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Miller Syncrowave 351 Owner's Manual

Arc welding power source
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Syncrowave 351
OM-354
147819 G
December 1997
Processes
TIG (GTAW) Welding
Stick (SMAW) Welding
Description
Arc Welding Power Source
R
60 Hz, 50 Hz –

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Summary of Contents for Miller Syncrowave 351

  • Page 1 OM-354 147819 G December 1997 Processes TIG (GTAW) Welding Stick (SMAW) Welding Description Arc Welding Power Source Syncrowave 351 60 Hz, 50 Hz – Visit our website at www.MillerWelds.com...
  • Page 2 Welding Process Manuals such as SMAW, GTAW, GMAW, and GMAW-P. Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual catalog sheets.

  • Page 3: Table Of Contents

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

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

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

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

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

  • Page 8: Emf Information

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

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

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

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

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

  • Page 12: Principales Normes De Sécurité

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

  • Page 13: Section 2 - Definitions

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

  • Page 14: Rating Label For Ce Products

    2-2. Rating Label For CE Products OM-354 Page 10...

  • Page 15: Symbols And Definitions

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

  • Page 16: Section 3 - Installation

    SECTION 3 – INSTALLATION 3-1. Specifications Amperes Input at AC Balanced Rated Load Output, Rated 50/60 Hz, Single-Phase Welding Amperage 200 V 220 V 230 V 380 V 415 V 460 V 575 V Output PFC** Range NEMA Class I 13.7 (60) –...

  • Page 17: Volt-Ampere Curves

    3-3. Volt-Ampere Curves 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. A. DC Mode B. AC Mode *During low arc voltage conditions (short arc length), increasing Arc Control setting increases amperage (see Section 4-2).

  • Page 18: Tipping

    3-5. Tipping Y Be careful when placing or moving unit over uneven surfaces. 3-6. Weld Output Terminals And Selecting Cable Sizes Y ARC WELDING can cause Electromagnetic Interference. To reduce possible interference, keep weld cables as short as possible, close together, and down low, such as on the floor. Locate welding operation 100 meters from any sensitive electronic equipment.

  • Page 19: Remote 14 Receptacle

    3-7. Remote 14 Receptacle Socket* Socket Information 24 volts ac. Contact closure to A completes 24 volts ac contactor control circuit. Command reference; 0 to +10 volts dc output to remote control. Remote control circuit common. C L N 0 to +10 volts dc input command signal from remote control. Chassis common.

  • Page 20: Electrical Service Guide

    3-9. Electrical Service Guide NOTE All values calculated at 60% duty cycle. Without Power With Power 60 Hertz Models Factor Correction Factor Correction Input Voltage Input Amperes At Rated Output Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes Min Input Conductor Size In AWG/Kcmil Max Recommended Input Conductor Length In (46)

  • Page 21: Placing Jumper Links And Connecting Input Power

    3-10. Placing Jumper Links And Connecting Input Power Check input voltage available at site. Jumper Link Label Check label – only one is on unit. Jumper Links 200 VOLTS 230 VOLTS 460 VOLTS Move jumper links to match input voltage. Input And Grounding Conductors Select size and length using Sec-...

  • Page 22: Section 4 - Operation

    SECTION 4 – OPERATION 4-1. Standard Controls HF, HF for arc starting only, or no HF. is set to 200 A, the range of the remote am- Place 4 switches in upper left corner up perage control is 0 to 200 A. High Frequency Control for SMAW and down for GTAW.

  • Page 23: Arc/Balance Control

    4-2. Arc/Balance Control Arc Control (DC SMAW): Control helps arc starting or making vertical or overhead welds by in- Balance Control Examples creasing amperage at low arc volt- Setting Output Waveforms age. When set at 0, short-circuit amper- Balanced 50% Electrode age at low arc voltage is the same Positive as normal welding amperage.

  • Page 24: Setting Optional Pulser Controls

    4-4. Setting Optional Pulser Controls Peak Amperage Background Amperage Use Background Amperage con- trol to set the low pulse of weld amperage which cools the weld puddle. Peak amperage, which is the front panel or remote control Pulser Examples amperage setting, is the high pulse which heats the weld Percent (%) On Time Pulsed Output Waveforms...

  • Page 25: Section 5 - Maintenance & Troubleshooting

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

  • Page 26: Adjusting Spark Gaps

    5-3. Adjusting Spark Gaps Y Turn power before adjusting spark gaps. Open access door. Tungsten End Of Point Replace point if tungsten end dis- appears; do not clean or dress tungsten. Spark Gap Normal spark gap is 0.008 in (0.203 mm).

  • Page 27: Troubleshooting

    5-4. Troubleshooting Trouble Remedy No weld output; unit completely Place line disconnect switch in On position (see Section 3-10). inoperative. Check and replace line fuse(s), if necessary (see Section 3-10). Check for proper input power connections (see Section 3-10). Check for proper jumper link position (see Section 3-10). No weld output;...
  • Page 28 Trouble Remedy Tungsten electrode oxidizing and not Shield weld zone from drafts. remaining bright after conclusion of weld. Increase postflow time. Check and tighten all gas fittings. Properly prepare tungsten. Check for water in torch, and repair torch if necessary. Fan not operating.

  • Page 29: Electrical Diagram

    5-5. Electrical Diagram SC-181 682-D OM-354 Page 25...

  • Page 30: Section 6 - High Frequency (Hf)

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

  • Page 31: Correct Installation

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

  • Page 32: Section 7 - Parts List

    SECTION 7 – PARTS LIST Hardware is common and not available unless listed. ST-149 844-D Figure 7-1. Main Assembly OM-354 Page 28...
  • Page 33 Item Dia. Part Mkgs. Description Quantity Figure 7-1. Main Assembly ....182 126 . . . COVER, top ...........
  • Page 34 Item Dia. Part Mkgs. Description Quantity Figure 7-2. HF Panel (Fig 7-1 Item 37) ....096 761 . . . CAPACITOR, mica .002uf 10000V ....... .
  • Page 35 Item Dia. Part Mkgs. Description Quantity Figure 7-3. Baffle, w/Components (Fig 7-1 Item 7) ....157 874 . . . BRACKET, mounting motor fan .
  • Page 36 Item Dia. Part Mkgs. Description Quantity Figure 7-5. Panel, Front Upper w/Components (Fig 7-6 Item 10) ..S1-3 ..145 475 . . . SWITCH, tgl SPDT 15A 125VAC ....... . .
  • Page 37 Item Dia. Part Mkgs. Description Quantity Figure 7-5. Panel, Front Upper w/Components (Fig 7-6 Item 10) (Continued) ..PLG6 ..131 056 . . . CONNECTOR & SOCKETS .
  • Page 38 Item Dia. Part Mkgs. Description Quantity Figure 7-6. Panel, Front w/Components (Fig 7-1 Item 36) ....169 133 . . . RECESS, handle switch .
  • Page 39 Item Dia. Part Mkgs. Description Quantity Figure 7-7. Panel, Front Lower w/Components (Fig 7-6 Item 13) ....182 118 . . . PANEL, HF door .
  • Page 40 Item Dia. Part Mkgs. Description Quantity 046 746 Figure 7-8. Switch, Push Button (Fig 7-6 Item 4) ....059 885 . . . BUTTON, push reset red .
  • Page 41 Call LIMITED WARRANTY – Subject to the terms and conditions APT, ZIPCUT & PLAZCUT Model Plasma Cutting below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants Torches 1-800-4-A-MILLER to its original retail purchaser that new Miller equipment sold...

  • Page 42: Options And Accessories

    FAX: 44 (0) 1204-598066 www.MillerWelds.com Contact the Delivering Carrier for: File a claim for loss or damage during shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. PRINTED IN USA 2000 Miller Electric Mfg. Co. 6/00...

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