Miller Syncrowave 350 LX  Owner's Manual
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Miller Syncrowave 350 LX  Owner's Manual

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Syncrowave 350 LX
OM-356
June 2004
Processes
TIG (GTAW) Welding
Stick (SMAW) Welding
Description
Arc Welding Power Source
R
And Non-CE Models
188694Z

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  • Page 1 OM-356 188694Z June 2004 Processes TIG (GTAW) Welding Stick (SMAW) Welding Description Arc Welding Power Source Syncrowave 350 LX And Non-CE Models Visit our website at 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 ........1-1.
  • Page 4 SECTION 6 − MAINTENANCE & TROUBLESHOOTING ......... . . 6-1.
  • Page 5 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 350LX...
  • Page 6 Notes...

  • Page 7: Section 1 − Safety Precautions - Read Before Using

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _8/03 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 8 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 9: 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 10: Principal Safety Standards

    1-5. Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Boulevard, Rexdale, Ontario, Canada (phone: from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 800−463−6727 or in Toronto 416−747−4044, website: www.csa−in- (phone: 305-443-9353, website: www.aws.org). ternational.org).

  • Page 11: Section 2 − Consignes De Sécurité − À Lire Avant Utilisation

    SECTION 2 − CONSIGNES DE SÉCURITÉ − À LIRE AVANT UTILISATION som_fre 8/03 2-1. Signification des symboles Signifie « Mise en garde. Faire preuve de vigilance. » Cette procédure présente des risques identifiés par les symboles adjacents aux directives. Ce groupe de symboles signifie « Mise en garde. Faire preuve de vigi- Y Identifie un message de sécurité...
  • Page 12 LES RAYONS DE L’ARC peuvent cau- LES ACCUMULATIONS DE GAZ peu- ser des brûlures oculaires et cuta- vent causer des blessures ou même nées. la mort. Le rayonnement de l’arc génère des rayons visibles et D Couper l’alimentation en gaz protecteur en cas de invisibles intenses (ultraviolets et infrarouges) suscep- non utilisation.

  • Page 13: Autres Symboles Relatifs À L'installation, Au Fonctionnement Et À L'entretien De L'appareil

    2-3. Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien de l’appareil. Risque D’INCENDIE OU D’EXPLO- LES ORGANES MOBILES peuvent SION causer des blessures. D Ne pas placer l’appareil sur une surface inflam- D Se tenir à l’écart des organes mobiles comme les mable, ni au−dessus ou à...

  • Page 14: Principales Normes De Sécurité

    2-4. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, norme ANSI Z49.1, Rexdale, Rexdale (Ontario) Canada M9W 1R3 (téléphone : (800) de l’American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 463−6727 ou à Toronto : (416) 747−4044, site Web : www.csa−interna- (téléphone : (305) 443−9353, site Web : www.aws.org).

  • Page 15: Section 3 − Definitions

    SECTION 3 − DEFINITIONS 3-1. Warning Label Definitions Warning! Watch Out! There are possible Breathing welding fumes can be 3.3 Do not weld on drums or any closed hazards as shown by the symbols. hazardous to your health. containers. 2.1 Keep your head out of the fumes. Arc rays can burn eyes and injure Electric shock from welding electrode skin.

  • Page 16: Torch/Cable Holder Label

    3-2. Torch/Cable Holder Label Warning! Watch Out! There are possible hazards as shown by the symbols. Electric shock from wiring can kill. Do not operate unit or reach inside when torch/cable holder is removed. Do not exceed 25 lb (12.4 kg) maximum load on gun/cable holder or holder may break.

  • Page 17: Manufacturer's Rating Label For Ce Products

    3-4. Manufacturer’s Rating Label For CE Products OM-356 Page 11...

  • Page 18: Symbols And Definitions

    3-5. 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 19: Section 4 − Installation

    SECTION 4 − INSTALLATION 4-1. Selecting A Location Y Falling Unit Can Cause Injury. Use lifting eye to lift unit only, NOT running gear, gas cylinders, or any other Movement accessories. Use equipment of adequate capacity to lift and support unit.

  • Page 20: Dimensions And Weights

    4-2. Dimensions And Weights Dimensions Dimensions 39-3/4 in (1010 mm) with retract- Height able lifting eye down Width 22-1/2 in (572 mm) Length 25 in (635 mm) 25 in (635 mm) 23-5/8 in (600 mm) 1-3/8 in (35 mm) Front Front 7/8 in (22 mm) 19-15/16 (506 mm)

  • Page 21: Duty Cycle And Overheating

    4-4. Duty Cycle And Overheating Duty Cycle is the percentage of 10 minutes that the unit can weld at rated load without overheating. If unit overheats, output stops, front panel voltmeter/ammeter displays a HLP3 or HLP5 message (see Section 6-4), and cooling fans run. Wait fifteen minutes for unit to cool.

  • Page 22: Weld Output Terminals And Selecting Cable Sizes

    4-6. 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. Be sure this welding machine is installed and grounded according to this manual.

  • Page 23: Shielding Gas Connections And 115 Volts Ac Duplex Receptacle

    4-8. Shielding Gas Connections And 115 Volts AC Duplex Receptacle Y Turn Off power before mak- ing connections. Gas Valve In Fitting Located on rear of unit. Gas Valve Out Fitting Fittings have 5/8-18 right-hand threads. Cylinder Valve Open valve slightly so gas flow blows dirt from valve.

  • Page 24: Electrical Service Guide

    4-9. Electrical Service Guide NOTE All values calculated at 60% duty cycle. NOTE Actual input voltage cannot exceed ± 10% of indicated required input voltage shown in both tables. If actual input voltage is outside of this range, damage to unit may occur.

  • Page 25: Placing Jumper Links

    4-10. Placing Jumper Links Y Disconnect and lockout/tag- input power before installing or moving jumper links. Check input voltage available at site. Jumper Link Label Check label − only one is on unit. Jumper Links Move jumper links to match input voltage.

  • Page 26: Connecting Input Power

    4-11. Connecting Input Power =GND/PE Earth Ground Tools Needed: 3/8 in Ref. ST-801 973-B Y Installation must meet all National and Welding Power Source Input Power Con- Disconnect Device Input Power Connec- Local Codes − have only qualified per- nections tions sons make this installation.

  • Page 27: Section 5 − Operation

    SECTION 5 − OPERATION 5-1. Controls A. For 200/230/460 Volts And Non CE Units Ammeter 12 Balance/DIG Control Top row of lights in upper left corner are On for SMAW. Bottom row are On for See Section 5-7 See Section 5-9. GTAW.
  • Page 28 B. For CE Units Ammeter 12 Balance/DIG Control Top row of lights in upper left corner are On for SMAW. Bottom row are On for See Section 5-7 See Section 5-9. GTAW. Amperage Adjustment Pulse Controls: Process Control Control 13 Pulser On/Off Switch See Section 5-3.

  • Page 29: Output Selector Switch

    5-2. Output Selector Switch Output Selector Switch (CE Nameplate Shown) 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 30: Current Control

    5-4. Current Control Current Control Use control to select front panel or remote current control. (CE Nameplate Only) For front panel current control, press button to toggle LED to Panel position. For remote current control, press button to toggle LED to Remote 14 position (see Section 4-7).

  • Page 31: Start Mode

    5-6. Start Mode (CE Nameplate Only) Lift-Arct Start Method 1 − 2 “Touch” Seconds Do NOT Strike Like A Match! Start Mode and slowly lift electrode. An arc will form turns off when arc is started, and turns on when electrode is lifted. whenever arc is broken to help restart arc.

  • Page 32: Meters

    5-7. Meters Voltmeter Voltmeter displays average voltage (to the nearest 0.1 V) at the weld output terminals. Ammeter Use meter to preset amperage. Me- ter displays average weld amper- age output of unit to nearest am- pere when welding. 5-8. Amperage Adjustment Control Amperage Adjustment Control Use control to adjust amperage, and preset amperage on ammeter...

  • Page 33: Balance/Dig Control

    5-9. Balance/DIG Control Balance/DIG Control (CE Nameplate Only) 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...

  • Page 34: Postflow Time Control

    5-11. Postflow Time Control Postflow Time Control Use control to set length of time (CE Nameplate Only) (0−50 seconds) gas flows after welding stops. It is important to set enough time to allow gas to flow un- til after the tungsten and weld puddle has cooled down.

  • Page 35: Setting Pulse Controls

    5-12. Setting Pulse Controls On/Off Switch Use switch to turn pulse function On and Off. Background Amps Use Background Amps control to set the low pulse of the weld am- perage, which cools the weld puddle and affects overall heat in- put.

  • Page 36: Optional Sequence Controls

    5-13. Optional Sequence Controls Sequence Selection Switch See Section 5-14. Start Time/Spot Time Control See Section 5-15. Start Current Control See Section 5-15. Crater Time Control See Section 5-16. Final Current Control See Section 5-16. (CE Nameplate Only) Ref. ST-191 372 5-14.

  • Page 37: Start Time/Spot Time Control And Start Current Control

    5-15. Start Time/Spot Time Control And Start Current Control Sequence Selection Switch (CE Nameplate Only) Place switch in Start position. Start Time/Spot Time Control Use control to select 0−15 seconds of start time. Start Current Control Use start control to select a starting current (3−400 amps) that is differ- ent from the weld current.

  • Page 38: Crater Time Control And Final Current Control

    5-16. Crater Time Control And Final Current Control Sequence Selection Switch (CE Nameplate Only) Place switch in Crater position. 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.

  • Page 39: Start/Crater Sequence Controls

    5-17. Start/Crater Sequence Controls Sequence Selection Switch Place switch in Start/Crater posi- (CE Nameplate Only) tion. Start Time/Spot Time Control Use control to select 0−15 sec- onds of start time. Start Current Control Use start control to select a start- ing current (3−400 amps) that is different from the weld current.

  • Page 40: Sequence Selection Controls

    5-18. 4T Sequence Selection Controls Start Sequence Switch − (CE Nameplate Only) 4T Position (Specific trigger method) Press and hold torch trigger to start Preflow Time and arc at the Start Current level. The arc will remain at the Start Current level as long as the trigger is depressed.

  • Page 41: Spot Time Control

    5-19. Spot Time Control Sequence Selection Switch − (CE Nameplate Only) Spot Position Used with the (GTAW) TIG Spot process, generally with a direct cur- rent electrode negative (DCEN) set- Start Time/Spot Time Control Use control to select 0−15 seconds of spot time.

  • Page 42: Section 6 − Maintenance & Troubleshooting

    SECTION 6 − MAINTENANCE & TROUBLESHOOTING 6-1. 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 14-Pin Cord Torch Cable Gas Hose 6 Months Blow Out Or Vacuum Inside,...

  • Page 43: Adjusting Spark Gaps

    6-3. Adjusting Spark Gaps Y Turn off welding power source and disconnect and lockout/tagout input power before adjusting 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 0.012 in (0.305 mm).

  • Page 44: Voltmeter/Ammeter Help Displays

    6-4. Voltmeter/Ammeter Help Displays overheated. The unit has shut down to allow Help 7 Display All directions are in reference to the front the fan to cool it (see Section 4-4). Operation of the unit. All circuitry referred to is lo- Not used.

  • Page 45: Troubleshooting

    6-5. Troubleshooting NOTE: The remedies listed below are recommendations only. If these remedies do not fix the trouble with your unit, have a Factory Authorized Service Agent check unit. There are not user serviceable parts inside unit. Refer to Section 6-4 for any Help (HLP) message displayed on voltmeter/ammeter. Trouble Remedy No weld output;...
  • Page 46 Notes Work like a Pro! Pros weld and cut safely. Read the safety rules at the beginning of this manual. OM-356 Page 40...

  • Page 47: Section 7 − Electrical Diagram

    SECTION 7 − ELECTRICAL DIAGRAM SC-187 950-H Figure 7-1. Circuit Diagram OM-356 Page 41...

  • Page 48: Section 8 − High Frequency

    SECTION 8 − HIGH FREQUENCY 8-1. Welding Processes Requiring High Frequency High-Frequency Voltage TIG − helps arc jump air gap between torch and workpiece and/ or stabilize the arc. Work high_freq 12/96 − S-0693 8-2. Incorrect Installation Weld Zone 11, 12 50 ft (15 m) Sources of Direct High-Frequency...

  • Page 49: Correct Installation

    8-3. Correct Installation Weld Zone 50 ft (15 m) 50 ft (15 m) Ground all metal ob- jects and all wiring in welding zone using #12 AWG wire. Ground workpiece if required by codes. Nonmetal Building Metal Building Ref. S-0695 / Ref. S-0695 High-Frequency Source (welding Conduit Joint Bonding and Grounding Metal Building Requirements...

  • Page 50: Section 9 − Parts List

    SECTION 9 − PARTS LIST Hardware is common and not available unless listed. Figure 9-1. Main Assembly OM-356 Page 44...
  • Page 51 17 18 ST-802 012-N OM-356 Page 45...
  • Page 52 Item Diagram Part marking Description Quantity Figure 9-1. Main Assembly ....204 659 . . . PANEL, side ..........
  • Page 53 Item Diagram Part marking Description Quantity Figure 9-1. Main Assembly (Continued) ....202 790 . . . TERMIMAL ASSEMBLY, pri 1ph 3V (consisting of) ....
  • Page 54 ....213 287 . . . LABEL, MILLER 12.563 x 5.376 horizontal ......
  • Page 55 Effective January 1, 2004 (Equipment with a serial number preface of “LE” 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 Induction Heating Coils and Blankets below, Miller Electric Mfg.

  • Page 56: 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...

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