Miller Syncrowave 250 Owner's Manual
  1. Manuals
  2. Brands
  3. Miller Manuals
  4. AC Power Distribution
  5. Syncrowave 250
  6. Owner's manual

Miller Syncrowave 250 Owner's Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Visit our website at
www.MillerWelds.com
Syncrowave 250
OM-353
122200T
October 2000
Processes
TIG (GTAW) Welding
Stick (SMAW) Welding
Description
Arc Welding Power Source
R
60 Hz, 50 Hz

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the Syncrowave 250 and is the answer not in the manual?

Questions and answers

Related Manuals for Miller Syncrowave 250

Summary of Contents for Miller Syncrowave 250

  • Page 1 OM-353 122200T October 2000 Processes TIG (GTAW) Welding Stick (SMAW) Welding Description Arc Welding Power Source Syncrowave 250 60 Hz, 50 Hz Visit our website at www.MillerWelds.com...
  • Page 2 – every power source from This Owner’s Manual is designed to help you get the most out of your Miller is backed by the most Miller products. Please take time to read the Safety precautions. They will hassle-free warranty in the business.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING ......1-1.
  • Page 4 Declaration of Conformity For European Community (CE) Products NOTE This information is provided for units with CE certification (see rating label on unit.) Miller Electric Mfg. Co. Manufacturer’s Name: 1635 W. Spencer Street Manufacturer’s Address: Appleton, WI 54914 USA Syncrowave 250...

  • Page 5: Section 1 - Safety Precautions - Read Before Using

    SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_5/97 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. This group of symbols means Warning! Watch Out! possible Y Marks a special safety message.
  • Page 6 ARC RAYS can burn eyes and skin. BUILDUP OF GAS can injure or kill. D Shut off shielding gas supply when not in use. Arc rays from the welding process produce intense D Always ventilate confined spaces or use visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin.

  • Page 7: Additional Symbols For Installation, Operation, And Maintenance

    1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury. D Do not install or place unit on, over, or near D Keep away from moving parts such as fans. combustible surfaces. D Keep all doors, panels, covers, and guards D Do not install unit near flammables.

  • Page 8: Emf Information

    1-5. EMF Information Considerations About Welding And The Effects Of Low Frequency 1. Keep cables close together by twisting or taping them. Electric And Magnetic Fields 2. Arrange cables to one side and away from the operator. Welding current, as it flows through welding cables, will cause electro- magnetic fields.

  • Page 9: Section 1 - Consignes De Securite - Lire Avant Utilisation

    SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT UTILISATION som _nd_fre 5/97 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives. Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des Y Identifie un message de sécurité...
  • Page 10 LES RAYONS DE L’ARC peuvent pro- LES ACCUMULATIONS DE GAZ ris- voquer des brûlures dans les yeux et quent de provoquer des blessures ou sur la peau. même la mort. Le rayonnement de l’arc du procédé de soudage D Fermer l’alimentation du gaz protecteur en cas de génère des rayons visibles et invisibles intenses non utilisation.

  • Page 11: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU DES ORGANES MOBILES peuvent D’EXPLOSION. provoquer des blessures. D Ne pas placer l’appareil sur, au-dessus ou à proxi- D Rester à l’écart des organes mobiles comme le mité...

  • Page 12: Principales Normes De Sécurité

    1-4. Principales normes de sécurité Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Wel- Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, ding Society, 550 N.W. Lejeune Rd, Miami FL 33126 de la Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202.

  • Page 13: Section 2 - Definitions

    SECTION 2 – DEFINITIONS 2-1. Warning Label Definitions Warning! Watch Out! There are possible hazards as shown by the symbols. Electric shock from welding electrode or wiring can kill. 1.1 Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves.

  • Page 14: Rating Label For Ce Products

    2-2. Rating Label For CE Products ISO/IEC 974-1 7A/10.2V 310A/22.4V 100% 310A 200A 155A = 80V 22.4V 18V 16.2V 5A/20.2V 310A/32.4V 100% 310A 200A 155A = 80V 32.4V 28V 26.2V = 220 = 117.2A I = 59A 1max 1Eff 50 Hz = 380 = 72.2A I = 36A...

  • Page 15: Symbols And Definitions

    2-3. Symbols And Definitions NOTE Some symbols are found only on CE products. Gas Tungsten Arc Shielded Metal Arc Amperes Panel–Local Welding (GTAW) Welding (SMAW) Do Not Switch Volts Arc Force (DIG) Spot Timer While Welding Output Circuit Breaker Remote Temperature Protective Earth High Frequency -...

  • Page 16: Section 3 - Installation

    SECTION 3 – INSTALLATION 3-1. Specifications Amperes Input at AC Balanced Rated Load Output, 50/60 Hz, Single-Phase Rated 200 V 230 V 460 V 575 V PFC** Welding Output Range Rating 11.4 NEMA Class II (4.6*) (4*) (2*) (1.6*) (0.89*) (0.68*) (40) –...

  • Page 17: Duty Cycle And Overheating

    3-3. Duty Cycle And Overheating Duty Cycle is percentage of 10 min- utes that unit can weld at rated load without overheating. If unit overheats, thermostat opens, output stops, light goes on (CE models only), and cooling fan runs. Wait fifteen minutes for unit to cool. Reduce amperage or duty cycle be- fore welding.

  • Page 18: Selecting A Location

    3-4. Selecting A Location Lifting Eye Lifting Forks Use lifting eye or lifting forks to move unit. Movement If using lifting forks, extend forks beyond opposite side of unit. Rating Label (Non CE Models Only) Rating Label (CE Models Only, See Section 2-2) Use rating label to determine input power needs.

  • Page 19: Tipping

    3-6. Tipping Y Be careful when placing or moving unit over uneven surfaces. 3-7. Weld Output Terminals And Selecting Cable Sizes Y ARC WELDING can cause Electromagnetic Interference. To reduce possible interference, keep weld cables as short as possible, close together, and down low, such as on the floor. Locate welding operation 100 meters from any sensitive electronic equipment.

  • Page 20: Remote 14 Receptacle

    3-8. Remote 14 Receptacle Socket* Socket Information 24 volts ac. Contact closure to A completes 24 volts ac contactor control circuit. Command reference; 0 to +10 volts dc output to remote control. Remote control circuit common. C L N 0 to +10 volts dc input command signal from remote control. Chassis common.

  • Page 21: Electrical Service Guide

    3-10. Electrical Service Guide NOTE All values calculated at 60% duty cycle. Without Power Factor 60 Hertz Models With Power Factor Correction Correction Input Voltage Input Amperes At Rated Output Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes Min Input Conductor Size In AWG/Kcmil Max Recommended Input Conductor Length (53)

  • Page 22: Placing Jumper Links And Connecting Input Power

    3-11. Placing Jumper Links And Connecting Input Power Check input voltage available at site. Jumper Link Label Check label inside your unit– only one label is on unit. 200 VOLTS 230 VOLTS 460 VOLTS Y Only make connections for the voltages shown on the la- bel inside your unit.

  • Page 23: Section 4 - Operation

    SECTION 4 – OPERATION 4-1. Controls Ammeter See Section 4-3. Voltmeter See Section 4-3. High Frequency Switch See Section 4-11. Output (Contactor) Switch See Section 4-8. Spot Time Switch And Control (Optional) See Section 4-5. Preflow Time Control (Optional) See Section 4-12. AC Balance Control See Section 4-6.

  • Page 24: Output Selector Switch

    4-2. Output Selector Switch Output Selector Switch Y Do not use AC output in damp areas, if movement is confined, or if there is dan- ger of falling. Use AC output ONLY if required for the welding process, and then use a remote control.

  • Page 25: Crater Time Controls

    4-4. Crater Time Controls Crater Time Control Use control to reduce current over a set period of time (0–15 seconds) at the end of the weld cycle when NOT using a remote current control. Crater Time Switch ON – provides crater time. OFF –...

  • Page 26: Ac Balance Control

    4-6. AC Balance Control AC Balance Control Balance Control (AC GTAW): Control changes the AC output square wave. Rotating the control towards 10 provides deeper pene- tration. Rotating the control towards 0 provides more cleaning action of the workpiece. When the control is in the Balanced position, the wave shape provides equal penetration and cleaning action.

  • Page 27: Amperage Adjustment Controls

    4-7. Amperage Adjustment Controls Amperage Adjustment Control Use control to adjust amperage, and preset amperage on ammeter (see Section 4-3). This control may be adjusted while welding. For remote amperage control, front panel control setting is the maximum amperage available. For example: If front panel control is set to 200 A, the range of the remote amperage control is 5 to 200 A.

  • Page 28: Arc Controls

    4-9. Arc Controls Arc Control (Dig) For AC And DC SMAW Welding When set at 0, short-circuit amper- age at low arc voltage is the same as normal welding amperage. When setting is increased, short- circuit amperage at low arc voltage increases.

  • Page 29: High Frequency Controls

    4-11. High Frequency Controls Y Place High Frequency switch in Off position before using the shielded metal arc welding (SMAW) process. High Frequency Switch START – (Up position) provides HF for arc starting only. High frequency turns on to help start arc when out- put is enabled.

  • Page 30: Section 5 - Maintenance & Troubleshooting

    SECTION 5 – MAINTENANCE & TROUBLESHOOTING 5-1. Routine Maintenance Y Disconnect power before maintaining. 3 Months Clean And Repair Or Replace Tighten Replace Unreadable Weld Cracked Labels Terminals Weld Cables Adjust Spark Replace Gaps Cracked Parts Torch Cable 14-Pin Cord Gas Hose 6 Months Blow Out Or Vacuum...

  • Page 31: Adjusting Spark Gaps

    5-3. Adjusting Spark Gaps Y Turn Off power before ad- justing spark gaps. Open access door. Tungsten End Of Point Replace point if tungsten end dis- appears; do not clean or dress tungsten. Spark Gap Normal spark gap is 0.008 in (0.203 mm).
  • Page 32 Trouble Remedy Fan not operating. NOTE: fan only Check and remove anything blocking fan movement. runs when cooling is necessary. Have Factory Authorized Service Agent check fan motor. Unit provides only maximum or Have Factory Authorized Service Agent check control board PC1. minimum weld output.

  • Page 33: Circuit Diagram

    5-5. Circuit Diagram SC-188 161-A OM-353 Page 29...

  • Page 34: Section 6 - High Frequency (Hf)

    SECTION 6 – HIGH FREQUENCY (HF) 6-1. Welding Processes Using HF HF Voltage GTAW – helps arc jump air gap between torch and workpiece and/ or stabilize the arc. SAW – helps arc reach workpiece through flux granules. Flux Work Work Gas Tungsten Arc Submerged Arc...

  • Page 35: Correct Installation

    6-3. Correct Installation Weld Zone 50 ft (15 m) 50 ft (15 m) Ground All Metal Objects And All Wiring In Welding Zone Using #12 AWG Ground Wire Workpiece If Required By Codes Nonmetal Building Metal Building Ref. S-0695 / Ref. S-0695 HF Source (Welder With Built-In HF Or Electrically join (bond) all conduit sections Metal Building Panel Bonding Methods...

  • Page 36: Section 7 - Parts List

    SECTION 7 – PARTS LIST Hardware is common and ST-120 135-R Figure 7-1. Main Assembly not available unless listed. OM-353 Page 32...
  • Page 37 Replace Coils at Factory or Authorized Factory Service Station Item Dia. Part Description Quantity Mkgs. Figure 7-1. Main Assembly ....182 605 COVER, top ........... . .
  • Page 38 Hardware is common and not available unless listed. Includes Item 26 Fig 7-6 ST-120 088-G Figure 7-2. Panel, Front w/Components OM-353 Page 34...
  • Page 39 Item Dia. Part Description Quantity Mkgs. Figure 7-2. Panel, Front w/Components (Fig 7-1 Item 29) ....097 922 KNOB, pointer ...........
  • Page 40 Item Dia. Part Description Quantity Mkgs. 181 106 Figure 7-3. Rectifier, Si Diode (Fig 7-1 Item 2) . . . C7-10 ..031 689 CAPACITOR, rectifier ..........
  • Page 41 Item Dia. Part Description Quantity Mkgs. Figure 7-5. Panel, Mtg Components (Fig 7-1 Item 7) ..186 468 RESISTOR, WW fxd 100W50 ohm ....... . .
  • Page 42 Hardware is common and not available unless listed. ST-120 003-P Figure 7-6. Control Panel, Lower Front OM-353 Page 38...
  • Page 43 Item Dia. Part Description Quantity Mkgs. Figure 7-6. Control Panel, Lower Front (Fig 7-2 Item 18) ....171 652 PANEL, front lower ..........
  • Page 44 Notes OM-353 Page 40...
  • Page 47 Effective January 1, 2000 (Equipment with a serial number preface of “LA” or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other Warranty Questions? guarantees or warranties expressed or implied. Call LIMITED WARRANTY – Subject to the terms and conditions APT, ZIPCUT &...

  • Page 48: Options And Accessories

    Distributor Address City State For Service Call 1-800-4-A-Miller or see our website at www.MillerWelds.com to locate a DISTRIBUTOR or SERVICE AGENCY near you. Always provide Model Name and Serial/Style Number. Contact your Distributor for: Welding Supplies and Consumables Options and Accessories...

Table of Contents

Save PDF