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Miller Syncrowave 180 SD User Manual

Miller Syncrowave 180 SD
44 pages
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Syncrowave 180 SD
OM-355 188 290A
March 2000
Processes
Description
TIG (GTAW) Welding
Stick (SMAW) Welding
Arc Welding Power Source
Visit our website at
www.MillerWelds.com

Table of Contents

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Miller Syncrowave 180 SD Specifications

General IconGeneral
Welding Amperage Range10 - 180 A
Max. Open-Circuit Voltage80 V
ProcessesTIG (GTAW), Stick (SMAW)
Input Power230V, 1-Phase, 50/60 Hz
Rated Output30% Duty Cycle

Summary

SECTION 1 - SAFETY PRECAUTIONS - READ BEFORE USING

1-1. Symbol Usage

Explains hazard symbols used in the manual.

1-2. Arc Welding Hazards

Details electric shock, fumes, gases, and other hazards related to arc welding.

1-3. Additional Symbols for Installation, Operation, and Maintenance

Explains symbols for installation, operation, and maintenance hazards.

1-4. Principal Safety Standards

Lists relevant safety standards and codes.

1-5. EMF Information

Discusses electromagnetic fields and their effects, with reduction procedures.

SECTION 2 – INSTALLATION

2-1. Included with Your Unit

Lists the components included with the welding unit.

2-2. Selecting A Location

Guidelines for choosing a suitable location for the unit, considering airflow and movement.

2-3. Dimensions And Weights

Provides physical dimensions and weight of the welding unit.

2-4. Specifications

Details electrical and performance specifications for different welding modes.

2-5. Duty Cycle Chart

Illustrates the duty cycle of the unit based on amperage and time.

2-6. Volt-Ampere Curves

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

2-7. Weld Output Terminals And Selecting Cable Sizes

Explains weld output terminals and guides for selecting appropriate cable sizes.

2-8. Remote 14 Receptacle

Details the function and pinout of the remote 14 receptacle.

2-9. Shielding Gas Connections

Provides instructions for connecting shielding gas to the unit.

2-10. Electrical Service Guide

Provides guidance on electrical service requirements for the unit.

2-11. Connecting Input Power

Step-by-step instructions for connecting the input power.

SECTION 3 – OPERATION

3-1. Controls

Overview and explanation of the unit's front panel controls.

3-2. Front Panel Amperage Control

Demonstrates using the front panel for amperage adjustment in Stick welding.

3-3. Remote Amperage Control

Explains using remote controls for amperage adjustment in TIG welding.

3-4. Typical TIG Connections

Illustrates typical connection setups for TIG welding.

3-5. Typical Stick Connections

Illustrates typical connection setups for Stick welding.

3-6. Process and Material Thickness Guide

A guide for selecting welding processes and output based on material type and thickness.

SECTION 4 – MAINTENANCE AND TROUBLESHOOTING

4-1. Routine Maintenance

Outlines regular maintenance tasks and schedules for the unit.

4-2. Adjusting Spark Gaps

Instructions for adjusting spark gaps within the unit.

4-3. Troubleshooting

Provides solutions for common problems and issues encountered with the unit.

SECTION 5 – ELECTRICAL DIAGRAM

SECTION 6 – HIGH FREQUENCY (HF)

6-1. Welding Processes Using HF

Explains how High Frequency is used in different welding processes.

6-2. Sources Of HF Radiation From Incorrect Installation

Identifies sources of HF radiation due to improper installation.

6-3. Correct Installation

Provides guidelines for correct installation to minimize HF interference.

SECTION 7 – SELECTING AND PREPARING TUNGSTEN ELECTRODE

7-1. Selecting Tungsten Electrode

Guide to selecting the correct tungsten electrode based on amperage and polarity.

7-2. Safety Information About Tungsten

Safety precautions and information when handling tungsten electrodes.

7-3. Preparing Tungsten For DC Electrode Negative (DCEN) Welding

Instructions for preparing tungsten electrodes for DCEN welding.

SECTION 8 – GUIDELINES FOR TIG WELDING (GTAW)

8-1. Positioning The Torch

Guidance on proper torch positioning for effective TIG welding.

8-2. Torch Movement During Welding

Demonstrates correct torch movement techniques during TIG welding.

8-3. Positioning Torch Tungsten For Various Weld Joints

Shows how to position the torch tungsten for different weld joint types.

SECTION 9 – STICK WELDING (SMAW) GUIDELINES

9-1. Stick Welding Procedure

Step-by-step instructions for performing Stick welding.

9-2. Electrode and Amperage Selection Chart

A chart for selecting electrodes and amperage for SMAW welding.

9-3. Striking an Arc – Scratch Start Technique

Demonstrates the scratch start technique for striking an arc.

9-4. Striking an Arc – Tapping Technique

Demonstrates the tapping technique for striking an arc.

9-5. Positioning Electrode Holder

Guidance on correct positioning of the electrode holder for different weld types.

9-6. Poor Weld Bead Characteristics

Illustrates common issues leading to poor weld bead quality.

9-7. Good Weld Bead Characteristics

Illustrates characteristics of a good weld bead.

9-8. Conditions That Affect Weld Bead Shape

Explains factors influencing weld bead shape like angle, arc length, and speed.

9-9. Electrode Movement During Welding

Demonstrates electrode movement techniques for stringer and weave beads.

9-10. Butt Joints

Details different types of butt joints and their preparation.

9-11. Lap Joint

Explains welding techniques for lap joints.

9-12. Tee Joint

Explains welding techniques for tee joints.

9-13. Weld Test

Describes how to perform a weld test to check for quality.

9-14. Troubleshooting – Porosity

Identifies causes and corrective actions for porosity in welds.

9-15. Troubleshooting – Excessive Spatter

Identifies causes and corrective actions for excessive spatter.

9-16. Troubleshooting – Incomplete Fusion

Identifies causes and corrective actions for incomplete fusion in welds.

9-17. Troubleshooting – Lack Of Penetration

Identifies causes and corrective actions for lack of penetration in welds.

9-18. Troubleshooting – Excessive Penetration

Identifies causes and corrective actions for excessive penetration in welds.

9-19. Troubleshooting – Burn-Through

Identifies causes and corrective actions for burn-through in welds.

9-20. Troubleshooting – Waviness Of Bead

Identifies causes and corrective actions for waviness of weld beads.

9-21. Troubleshooting – Distortion

Identifies causes and corrective actions for weld distortion.

SECTION 10 – PARTS LIST

Main Assembly Parts

Lists part numbers and descriptions for the main assembly of the unit.

Front Panel Components Parts

Lists part numbers and descriptions for front panel components.

MILLER TRUE BLUE® LIMITED WARRANTY

Warranty Terms and Conditions

Details the terms, conditions, and periods of the limited warranty.

Warranty Exclusions

Lists items and conditions not covered by the Miller warranty.

OWNER'S RECORD AND SERVICE INFORMATION

Owner's Record

A section to record purchase details and serial numbers for personal records.

Service Contact Information

Information on contacting distributors and service agencies for support.

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