecting and Preparing Tungsten Electrode for DC or AC Welding

Selecting Tungsten Electrode

Provides guidance on choosing the correct tungsten electrode based on diameter, amperage, and welding process.

Preparing Tungsten Electrode For Welding

Explains how to properly prepare tungsten electrodes for DCEN, AC, and conventional welding.

Guidelines for TIG Welding (GTAW)

Positioning The Torch

Details the correct angles and distances for positioning the TIG torch during welding.

Torch Movement During Welding

Illustrates the proper torch movement techniques for forming the weld pool and adding filler metal.

Positioning Torch Tungsten For Various Weld Joints

Shows the optimal torch tungsten angles for different types of weld joints like butt, T, lap, and corner.

Parts List

Warranty Information

Limited Warranty Terms

Outlines the terms, conditions, and exclusions of Miller's limited warranty for new equipment.

Warranty Coverage Periods

Lists the specific warranty time periods for different types of equipment and components.