Miller Electric SYNCROWAVE 250 Technical Manual
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
R
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
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
1
1
50 Hz
1
= 80V
U
0
= 80V
U
0
U
= 220 I
1
U
= 380 I
1
U
= 415 I
1
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
2
22.4V 18V 16.2V
2
310A 200A 155A
2
32.4V 28V 26.2V
2
= 117.2A I
1max
= 72.2A I
1max
= 63.8A I
1max
1Eff
1Eff
1Eff
= 59A
= 36A
= 32A
IP 21S
S-178 813-A
TM-353 Page 4 Syncrowave 250
2-3. Symbols And Definitions
NOTE
A
V
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
U
I
1
IP
S
Balance Control Maximum Cleaning
Electrode
Negative
Voltage (A verage)
0
Rated No Load
Primary Current
Degree Of
Protection
Electrode Work Thickness Gauge Spark Gap
Seconds
U
I
I
1eff
1
2
Maximum
Penetration
Crater Time Meter Single-Phase
Primary Voltage
Rated Welding
Current
Maximum Effective
Supply Current
U
X
I
1max
Conventional Load
2
Rated Maximum
Supply Current
Voltage
Duty Cycle
1
Hz
Electrode Positive
Line Connection
Single-Phase
1
Combined AC/DC
Power Source
Hertz
TM-353 Page 5Syncrowave 250
3-1. Specifications
Rated
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**
No
PFC
With
PFC
200V220V230V260V380V415V460V520V575
**
No
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
92
(4*)
46
(2*)
37
(1.6*)21(0.89*)
Amperes Input at AC Balanced
Rated Load Output,
50/60 Hz, Single-Phase
KVA KW
11.4
(0.68*)
V
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
IP
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
0
15
Minutes
A
OR
Reduce Duty Cycle
duty1 4/95 / SB-116 198
TM-353 Page 7Syncrowave 250
3-4. Selecting A Location
Movement
Location And Airflow
3
5
1 Lifting Eye
2 Lifting Forks
Use lifting eye or lifting forks to
move unit.
1
OR
2
6
4
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
A
B
C
Front
ST-800 402 / ST-117 264-F
Dimensions
Height 30-3/4 in (781 mm)
D
E
F
F
G
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
H
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
F
Socket* Socket Information
A 24 volts ac.
AJ
K
B
L
C
D
*The remaining sockets are not used.
I
NH
M
G
F
E
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.
A
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
5
6
1 7
4
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
86
(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
LL
220 VOLTS
LL
260 VOLTS
LL
460 VOLTS
LL
380 VOLTS
LL
380 VOLTS
LL
1
575 VOLTS
LL
S-010 587-B
415 VOLTS
LL
S-131 783-A
520 VOLTS
LL
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
2
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
4
L1 (U)
L2 (V)
3
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
6
5
4
3
2
SECTION 4 – OPERATION
1 Ammeter
87
9
10
11
12
13
14
1
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.
15
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-
1
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
1
2
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.
2
1
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
3
More Penetration
10
More Cleaning
0
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-
1
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
2
1 Amperage Adjustment Control
Use control to adjust amperage,
1
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
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
1
2
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-
1
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
1
2
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.
1
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
V1
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
S1
Main
Transformer
T1
Circuit
Breaker
CB1
115 VAC
115 VAC Duplex
Receptacle
RC2
Fan
Motor
FM
Control
Board
PC1
Arc Control
Output
Amperage
Crater Time
Switch
S6
Control
Switch S5
Switch
S7
AC
115 VAC
Thermostat
TP1
Line
Input
Power
DC
Synchronization
Signal
SCR
Gating
Signals
Main
Rectifier
SR1
1
φ1φ
124
31423
15
6
9
12
7
5
8
Arc Control
R2
Amperage
Adjustment
Control R1
Crater Time
Control
R11
AC Balance
Control
R3
10
Ammeter
A1
11
Postflow
Timer
TD1
16
Gas
Valve
GS1
17
6
12
Remote
13
Remote 14
Filter Board
PC2
13
7
1φ
, 10 VAC
(Contactor)
Switch S3
24
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
T2
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
Z1
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
T2
♦
1φ Power
25
26
28
30
21
30
22
21
20
Capacitor
C4
Integrated
Rectifier
SR2
29
Line
Filter
FL1
Preflow
Timer
TD3
Preflow Time
Control
R12
Switch
S9
♦
♦
Spot
Timer
TD2
Spot Time
Control
R10
♦
♦
Voltmeter
V1
18
18
19
19
11
27
115 VAC
Spot Time
19♦
Switch
S8
Output
Selector
Switch
S4
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.
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