Miller Syncrowave 400 CE Owner's Manual
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Miller Syncrowave 400 CE Owner's Manual

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Syncrowave
OWNER'S MANUAL
OM-289397B
Processes
TIG (GTAW) Welding
Stick (SMAW) Welding
Description
380-400V Arc Welding Power Source
400 CE
®
2021-02

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  • Page 1 OM-289397B 2021-02 Processes TIG (GTAW) Welding Stick (SMAW) Welding Description 380-400V Arc Welding Power Source Syncrowave 400 CE ® OWNER’S MANUAL For product information, Owner’s Manual translations, and more, visit www.MillerWelds.com...
  • Page 2 We know you don’t have time to do it any other way. That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS – READ BEFORE USING..............1 Symbol Usage .
  • Page 4 TABLE OF CONTENTS 12-1 Selecting Tungsten Electrode ..................44 12-2 Preparing Tungsten Electrode For DC Electrode Negative (DCEN) Welding Or AC Welding With Inverter Machines.
  • Page 5 DECLARATION OF CONFORMITY for European Community (CE marked) products. MILLER Electric Mfg. LLC., 1635 Spencer Street, Appleton, WI 54914 U.S.A. declares that the product(s) identified in this declaration conform to the essential requirements and provisions of the stated Council Directive(s), Commission Regulation(s) and Standard(s).
  • Page 6 DECLARATION OF CONFORMITY for European Community (CE marked) products. MILLER Electric Mfg. LLC., 1635 Spencer Street, Appleton, WI 54914 U.S.A. declares that the product(s) identified in this declaration conform to the essential requirements and provisions of the stated Council Directive(s), Commission Regulation(s) and Standard(s).
  • Page 7 EMF DATA SHEET FOR ARC WELDING POWER SOURCE Product/Apparatus Identification DYNASTY 350 (AUTO−LINE 380−575) CE 907204021 DYNASTY 400 (AUTO−LINE 380−575) CE 907717002 SYNCROWAVE 400 380−400, CE 907783002 SYNCROWAVE 400 TIGRUNNER 380−400, CE 907783003 Compliance Information Summary Applicable regulation Directive 2014/35/EU Reference limits Directive 2013/35/EU, Recommendation 1999/519/EC Applicable standards...

  • Page 9: Section 1 - Safety Precautions - Read Before Using

    SECTION 1 – SAFETY PRECAUTIONS – READ BEFORE USING Protect yourself and others from injury—read, follow, and save these important safety precautions and operating instructions. 1-1. Symbol Usage DANGER! – Indicates a hazardous situation which, if not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text.
  • Page 10 HOT PARTS can burn. WELDING can cause fire or explosion. � Do not touch hot parts bare handed. � Allow cooling period before working on equipment. Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. �...

  • Page 11: Additional Hazards For Installation, Operation, And Maintenance

    � Never weld on a pressurized cylinder — explosion will result. CYLINDERS can explode if � Use only correct compressed gas cylinders, regulators, hoses, damaged. and fittings designed for the specific application; maintain them Compressed gas cylinders contain gas under high and associated parts in good condition.

  • Page 12: California Proposition 65 Warnings

    � Have the installation regularly checked and maintained. � Be sure all equipment in the welding area is electromagnetically compatible. � Keep high-frequency source doors and panels tightly shut, keep spark gaps at correct setting, and use grounding and shielding to �...

  • Page 13: Section 2 - Consignes De Sécurité - Lire Avant Utilisation

    SECTION 2 – CONSIGNES DE SÉCURITÉ - LIRE AVANT UTILISATION Pour écarter les risques de blessure pour vous-même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives aux précautions de sécurité et au mode opératoire. 2-1.
  • Page 14 � Porter un harnais de sécurité si l’on doit travailler au-dessus du � Ne pas souder des métaux munis d’un revêtement, tels que l’acier sol. galvanisé, plaqué en plomb ou au cadmium à moins que le revête- ment n’ait été enlevé dans la zone de soudure, que l’endroit soit �...

  • Page 15: Symboles De Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    � Ne pas couper ou souder des jantes ou des roues. Les pneus peu- Les CHAMPS vent exploser s’ils sont chauffés. Les jantes et les roues réparées ÉLECTROMAGNÉTIQUES (CEM) peuvent défaillir. Voir OSHA 29 CFR 1910.177 énuméré dans les peuvent affecter les implants normes de sécurité.
  • Page 16 � Suivre les consignes du Manuel des applications pour l’équation � Lorsque cela est nécessaire pour des travaux d’entretien et de dé- de levage NIOSH révisée (Publication Nº94– 110) lors du levage pannage, faire retirer les portes, panneaux, recouvrements ou dis- manuelle de pièces ou équipements lourds.

  • Page 17: Proposition Californienne 65 Avertissements

    2-4. Proposition californienne 65 Avertissements AVERTISSEMENT – Ce produit peut vous exposer à des pro- Pour plus d’informations, consulter www.P65Warnings.ca.gov. duits chimiques tels que le plomb, reconnus par l’État de Californie comme cancérigènes et sources de malforma- tions ou d’autres troubles de la reproduction. 2-5.

  • Page 18: Section 3 - Definitions

    Reuse or recycle Waste Electrical and Electronic Equipment (WEEE) by disposing at a designated collection Some symbols are found only on CE products. Warning! Watch Out! There are possible hazards as shown by the symbols. Some symbols are found only on CE products. facility.
  • Page 19 Cutting sparks can cause fires. Have a fire extinguisher nearby, and have a watchperson ready to use it. Do not grip material near cutting path. � Complete Parts List is available at www.MillerWelds.com Safe1 Safe Do not fuel a hot engine. Do not fuel a hot engine.

  • Page 20: Miscellaneous Symbols And Definitions

    machine or welding. Engine fuel plus flames or sparks can cause fire. Keep your head out of the fumes Engine fuel plus flames or sparks can cause fire. � Safe65 2012 06 Complete Parts List is available at www.MillerWelds.com Safe45 2012 05 Safe7 2017 04 Safe45 201 Hazardous voltage remains on input capacitors after power is turned...
  • Page 21 � Complete Parts List is available at www.MillerWelds.com Rated Welding Rated Maximum Voltage Output Current Pressure (Coolers) Increase/Decrease Remote Duty Cycle Of Quantity Seconds Percent Direct Current Line Connection Hertz Conventional Load Pulser Voltage Pulse Frequency Positive Primary Voltage Degree of Process Negative Protection...

  • Page 22: Section 4 - Specifications

    Information About Default Weld Parameters And Settings NOTICE – Each welding application is unique. Although certain Miller Electric products are designed to determine and default to certain typical welding parameters and settings based upon specific and relatively limited application variables input by the end user, such default settings are for reference purposes only;...

  • Page 23: Coolant Specifications

    � Complete Parts List is available at www.MillerWelds.com 4-6. Coolant Specifications Do not use conductive coolant. Application Coolant GTAW Or Where High Frequency Current Is Used Low Conductivity Coolant 043810* Distilled Or Deionized Water Okay Above 32°F (0°C) *Coolants 043810 and 043809 protect to -37°F (-38°C) and resist algae growth. NOTICE –...
  • Page 24 � Complete Parts List is available at www.MillerWelds.com C. Mounting Options Dimensions 19-1/2 in. (495 mm) 2 in. (51 mm) 4 x .500 in. Dia. (13 mm) Base 1 in. (25 mm) 805620-A 13 in. (330 mm) OM-289397 Page 16...

  • Page 25: Duty Cycle And Overheating

    � Complete Parts List is available at www.MillerWelds.com 4-8. Duty Cycle And Overheating Duty Cycle is percentage of 10 minutes that unit weld rated load without overheating. If unit overheats, output stops, a Help mes- sage is displayed (see Section 8-4), and cool- ing fan runs.

  • Page 26: 4-10. Environmental Specifications

    � Complete Parts List is available at www.MillerWelds.com 4-10. Environmental Specifications A. IP Rating IP Rating IP23 This equipment is designed for outdoor use. B. Temperature Specifications Operating Temperature Range* Storage/Transportation Temperature Range 14 to 104°F (-10 to 40°C) -4 to 131°F (-20 to 55°C) *Output is derated at temperatures above 104°F (40°C).

  • Page 27: Section 5 - Installation

    A complete Parts List is available at www.MillerWelds.com � Writers: Remember to move unit dimension and weight and rating la- Complete Parts List is available at www.MillerWelds.com bel location information to the appropriate sections. SECTION 5 – INSTALLATION 5-1. Selecting A Location 1-3.

  • Page 28: Selecting Cable Sizes

    � Complete Parts List is available at www.MillerWelds.com 5-2. Selecting Cable Sizes NOTICE – The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is 100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine cable size.

  • Page 29: Connecting Weld Cables, Remote Control, And Shielding Gas

    � Complete Parts List is available at www.MillerWelds.com 5-3. Connecting Weld Cables, Remote Control, And Shielding Gas Turn off power before connecting Front Panel to weld output terminals. Do not use worn, damaged, under- sized, or repaired cables. Connections 1 Remote Control Receptacle (See Section 5-7) 2 Electrode Weld Output Terminal For TIG (GTAW), connect torch to this...

  • Page 30: Cooler Connections

    � Complete Parts List is available at www.MillerWelds.com 5-4. Cooler Connections � Cart cooler optional equipment. 1 Electrode Weld Output Terminal Connect TIG torch to this terminal. 2 Gas Out Connection Connect TIG torch gas hose to gas out fitting. 3 Work Weld Output Terminal Connect work lead to this terminal.

  • Page 31: Electrical Service Guide

    � Complete Parts List is available at www.MillerWelds.com 5-5. Electrical Service Guide A. Electrical Service Guide For Three-Phase Operation Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommen- dations are for an individual branch circuit sized for the rated output and duty cycle of one welding power source. In individual branch circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating of the circuit protection device.

  • Page 32: Connecting 3-Phase Input Power

    � Complete Parts List is available at www.MillerWelds.com 5-6. Connecting 3-Phase Input Power Installation must meet all National and Local Codes—have only quali- fied persons make this installation. Disconnect and lockout/tagout in- put power before connecting input = GND/PE Earth Ground conductors from unit.

  • Page 33: Remote 14 Receptacle Information

    � Complete Parts List is available at www.MillerWelds.com 5-7. Remote 14 Receptacle Information Remote 14 Socket Socket Information Contactor control +15 volts DC, referenced to G. 15 Volts DC Output Contact closure to A completes 15 volts DC con- Contactor C L N tactor control circuit and enables output.
  • Page 34 � Complete Parts List is available at www.MillerWelds.com B. Installing Software Updates Syncrowave 300 Shown Ref. 805618-A Inserting card while welding will interrupt the Troubleshooting: � Software updates may reset machine welding process. back to default values. Indicator LED is blinking red: Error updating LED indicator blinks green when machine is software, or software is not compatible.

  • Page 35: Section 6 - Syncrowave Operation

    � Complete Parts List is available at www.MillerWelds.com SECTION 6 – SYNCROWAVE OPERATION 6-1. Syncrowave Controls 280539-B Displays actual rectified average voltage 8 Process Selector Control 1 Main Power Switch when voltage is present at the weld output terminals. It is also used to display parame- select following Use switch to turn machine on or off.

  • Page 36: Accessing Process Menu: Ac Tig

    150A � Complete Parts List is available at www.MillerWelds.com 6-2. Accessing Process Menu: AC TIG 1 Menu Button Press Menu button to cycle through parame- ters that can be set. 2 Parameter Display 3 Setting Display 4 Amperage Adjustment Control Rotate Amperage Adjustment control to ad- 247222-D just parameter setting.

  • Page 37: Accessing Process Menu: Dc Tig And Dc Tig Pulse

    � Complete Parts List is available at www.MillerWelds.com 6-3. Accessing Process Menu: DC TIG And DC TIG Pulse 1 Menu Button Press Menu button to cycle through parame- ters that can be set. 2 Parameter Display 3 Setting Display 4 Amperage Adjustment Control 150A Rotate Amperage Adjustment control to ad- just parameter setting.

  • Page 38: Accessing Process Menu: Dc Stick

    � Complete Parts List is available at www.MillerWelds.com 6-4. Accessing Process Menu: DC Stick 1 Menu Button Press Menu button to cycle through parame- ters that can be set. 2 Parameter Display 3 Setting Display 4 Amperage Adjustment Control 110A Rotate Amperage Adjustment control to ad- just parameter setting.

  • Page 39: Accessing User Menu: Ac/Dc Tig And Dc Tig Pulse

    � Complete Parts List is available at www.MillerWelds.com 6-5. Accessing User Menu: AC/DC TIG And DC TIG Pulse 1 Menu Button Press and hold Menu button for approxi- mately two seconds until USER MENU ap- pears to access machine configuration menus.

  • Page 40: Accessing User Menu: Dc Stick

    � Complete Parts List is available at www.MillerWelds.com 6-6. Accessing User Menu: DC Stick 1 Menu Button Press and hold Menu button for approxi- mately 2 seconds to access machine configu- ration menus. Use Menu button to cycle through parameters that can be set. 2 Parameter Display 3 Setting Display USER...

  • Page 41: Section 7 - Advanced Menu Functions

    � Complete Parts List is available at www.MillerWelds.com SECTION 7 – ADVANCED MENU FUNCTIONS 7-1. Accessing Tech Menu 1 Menu Button Press and hold Menu button for approxi- mately four seconds to scroll past User Menu to Tech Menu. Use Menu button to cycle through parameters that can be set.

  • Page 42: Summary Of Default And Pro-Set Parameters

    � Complete Parts List is available at www.MillerWelds.com 7-2. Summary Of Default And Pro-Set Parameters AC TIG DC TIG DC PULSE TIG STICK Default Default Default Default (Pro- Process Menu Range Range Range Range (Pro-Set) (Pro-Set) (Pro-Set) Set) [BAL] Ball 30%, —...

  • Page 43: Output Control And Trigger Functions

    � Complete Parts List is available at www.MillerWelds.com 7-3. Output Control And Trigger Functions A. Remote (Standard), 2T, Torch Trigger Operation Natężenie (A) Current (A) Current (A) Natężenie główne Main Amps Nachylenie końcowe Main Amps Initial Slope Final Slope Initial Slope Final Slope Natężenie końcowe Initial Amps...

  • Page 44: Section 8 - Maintenance And Troubleshooting

    � Complete Parts List is available at www.MillerWelds.com SECTION 8 – MAINTENANCE AND TROUBLESHOOTING 8-1. Routine Maintenance Disconnect power before maintaining. � Maintain more often during severe conditions. A complete Parts List is available at www.MillerWelds.com A complete Parts List is available at www.MillerWelds.com A complete Parts List is available at www.MillerWelds.com A.

  • Page 45: Blowing Out Inside Of Unit

    � Complete Parts List is available at www.MillerWelds.com 8-2. Blowing Out Inside Of Unit Do not remove case when blowing out inside of unit. To blow out unit, direct airflow through front and back louvers as shown. 8-3. Coolant Maintenance Disconnect input power before maintaining.

  • Page 46: Voltmeter/Ammeter Display Messages

    � Complete Parts List is available at www.MillerWelds.com 8-4. Voltmeter/Ammeter Display Messages � All directions are in reference to the front of the unit. All circuitry referred to is located inside the unit. Message Type Display Message Description Release Trigger [RELE] [ASE] / Remote 14 receptacle contactor control (Pins A-B) must be opened before [TRIG] [GER]...

  • Page 47: Troubleshooting Table

    � Complete Parts List is available at www.MillerWelds.com 8-5. Troubleshooting Table Trouble Remedy No weld output; unit completely Place line disconnect switch in On position (see Section 5-6). inoperative. Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 5-6). Check for proper input power connections (see Section 5-6).

  • Page 48: Section 9 - Parts List

    � Complete Parts List is available at www.MillerWelds.com SECTION 9 – PARTS LIST 9-1. Recommended Spare Parts Recommended Spare Parts Dia. Mkgs. Part No. Description Quantity 239494 Screen, Filter Lp Cyl 100x100x0.0045 SST A 043810 Coolant +When ordering a component originally displaying a precautionary label, the label should also be ordered. Labels available separately or as part of label kit.

  • Page 49: Section 10 - Electrical Diagrams

    SECTION 10 – ELECTRICAL DIAGRAMS 285165-B Figure 10-1. Circuit Diagram OM-289397 Page 41...

  • Page 50: Section 11 - High Frequency

    SECTION 11 – HIGH FREQUENCY SECTION 1 HIGH FREQUENCY 11-1. Welding Processes Requiring High Frequency SECTION 1 HIGH FREQUENCY 1 High-Frequency Voltage TIG – helps arc jump air gap between torch and workpiece and/or stabilize the arc. 11-2. Installation Showing Possible Sources Of HF Interference 11, 12 Best Practices Not Followed 11, 12...

  • Page 51: 11-3. Recommended Installation To Reduce Hf Interference

    11-3. Recommended Installation To Reduce HF Interference Best Practices Followed 50 ft (15 m) 50 ft (15 m) 1 High-Frequency Source (welding power Conduit Joint Bonding and Grounding Ground workpiece if required by codes. source with built-in HF or separate HF Electrically join (bond) all conduit sections 9 Nonmetal Building unit)

  • Page 52: Section 12 - Selecting And Preparing A Tungsten For Dc Or Ac Welding With Inverter Machines

    SECTION 12 – SELECTING AND PREPARING A TUNGSTEN FOR DC OR AC WELDING WITH INVERTER MACHINES 12-1. Selecting Tungsten Electrode Whenever possible and practical, use DC weld output instead of AC weld output. NOTICE – Wear clean gloves to prevent contamination of tungsten. A.

  • Page 53: Preparing Tungsten Electrode For Dc Electrode Negative (Dcen) Welding Or Ac Welding With Inverter Machines

    1-1. Preparing Tungsten Electrode For DC Electrode Negative (DCEN) Welding Or AC Welding With Inverter Machines Grinding the tungsten electrode produces dust and flying sparks which can cause injury and start fires. 12-2. Preparing Tungsten Electrode For DC Electrode Negative (DCEN) Welding Or AC Use local exhaust (forced ventilation) at the grinder or wear an approved respirator.

  • Page 54: Section 13 - Tig Procedures

    SECTION 5 TIG PROCEDURES SECTION 13 – TIG PROCEDURES SECTION 5 TIG PROCEDURES SECTION 5 TIG PROCEDURES Lift-Arc And HF TIG Start Procedures 13-1. Lift-Arc And HF TIG Start Procedures Lift-Arc And HF TIG Start Procedures Lift-Arc And HF TIG Start Procedures Lift-Arc Start Lift-Arc Start Method When Lift-Arc...

  • Page 55: Section 14 - Stick Welding (Smaw) Guidelines

    SECTION 14 – STICK WELDING (SMAW) GUIDELINES 14-1. Electrode And Amperage Selection Chart 6010 DEEP 3/32 MIN. PREP, ROUGH HIGH SPATTER 6011 DEEP 6010 5/32 & 6013 EP,EN GENERAL 3/16 6011 7/32 SMOOTH, EASY, 7014 EP,EN FAST 1/16 LOW HYDROGEN, 7018 5/64 STRONG...
  • Page 56 Notes...
  • Page 57 Notes...
  • Page 58 Notes...

  • Page 59: Warranty

    Effective January 1, 2021 (Equipment with a serial number preface of NB or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. LIMITED WARRANTY − Subject to the terms and conditions TIG Torches (No Labor) below, Miller Electric Mfg.
  • Page 60 Appleton, WI 54914 USA tact your distributor and/or equipment manu- facturer’s Transportation Department. International Headquarters–USA USA Phone: 920-735-4505 USA & Canada FAX: 920-735-4134 International FAX: 920-735-4125 For International Locations Visit www.MillerWelds.com ORIGINAL INSTRUCTIONS – PRINTED IN USA © Miller Electric Mfg. LLC 2021-02...

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