Miller Syncrowave 250 DX Technical Manual page 63

Trouble
Unit provides only maximum or minimum weld output. Be sure Amperage switch is in proper position (see Section 4-1).
Erratic or improper weld output.
No arc/balance control.
No control of weld output.
No power output from duplex receptacle RC2.
Syncrowave 250 DX
Check main control board PC1 and connections, and replace if necessary (see Section
6-6).
Be sure remote control is operating properly.
Check hall device HD1; pin 1 is +15 volts dc, pin 2 is -15 volts dc, pin 3 is +2 volt per 100
amps feedback, and pin 4 is ground (GND) (see Section 6-3). Replace if necessary.
Use proper size and type of weld cable (see Section 3-6).
Use proper size and type tungsten.
Clean and tighten all weld connections (see Section 3-6).
Be sure Output Selector switch is in proper position for welding process (see Section 4-1).
If using a remote control, check position of Amperage Adjustment control R2 (see Section
4-1).
Check hall device HD1; pin 1 is +15 volts dc, pin 2 is -15 volts dc, pin 3 is +2 volt per 100
amps feedback, and pin 4 is ground (GND) (see Section 6-3). Replace if necessary.
Check capacitors C1 and C11 for a short or open, and check for proper connections. Re-
place C1 and C11 if necessary (see Section 6-3).
Check resistance and connections of resistor R1; R1 is 50 ohms
essary (see Section 6-3).
Check resistance and connections of resistor R2; R2 is 10 ohms
essary (see Section 6-3).
Check modules Mod1 and Mod2 in main rectifier, and replace if necessary. If any modules
are replaced, check capacitors C7 through C10 for a short or open, and check for proper
connections. Replace C7 through C10 if necessary (see Section 6-3).
Check main control board PC1 and connections, and replace if necessary (see Section
6-6).
Check pulser board PC2 and connections, and replace if necessary (see Section 6-8).
Check timer board PC3 and connections, and replace if necessary (see Section 6-10).
Be sure Arc/Balance control R3 is in proper position (see Section 4-1).
Check main control board PC1 and connections, and replace if necessary (see Section
6-6).
Place Output switch in On position, or place switch in Remote 14 position and connect re-
mote contactor control to Remote 14 receptacle RC1 (see Sections 4-1 and 3-7).
Be sure Amperage control switch is in proper position (see Section 4-1).
Check modules Mod1 and Mod2 in main rectifier, and replace if necessary. If any modules
are replaced, check capacitors C7 through C10 for a short or open, and check for proper
connections. Replace C7 through C10 if necessary (see Section 6-3).
Check hall device HD1; pin 1 is +15 volts dc, pin 2 is -15 volts dc, pin 3 is +2 volt per 100
amps feedback, and pin 4 is ground (GND) (see Section 6-3). Replace if necessary.
Check main control board PC1 and connections, and replace if necessary (see Section
6-6).
Check pulser board PC2 and connections, and replace if necessary (see Section 6-8).
Check optional timer board PC3 and connections, and replace if necessary (see Section
6-10).
Check circuit breaker CB1, and reset if necessary (see Section 7-2).
Check wiring of duplex receptacle RC2. Repair or replace if necessary (see Section 6-3).
Check main transformer T1 for signs of winding failure. Check continuity across windings,
and check for proper connections. Check secondary voltages. Replace T1 if necessary
(see Section 6-3).
Remedy
±
10%. Replace R1 if nec-
±
10%. Replace R2 if nec-
TM-359 Page 59