Miller Syncrowave 250 DX User Manual
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Miller Syncrowave 250 DX User Manual

Arc welding power source with optional running gear and cooler
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Syncrowave 250 DX / 350 LX
With Optional Running Gear And Cooler
OM-363
2012−01
Processes
Description
Arc Welding Power Source
R
213117AL
TIG (GTAW) Welding
Stick (SMAW) Welding
File: TIG (GTAW)

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Summary of Contents for Miller Syncrowave 250 DX

  • Page 1 OM-363 213117AL 2012−01 Processes TIG (GTAW) Welding Stick (SMAW) Welding Description Arc Welding Power Source Syncrowave 250 DX / 350 LX With Optional Running Gear And Cooler File: TIG (GTAW) Visit our website at www.MillerWelds.com...
  • Page 2 We know you don’t have time to do it any other way. That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS FOR ADDITIONAL WELDING INFORMATION AND RESOURCES, VISIT: www.MillerWelds.com SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING ........1-1.
  • Page 4 TABLE OF CONTENTS SECTION 5 − OPERATION ..............5-1.

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

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som 2011−10 Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if Indicates special instructions.
  • Page 6 D Remove stick electrode from holder or cut off welding wire at FUMES AND GASES can be hazardous. contact tip when not in use. D Wear oil-free protective garments such as leather gloves, heavy Welding produces fumes and gases. Breathing shirt, cuffless trousers, high shoes, and a cap.

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

    1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. BATTERY EXPLOSION can injure. D Do not install or place unit on, over, or near D Do not use welder to charge batteries or jump combustible surfaces. start vehicles unless it has a battery charging feature designed for this purpose.

  • Page 8: California Proposition 65 Warnings

    1-4. California Proposition 65 Warnings Welding or cutting equipment produces fumes or gases This product contains chemicals, including lead, known to which contain chemicals known to the State of California to the state of California to cause cancer, birth defects, or other cause birth defects and, in some cases, cancer.

  • Page 9: Section 2 − Consignes De Sécurité − Lire Avant Utilisation

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som_2011−10 Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives aux précautions de sécurité et au mode opératoire. 2-1.
  • Page 10 Il reste une TENSION DC NON NÉGLIGEABLE dans LE SOUDAGE peut provoquer un les sources de soudage onduleur UNE FOIS incendie ou une explosion. l’alimentation coupée. Le soudage effectué sur des conteneurs fermés tels D Arrêter les convertisseurs, débrancher le courant électrique et que des réservoirs, tambours ou des conduites peut décharger les condensateurs d’alimentation selon les instructions provoquer leur éclatement.

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

    ACCUMULATIONS LES BOUTEILLES peuvent exploser risquent de provoquer des blessures si elles sont endommagées. ou même la mort. Les bouteilles de gaz comprimé contiennent du gaz sous haute pression. Si une bouteille est D Fermer l’alimentation du gaz comprimé en cas endommagée, elle peut exploser.

  • Page 12: Proposition Californienne 65 Avertissements

    Les PIÈCES MOBILES peuvent RAYONNEMENT HAUTE causer des blessures. FRÉQUENCE (H.F.) risque provoquer des interférences. D Ne pas s’approcher des organes mobiles. D Ne pas s’approcher des points de coincement D Le rayonnement haute fréquence (H.F.) peut tels que des rouleaux de commande. provoquer des interférences avec les équi- pements de radio−navigation et de com- LES FILS DE SOUDAGE peuvent...

  • Page 13: Principales Normes De Sécurité

    2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone: is available as a free download from the American Welding Society at 800-463-6727, website: www.csa-international.org). http://www.aws.org or purchased from Global Engineering Documents Safe Practice For Occupational And Educational Eye And Face Protec- (phone: 1-877-413-5184, website: www.global.ihs.com).
  • Page 14 OM-363 Page 10...

  • Page 15: Section 3 − Definitions

    A complete Parts List is available at www.MillerWelds.com SECTION 3 − DEFINITIONS 3-1. Warning Label Definitions Warning! Watch Out! There are possible 2.2 Use forced ventilation or local exhaust welding helmet with correct shade of hazards as shown by the symbols. to remove the fumes.

  • Page 16: Symbols And Definitions

    A complete Parts List is available at www.MillerWelds.com 3-3. Symbols And Definitions Gas Tungsten Arc Shielded Metal Arc Amperes Panel−Local Welding (GTAW) Welding (SMAW) Do Not Switch Volts Arc Force (DIG) Background Amps While Welding Output Circuit Breaker Remote Temperature Protective Earth High Frequency - Alternating Current...

  • Page 17: Section 4 − Installation

    A complete Parts List is available at www.MillerWelds.com SECTION 4 − INSTALLATION 4-1. Important Information Regarding IEC Products A. Information On Compliance With Essential Requirements This equipment conforms to the essential requirements and provisions of the stated Standard(s): IEC 60974-1: 2005 Arc Welding Equipment − Welding Power Sources IEC 60974-10: 2004 Arc Welding Equipment −...

  • Page 18: Selecting A Location

    A complete Parts List is available at www.MillerWelds.com 4-3. Selecting A Location Movement Location And Airflow 18 in. (460 mm) 18 in. (460 mm) Ref. 117 264-C / 803 584-B Line Disconnect Device Falling Unit Can Cause Injury. If using lift forks to move unit, be sure forks are long enough to extend Locate unit near correct input power supply.

  • Page 19: Dimensions And Weights

    A complete Parts List is available at www.MillerWelds.com 4-4. Dimensions And Weights Dimensions Height 36-1/4 in. (921 mm) Width 23 in. (584 mm) Length 28 in. (711 mm) 25 in. (635 mm) 1-25/64 in. (35 mm) Front 1-5/8 in. (41 mm) 22 in.
  • Page 20 A complete Parts List is available at www.MillerWelds.com B. For 250 DX Models Amperes Input at AC Balanced Rated Rated Load Output, 60 Hz, Single-Phase Peak Starting Rated Amperage Voltage Welding 200V 230V 460V 575V (Up) Output Range (Uo) NEMA Class 17.6 3 −...

  • Page 21: Duty Cycle And Overheating

    A complete Parts List is available at www.MillerWelds.com 4-7. Duty Cycle And Overheating Duty Cycle is the percentage of 10 minutes that the unit can weld at rated load without overheating. If unit overheats, output stops, front panel voltmeter/ammeter displays a HLP3 or HLP5 message (see Section 7-1), and cooling fans run.

  • Page 22: Volt-Ampere Curves

    A complete Parts List is available at www.MillerWelds.com 4-8. Volt-Ampere Curves A. For 250 DX Models 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.

  • Page 23: Weld Output Terminals And Selecting Cable Sizes

    ****For distances longer than 100 ft (30 m) and up to 200 ft (60 m), use direct current (DC) output only. For distances longer than those shown in this guide, call a factory applications rep. at 920-735-4505 (Miller) or 1-800-332-3281 (Hobart).

  • Page 24: Remote 14 Receptacle Information

    A complete Parts List is available at www.MillerWelds.com 4-10. Remote 14 Receptacle Information Socket* Socket Information Turn off power before connecting to receptacle. Contactor control 24 volts DC. 24 VOLTS DC OUTPUT Contact closure to A completes 24 volts DC CONTACTOR contactor control circuit and enables output.

  • Page 25: Tig Connections With A Two-Piece Air-Cooled Torch

    A complete Parts List is available at www.MillerWelds.com 4-12. TIG Connections With A Two-Piece Air-Cooled Torch Turn Off power before making connections. Gas-In Connection Connect gas hose from gas supply to gas-in connection. Output Selector Switch (See Section 5-2) Switch is shown in DCEN (direct cur- rent electrode negative) position for TIG HF Impulse DCEN welding.

  • Page 26: Front Panel Display For Tig Hf Impulse Dcen (Direct Current Electrode Negative)

    A complete Parts List is available at www.MillerWelds.com 4-14. Front Panel Display For TIG HF Impulse DCEN (Direct Current Electrode Negative) Front Panel Green on nameplate indicates a For all front panel switch pad TIG function (see Section 5-1 for Correct front panel display for ba- controls: press switch pad to description of controls).

  • Page 27: Front Panel Display For Tig Ac

    A complete Parts List is available at www.MillerWelds.com 4-15. Front Panel Display For TIG AC Front Panel Green on nameplate indicates a For all front panel switch pad TIG function (see Section 5-1 for controls: press switch pad to description of controls). Correct front panel display for turn on light and enable basic TIG AC welding.

  • Page 28: Optional Cooler Connections

      ter for operations above 32 F (0 C), or three gallons of Miller coolant part no. 043 810. Gas Out Connection Connect TIG torch gas hose to gas out fitting. Electrode Weld Output...

  • Page 29: Stick Connections

    A complete Parts List is available at www.MillerWelds.com 4-17. Stick Connections Turn Off power before mak- ing connections. Work Weld Output Terminal Connect work lead to work weld output terminal. Electrode Weld Output Terminal Connect electrode holder to elec- trode weld output terminal. Remote 14 Receptacle If desired, connect remote control to Remote 14 receptacle (see Sec-...

  • Page 30: Front Panel Display For Stick Dcep (Direct Current Electrode Positive)

    A complete Parts List is available at www.MillerWelds.com 4-18. Front Panel Display For Stick DCEP (Direct Current Electrode Positive) Front Panel Gray on nameplate indicates a For all front panel switch pad Stick function (see Section 5-1 controls: press switch pad to for description of controls).

  • Page 31: Front Panel Display For Stick Ac

    A complete Parts List is available at www.MillerWelds.com 4-19. Front Panel Display For Stick AC Front Panel Gray on nameplate indicates a For all front panel switch pad Stick function (see Section 5-1 controls: press switch pad to for description of controls). Correct front panel display for turn on light and enable basic Stick AC welding.

  • Page 32: Electrical Service Guide

    A complete Parts List is available at www.MillerWelds.com 4-20. Electrical Service Guide A. For 250 DX Models Input amperage may be higher than shown in table when Balance Control is in an unbalanced position. All values in both tables were calculated at 60% duty cycle. Actual input voltage cannot exceed ...
  • Page 33 A complete Parts List is available at www.MillerWelds.com B. For 350 LX Models Input amperage may be higher than shown in table when Balance Control is in an unbalanced position. All values in both tables were calculated at 60% duty cycle. Actual input voltage cannot exceed ...

  • Page 34: Placing Jumper Links

    A complete Parts List is available at www.MillerWelds.com 4-21. Placing Jumper Links Disconnect and lockout/tag- Label found on 250 DX models with the following stock numbers: input power before 907194, 907194-021 907194-031 and, 907194-032 installing or moving jumper links. Label found on 350 LX models with the following stock numbers: 907198, 907198-011, 907198-021, 907198-031 and 907198-032 Check input voltage available at site.

  • Page 35: Connecting Input Power

    A complete Parts List is available at www.MillerWelds.com 4-22. Connecting Input Power =GND/PE Earth Ground Tools Needed: 3/8 in. 803 585-C Welding Power Source Input Power Con- Disconnect Device Input Power Connec- Installation must meet all National and nections tions Local Codes −...

  • Page 36: Section 5 − Operation

    A complete Parts List is available at www.MillerWelds.com SECTION 5 − OPERATION 5-1. Controls (350 LX Nameplates Shown) available. Power Switch Top row of lights in upper left corner are Amperage Adjustment Use switch to turn unit Off and On. On for SMAW.

  • Page 37: Output Selector Switch

    A complete Parts List is available at www.MillerWelds.com 5-2. Output Selector Switch Output Selector Switch Do not use AC output in damp areas, if movement is confined, or if there is dan- ger of falling. Use AC output ONLY if required for the welding process, and then use a remote control.

  • Page 38: Output Control

    A complete Parts List is available at www.MillerWelds.com 5-5. Output Control Remote (Standard)Torch Trigger Operation Current (A) Remote (Standard)Torch Trigger Operation Weld Amps Final Slope Initial Amps Final Amps Postflow Preflow Push & Hold Release For Release Foot Or Foot Or Finger Finger Remote Maintained Switch Remote Control...
  • Page 39 A complete Parts List is available at www.MillerWelds.com Trigger Hold (2T) Current (A) 2T Torch Trigger Operation Weld Amps Final Slope Initial Amps Final Amps Postflow Preflow Push & Release Trigger Push & Release Trigger In Less Than 3/4 Sec. In Less Than 3/4 Sec.

  • Page 40: 4T Momentary, And Mini Logic Trigger Operation (Requires Optional Sequence Controls)

    A complete Parts List is available at www.MillerWelds.com 5-6. 4T, 4T Momentary, And Mini Logic Trigger Operation (Requires Optional Sequence Controls) 4T Torch Trigger Operation If unit is equipped with optional Sequence lows the operator to toggle between weld Application: Controls (see Section 5-13), 4T trigger current and final current without breaking Use 4T trigger method when the functions...
  • Page 41 A complete Parts List is available at www.MillerWelds.com Mini Logic Operation If unit is equipped with optional Sequence from the initial amps level to the main weld welding power source. Controls (see Section 5-13), Mini Logic op- amps level by pressing and releasing the Application: This ability to change amper- eration is available.

  • Page 42: Reconfiguring Trigger Hold For 4T And Mini Logic Control

    A complete Parts List is available at www.MillerWelds.com 5-7. Reconfiguring Trigger Hold For 4T And Mini Logic Control Output Control Power Switch To reconfigure Trigger Hold, turn Off power, push and hold Output control button and turn On power switch. Hold button for approximately 7 sec- onds (or until software version num- ber _ _ _ _ _ _-_clears, and meters...

  • Page 43: Selecting Tig Starting Characteristics Using Syncro-Startt Technology

    A complete Parts List is available at www.MillerWelds.com 5-8. Selecting TIG Starting Characteristics Using Syncro-Startt Technology E− −2− Use this function to select desired TIG start- button and turn On power. Hold button for Press torch trigger or turn Off power to save ing characteristics.

  • Page 44: Start Mode

    A complete Parts List is available at www.MillerWelds.com 5-9. Start Mode Lift-Arct Start Method 1 − 2 “Touch” Seconds Do NOT Strike Like A Match! Start Mode onds, and slowly lift electrode. An arc will turns off when arc is started, and turns on form when electrode is lifted.

  • Page 45: Balance/Dig Control

    A complete Parts List is available at www.MillerWelds.com 5-10. Balance/DIG Control Balance/DIG Control Balance Control (AC GTAW): AC Balance controls the cleaning action. Increasing the balance set- ting reduces the oxide cleaning. Adjusting balance: Set the balance level in the AC TIG zone. Make a test weld.

  • Page 46: Preflow Time Control

    A complete Parts List is available at www.MillerWelds.com 5-11. Preflow Time Control 00.4 Use control to set length of time (0.2, 0.4, Turn power off. Push and hold Process Con- time, press and release Process Control 0.6, 0.8, 1.0, 1.5, 2.0, 2.5, 3.0, 3.5, 4.0, 4.5, trol button and turn On power.

  • Page 47: Pulse Controls (Standard On 350 Lx Models, Optional On 250 Dx Models)

    A complete Parts List is available at www.MillerWelds.com 5-12. Pulse Controls (Standard On 350 LX Models, Optional On 250 DX Models) On/Off Control Use control to turn pulse function On and Off. Pulser ON LED LED is lit when pulser function is enabled.

  • Page 48: Sequence Controls (Optional)

    A complete Parts List is available at www.MillerWelds.com 5-13. Sequence Controls (Optional) Initial Time Control See Section 5-14. Initial Amperage Control See Section 5-14. Final Slope Control See Section 5-15. Final Amperage Control See Section 5-15. Spot Time Control See Section 5-16. 5-14.

  • Page 49: Final Slope Control And Final Amperage Control

    A complete Parts List is available at www.MillerWelds.com 5-15. Final Slope Control And Final Amperage Control Final Slope Control Indicator light is on when Final Slope control function is active. Final Slope control function is inactive when Spot Time function is active. Use control to reduce amperage over a set period of time (0−15 seconds) at the end of the weld cycle when NOT...

  • Page 50: Timer/Cycle Counter

    A complete Parts List is available at www.MillerWelds.com 5-17. Timer/Cycle Counter 1 2 3 4 5 6 1 2 3 4 5 6 Amperage Control software number and revision for the first seconds, and are read as 1, 234 hours seven seconds.

  • Page 51: Resetting Unit To Factory Default Settings (All Models)

    A complete Parts List is available at www.MillerWelds.com 5-18. Resetting Unit To Factory Default Settings (All Models) Process Control Amperage Control Output Control Start Control Power Switch To reset all welding power source functions to original factory settings, turn power off. Push and hold the Process, Amperage, Output, and Start controls and turn On power.

  • Page 52: Section 6 − Maintenance

    A complete Parts List is available at www.MillerWelds.com SECTION 6 − MAINTENANCE 6-1. Routine Welding Power Source Maintenance Disconnect power before maintaining. Maintain more often during severe conditions. n = Check Z = Change ~ = Clean = Repair l = Replace * To be done by Factory Authorized Service Agent Every Months...

  • Page 53: Adjusting Spark Gaps

    ~ Coolant Strainer ~ Heat Exchanger Fins Every Months l Unreadable Labels n l Cracked Hoses Z Change Coolant If Using Water (See Section 6-5) Every Twelve Months Z Change Coolant (If Using Miller Cool- ant) (See Section 6-5) OM-363 Page 49...

  • Page 54: Coolant Maintenance

    A complete Parts List is available at www.MillerWelds.com 6-5. Coolant Maintenance Disconnect power before maintaining. Coolant Filter Unscrew housing to clean filter. Changing coolant: Drain coolant by tipping unit forward. Fill with clean water and run for 10 minutes. Drain and refill.

  • Page 55: Section 7 − Troubleshooting

    A complete Parts List is available at www.MillerWelds.com SECTION 7 − TROUBLESHOOTING 7-1. Voltmeter/Ammeter Help Displays −−0 −−2 −−4 −−1 −−3 −−5 −11 −12 −−9 −10 Help 4 Display All directions are in reference to the front of the unit. All cir- Indicates an open in the thermal protection circuitry located on cuitry referred to is located inside the unit.

  • Page 56: Troubleshooting The Welding Power Source

    A complete Parts List is available at www.MillerWelds.com 7-2. Troubleshooting The Welding Power Source NOTICE − The remedies listed below are recommendations only. If these remedies do not fix the trouble with your unit, have a Factory Authorized Service Agent check unit. There are no user serviceable parts inside unit.

  • Page 57: Troubleshooting The Optional Cooler

    A complete Parts List is available at www.MillerWelds.com 7-3. Troubleshooting The Optional Cooler Trouble Remedy Coolant system does not work. Be sure input power cord is plugged in to energized receptacle. Check line fuses or circuit breaker, and replace or reset if necessary. Motor overheated.

  • Page 58: Section 9 − Electrical Diagram

    SECTION 9 − ELECTRICAL DIAGRAM Figure 9-1. Circuit Diagram For 250 DX Models 231 394-C OM-363 Page 54...
  • Page 59 Figure 9-2. Circuit Diagram For 350 LX Models 231 395-B OM-363 Page 55...
  • Page 60 225 650-A Figure 9-3. Circuit Diagram For Optional Cooler OM-363 Page 56...

  • Page 61: Section 10 − High Frequency

    SECTION 10 − HIGH FREQUENCY 10-1. Welding Processes Requiring High Frequency High-Frequency Voltage TIG − helps arc jump air gap between torch and workpiece and/ or stabilize the arc. Work high_freq 5/10 − S-0693 10-2. Installation Showing Possible Sources Of HF Interference Weld Zone 11, 12 50 ft...

  • Page 62: Recommended Installation To Reduce Hf Interference

    10-3. Recommended Installation To Reduce HF Interference Weld Zone 50 ft (15 m) 50 ft (15 m) Ground all metal ob- jects and all wiring in welding zone using #12 AWG wire. Ground workpiece if required by Nonmetal codes. Building Best Practices Followed Metal Building Ref.

  • Page 63: Section 11 − Selecting And Preparing A Tungsten For Dc Or Ac Welding

    SECTION 11 − SELECTING AND PREPARING A TUNGSTEN FOR DC OR AC WELDING gtaw_Phase_2011−06 Whenever possible and practical, use DC weld output instead of AC weld output. 11-1. Selecting Tungsten Electrode ( Wear Clean Gloves To Prevent Contamination Of Tungsten Not all tungsten electrode manufacturers use the same colors to identify tungsten type.
  • Page 64 Notes For additional welding information and resources, visit: www.MillerWelds.com/resources/improving-your skills...
  • Page 65 Notes TM-216 869 Page 2 Dynasty 350/700, Maxstar 350/700...
  • Page 66 Notes...
  • Page 67 Effective January 1, 2012 (Equipment with a serial number preface of MC or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other Warranty Questions? guarantees or warranties expressed or implied. LIMITED WARRANTY − Subject to the terms and conditions 90 Days —...

  • Page 68: Options And Accessories

    Contact the Delivering Carrier to: 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.  ORIGINAL INSTRUCTIONS − PRINTED IN USA 2012 Miller Electric Mfg. Co. 2012−01...

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Syncrowave 350 lx

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