Miller Electric SYNCROWAVE 250 Technical Manual

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Processes

TM-353E January 2001

Eff. w/Serial Number JJ339876

Description

TIG (GTAW) Welding

Stick (SMAW) Welding

Arc Welding Power Source

Syncrowave 250

60 Hz, 50 Hz

Visit our website at

www.MillerWelds.com

TABLE OF CONTENTS

1. Safety Precautions – Read Before Using 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1 Symbol Usage 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2 Servicing Hazards 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3 EMF Information 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 – DEFINITIONS 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1. Warning Label Definitions 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2. Rating Label For CE Products 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-3. Symbols And Definitions 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 – INSTALLATION 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1. Specifications 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2. Volt-Ampere Curves 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3. Duty Cycle And Overheating 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-4. Selecting A Location 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-5. Dimensions And Weights 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-6. Tipping 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-7. Weld Output Terminals And Selecting Cable Sizes 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-8. Remote 14 Receptacle 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-9. 115 Volts AC Duplex Receptacle And Shielding Gas Connections 10. . . . . . . . . . . . . . . . . . . . . .

3-10.Electrical Service Guide 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-11.Placing Jumper Links And Connecting Input Power 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 – OPERATION 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1. Controls 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2. Output Selector Switch 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3. Meters 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-4. Crater Time Controls 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-5. Spot Time Controls 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-6. AC Balance Control 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-7. Amperage Adjustment Controls 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-8. Output (Contactor) Control Switch 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-9. Arc Controls 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-10.Postflow Time Control 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-11.High Frequency Controls 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-12.Preflow Time Control (Optional) 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 – THEORY OF OPERATION 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 – TROUBLESHOOTING 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1. Troubleshooting Table 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2. Troubleshooting Circuit Diagram For Welding Power Source 26. . . . . . . . . . . . . . . . . . . . . . . . . .

6-3. Waveforms For Section 6-2 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-4. Control Board PC1 Testing Information (Use With Section 6-5) 30. . . . . . . . . . . . . . . . . . . . . . . .

6-5. Control Board PC1 Test Point Values 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-6. Remote Board PC2 Testing Information (Use With Section 6-7) 33. . . . . . . . . . . . . . . . . . . . . . . .

6-7. Remote 14 Filter Board PC2 Test Point V alues (Use With Section 6-2 And Section 6-6) 34. . . .

6-8. Meter Calibration 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-9. Input Voltage Labels And Connections 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 – MAINTENANCE 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1. Routine Maintenance 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-2. Circuit Breaker CB1 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-3. Fuses F1 And F2 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-4. Adjusting Spark Gaps 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 8 – HIGH FREQUENCY (HF) 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-1. Welding Processes Using HF 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-2. Sources Of HF Radiation From Incorrect Installation 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-3. Correct Installation 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 9 – ELECTRICAL DIAGRAMS 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 10 – PARTS LIST 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TM-353D

Declaration of Conformity For

European Community (CE) Products

NOTE

Manufacturer’s Name: Miller Electric Mfg. Co.

Manufacturer’s Address: 1635 W. Spencer Street

This information is provided for units with CE certification (see rating label on unit.)

Appleton, WI 54914 USA

Declares that the product: Syncrowave 250

conforms to the following Directives and Standards:

Directives

Low Voltage Directive: 73/23/EEC

Machinery Directives: 89/392/EEC, 91/368/EEC, 93/C 133/04, 93/68/EEC

Electromagnetic Capability Directives: 89/336, 92/31/EEC

Standards

Safety Requirements for Arc Welding Equipment part 1: EN 60974-1: 1990

Arc Welding Equipment Part 1: Welding Power Sources: IEC 974-1

(April 1995 – Draft revision)

Degrees of Protection provided by Enclosures (IP code): IEC 529: 1989

Insulation coordination for equipment within low-voltage systems:

Part 1: Principles, requirements and tests: IEC 664-1: 1992

Electromagnetic compatibility (EMC) Product standard for arc welding equipment:

EN50199: August 1995

European Contact: Mr. Luigi Vacchini, Managing Director

MILLER Europe S.P.A. Via Privata Iseo 20098 San Giuliano Milanese, Italy

Telephone: 39(02)98290-1

Fax: 39(02)98281-552

dec_con1 10/95

SECTION 1 – SAFETY PRECAUTIONS FOR SERVICING

1-1. Symbol Usage

safety_stm1 4/95

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 ELECTRIC SHOCK, MOVING P ARTS, and HOT P ARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the hazards.

Y Marks a special safety message.

. Means NOTE; not safety related.

1-2. Servicing Hazards

WARNING

The symbols shown below are used throughout this manual to call attention to and identify possible hazards. When you see the symbol, watch out, and follow the related instructions to avoid the hazard.

Only qualified persons should service, test, maintain, and repair this unit. During servicing, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

1. Do not touch live electrical parts.

2. Stop engine or turn OFF welding power source and wire feeder, and disconnect and lockout input power using line disconnect switch, circuit breakers, or by removing plug from receptacle before servicing unless the procedure specifically requires an energized unit.

3. Insulate yourself from ground by standing or working on dry insulating mats big enough to prevent contact with the ground.

4. Do not leave live unit unattended.

5. When testing a live unit, use the one-hand method. Do not put both hands inside unit. Keep one hand free.

6. Disconnect input power conductors from deenergized supply line BEFORE moving a welding power source.

SIGNIFICANT DC VOLTAGE exists after removal of input power on inverters.

7. Turn Off inverter, disconnect input power, and discharge input capacitors according to instructions in Maintenance Section before touching any parts.

STATIC ELECTRICITY can damage parts on circuit boards.

1. Put on grounded wrist strap BEFORE handling boards or parts.

2. Use proper static-proof bags to store, move, or ship PC boards.

FIRE OR EXPLOSION can result from placing unit on, over, or near combustible surfaces.

1. Do not place unit on, over, or near combustible surfaces.

2. Do not service unit near flammables.

FLYING PIECES OF METAL or DIRT can injure eyes.

1. Wear safety glasses with side shields or face shield during servicing.

2. Be careful not to short metal tools, parts, or wires together during testing and servicing.

HOT PARTS can cause severe burns.

1. Do not touch hot parts bare handed.

2. Allow cooling period before servicing welding gun or torch.

EXPLODING PARTS can cause injury.

1. Failed parts can explode or cause other parts to explode when power is applied to inverters.

2. Always wear a face shield and long sleeves when servicing inverters.

ELECTRIC SHOCK HAZARD from incorrect use of test equipment.

1. Turn Off welding power source and wire feeder or stop engine before making or changing meter lead connections.

2. At least one meter lead should be a self-retaining spring clip such as an alligator clamp.

3. Read instructions for test equipment.

HIGH-FREQUENCY RADIATION can interfere with radio navigation, safety services, computers, and communications equipment.

1. Have only qualified persons familiar with electronic equipment perform this installation.

2. The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.

3. If notified by the FCC about interference, stop using the equipment at once.

4. Have the installation regularly checked and maintained.

5. Keep high-frequency source doors and panels tightly shut, keep spark gaps at correct setting, and use grounding and shielding to minimize the possibility of interference.

TM-353 Page 1Syncrowave 250

FALLING EQUIPMENT can cause serious personal injury and equipment damage.

1. Use lifting eye to lift unit only, NOT running gear, gas cylinders, or any other accessories.

2. Use equipment of adequate capacity to lift unit.

MAGNETIC FIELDS FROM HIGH CURRENTS can affect pacemaker operation.

1. Pacemaker wearers keep away from servicing areas until consulting your doctor.

MOVING PARTS can cause injury.

1. Keep away from moving parts such as fans.

2. Keep all doors, panels, covers, and guards closed and securely in place.

1-3. EMF Information

MOVING PARTS can cause injury.

1. Keep away from moving parts.

2. Keep away from pinch points such as drive rolls.

OVERUSE can cause OVERHEATED EQUIPMENT.

1. Allow cooling period.

2. Reduce current or reduce duty cycle before starting to weld again.

3. Follow rated duty cycle.

READ INSTRUCTIONS.

1. Use MILLER Testing Booklet (Part No. 150 853) when servicing this unit.

2. Consult the Owner ’s Manual for welding safety precautions.

3. Use only genuine MILLER replacement parts.

Considerations About Welding And The Effects Of Low Frequency Electric And Ma g netic Fields

The following is a quotation from the General Conclusions Section of the U.S. Congress, Office of Technology Assessment, Biological

Effects of Power Frequency Electric & Magnetic Fields – Background Paper, OTA-BP-E-53 (Washington, DC: U.S. Government Printing

Office, May 1989): “. . . there is now a very large volume of scientific findings based on experiments at the cellular level and from studies with animals and people which clearly establish that low frequency magnetic fields can interact with, and produce changes in, biological systems. While most of this work is of very high quality , the results are complex. Current scientific understanding does not yet allow us to interpret the evidence in a single coherent framework. Even more frustrating, i t does not yet allow us to draw definite conclusions about questions of possible risk or to offer clear science-based advice on strategies to minimize or avoid potential risks.”

To reduce magnetic fields in the workplace, use the following procedures:

1. Keep cables close together by twisting or taping them.

2. Arrange cables to one side and away from the operator.

3. Do not coil or drape cables around the body.

4. Keep welding power source and cables as far away as practical.

5. Connect work clamp to workpiece as close to the weld as possible.

About Pacemakers:

The above procedures are also recommended for pacemaker wearers. Consult your doctor for complete information.

TM-353 Page 2 Syncrowave 250

SECTION 2 – DEFINITIONS

2-1. Warning Label Definitions

1 1.1 1.2

3 3.1 3.2 3.3

4 4.1

2.1

2.2

2.3

1.3

Warning! Watch Out! There are possible hazards as shown by the symbols.

1 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.

1.2 Protect yourself from electric shock by insulating yourself from work and ground.

1.3 Disconnect input plug or power before working on machine.

2 Breathing welding fumes can

be hazardous to your health.

2.1 Keep your head out of the fumes.

2.2 Use forced ventilation or local exhaust to remove the fumes.

2.3 Use ventilating fan to remove fumes.

3 Welding sparks can cause

explosion or fire.

3.1 Keep flammables away from welding. Don’t weld near flammables.

3.2 Welding sparks can cause fires. Have a fire extinguisher nearby and have a watch person ready to use it.

3.3 Do not weld on drums or any closed containers.

4 Arc rays can burn eyes and

injure skin.

4.1 Wear hat and safety glasses. Use ear protection and button shirt collar. Use welding helmet with correct shade of filter. Wear complete body protection.

5 Become trained and read the

instructions before working on the machine or welding.

6 Do not remove or paint over

(cover) the label.

5 6

S-176 254-A

TM-353 Page 3Syncrowave 250

2-2. Rating Label For CE Products

50 Hz

= 80V

= 220 I

= 380 I

= 415 I

ISO/IEC 974-1

7A/10.2V 310A/22.4V

X 25% 60% 100% I U

5A/20.2V 310A/32.4V

X 25% 60% 100% I U

310A 200A 155A

22.4V 18V 16.2V

310A 200A 155A

32.4V 28V 26.2V

= 117.2A I

1max

= 72.2A I

1max

= 63.8A I

1max

1Eff

= 59A = 36A

= 32A

IP 21S

S-178 813-A

TM-353 Page 4 Syncrowave 250

2-3. Symbols And Definitions

NOTE

Some symbols are found only on CE products.

Amperes Panel–Local

Volts

Output Circuit Breaker Remote Temperature

Protective Earth

(Ground)

Postflow Timer Preflow Timer

Gas (Supply) Gas Input Gas Output

On Off Percent Direct Current

Do Not Switch

While Welding

Alternating Current

Gas Tungsten Arc

Welding (GT AW)

Arc Force (DIG) Spot Timer

High Frequency -

Start

High Frequency -

Continuous

Shielded Metal Arc

Welding (SMAW)

High Frequency

Increase/Decrease

Of Quantity

Input

Balance Control Maximum Cleaning

Electrode

Negative

Voltage (A verage)

Rated No Load

Primary Current

Degree Of Protection

Electrode Work Thickness Gauge Spark Gap

Seconds

1eff

Maximum

Penetration

Crater Time Meter Single-Phase

Primary Voltage

Rated Welding

Current

Maximum Effective

Supply Current

1max

Conventional Load

Rated Maximum

Supply Current

Voltage

Duty Cycle

Electrode Positive

Line Connection

Single-Phase

Combined AC/DC

Power Source

Hertz

TM-353 Page 5Syncrowave 250

3-1. Specifications

Rated

Welding Output

NEMA Class II

(40) – 250

Amperes, 30 Volts

AC, 40% Duty

Cycle

*While idling **Power Factor Correction

Rated

Welding

PFC

Output

NEMA Class I

(60) – 200

Amperes,

28 Volts

AC, 60%

Duty Cycle *While idling

**Power Factor Correction

PFC85(4.6*)77(4.2*)74(4*)65(3.5*)45(2.4*)41(2.2*)37(2*)33(1.8*)30(1.6*)17(0.9*)

With PFC55(57*)64(51*)48(49*)48(49*)37(30*)34(27*)24(25*)48(49*)19(20*)11(11*)

PFC**

PFC With

PFC

200V220V230V260V380V415V460V520V575

SECTION 3 – INSTALLATION

Amperes Input at AC Balanced

Rated Load Output,

50/60 Hz, Single-Phase

200 V 230 V 460 V 575 V

106

(4.6*)

76 66 33 26 15.2 11.4

(4*)

(2*)

(1.6*)21(0.89*)

Amperes Input at AC Balanced

Rated Load Output,

50/60 Hz, Single-Phase

KVA KW

11.4

(0.68*)

KVA KW

Amp

Range

5–310 A 80 V 21

8.3

(0.7*)

8.3

(0.6*)

Max

OCV

Amp

Range

5–310 A 80 V 21

Rating

Max

OCVIPRating

3-2. Volt-Ampere Curves

A. DC Mode

The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities of the welding power source. Curves of other settings fall between the curves shown.

B. AC Mode

ssb1.1 10/91 – SB-116 199 / SB-116 200

TM-353 Page 6 Syncrowave 250

3-3. Duty Cycle And Overheating

40% Duty Cycle At 250 Amperes (60 Hz Models Only)

4 Minutes Welding 6 Minutes Resting

Duty Cycle is percentage of 10 mi n 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 before welding.

Y Exceeding duty cycle can

damage unit and void warranty.

Overheating

60% Duty Cycle At 200 Amperes

6 Minutes Welding 4 Minutes Resting

Minutes

Reduce Duty Cycle

duty1 4/95 / SB-116 198

TM-353 Page 7Syncrowave 250

3-4. Selecting A Location

Movement

Location And Airflow

1 Lifting Eye 2 Lifting Forks Use lifting eye or lifting forks to

move unit.

18 in (460

mm)

If using lifting forks, extend forks beyond opposite side of unit.

3 Rating Label (Non CE Models

Only)

4 Rating Label (CE Models

Only, See Section 2-2)

Use rating label to determine input power needs. CE label located on rear panel.

5 Plate Label (CE Models Only) 6 Line Disconnect Device Locate unit near correct input pow-

er supply.

Y Special installation may be

required where gasoline or volatile liquids are present – see NEC Article 511 or CEC Section 2 0 .

18 in (460

mm)

3-5. Dimensions And Weights

Front

ST-800 402 / ST-117 264-F

Dimensions

Height 30-3/4 in (781 mm)

Width 19-3/4 i n (502 mm)

Length 27-1/2 i n (698 mm)

A 27 in (686 mm) B 26 in (661 mm) C 25-1/4 i n (642 mm) D 1-1/2 in (38 mm) E 1-1/8 (29 mm) F 17-7/8 (454 mm) G 19-1/4 (489 mm) H 1/2 in (13 mm) Dia

6 Holes

TM-353 Page 8 Syncrowave 250

ST-154 792-B

Weight

355 lbs (161 kg)

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. Be sure this welding machine is installed and grounded according to this manual. If interference still occurs, the user must take extra measures such as moving the welding machine, using shielded cables, using line filters, or shielding the work area.

Total Cable (Copper) Length In Weld Circuit Not Exceeding

Weld Output

Terminals

100 ft (30 m) Or Less

Welding

Amperes

100 4 4 4 3 2 1 1/0 1/0

150 3 3 2 1 1/0 2/0 3/0 3/0

200 3 2 1 1/0 2/0 3/0 4/0 4/0

250 2 1 1/0 2/0 3/0 4/0 2-2/0 2-2/0

300 1 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0

10 – 60%

Duty

Cycle

60 – 100%

Duty

Cycle

150 ft

(45 m)

200 ft

(60 m)

250 ft

(70 m)

300 ft

(90 m)

10 – 100% Duty Cycle

350 ft

(105 m)

400 ft

(120 m)

350 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0 2-4/0

ElectrodeWork

ST-154 795-C

Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere. Contact your distributor for the mm2 equivalent weld cable sizes. S-0007-E

400 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 2-4/0

500 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 3-3/0 3-3/0

TM-353 Page 9Syncrowave 250

3-8. Remote 14 Receptacle

Socket* Socket Information

A 24 volts ac.

*The remaining sockets are not used.

ST-154 795-C

B Contact closure to A completes 24 volts ac contactor control

C Command reference; 0 to +10 volts dc output to remote control.

D Remote control circuit common.

E 0 to +10 volts dc input command signal from remote control.

K Chassis common.

circuit.

3-9. 115 Volts AC Duplex Receptacle And Shielding Gas Connections

Y Turn Off power before

connecting to receptacle.

1 115 V AC Receptacle

1 7

Receptacle is protected from overload by circuit breaker CB1 (see Section 7-2).

2 Gas Valve In Fitting 3 Gas Valve Out Fitting Fittings have 5/8-18 right-hand

threads 4 Cylinder Valve Open valve slightly so gas flow

blows dirt from valve. Close valve. 5 Regulator/Flow Gauge 6 Flow Adjust Typical flow rate is 20 cfh (cubic feet

per hour) (9.4 L/min) 7 High Frequency Control (see

Section 4-1)

3 2

Ref. ST-154 795-C / Ref. ST-157 858

TM-353 Page 10 Syncrowave 250

3-10. Electrical Service Guide

NOTE

60 Hertz Models

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

In Feet (Meters) Min Grounding Conductor Size In AWG/Kcmil

Reference: 1996 National Electrical Code (NEC) S-0092-J

50 Hertz Models Without Power Factor Correction

Input Voltage Input Amperes At Rated Output

All values calculated at 60% duty cycle.

Without Power Factor

Correction

200 230 460 575 200 230 460 575

85 74 37 30 55 48 24 19

125 110 60 45 80 70 35 30

4 6 10 10 8 8 12 14

173

(53)

6 6 10 10 8 8 12 14

220 260 380 415 520 220 380 415

77 65 45 41 33 64 37 34

158 (48)

291 (89)

455

(139)

With Power Factor Correction

(26)

114

(35)

186 (58)

189 (48)

With Power Factor

Correction

Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes

Min Input Conductor Size In AWG/Kcmil Max Recommended Input Conductor Length

In Feet (Meters) Min Grounding Conductor Size In AWG/Kcmil

Reference: 1996 National Electrical Code (NEC) S-0092-J

125 100 70 60 50 90 60 50

6 6 8 8 10 6 10 10

145 (44)

6 8 8 10 10 6 8 10

202 (62)

291 (89)

347

(106)

372

(113)

145

(44)

291 (89)

347

(106)

TM-353 Page 11Syncrowave 250

3-11. Placing Jumper Links And Connecting Input Power

230 VOLTS 460 VOLTS200 VOLTS

LL LL LL

S-083 566-C

230 VOLTS

220 VOLTS

260 VOLTS

460 VOLTS

380 VOLTS

575 VOLTS

S-010 587-B

415 VOLTS

S-131 783-A

520 VOLTS

S-047 672-A

Connect GND/PE Conductor First

Check input voltage available at site.

1 Jumper Link Label

Check label inside your unit– only one label is on unit.

Y Only make connections for

the voltages shown on the label inside your unit. Do not make connections for any other voltages. If jumper link label is missing from inside

unit, check rating label (see Section 3 - 4 ) f o r a l lowable i nput voltages.

2 Jumper Links Move jumper links to match input

voltage. 3 Input And Grounding

Conductors

Select size and length using Section 3-10.

4 Line Disconnect Device Select type and size of overcurrent

protection using Section 3-10. Reinstall side panel.

Y Special installation may be

required where gasoline or volatile liquids are present – see NEC Article 511 or CEC Section 2 0 .

Tools Needed:

GND/PE Earth Ground

L1 (U) L2 (V)

Connect GND/PE Conductor First

3/8 in

3/8, 1/2, 7/16 in

ST-117 263-K

TM-353 Page 12 Syncrowave 250

4-1. Controls

4 3

SECTION 4 – OPERATION

1 Ammeter

See Section 4-3. 2 Voltmeter See Section 4-3. 3 High Frequency Switch See Section 4-11. 4 Output (Contactor) Switch See Section 4-8. 5 Spot Time Switch And Control

(Optional) See Section 4-5. 6 Preflow Time Control (Optional) See Section 4-12. 7 AC Balance Control See Section 4-6. 8 Crater Time Control And Switch See Section 4-4. 9 Amperage Adjustment Control And

Switch See Section 4-7. 10 Arc Force (Dig) Switch And Control See Section 4-9. 11 Postflow Time Control See Section 4-10. 12 High Temperature Shutdown Light

(CE Models Only) Lights when unit overheats and shuts

down (see Section 3-3). 13 Power Switch And Pilot Light Use switch to turn unit and light On and

Off. 14 Output Selector Switch See Section 4-2. 15 High Frequency Control See Section 4-11.

Ref. ST-117 264-F / Ref. ST-154 795-C

TM-353 Page 13Syncrowave 250

4-2. Output Selector Switch

1 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.

Y Do not change position of

switch while welding or while under load.

Use switch to select (DCEN) Direct Current Electrode Negative, AC, or (DCEP) Direct Current Electrode Positive output without changing weld output cable connections.

4-3. Meters

1 2

Ref. ST-181 675-A

1 Voltmeter Voltmeter displays voltage at the

weld output terminals, but not necessarily the welding arc due to cable resistance, poor connections, etc.

2 Ammeter Ammeter displays weld amperage

output o f unit.

TM-353 Page 14 Syncrowave 250

4-4. Crater Time Controls

1 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.

2 Crater Time Switch ON – provides crater time. OFF – provides no crater time. Place switch in the OFF position for

Shielded Metal Arc Welding (SMAW).

Application:

Crater Time should be used while GTAW welding materials that are crack sensitive, and/or the operator wants to eliminate the crater at the end of the weld.

Note: This applies if the operator is using an on/off only type control to start and stop the welding process.

4-5. Spot Time Controls

1 Spot Time Switch Place switch in the ON position to

turn on spot weld circuitry.

The (GTAW) TIG Spot process is generally used with a direct current electrode negative (DCEN) set-up.

Place switch in the OFF position to turn off spot weld circuitry. Put switch in the OFF position while doing Shielded Metal Arc Welding (SMAW).

2 Spot T ime Control Use control to set time (0–5.7 sec-

onds) for Gas Tungsten Arc (GTAW) spot welds. Spot time begins at arc initiation. If the arc is broken during the spot time cycle, the timer stops but does not reset. When the spot time has ended, weld output stops. Postflow starts when the remote contactor is opened. The spot timer resets after the contactor opens.

Application:

TIG spot welding is used for joining thinner materials that are in close contact, with the fusion method. A good example would be joining coil ends.

TM-353 Page 15Syncrowave 250

4-6. AC Balance Control

Balanced

More Penetration

More Cleaning

50% Electrode

Positive

50% Electrode

Negative

32% Electrode

Positive

68% Electrode

Negative

55% Electrode

Positive

45% Electrode

Negative

1 AC Balance Control

Balance Control (AC GTAW):

Control changes the AC output square wave. Rotating the control towards 10 provides deeper pene-

Output Waveforms ArcSetting

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.

Application:

When welding on oxide forming materials such as aluminum or magnesium, excess cleaning is not necessary. To produce a good weld, only a minimal amount, approximately a

0.10 in (2.5mm) of etched zone along the weld toes is required.

Set control to 7 and adjust as necessary. Joint configuration, set-up, process variables, and oxide thickness may affect setting.

Arc rectification can occur when welding above 200 amps and/or while welding with helium gas. If this condition occurs, increasing the Balance control towards maximum penetration, may help to restabilize the arc.

Ref. S-0795-A

TM-353 Page 16 Syncrowave 250

4-7. Amperage Adjustment Controls

1 Amperage Adjustment Control Use control to adjust amperage,

and preset amperage on ammeter (see Sect i o n 4 - 3 ) . T h i s c o n t r o l m a y be adjusted while welding.

For remote amperage control, front panel control setting is the maximum amperage available. For example: I f front panel control is set to 200 A, the range of the remote amperage control is 5 to 200 A.

For spot welding, use Amperage Adjust control to select from 5–310 amps of peak amperage (see Section 4-5).

2 Amperage Control Switch Use switch to select way of control-

ling amperage adjustment. For front panel control, place switch

in the PANEL position. For remote control, place switch in

REMOTE 14 position, and connect remote control device (see Section 3-8).

4-8. Output (Contactor) Control Switch

Y Weld output terminals are

energized when Output (Contactor) switch is On and Power is On.

1 Output/Contactor Switch Use switch to select way of control-

ling unit output. For front panel control, place switch

in ON position. When On is selected, HF and gas

control are disabled. For remote control, place switch in

REMOTE 14 position, and connect remote control device (see Section 3-8).

TM-353 Page 17Syncrowave 250

4-9. Arc Controls

1 Arc Control (Dig)

For AC And DC SMAW Welding

When set at 0, short-circuit amperage at low arc voltage is the same

as normal welding amperage. When setting is increased, short-

circuit amperage at low arc voltage increases.

Set at 0 for GTA W welding. 2 Arc Control Switch Place switch in the ON position to

turn on arc control circuitry. When switch is i n the OFF position, no additional amperage is available at low arc voltages. Place switch in the OFF position while performing Gas Tungsten Arc Welding (GTAW).

Application:

Control helps arc starting or making vertical or overhead welds by increasing amperage at low arc voltage, and reduces electrode sticking while welding.

4-10. Postflow Time Control

1 Postflow Time Control Use control to set length of time

(0–70 seconds) gas flows after welding stops. It is important to s e t enough time to allow gas to flow un-

til after the tungsten and weld puddle has cooled down.

Application:

Postflow is required to cool tungsten and weld, and to prevent contamination of tungsten and weld. Increase postflow time if tungsten or weld are dark in appearance.

TM-353 Page 18 Syncrowave 250

4-11. High Frequency Controls

Y Place High Frequency

switch in Off position before using the shielded metal arc welding (SMAW) process.

1 High Frequency Switch START – (Up position) provides H F

for arc starting only. High frequency turns on to help start arc when output is enabled. High frequency turns off when arc is started, and turns on whenever arc is broken to help restart arc.

Application:

HF Start is used when the DCEN GTA W process is required.

OFF – provides no HF. Use OFF for SMAW (stick electrode) welding.

CONTINUOUS – (Down position) provides HF continuously throughout the weld.

Application:

HF Continuous is used when the AC GTAW process is required.

2 High Frequency Intensity

Control

Use control to change amount of HF energy used to start and maintain the arc. Set as low as practical to prevent interfering with electronic equipment.

4-12. Preflow Time Control (Optional)

1 Preflow Time Control Use control to set the length of time

(0–15 seconds) that gas flows before an arc is started.

Application:

Preflow is used to purge the immediate weld area of atmosphere. Preflow also aids in consistent arc starting.

TM-353 Page 19Syncrowave 250

TM-353 Page 20 Syncrowave 250

1 Input Terminal Board TE1 Provides means for operation on

different input voltages. 2 Power Switch S1 Provide on/off control of unit. 3 Fan Motor FM Provides cooling of internal compo-

nents. 4 Main T ransformer T1 Supplies power to weld output cir-

cuit, various control circuits, main control board PC1, and fan motor FM.

5 Control Board PC1 Controls weld output by changing

the SCR gate pulses (conduction times) after comparing current feedback to selected amperage signal.

Also provides input connections for switches S3, S5, S6, and S7.

6 Arc Control Switch S6 And

Control R2

R2 selects short-circuit amperage when S6 i s O n , and High Frequency control R13 is Off.

7 Crater Time Switch S7 And

Control R11

R11 selects crater time when S7 is on, and Amperage Control switch S5 is in Panel position.

8 Thermostat TP1 If T1 overheats, TP1 opens stop-

ping all weld output. 9 Output (Contactor) Switch S3 Selects On or remote contactor

control. 10 AC Balance Control R3 Controls changes to ac output

square wave. 11 Ammeter A1 And Voltmeter

Display weld amperage and voltage while welding.

12 Amperage Control Switch S5

And Adjustment Control R1

R1 selects weld output amperage when S5 is in Panel.

13 Remote 14 Filter Board

PC2/Remote 14 Receptacle RC1

PC2 protects unit from high frequency, and RC1 connects remote amperage and contactor controls to power source.

14 Circuit Breaker CB1 Protects 115 volts ac duplex recep-

tacle RC2 from overload.

SECTION 5 – THEORY OF OPERATION

1-Phase

Input

Terminal

Board TE1

Power Switch

Main

Transformer

Circuit

Breaker

CB1

115 VAC

115 VAC Duplex

Receptacle

RC2

Fan

Motor

Control

Board

PC1

Arc Control

Output

Amperage

Crater Time

Switch

Control

Switch S5

Switch

115 VAC

Thermostat

TP1

Line

Input

Power

Synchronization Signal

SCR Gating Signals

Main

Rectifier

SR1

φ1φ

124

31423

Arc Control

Amperage Adjustment Control R1

Crater Time

Control

R11

AC Balance

Control

Ammeter

Postflow

Timer

TD1

Gas

Valve

GS1

Remote

Remote 14

Filter Board

PC2

1φ

, 10 VAC

(Contactor)

Switch S3

Background

Power

Source

Amperage

Control

♦

TM-353 Page 21Syncrowave 250

15 115 Volts AC Duplex Recep-

tacle RC2

Provides connection point for auxiliary equipment.

16 Postflow Timer TD1 Controls shielding gas and coolant

postflow time. 17 Gas Valve GS1 Provides shielding gas during the

weld cycle. 18 Preflow Timer TD3, Control

R12, And Switch S9

R12 selects time shielding gas flows before arc starts. S9 is an integral part of R12 so that when R12 is turned past zero (0), TD3 is off.

19 Spot Timer TD2, Switch S8,

And Control R10

R10 selects time output is available when spot welding. S8 selects Off or spot welding with remote contactor control.

20 High Frequency Transformer

Steps up input voltage and charges capacitor C4 .

21 Spark Gaps G And High Fre-

quency Coupling Coil T3

G provides path for C4 to discharge into T3. T3 supplies high-frequency to welding circuit.

22 High Frequency Intensity

Control R13

Changes amount of HF energy used to sta r t and maintain the arc.

23 Main Rectifier SR1 Changes the ac output from T1 to

full-wave rectified dc. 24 Background Power Source Provides reduced weld output rip-

ple at low weld output levels. 25 Stabilizer Z1 Smooths dc welding current. 26 Hall Device HD1 Provides current feedback signal to

PC1 through line filter FL1. 27 Line Filter FL1 Filters current feedback signal. 28 Output Selector Switch S4 Provides either AC or DC and out-

put polarity. 29 Integrated Rectifier SR2 Provides dc voltage feedback to

PC1. 30 Electrode And Work W eld

Output Terminals

Provide weld output.

Hall Device

HD1

Optional

AC Or DC Control

External Circuits

Weld Current Circuit

Stabilizer

Work Weld

Electrode

Output

Terminal

Weld Output

Terminal

High

Frequency

Coupling

Coil T3

Current Feedback

Voltage Feedback

High

Frequency

Intensity

Control R13

Spark Gaps G

High

Frequency

Transformer

♦

1φ Power

Capacitor

Integrated

Rectifier

SR2

Line

Filter

FL1

Preflow

Timer

TD3

Preflow Time

Control

R12

Switch

♦

Spot Timer

TD2

Spot Time

Control

R10

♦

Voltmeter

115 VAC

Spot Time

19♦

Switch

Output

Selector

Switch

Voltage Feedback

♦

SECTION 6 – TROUBLESHOOTING

6-1. Troubleshooting Table

. See Section 6-2 for test points and values and

Section 10 for parts location.

. Use MILLER Testing Booklet (Part No. 150 853)

when servicing this unit.

Trouble Remedy

Prior to Serial No. KG164875, no weld output; unit completely inoperative – Effective with Serial No. KG164875, no weld output; unit completely inoperative; PL2 off.

Replace building line fuse(s) or reset circuit breaker(s) if open. Check for proper electrical input connections (see Section 3-11). Check for proper jumper link position (see Section 3-11). Check Power switch S1 and replace if necessary. Prior to Serial No. KG164875, no weld

output; fan runs – Effective with Serial No. KG164875, no weld output; fan runs; PL2 on.

Check, repair or replace remote control device. Allow a cooling period of approximately 15 minutes. If thermostats TP1 remain open, check continuity

Check circuit breaker CB1, and reset if open (see Section 7-2). Place Output Selector switch S4 in desired position (see Section 4-2). Check optional preflow timer board TD3, and replace if necessary. Check optional spot timer relay TD2 for proper connections and resistance. Replace TD2 if

Check continuity of Spot Time switch S8. Check condition of contacts. Repair or replace S8 if neces-

Check SR1, and replace necessary components. If components are replaced, check capacitors C7

Unit provides only minimum weld output.

Check control board PC1 and connections, and replace if necessary.

Unit provides only maximum weld output.

Check connections for continuity to shunt device on units with Serial No. prior to KB110695.

TM-353 Page 22 Syncrowave 250

Be sure line disconnect switch is in the On position.

If using remote control, place Output (Contactor) switch S3 in Remote 14 position, and connect remote control to Remote 14 receptacle RC1 (see Sections 3-8 and Section 4-8). If remote is not being used, place Output switch S3 in On position.

and replace if necessary (see Section 3-3).

necessary.

sary.

thru C10. Replace capacitor(s) if necessary. Check control board PC1 and connections, and replace if necessary. Effective with Serial No. KB1 10695, check resistance and connections of HD1; HD1 is 1600 ohms

±10% between pins 1 and 3 of plug PLG3. Check input and output voltages. Replace HD1 if necessary.

Check position of Amperage Control switch S5 (see Section 4-7).

Increase Amperage Adjustment control R1 setting if a remote control is used (see Section 4-7). Check, repair or replace remote control device.

Check resistance and connections of Amperage Adjustment control R1; R1 is 1000 ohms ±10%. Replace R1 if necessary.

Check SCRs in main rectifier SR1, and replace if necessary. If any SCRs are replaced, Check capacitors C7 through C10 for a short or open, and check for proper connections. Replace C7 through C10 if necessary.

Effective with Serial No. KB1 10695, check resistance and connections of HD1; HD1 is 1600 ohms ±10% between pins 1 and 3 of plug PLG3. Check input and output voltages. Replace HD1 if necessary.

Check Amperage Adjustment control R1 for proper connections and resistance; R1 is 1000 ohms ±10%. Replace R1 if necessary.

Effective with Serial No. KB1 10695, check resistance and connections of HD1; HD1 is 1600 ohms ±10% between pins 1 and 3 of plug PLG3. Check input and output voltages. Replace HD1 if necessary.

Check bypass capacitors C13, C14, C16, C17, C18, and C19 for broken leads, shorts, and leakage. Replace if necessary.

Trouble Remedy

Check control board PC1 and connections, and replace if necessary.

Check connections to line filter FL1. Check input to PC1. Replace FL1 if necessary.

Erratic weld output.

No or limited ac balance control. Check AC Balance control R3 for proper connections and resistance; R3 is 5000 ohms ±10%.

Check control board PC1 and connections, and replace if necessary. Check SCRs in main rectifier SR1, and replace if necessary. If any SCRs are replaced, Check capac-

No crater fill time. Check position of Crater switch S7 (see Section 4-4).

Be sure arc voltage is below 24 volts (see Section 3-2. Volt-Ampere Curves). Check position of Amperage Control switch S5, S5 must be in Panel position (see Section 4-7). Check control board PC1 and connections, and replace if necessary. Crater fill time too long or does not

time out.

Check for poor or improper input or output connections. See Sections 3-11 and 3-8. Replace electrode. Check torch assembly, and replace if necessary. Check fuse F2 in rectifier SR3 circuit, and replace if necessary. If Amperage Control switch S5 is in the Remote position check, repair, or replace remote amperage

control device if necessary. Check connections for continuity to shunt device on units with Serial No. prior to KB110695. Check Amperage Adjustment control R1 for proper connections and resistance; R1 is 1000 ohms

±10%. Replace R1 if necessary. Check bypass capacitors C13, C14, C16, C17, C18, and C19 for broken leads, shorts, and leakage.

Replace if necessary. Check SCRs in main rectifier SR1, and replace if necessary. If any SCRs are replaced, Check capac-

itors C7 through C10 for a short or open, and check for proper connections. Replace C7 through C10 if necessary.

Check control board PC1 and connections, and replace if necessary.

Replace R3 if necessary.

itors C7 through C10 for a short or open, and check for proper connections. Replace C7 through C10 if necessary.

Check position of Crater control R11 (see Section 4-4).

Check resistance and connections of Crater control R11; R11 is 5 meg ohms ±10%. Replace R11 if

necessary. Check control board PC1 and connections, and replace if necessary. No arc control.

Lack of high frequency at tungsten electrode; difficulty in starting an arc.

Use shortest possible cables (see Section 3-7). Check cables and torch for cracked or deteriorated insulation or bad connections. Repair or replace

Be sure to disconnect SMAW electrode cable from weld output terminal when GT AW welding. Decrease gas flow setting. Use properly prepared tungsten. Increase setting of High Frequency Intensity control R13 (see Section 4-11). Check spark gaps G, and readjust if necessary (see 7-4).

Place Arc Control switch S6 in the On position.

Place High Frequency switch S2 in the Off position.

Be sure arc voltage is below 24 volts (see Section 3-2. Volt-Ampere Curves).

Check position of Arc Control R2 (see Section 4-9).

Check fuse F1 in rectifier SR3 circuit, and replace if necessary.

Check resistance and connections of Arc control R2; R2 is 1000 ohms ±10%. Replace R1 if

necessary.

Check control board PC1 and connections, and replace if necessary.

Use proper size tungsten for welding application.

necessary parts.

TM-353 Page 23Syncrowave 250

Trouble Remedy

No high frequency at spark gaps G.

No preflow time (optional). Place Output (Contactor) switch S3 in Remote position and be sure remote control is connected to

Check continuity of Preflow Time switch S9. Check condition of contacts. Repair or replace S9 if nec-

Remove jumper link 1 on terminal strip 1T. Check optional preflow timer board TD3, and replace if necessary. Optional spot timer relay TD2 does not

time out. Remove jumper link 2 from terminal strip 1T. Place Spot Time control R10 in desired position. Check coil voltage and connections of spot timer relay TD2. Check continuity of coil and condition of

Check coil voltage and connections of control relay CR3. Check continuity of coil and condition of

Check coil voltage and connections of control relay CR1. Check continuity of coil and condition of

Postflow timer does not time out. Check position of Postflow Time control setting (see Section 4-10). Check Control relay CR5 contacts 2 and 5 for proper operation. Replace CR5 if necessary. Check coil voltage and connections of gas valve GS1. Check continuity of coils. Replace GS1 if nec-

Check control board PC1 and connections, and replace if necessary. No postflow time. Check position of Postflow Time control setting (see Section 4-10). Place Output(Contactor) switch S3 in the Remote position, and connect a remote control to recep-

Check coil voltage and connections of control relay CR5. Check continuity of coil and condition of

Check control board PC1 and connections, and replace if necessary. No gas flow. Place Output(Contactor) switch S3 in the Remote position, and connect a remote control to recep-

TM-353 Page 24 Syncrowave 250

Check position of High Frequency switch S2 (see Section 4-11).

Place Output (Contactor) switch S3 in Remote position and be sure remote control is connected to

Remote receptacle RC1 (see Section 3-8).

Check circuit breaker CB1, and reset if open (see Section 7-2).

Check fuse F1 in rectifier SR2 circuit, and replace if necessary.

Check coil voltage and connections of contactor control relay CR1. Check continuity of coil and con-

dition of contacts. Replace CR1 if necessary.

Check coil voltage and connections of contactor control relay CR5. Check continuity of coil and con-

dition of contacts. Replace CR5 if necessary.

Check spark gaps G, and readjust if necessary (see Section 7-4).

Check resistance and connections of High Frequency Intensity control R13; R13 is 1.5 ohms ±10%.

Replace R1 if necessary.

Check capacitor C4 for a short or open, and check for proper connections. Replace C4 if necessary.

Check transformer T2 for signs of winding failure. Check continuity across windings, and check for

proper connections. Check secondary voltages. Replace T2 if necessary.

Check coupling coil T3 for signs of winding failure. Check continuity across windings, and check for

proper connections. Replace T3 if necessary.

Check control board PC1 and connections, and replace if necessary.

Remote receptacle RC1 (see Section 3-8).

Check position of Preflow Time control R12.

essary.

Place Spot Time switch S8 in the On position.

contacts. Replace TD2 if necessary.

contacts. Replace CR3 if necessary.

contacts. Replace CR1 if necessary.

essary.

Check input voltage and connections to Postflow timer board TD1. Check continuity of contacts. Re-

place TD1 if necessary.

tacle RC1 according to Section 3-8.

contacts. Replace CR5 if necessary.

Check coil voltage and connections of gas valve GS1. Check continuity of coils. Replace GS1 if nec-

essary.

Check input voltage and connections to Postflow timer board TD1. Check continuity of contacts. Re-

place TD1 if necessary.

tacle RC1 according to Section 3-8.

Check circuit breaker CB1, and reset if open (see Section 7-2).

Trouble Remedy

Check Control relay CR2 contacts 4 and 7 for proper operation. Replace CR2 if necessary. Check coil voltage and connections of gas valve GS1. Check continuity of coils. Replace GS1 if nec-

No power output at 115 volts ac receptacle RC1; weld output available.

Fan motor FM does not run; weld output available. Effective with Serial No. KG164875, unit is equipped with FanOn-Demand, which only runs when cooling is required.

Check coil voltage and connections of fan motor FM, and replace if necessary. Line fuse opens immediately when

solid-state contactor SR1 turns on in DC mode only.

Check SCRs in main rectifier SR1, and replace if necessary. If any SCRs are replaced, Check capac-

No control of weld output. Check position of Amperage Control switch S5 (see Section 4-7).

Check control board PC1 and connections, and replace if necessary. Tungsten electrode oxidizing and not

remaining bright after conclusion of weld.

Check and tighten all gas fittings if necessary. Increase gas flow setting.

Properly prepare tungsten.

Wandering arc - poor control of direction of arc.

Controls connected to Remote 14 receptacle RC1 do not work properly.

Ammeter A1 not displaying correct weld output amperage.

Voltmeter V1 not displaying correct arc voltage.

Electronic equipment in welding area not working properly.

essary.

Check circuit breaker CB1, and reset if open (see Section 7-2).

Check and clear fan blade obstruction.

Check diode D1, and replace if necessary.

itors C7 through C10 for a short or open, and check for proper connections. Replace C7 through C10

if necessary.

Check resistance and connections of Amperage Adjustment control R1; R1 is 1000 ohms ±10%.

Replace R1 if necessary.

Check, repair or replace remote control device.

Effective with Serial No. KB1 10695, check resistance and connections of HD1; HD1 is 1600 ohms

±10% between pins 1 and 3 of plug PLG3. Check input and output voltages. Replace HD1 if

necessary.

Check position of Postflow Time control R12 (see Section 4-10).

Shield weld zone from drafts.

Place High Frequency switch S2 in Start or Continuous position.

Use proper size tungsten for welding application.

Properly prepare tungsten.

Check, repair or replace remote control device.

Check Amperage Control switch S5 position (see Section 4-7). Check and replace S5 if necessary.

Check Output (Contactor) switch S3 position (see Section 4-8). Check and replace S3 if necessary.

Check position of jumper links 1 and 2 on terminal strip 1T according to Section 6-2.

Check coil voltage and connections of control relay CR2. Check continuity of coil and condition of

contacts. Replace CR2 if necessary.

Prior to Serial No. KF959379, check choke RFC1 connections. Check continuity of RFC1. Replace if

necessary. Effective with Serial No. KF959379 check remote 14 filter board PC2 (see Section 6-6).

Replace PC2 if necessary.

Check control board PC1 and connections, and replace if necessary.

Calibrate ammeter as instructed in Section 6-8.

Check ammeter A1 voltage; +1 millivolts dc per 3 ampere of weld output. Replace A1 if necessary.

Check control board PC1 and connections, and replace if necessary.

Effective with Serial No. KB1 10695, check resistance and connections of hall device HD1; HD1 is

1600 ohms ±10% between pins 1 and 3 of plug PLG3. Check input and output voltages. Replace HD1

if necessary.

Check connections for continuity to voltmeter V1. Replace V1 if necessary.

HF interference problem. Check for proper installation, and correct problem (see Section 8).

TM-353 Page 25Syncrowave 250

TM-353 Page 26 Syncrowave 250

6-2. Troubleshooting Circuit Diagram For Welding Power Source

Y Disable high frequency by placing High Frequency

switch S2 in Off position before testing unit.

V13

V14

V15

V16

Link 1 Link 2

V10

V11

V17

V12

See Section 3-8

for RC1

information

TD1 begins to time out

when CR5 deenergizes

TD3 begins to time out

when CR4 energizes

See Figure 9-19

for PC3 circuit

CR3 energizes during spot time

when an arc is detected

CR4 energizes when remote contactor

switch closes

CR2 energizes when

remote contactor

switch closes

See Section 6-6

for PC2 data

V25

TM-353 Page 27Syncrowave 250

SC-188 161

Test Equipment Needed:

V24

V22

V21

V20

V25

Resistance Values

a) Tolerance – ±10% unless specified b) Turn Off unit and disconnect input

power before checking resistance

R1 All values for T1, Z1, and T3 are less

than 1 ohm R2 5.3 ohms R3 6.1 K ohms

Voltage Readings

a) Tolerance – ±10% unless

specified

b) Reference – to circuit

common (lead 42) unless noted

c) Wiring Diagram – see

Section 10

V1 230 volts ac V2 77 volts ac V3 82.5 volts ac V4 57 volts ac V5, V6 115 volts ac V7 24 volts ac V8, V9 18 volts ac V10 10 volts ac V11 80 volts dc V12. V13, V14 115 volts ac V15, V16, V17 24 volts ac V18 115 volts ac with S2

in Start or Continuous

V19 0 to +10 volts dc

with contactor on V20, V21 24 volts dc V22 0-80 volts dc (rec-

tified arc voltage) V23 maximum 80 volts

ac/dc V24 24 volts dc V25 16.5 millivolts dc

per 1 ampere of

weld output

CR1 energizes

when open-circuit voltage

is present; denergizes

when an

arc is struck

See Figure 10-1 for

HD1 location

No calibration available

for voltmeter V1

V23, B, C, D, E

See Section 6-3

for waveforms

B, C, D, E

See also

Sections 6-4 and 6-5

for PC1 data

CR5 energizes when

contactor is on

See Section 6-8 for ammeter A1

calibration

V19

V18

See Section 6-3 for waveform A

TM-353 Page 28 Syncrowave 250

6-3. Waveforms For Section 6-2

Waveforms shown are for 60 Hertz models; waveforms for 50 Hertz models are similar.

5 ms 1 V

A. SR1 Gate Pulse With Respect To Cathode

At No Load

5 ms 50 V

B. DC Open-Circuit Voltage With Amperage

Adjustment Control At Maximum

5 ms 20 V

C. DC Output, 100 Amperes, 24 Volts DC

(Resistive Load)

5 ms 50 V

D. AC Open-Circuit Voltage With Amperage

Adjustment Control At Maximum

gnd

gnd gnd

TM-353 Page 29Syncrowave 250

Test Equipment Needed:

5 ms 50 V

E. AC Output, 100 Amperes, 24 Volts AC (Re-

sistive Load)

gnd

6-4. Control Board PC1 Testing Information (Use With Section 6-5)

Y Disable high frequency by

Be sure plugs are secure before testing. See Section 6-5 for specific values during testing.

1 Control Board PC1 2 Receptacle RC51 3 Receptacle RC52 4 Receptacle RC53 5 Receptacle RC54 6 Receptacle RC55

1 23

placing High Frequency switch S2 in Off position before testing unit.

Test Equipment Needed:

SB-178 976-A / ST-800 344-A

TM-353 Page 30 Syncrowave 250

6-5. Control Board PC1 Test Point Values

PC1 Voltage Readings

Receptacle Pin Value

RC51 1 18 volts ac input

2 18 volts ac input 3 +10 volts dc output 4 Circuit common 5 Not used 6 Not used

RC52 1 Circuit common

2 +1 millivolt dc per 3 ampere of weld output

RC53 1 Gate pulse for SCR1 with respect to pin 2 (see Section 6-3)

2 Reference for gate pulse to SCR1 3 Gate pulse for SCR3 with respect to pin 4 (see Section 6-3) 4 Reference for gate pulse to SCR3

a) Tolerance –

±10% unless

specified

b) Reference – to circuit common

(lead 42) unless noted

5 Gate pulse for SCR2 with respect to pin 6 (see Section 6-3) 6 Reference for gate pulse to SCR2 7 Gate pulse for SCR4 with respect to pin 8 (see Section 6-3) 8 Reference for gate pulse to SCR4

RC54 1 Not used

2 0 to +10 volts dc input from min. to max. of Amperage Adjustment control R1 with Amperage Control

3 0 volts with Output (Contactor) switch S3 in On position or +7.8 volts dc with S3 in Remote position 4 0 to +10 volts dc input from min. to max. of Crater Control R11 with Crater Fill switch S7 in On posi-

5 +10 volts dc output with Output (Contactor) switch S3 in On position 6 –24 volts dc 7 –24 volts dc with contactor on or off 8 0 to +10 volts dc input from min. to max. of Amperage Adjustment control R1 with contactor on 9 0 to +10 volts dc input from min. to max. of Amperage Adjustment control R1 with contactor on

10 Circuit common

11 +24 volts dc

switch S5 in Panel position, and contactor on

tion, or +10 volts dc with S7 in Off position

12 0 volts during open-circuit voltage condition; +24 volts with arc on or contactor off

TM-353 Page 31Syncrowave 250

Receptacle ValuePin

RC55 1 Circuit common

2 +1.65 volts dc per 100 amperes of weld output with respect to pin 1 3 –15 volts dc output 4 0 to +4 volts dc input from min. to max. of Arc Control R2 with Arc Control switch S6 On 5 10 volts ac input for synchronization 6 +5.8 volts dc output 7 –15 volts dc input from Max. Penetration setting of AC Balance control R3 to +5.8 volts dc input at

8 0 to 80 volts dc voltage feedback signal (rectified arc voltage) with respect to pin 9 9 0 to 80 volts dc voltage feedback signal (rectified arc voltage) with respect to pin 8

10 0 to +4 volts dc input from min. to max. of Arc Control R2 with Arc Control switch S6 Off

Max. Cleaning setting of R3

TM-353 Page 32 Syncrowave 250

6-6. Remote Board PC2 Testing Information (Use With Section 6-7)

Y Disable high frequency by

Be sure plugs are secure before testing. See Section 6-7 for specific values during testing.

1 Remote 14 Filter Board PC2 2 Remote 14 receptacle RC1 See Section 3-8 for information. 3 Receptacle RC2 4 Receptacle RC3

placing High Frequency switch S2 in Off position before testing unit.

Test Equipment Needed:

ST-157 960-B / ST-800 344-A

TM-353 Page 33Syncrowave 250

6-7. Remote 14 Filter Board PC2 Test Point Values (Use With Section 6-2 And Section 6-6)

PC2 Voltage Readings

Receptacle Pin Value

RC1 A 24 volts ac

B Contact closure to A completes 24 volts ac contactor control circuit C Command reference; 0 to +10 volts dc output to remote control D Remote control circuit common E 0 to +10 volts dc input command signal from remote control K Chassis common

RC2 1 Command reference; 0 to +10 volts dc output to remote control

3 Contact closure to A completes 24 volts ac contactor control circuit 4 Remote control circuit common 5 0 to +10 volts dc input command signal from remote control 6 24 volts ac

RC3 1 Chassis common

a) Tolerance –

±10% unless

specified

b) Reference – to circuit common

(lead 42) unless noted

TM-353 Page 34 Syncrowave 250

6-8. Meter Calibration

No calibration available for ammeter offset, or for voltmeter V1.

Be sure plugs are secure before calibrating meter.

1 Control Board PC1 2 Voltmeter V1 3 Ammeter A1

Top View

R19

Amperes

Adjust R19 for amperage gain to match external calibrated meter using load bank set at desired load.

SB-130 690-D / ST-800 344-A

TM-353 Page 35Syncrowave 250

6-9. Input Voltage Labels And Connections

Test Equipment Needed:

1 Input Voltage Label A n d C o n -

nection Diagram – Only One Label Is On Unit

2 Terminal Strip TE1

ST-154 793-A / ST-114 947-A / ST-121 000-A / ST-131 735

TM-353 Page 36 Syncrowave 250

SECTION 7 – MAINTENANCE

7-1. Routine Maintenance

Y Disconnect power before maintaining.

3 Months

Replace

Unreadable

Labels

Adjust Spark

Gaps

7-2. Circuit Breaker CB1

14-Pin Cord Gas Hose

6 Months

Blow Out Or Vacuum

Inside,

During Heavy Service,

Clean Monthly

Repair Or

Replace Cracked

Weld

Cables

Clean An d

Tighten

Weld

Terminals

Replace Cracked

Parts

Torch Cable

1 Circuit Breaker CB1 If CB1 opens, output to the 115 volts

ac duplex receptacle, high frequency, and gas flow stop. Press button to reset breaker.

CB1

Ref. ST-154 795-C

TM-353 Page 37Syncrowave 250

7-3. Fuses F1 And F2

1 Fuse F1 (See Parts List For

Rating)

Fuse F1 (between leads 50 and

150) protects wiring harness from

Tools Needed:

3/8 in

shorted SR2. If F1 opens, you may experience problems with arc starting and arc performance in the DC TIG mode.

2 Fuse F2 (See Parts List For

Rating)

Fuse F2 (between leads 22 and

149) protects wiring harness from shorted SR3. If F2 opens, you may experience problems with arc control, and no high frequency in start high frequency.

7-4. Adjusting Spark Gaps

Tools Needed:

Y Turn Off power before

adjusting spark gaps.

Open access door. 1 Tungsten End Of Point Replace point if tungsten end dis-

appears; do not clean or dress tungsten.

2 Spark Gap Normal spark gap is 0.008 in (0.203

mm). If adjustment is needed, proceed as

follows: 3 Adjustment Screws Loosen screws. Place gauge of

proper thickness in spark gap. 4 Pressure Point Apply slight pressure at point until

gauge is held firmly in gap. Tighten screws to 12 in/lbs torque (overtightening will deform plastic base). Adjust other gap.

Close access door.

Ref. ST-154 795-C / Ref. S-0043

TM-353 Page 38 Syncrowave 250

SECTION 8 – HIGH FREQUENCY (HF)

8-1. Welding Processes Using HF

Work Work

1 HF V oltage GTAW – helps arc jump air gap

between torch and workpiece and/ or stabilize the arc.

SAW – helps arc reach workpiece

2 1

through flux granules. 2 Flux

Gas Tungsten Arc

Welding (GT AW)

Submerged Arc

Welding (SAW)

8-2. Sources Of HF Radiation From Incorrect Installation

Weld Zone

11, 12

50 ft

(15 m)

10 9 8

high_freq1 7/95 – S-0693

Sources Of Direct HF Radiation

1 HF source (welding power source with

built-in HF or separate HF unit) 2 Weld Cables 3 Torch 4 Work Clamp

4 5 6

5 Workpiece 6 Work Table

Sources Of Conduction Of HF

7 Input Power Cable 8 Line Disconnect Device 9 Input Supply Wiring

S-0694

Sources Of Reradiation Of HF

10 Ungrounded Metal Objects 11 Lighting 12 Wiring 13 Water Pipes And Fixtures 14 External Phone And Power Lines

TM-353 Page 39Syncrowave 250

8-3. Correct Installation

50 ft

(15 m)

Ground All Metal Objects And All Wiring

In Welding Zone Using #12 AWG

Wire

Nonmetal

Building

Weld Zone

Ground Workpiece If Required

By Codes

50 ft

(15 m)

1 HF Source (Welder With Built-In HF Or

Separate HF Unit)

Ground metal machine case, work output terminal, line disconnect device, input supply, and worktable.

2 Welding Zone And Centerpoint A circle 50 ft (15 m) from centerpoint

between HF source and welding torch in all directions.

3 Weld Output Cables Keep cables short and close together. 4 Conduit Joint Bonding And Grounding

Electrically join (bond) all conduit sections using copper straps or braided wire. Ground conduit every 50 ft (15 m).

5 Water Pipes And Fixtures Ground water pipes every 50 ft (15 m). 6 External Power Or Telephone Lines Locate HF source at least 50 ft (15 m) away

from power and phone lines. 7 Grounding Rod Consult the National Electrical Code for

specifications.

Metal Building

Ref. S-0695 / Ref. S-0695

8 Metal Building Panel Bonding Methods Bolt or weld building panels together, install

copper straps or braided wire across seams, and ground frame.

9 Windows And Doorways Cover all windows and doorways with

grounded copper screen of not more than 1/4 in (6.4 mm) mesh.

10 Overhead Door Track Ground the track.

TM-353 Page 40 Syncrowave 250

SECTION 9 – ELECTRICAL DIAGRAMS

. The circuits in this manual can be used for troubleshooting, but there might be minor circuit differences from your machine. Use circuit inside

machine case or contact distributor for more information.

The following is a list of all diagrams for models covered by this manual.

Model Serial Or Style Number Circuit Diagram Wiring Diagram

Syncrowave 250 JJ339876 thru JJ351864 SC-114 914 D-116 884-B♦♦

JJ351865 thru JJ365633 SC-120 877 D-120 878-B♦♦ JJ365634 thru JJ503983 SC-121 280 D-121 281-D♦♦ JJ503984 thru JK572897 SC-124 314 D-124 307-C♦♦ JK572898 thru JK617846 SC-124 785-B D-124 786-B♦♦ JK617847 thru JK682713 SC-124 785-B D-129 200-B♦♦ JK682714 thru JK690986 SC-124 785-B D-130 576-B♦♦ JK690987 thru KA806712 SC-132 697-A D-132 431-D♦♦ KA806713 thru KA877024 SC-137 431 D-137 430-A♦♦ KA877025 thru KB010829 SC-135 581 D-135 734-A♦♦ KB010830 thru KB110694 SC-142 524 D-142 525-A♦♦ KB110695 thru KC252675 SC-148 144 D-148 145-A♦♦ KC252676 thru KG029204 SC-154 649-C D-154 648-E♦♦ KG029205 thru KG062109 SC-178 835 D-174 039-A♦♦ KG062110 thru KG170300 SC-179 303-A D-179 305-A♦♦ KG170301 thru KH526230 SC-181 109-E SD-181 110-F♦♦ KH526231 and following SC-188 161-A SD-188162-A

Circuit Board PC1 JJ339876 thru JJ399987 D-118 765♦♦

JJ399988 thru JK682713 D-122 270♦♦ JK682714 thru KA797306 D-130 691-A♦♦ KA797307 thru KG062109 D-135 253♦♦ KG062110 thru KH5082 5 4 SD-178 975♦♦ KH508255 and following SD-187644

RFC Circuit Board PC2 JJ365634 thru KB010829 SA-121 282

Remote 14 Filter Board PC2 KF959379 and following SA-158 763

Circuit Board PC3♦ JJ351865 and following SA-120 872

Timer TD1 JJ339876 and following SA-044 725-C

Timer TD3♦ JJ339876 and following SA-045 288-D

♦ Optional ♦♦ Not included in this manual

TM-353 Page 41Syncrowave 250

SC-114 914

Figure 9-1. Circuit Diagram For Syncrowave 250 Effective With Serial No. JJ339876 Thru JJ351864

TM-353 Page 42 Syncrowave 250

Figure 9-2. Circuit Diagram For Syncrowave 250 Effective With Serial No. JJ351865 Thru JJ365633

TM-353 Page 43Syncrowave 250

SC-120 877

SC-121 280

Figure 9-3. Circuit Diagram For Syncrowave 250 Effective With Serial No. JJ365634 Thru JJ503983

TM-353 Page 44 Syncrowave 250

Figure 9-4. Circuit Diagram For Syncrowave 250 Effective With Serial No. JJ503984 Thru JK572897

TM-353 Page 45Syncrowave 250

SC-124 314

SC-124 785-B

Figure 9-5. Circuit Diagram For Syncrowave 250 Effective With Serial No. JK572898 Thru JK690986

TM-353 Page 46 Syncrowave 250

SC-132 697-A

Figure 9-6. Circuit Diagram For Syncrowave 250 Effective With Serial No. JK690987 Thru KA806712

TM-353 Page 47Syncrowave 250

SC-137 431

Figure 9-7. Circuit Diagram For Syncrowave 250 Effective With Serial No. KA806713 Thru KA877024

TM-353 Page 48 Syncrowave 250

SC-135 581

Figure 9-8. Circuit Diagram For Syncrowave 250 Effective With Serial No. KA877025 Thru KB010829

TM-353 Page 49Syncrowave 250

SC-142 524

Figure 9-9. Circuit Diagram For Syncrowave 250 Effective With Serial No. KB010830 Thru KB110694

TM-353 Page 50 Syncrowave 250

SC-148 144

Figure 9-10. Circuit Diagram For Syncrowave 250 Effective With Serial No. KB110695 Thru KC252675

TM-353 Page 51Syncrowave 250

SC-154 649-C

Figure 9-11. Circuit Diagram For Syncrowave 250 Effective With Serial No. KC252676 Thru KG029204

TM-353 Page 52 Syncrowave 250

SC-178 835

Figure 9-12. Circuit Diagram For Syncrowave 250 Effective With Serial No. KG029205 Thru KG062109

TM-353 Page 53Syncrowave 250

SC-179 303-A

Figure 9-13. Circuit Diagram For Syncrowave 250 Effective With Serial No. KG062110 Thru KG170300

TM-353 Page 54 Syncrowave 250

SC-181 109-E

Figure 9-14. Circuit Diagram For Syncrowave 250 Effective With Serial No. KG170301 Thru KH526230

TM-353 Page 55Syncrowave 250

SC-188 161-A

Figure 9-15. Circuit Diagram For Syncrowave 250 Effective With Serial No. KH526231 And Following

TM-353 Page 56 Syncrowave 250

Notes

TM-353 Page 57Syncrowave 250

TM-353 Page 58 Syncrowave 250

Figure 9-16. Wiring Diagram For Syncrowave 250 Effective With Serial No. KH526231 And Following

TM-353 Page 59Syncrowave 250

SD-188 162-A

TM-353 Page 60 Syncrowave 250

Figure 9-17. Circuit Diagram For Control Board PC1 Effective With

Serial No. KH508255 And Following (Part 1 Of 2)

TM-353 Page 61Syncrowave 250

SD-187 644 (1 of 2)

Figure 9-18. Circuit Diagram For Control Board PC1 Effective With

Serial No. KH508255 And Following (Part 2 Of 2)

TM-353 Page 62 Syncrowave 250

TM-353 Page 63Syncrowave 250

SD-187 644 (2 of 2)

Figure 9-19. Circuit Diagram For RFC Board PC2 Effective With Serial No. JJ365634 Thru KB010829

SA-121 282

Figure 9-20. Circuit Diagram For Remote 14 Filter Board PC2

Effective With Serial No. KF959379 And Following

Figure 9-21. Circuit Diagram For Optional Snubber Board PC3

Effective With Serial No. JJ351865 And Following

SA-158 763

SA-120 872

TM-353 Page 64 Syncrowave 250

Figure 9-23. Circuit Diagram For Postflow Timer Board TD1

Effective With Serial No. JJ339876 And Following

SA-044 725-C

Figure 9-22. Circuit Diagram For Optional Preflow Timer Board TD3

Effective With Serial No. JJ339876 And Following

SA-045 288-D

TM-353 Page 65Syncrowave 250

Notes

TM-353 Page 66 Syncrowave 250

Syncrowave 250

Processes

60 Hz, 50 Hz

TM-353E

January 2001

Eff. w/Serial Number JJ339876

Description

TIG (GTAW) Welding

Stick (SMAW) Welding

Arc Welding Power Source

Visit our website at

www.MillerWelds.com

17–Fig.10-4

SECTION 10 – PARTS LIST

7–Fig.10-5

2–Fig.10-3

29–Fig.10-2

. Hardware i s common and

not available unless listed.

TM-353 Page 68 Syncrowave 250

Figure 10-1. Main Assembly

ST-120 135-R

Item

No.

1 114 741 COVER, top (Prior to KG170301) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 182 605 COVER, top (Eff w/KG170301) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 SR1 181 106 RECTIFIER, si diode (Fig 10-3) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 S4 112 630 SWITCH, plrty/changeover (Prior to KA759476) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 S4 133 061 SWITCH, plrty/changeover (Eff w/KA759476) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 057 357 BUSHING, snap-in nyl .937 ID x 1.125mtg hole 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 010 494 BUSHING, snap-in nyl 1.375 ID x1.750mtg hole 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 110 375 STAND-OFF SUPPORT, PC card No. 6 screw (Prior to KG170301) 3. . . . . . . . . . . . . . . . . . . . . . . .

6 134 201 STAND-OFF SUPPORT, PC card No. 6 screw (Eff w/KG170301) 3. . . . . . . . . . . . . . . . . . . . . . . . . .

7 Fig 10-4 PANEL, mtg components 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 083 147 GROMMET, screw No. 8/10 panel hole .312sq .500 high 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 114 754 FRAME, lifting (Prior to KG170301) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 181 101 FRAME, lifting (Eff w/KG170301) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 026 627 GASKET, lift eye 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 070 026 STAND-OFF, 6-32 x .437 lg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 PC1 117 981 CIRCUIT CARD, control (Prior to JJ389988) (Fig 10-5) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 PC1 138 058 CIRCUIT CARD, control (Eff w/JJ389988 thru KB110694) (Fig 10-5) 1. . . . . . . . . . . . . . . . .

12 PC1 180 014 CIRCUIT CARD, control (Eff w/ KB110695 thru KG060803) 1. . . . . . . . . . . . . . . . . . . . . . . . .

12 PC1 187 642 CIRCUIT CARD, control (Eff w/KG060804) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 R14 138 105 RESISTOR, (Eff w/KB110695 thru KG062110) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 FL1 084 171 FILTER, line power 115/250V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 HD1 156 313 TRANSDUCER, current 300A (Eff w/KB110695) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 073 756 STAND-OFF, 6-32 x .625 lg (Eff w/KB110695) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 Z1 114 826 REACTOR 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 Fig 10-4 PANEL, rear w/components 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 C11,12 111 634 CAPACITOR 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 TE1 034 587 TERMINAL ASSEMBLY, pri (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 +114 751 PANEL, side (Prior to KG170301) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 +181 097 PANEL, side (Eff w/KG170301 thru KG181270) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 +182 606 PANEL, side (Eff w/KG181271 and on) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 T1 115 097 TRANSFORMER, pwr main 200/230/460 (Prior to KA877025) 1. . . . . . . . . . . . . . . . . . . . . . .

21 T1 138 171 TRANSFORMER, pwr main 200/230/460 (Eff w/KA877025 thru KG082621) 1. . . . . . . . . . .

21 T1 180 674 TRANSFORMER, pwr main 200/230/460 (Eff w/KG082622) 1. . . . . . . . . . . . . . . . . . . . . . . . .

21 T1 138 175 TRANSFORMER, pwr main (220/380/415 (Prior to KG082622) 1. . . . . . . . . . . . . . . . . . . . . .

21 T1 180 673 TRANSFORMER, pwr main 220/380/415 (Eff w/KG082622) 1. . . . . . . . . . . . . . . . . . . . . . . . .

21 T1 121 161 TRANSFORMER, pwr main 230/460/575 (Prior to KA877025) 1. . . . . . . . . . . . . . . . . . . . . . .

21 T1 138 172 TRANSFORMER, pwr main 230/460/575 (Eff w/KA877025 thru KG082621) 1. . . . . . . . . . .

21 T1 180 672 TRANSFORMER, pwr main 230/460/575 (Eff w/KG082622) 1. . . . . . . . . . . . . . . . . . . . . . . . .

21 T1 191 887 TRANSFORMER, pwr main 260/380/520 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dia.

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PLG10 164 899 CONNECTOR & SOCKETS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG11 168 809 CONNECTOR & SOCKETS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C13 155 082 CAPACITOR, cer disc. .003 200VAC (Prior to JK690987) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C13 132 433 CAPACITOR, cer disc. .05uf 500VDC (Eff w/JK690987) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG51 115 093 CONNECTOR PLUG & SOCKETS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG54 130 203 CONNECTOR PLUG & SOCKETS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG55 115 091 CONNECTOR PLUG & SOCKETS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG3 130 204 CONNECTOR & SOCKETS, (Eff w/KB110695) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TP1 020 520 THERMOSTAT, NC (included w/transformer) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TP2 168 891 THERMOSTAT, NC (Eff w/KG170301) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Part

No.

Figure 10-1. Main Assembly

109 035 LABEL, warning electric shock can kill etc 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

172 078 BRACKET, mtg primary board (Eff w/KE727074) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

601 835 NUT, brs hex 10-32 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

601 836 NUT, brs hex .250-20 jam hvy 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

010 915 WASHER, flat brs .250 ID x .625 OD x .031thk 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

083 426 TERMINAL BOARD, primary 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

038 888 STUD, primary board brs .250-20 x 1.500 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

010 913 WASHER, flat brs .218 ID x 460 OD x .031thk 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

038 887 STUD, primary board brs 10-32 x 1.375 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

038 618 LINK, jumper term bd pri 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Description Quantity

TM-353 Page 69Syncrowave 250

Item

No.

22 114 755 BASE, (Prior to KE727074) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 170 748 BASE, (Eff w/KE727074 thru KF959176) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 171 677 BASE, (Eff w/KF959177) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 157 196 INSULATOR, upright (Eff w/KC307050) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 010 199 TUBING, stl .500 OD x 17ga x 1 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 108 105 CLAMP, capacitor 2.500dia 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 C2 031 668 CAPACITOR, elctlt 4000uf 100VDC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 R5 117 803 RESISTOR, WW fxd 10W 1K ohm 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 114 722 BRACKET, mtg rectifier 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 Fig 10-2 PANEL, front w/components 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 098 376 FUSE, holder (Eff w/KH526231) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 F1,2 085 874 FUSE, mintr gl slo-blo 10A (Eff w/KH526231) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

+When ordering a component originally displaying a precautionary label, the label should also be ordered. BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

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Part

No.

Figure 10-1. Main Assembly (Continued)

092 368 TUBING, stl .250 ID x 16ga x 3 (Prior to JK682714) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

130 764 TUBING, stl .250 ID x 16ga wall x 1.500 (Eff w/JK682714) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Description Quantity

TM-353 Page 70 Syncrowave 250

4 5 6

Includes Item 26

2224

Figure 10-6

ST-120 088-G

Figure 10-2. Panel, Front w/Components

Item

No.

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Part

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Description Quantity

Figure 10-2. Panel, Front w/Components (Fig 10-1 Item 29)

1 097 922 KNOB, pointer 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 NAMEPLATE, (order by model & serial number) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 109 013 BUSHING, snap-in nyl .375 ID x .562mtg hole 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 S6,7 089 085 SWITCH, tgl SPST 20A 125VAC (Prior to KF988252) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 S6,7 176 882 SWITCH, tgl SPST 20A 125VAC (Eff w/KF988252) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

107 983 BLANK, snap-in nyl .500mtg hole 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

057 359 BLANK, snap-in nyl .375mtg hole 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 R3 030 109 POTENTIOMETER, C sltd sft 1/T 2W 5000 ohm 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 R11 030 684 POTENTIOMETER, C sltd sft 1/T 2W 5 meg ohm 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 R1,2 035 897 POTENTIOMETER, C sltd sft 1/T 2W 1000 ohm 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 S5 011 609 SWITCH, tgl SPDT 15A 125VAC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 S3 052 769 SWITCH, tgl 4PDT 15A 125VAC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 S2 011 610 SWITCH, tgl SPDT 15A 125VAC (Prior to JJ503984) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 S2 088 409 SWITCH, tgl 2PDT 15A 125VAC (Eff w/JJ503984) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 TD1 052 192 TIMER, delay on make - postflow (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 039 449 BRACKET, mtg - circuit card 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TM-353 Page 71Syncrowave 250

Item

No.

13 044 723 CIRCUIT CARD, postflow 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 S1 045 834 SWITCH, tgl DPST 60A 600VAC (Prior to KA759476) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 S1 128 757 SWITCH, tgl DPST 60A 600VAC (Eff w/KA759476) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 106 398 PIN, spring CS .156 x .625 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 114 721 SHAFT, extension switch (Prior to KA759476) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 133 276 EXTENSION, handle switch (Eff w/KA759476 thru KF959378) 1. . . . . . . . . . . . . . . . . . . . . . . . . .

16 171 420 EXTENSION, handle switch (Eff w/KF959379) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 164 481 PANEL, front (Prior to KF959379) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 169 476 PANEL, front (Eff w/KF959379 thru KG170300) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 181 096 PANEL, front (Eff w/KG170301) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 CONTROL PANEL, lower front (Fig 10-6) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 128 230 LABEL, warning electric shock etc 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 134 327 LABEL, warning electric shock etc CE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 +114 759 DOOR, access front (Prior to KG170301) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 +181 589 DOOR, access front (Eff w/KG170301) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 134 327 LABEL, warning general precautionary 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 176 254 LABEL, warning general precautionary CE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 PL2 157 958 LIGHT, ind wht lens 28V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 PL1 155 500 LED, yellow (50 Hz model) (Eff w/ KG060803) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 010 647 PIN, spring CS .156 x 1.250 (Prior to KF959379) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 169 136 PIN, handle (Eff w/KF959379) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 098 279 HANDLE, plrty/changeover switch (Prior to KF959379) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 169 135 HANDLE, switch (Eff w/KF959379) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 052 370 KNOB, indicator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 097 924 KNOB, pointer 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 ♦115 920 METER, amp AC/DC 100MV 0-300 scale 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 ♦004 189 METER, volt AC/DC 0–100 scale 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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PLG5 135 635 CONNECTOR & SOCKETS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG6 131 054 CONNECTOR & SOCKETS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Part

No.

Figure 10-2. Panel, Front w/ Components (Continued)

605 583 CATCH, spring loaded door (Prior to KG170301) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Description Quantity

+When ordering a component originally displaying a precautionary label, the label should also be ordered. ♦OPTIONAL BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

TM-353 Page 72 Syncrowave 250

Item

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Description Quantity

Figure 10-3. Rectifier, Si Diode (Fig 10-1 Item 2)

1 C7-10 031 689 CAPACITOR, rectifier 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 083 884 CLAMP, thyristor rectifier (Prior to KG023560) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 166 667 CLAMP, spring rectifier (Eff w/KG023560) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 D1 037 956 DIODE, rect 275A 300V SP 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 TP3 168 898 THERMOSTAT, NC open 125°C (Eff w/KG170301) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 SCR1-4 115 114 THYRISTOR, SCR 300A 300V 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 176 645 CLAMP, thyristor w/o thermostat (Eff w/KG023560) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 173 714 CLAMP, thyristor with thermostat (Eff w/KG170030) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

028 516 PIN, spring CS .125 x .250 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG53 115 092 CONNECTOR & SOCKETS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ST-120 205-A

Figure 10-3. Rectifier, Si Diode

Item

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Part

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Description Quantity

Figure 10-4. Panel, Rear w/Components (Fig 10-1 Item 17)

1 R4 186 949 RESISTOR, WW fxd 175W 20 ohm 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 032 604 BLADE, fan 14 in 3 wing 19deg .375 bore CCW (Prior to KG198783) 1. . . . . . . . . . . . . . . . . . . . .

2 180 165 BLADE, fan 14 in 3 wing 19deg .375 bore CCW (Eff w/KG198783) 1. . . . . . . . . . . . . . . . . . . . . . .

3 114 752 PANEL, rear (Prior to KG170301) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 181 099 PANEL, rear (Eff w/KG170301) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 131 361 CHAMBER, plenum 14 in (Prior to KG128812) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 173 283 CHAMBER, plenum 14 in (Eff w/KG128812) (50 Hz only) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 124 274 BRACKET, mtg fan motor (Eff w/KG128812) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 FM 116 190 MOTOR, 1/12 hp 230V 1550 RPM 50/60Hz 1.5A 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

026 947 STAND-OFF, insul .250-20 x 1.000 lg (Prior to KB110695) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shunt 114 723 SHUNT, (Prior to KB110695) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

176 272 CONNECTOR, clamp cable (50 Hz model) (Eff w/KG060803) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 10-4. Panel, Rear w/Components

BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

TM-353 Page 73Syncrowave 250

ST-120 089-F

Item

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Description Quantity

Figure 10-5. Panel, Mtg Components (Fig 10-1 Item 7)

1 R7 186 468 RESISTOR, WW fxd 100W 50 ohm 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 117 721 PANEL, mtg relay 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 CR2,6 110 386 RELAY, encl 24VAC DPDT 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 2T 072 253 STUD, single connection 10-32 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 SR2,3 035 704 RECTIFIER, integ 40A 800V 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 SN1,2 118 625 SNUBBER, poly metal film .5uf 200VDC 100 ohm 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 R6 117 803 RESISTOR, WW fxd 10W 1K ohm 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 C20 119 834 CAPACITOR, cer disc .05uf 500V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 1T 117 372 BLOCK, term 10A 15P 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

108 023 LINK, jumper term blk 10A 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 CR5 000 770 RELAY, encl 24VDC 3PDT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 CR1 052 964 RELAY, encl 24VDC DPDT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ST-120 090-F

Figure 10-5. Panel, Mtg Components

BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

TM-353 Page 74 Syncrowave 250

Figure 10-6. Control Panel, Lower Front

Item

No.

Dia.

Mkgs.

Part

No.

Description Quantity

Figure 10-6. Control Panel, Lower Front (Fig 10-2 Item 18)

116 477 CONTROL PANEL, lower (Prior to JK572898) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

124 647 CONTROL PANEL, lower (Eff w/JK572898 thru JK682712) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

131 217 CONTROL PANEL, lower (Eff w/JK682714 thru JK690986) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

132 430 CONTROL PANEL, lower (Eff w/JK690987 thru KA806713) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

137 516 CONTROL PANEL, lower (Eff w/KA806713 thru KA877024) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

147 793 CONTROL PANEL, lower (Eff w/KA877025 thru KF959378) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

174 067 CONTROL PANEL, lower (Eff w/KF959379 thru KG170300) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

181 108 CONTROL PANEL, lower (Eff w/KG170301) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 114 742 PANEL, lower front (Prior to JK572898) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 124 784 PANEL, lower front (Eff w/JK572898 thru JK690986) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 130 582 PANEL, lower front (Eff w/JK690987 thru KB093120) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 147 795 PANEL, lower front (Eff w/KB093121 thru KF959176) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 171 652 PANEL, lower front (Eff w/KF959177) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 R25 137 429 RESISTOR, C 2W 3.3K ohm (Eff w/KA806713) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ST-120 003-P

TM-353 Page 75Syncrowave 250

Item

No.

3 126 750 CAPACITOR ASSEMBLY, (Eff w/JK537589 thru JK690986) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 C14 098 566 CAPACITOR, (Prior to JK537589) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 C14 132 433 CAPACITOR, (Eff w/JK690987) 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 PC2/RC1 157 959 CIRCUIT CARD ASSEMBLY, (Eff w/KF959379) (consisting of) 1. . . . . . . . . . . . . . . .

5 C6 164 290 CAPACITOR, polyp film 3.5uf 600VDC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 PLG3 131 204 CONNECTOR & SOCKETS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 RC2 604 176 RECEPTACLE, straight duplex grd 2P3W 15A 125V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 C15 170 920 CAPACITOR 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 CB1 093 995 CIRCUIT BREAKER, man reset 1P 15A 250V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 R13 605 828 RHEOSTAT, WW 50W 1.5 ohm (Prior to KG170301) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 R13 174 037 RHEOSTAT, WW 50W 1.5 ohm (Eff w/KG170301 thru LA292998) 1. . . . . . . . . . . . . . . . .

10 R13 198 547 RHEOSTAT, WW 25W 1.5 ohm (Eff w/LA292999) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 G ♦♦020 623 SPARK GAP ASSEMBLY (Prior to LA337284) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 G ♦♦203 419 SPARK GAP ASSEMBLY SERVICE KIT (for units prior to LA337284)) 1. . . . . . . . . . . . .

11 G ♦♦199 854 SPARK GAP ASSEMBLY (Eff w/LA337284) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 097 712 STRIP, insulator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 174 070 BRACKET, mtg components (Eff w/KG959379) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 C3 106 935 CAPACITOR, polyp film 10uf 250VAC (Prior to KK001554) 1. . . . . . . . . . . . . . . . . . . . . . . . . .

14 C3 191 944 CAPACITOR, polyp film 10uf 250VAC (Eff w/KK001554) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 R8 083 784 RESIST OR, WW fxd 100W 10 ohm (Prior to KG170301) 1. . . . . . . . . . . . . . . . . . . . . . . . . . .

15 R8 181 107 RESISTOR ASSEMBLY w/LEADS, (Eff w/KG170301) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 C4 096 761 CAPACITOR, mica .002uf 10000V (CE Models Only) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 C4 096 761 CAPACITOR, mica .002uf 10000V. . . . . . . . . . . . . .

16 C4 201 197 CAPACITOR, polyp met film .002uf 10000VDC/4400VAC pnl mtg. . . . . . . . . . . . . .

17 T2 074 398 TRANSFORMER, high voltage 115V pri 3600V sec 30mA 1. . . . . . . . . . . . . . . . . . . . . . . . . .

TM-353 Page 76 Syncrowave 250

Dia.

Mkgs.

RC2 035 523 CONNECTOR, circ 5skt rcpt Amphenol MS-3102A-16S-8S 1. . . . . . . . . . . . . . . . . . . . . . . . . .

C16-19 119 856 CAPACITOR 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PC2/RFC1 121 273 CIRCUIT CARD, snubber 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RC2 143 976 CONNECTOR w/SOCKETS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C16 143 899 LEAD ASSY, elect 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C17 143 897 LEAD ASSY, elect 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C18 143 898 LEAD ASSY, elect 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C19 143 900 LEAD ASSY, elect 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RFC1/PC2 142 522 CHOKE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG21 153 501 CONNECTOR & SOCKETS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Part

No.

Figure 10-6. Control Panel, Lower Front (Continued)

121 270 RECEPTACLE/CAPACITOR,w/leads (Prior to JK682714). . . . . . . . . . . . . . . . . . . . .

(consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

039 273 CONNECTOR, circ 5 pin size 16S plug Amphenol MS-3106A-16S-8P. . . . . . . . . . . . . . . . . . . . .

039 685 CONNECTOR, circ clamp str rlf size 16 Amphenol 97-3057-8. . . . . . . . . . . . . . . . . . . . .

142 523 CONNECTOR/CAPACITOR, w/leads (Eff w/JK674521 thru . . . . . . . . . . . . . . . . . . . . .

KF959378) (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

134 734 CONNECTOR, circ 14 pin size 20 plug Amp 213571-2. . . . . . . . . . . . . . . . . . . . .

079 534 CONNECTOR, circ skt push-in 14-18ga Amp 66358-6. . . . . . . . . . . . . . . . . . . . .

079 739 CONNECTOR, circ clamp str rlf size 17-20 Amp 206322-2. . . . . . . . . . . . . . . . . . . . .

073 690 CAP, straight P & S 2P3W 5266 DF. . . . . . . . . . . . . . . . . . . . .

010 493 BUSHING, snap-in nyl .625 ID x .875 mtg hole 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦♦095 621 BASE, spark gap (Prior to LA337284) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦♦020 622 HOLDER, points (Prior to LA337284) 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦♦*020 603 POINT, spark gap (Prior to LA337284) 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦♦199 855 BASE, spark gap (Eff w/LA337284) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦♦199 856 HOLDER, points (Eff w/LA337284) 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦♦*196 455 POINT, spark gap (Eff w/LA337284) 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

088 731 BUSHING, snap-in nyl .375 ID x .500mtg hole 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(Prior to KK001554 for nonCE Models) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(Eff w/KK001554 for nonCE Models) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

000 681 STRIP, mtg HF coil (Prior to JK572898) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

124 649 STRIP, mtg HF coil (Eff w/JK572898) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

000 682 TUBING, fiber vulc .250 ID x .312 OD x .812 (Prior to JK572898) 2. . . . . . . . . . . . . . . . . . . . . . . . . . .

125 949 TUBING, fiber vulc .250 ID x .312 OD x 1.125 (Eff w/JK572898) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Description Quantity

Item

No.

18 T3 115 967 COIL, HF coupling (Prior to JK572898) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 T3 124 650 COIL, HF coupling (Eff w/JK572898 thru KF959378) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 T3 174 692 COIL, HF coupling (Eff w/KF959379) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 Work. . . . . . .

20 GS1 174 036 VALVE, w/fittings & leads (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 174 038 PANEL, door access HF (Eff w/KF959379) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 097 922 KNOB, pointer (Eff w/JK572898) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 010 357 SPEED NUT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 605 742 CLIP, mtg resistor .500 ID core 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*Recommended Spare Parts ♦♦Effective with Serial No.LA337284, Spark Gap Assembly 020 623 consisting of: Base 095 621, Holder 020 622,

and Points 020 603, is no longer available. If replacement parts are needed for any units with a Serial No. prior to LA337284, you must first order and install Spark Gap Assembly Service Kit 203 419. To replace spark gap parts in units with Serial No. LA337284 and following, or for units with Spark Gap Assembly Service Kit 203 419 installed, order appropriate spark gap parts listed above as, eff/w Serial No. LA337284. BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

Dia.

Mkgs.

R9 030 603 RESISTOR, WW fxd 10W 10K ohm (Prior to KA877025) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrode 039 047 TERMINAL, power output (consisting of) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG4 131 203 CONNECTOR & SOCKETS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Part

No.

Figure 10-6. Control Panel, Lower Front (Fig 10-2 Item 18) (Continued)

601 976 SCREW, stl hexhd .500-13 x 1.500 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

039 049 TERMINAL BOARD, red 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

601 880 NUT, stl hex jam .500 -13 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

039 044 BUS BAR, term bd 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

601 879 NUT, stl hex full fnsh .500-13 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

010 296 FITTING, hose brs elbow M 1/4NPT x .625-18 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

035 601 VALVE, 115VAC 2 way 1/4 IPS port 1/8 orf 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Description Quantity

TM-353 Page 77Syncrowave 250

Eff w/KE558763 the Water Valve Option (042 138) is no longer available

and all other options are available as Field Options only.

Dia.

Mkgs.

WSI 035 601 VALVE, 115VAC 2 way 1/4 IPS port 1/8 orf 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A 115 920 METER, amp AC/DC 100MV 0-300 scale 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

V 004 189 METER, volt AC/DC 0-100 scale 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CR3 006 393 RELAY, encl 24VAC DPDT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RFC,VR1/PC3 120 875 CIRCUIT CARD, snubber 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

R10 030 108 POTENTIOMETER, C sltd sft 1/T 2W 100K ohm 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

S8 011 611 SWITCH, tgl DPDT 15A 125V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TD2 047 133 RELAY, delay adj 120VAC DPDT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CR4 006 393 RELAY, encl 24VAC DPDT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

R12,S9 115 862 POTENTIOMETER, C sltd sft 1/T .50W 500K ohm 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TD3 116 476 TIMER, delay on make - preflow (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A50 008 971 IC, linear 741 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C50 039 482 CAPACITOR, elctlt 100uf 35VDC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C51 091 378 CAPACITOR, tantlm 33uf 35VDC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C52 039 481 CAPACITOR, elctlt 3.3uf 50VDC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C53 031 677 CAPACITOR, elctlt 5.6uf 35VDC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C54 166 199 CAPACITOR, cer disc .05uf 500VDC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CR50 039 486 RELAY, encl 24VDC SPDT 2.5A 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

D50,51 026 202 DIODE, rect 1A 400V SP 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Q50 000 088 TRANSISTOR, NPN 800mA 400V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

R50 074 121 RESISTOR, C 2W 3.3K ohm 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

R52 108 432 RESISTOR, MF .25W 2.21K ohm 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

R53 000 342 POTENTIOMETER, cermet trmr 1/T .5W 5K ohm 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

R54 093 030 RESISTOR, MF .25W 15K ohm 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

R55 028 273 RESISTOR, C .5W 2.7K ohm 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

R56 093 037 RESISTOR, MF .25W 47.5K ohm 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

R57 605 919 RESISTOR, C .25W 47 ohm 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C1 125 781 CAPACITOR, polyp film 150uf 250VAC 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Part

No.

Optional Equipment

042 138 WATER VALVE, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

010 295 FITTING, pipe brs elbow M 1/4NPT x .625-18 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

116 201 BRACKET, mtg valve 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

042 140 METER KIT, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

131 054 CONNECTOR & SOCKETS, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

113 746 CONNECTOR, rect skt 24-18ga Molex 39-00-0038 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

042 142 SPOT TIMER, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

097 922 KNOB, pointer 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

042 144 PRE-FLOW TIMER, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

115 856 CIRCUIT CARD, preflow (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

039 449 BRACKET, mtg circuit card 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

097 922 KNOB, pointer 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

042 353 POWER FACTOR CORRECTION, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

129 201 BRACKET, mtg capacitor 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Description Quantity

TM-353 Page 78 Syncrowave 250

PRINTED IN USA  1998 Miller Electric Mfg. Co.

Miller Electric Mfg. Co.

An Ill inoi s Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA

International Headquarters–USA

Phone: 920-735-4505 USA & Canada FAX: 920-735-4134 International FAX: 920-735-4125

European Headquarters – United Kingdom

Phone: 44 (0) 1204-593493 FAX: 44 (0) 1204-598066

Call 1-800-4-AMILLER for your local Miller distributor.

Miller Electric SYNCROWAVE 250 Technical Manual

Specifications and Main Features

Frequently Asked Questions

User Manual