Miller Syncrowave 250 DX Owner's Manual
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Miller Syncrowave 250 DX Owner's Manual

Ce and non-ce model
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Syncrowave 250 DX / 350 LX
CE And Non-CE Models
OM-363
2008−12
Processes
Description
Arc Welding Power Source
R
213117Z
TIG (GTAW) Welding
Stick (SMAW) Welding
File: TIG (GTAW)

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  • Page 1 OM-363 213117Z 2008−12 Processes TIG (GTAW) Welding Stick (SMAW) Welding Description Arc Welding Power Source Syncrowave 250 DX / 350 LX CE And Non-CE Models 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 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING ........1-1.
  • Page 4 TABLE OF CONTENTS SECTION 5 − MAINTENANCE ..............5-1.
  • Page 5 DECLARATION OF CONFORMITY for European Community (CE marked) products. MILLER Electric Mfg. Co., 1635 Spencer Street, Appleton, WI 54914 U.S.A. declares that the product(s) identified in this declaration conform to the essential requirements and provisions of the stated Council Directive(s) and Standard(s).

  • Page 7: Section 1 − Safety Precautions - Read Before Using

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _2007−04 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if Indicates special instructions. not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text.
  • Page 8 D Do not use welder to thaw frozen pipes. FUMES AND GASES can be hazardous. D Remove stick electrode from holder or cut off welding wire at contact tip when not in use. Welding produces fumes and gases. Breathing D Wear oil-free protective garments such as leather gloves, heavy these fumes and gases can be hazardous to your shirt, cuffless trousers, high shoes, and a cap.

  • Page 9: 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 10: California Proposition 65 Warnings

    1-4. California Proposition 65 Warnings For Gasoline Engines: Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to Engine exhaust contains chemicals known to the State of cause birth defects and, in some cases, cancer. (California California to cause cancer, birth defects, or other reproduc- Health &...

  • Page 11: Section 2 − Definitions

    SECTION 2 − DEFINITIONS 2-1. Warning Label Definitions Warning! Watch Out! There are possible Breathing welding fumes can be 3.3 Do not weld on drums or any closed hazards as shown by the symbols. hazardous to your health. containers. 2.1 Keep your head out of the fumes. Arc rays can burn eyes and injure Electric shock from welding electrode skin.

  • Page 12: Symbols And Definitions

    2-3. Symbols And Definitions 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) Background Amps While Welding Output Circuit Breaker Remote Temperature Protective Earth High Frequency - Alternating Current...

  • Page 13: Section 3 − Installation

    SECTION 3 − INSTALLATION 3-1. Serial Number And Rating Label Location The serial number and rating information for the power source is located on the rear of the machine. Use the rating labels to determine input power requirements and/or rated output. For future reference, write serial number in space provided on back cover of this manual. 3-2.

  • Page 14: Dimensions And Weights

    3-3. 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 (559 mm) 20 in (508 mm) 22-1/4 (565 mm) 1-1/8 in (29 mm) 803 616-A...
  • Page 15 B. For 250 DX Models Amperes Input at AC Balanced Rated Rated Load Output, 60 Hz, Single-Phase Peak Starting Rated Welding Amperage Voltage 200V 230V 460V 575V Range (Up) Output (Uo) NEMA Class 17.6 3 − 310A 15 KV I (40) − 200 *3.3 *2.8 *1.5...

  • Page 16: Duty Cycle And Overheating

    3-6. 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 6-1), and cooling fans run. Wait fifteen 250 DX Models minutes for unit to cool.

  • Page 17: Volt-Ampere Curves

    3-7. 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 Non CE Models curves shown. AMPS AMPS 194 385-A / 194 384-A CE Models AMPS...
  • Page 18 B. For 350 LX Models The volt-ampere curves show the minimum and maximum voltage 350 Amperes Models and amperage output capabilities of the welding power source. Curves of other settings fall between the curves shown. ssb1.1 10/91 − ST-190 277 / ST-190 278 OM-363 Page 12...

  • Page 19: Weld Output Terminals And Selecting Cable Sizes

    3-8. Weld Output Terminals And Selecting Cable Sizes 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.

  • Page 20: Remote 14 Receptacle Information

    3-9. 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. C L N Output to remote control;...

  • Page 21: Tig Connections With A Two-Piece Air-Cooled Torch

    3-11. 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 4-2) Switch is shown in DCEN (direct cur- rent electrode negative) position for TIG HF Impulse DCEN welding.

  • Page 22: Front Panel Display For Tig Hf Impulse Dcen (Direct Current Electrode Negative)

    3-13. Front Panel Display For TIG HF Impulse DCEN (Direct Current Electrode Negative) Front Panel NOTE: Green on nameplate indi- For all front panel switch pad cates a TIG function (see Section Correct front panel display for ba- controls: press switch pad to 4-1 for description of controls).

  • Page 23: Front Panel Display For Tig Ac

    3-14. Front Panel Display For TIG AC Front Panel NOTE: Green on nameplate indi- For all front panel switch pad cates a TIG function (see Sec- controls: press switch pad to tion 4-1 for description of con- Correct front panel display for turn on light and enable trols).

  • Page 24: 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 25: Stick Connections

    3-16. 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- tion 3-9).

  • Page 26: Front Panel Display For Stick Dcep (Direct Current Electrode Positive)

    3-17. Front Panel Display For Stick DCEP (Direct Current Electrode Positive) Front Panel NOTE: Gray on nameplate indi- For all front panel switch pad cates a Stick function (see Sec- controls: press switch pad to tion 4-1 for description of con- Correct front panel display for turn on light and enable trols).

  • Page 27: Front Panel Display For Stick Ac

    3-18. Front Panel Display For Stick AC Front Panel NOTE: Gray on nameplate indi- For all front panel switch pad cates a Stick function (see Sec- controls: press switch pad to tion 4-1 for description of con- Correct front panel display for turn on light and enable trols).

  • Page 28: Electrical Service Guide

    3-19. Electrical Service Guide A. For 250 DX Models All values in both tables were calculated at 60% duty cycle. Actual input voltage cannot exceed ± 10% of indicated required input voltage shown in both tables. If actual input voltage is outside of this range, damage to unit may occur.
  • Page 29 B. For 350 LX Models All values in both tables were calculated at 60% duty cycle. Actual input voltage cannot exceed ± 10% of indicated required input voltage shown in both tables. If actual input voltage is outside of this range, damage to unit may occur.

  • Page 30: Placing Jumper Links

    3-20. Placing Jumper Links Disconnect and lockout/tag- Label found on 250 DX models with the following stock numbers: input power before 907194, 907194-021 and, 907194-031 installing or moving jumper links. Label found on 350 LX models with the following stock numbers: 907198, 907198-011, 907198-021, and 907198-031 Check input voltage available at site.

  • Page 31: Connecting Input Power

    3-21. 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 − have only qualified per- sons make this installation. Disconnect Device (switch shown in Strain Relief OFF position)

  • Page 32: Section 4 − Operation

    SECTION 4 − OPERATION 4-1. Controls (350 LX Nameplates Shown) A. For 200/230/460 Volts And Non CE Units ment 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 33 B. For CE Units NOTE: Meters are self-calibrating. No adjust- Power Switch Top row of lights in upper left corner are ment available. Use switch to turn unit Off and On. On for SMAW. Bottom row are On for Amperage Adjustment GTAW.

  • Page 34: Output Selector Switch

    4-2. 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. Do not change position of switch while welding or while under load.
  • Page 35 Notes OM-363 Page 29...

  • Page 36: Output Control

    4-5. Output Control Remote (Standard)Torch Trigger Operation (CE Nameplate) Current (A) Remote (Standard)Torch Trigger Operation Weld Amps Final Slope Initial Amps Final Amps Postflow Preflow Push & Hold Release Foot Or Release For Foot Or Finger Finger Remote Maintained Switch Remote Control Control Output Control...
  • Page 37 Trigger Hold (2T) (CE Nameplate) 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. NOTE: If torch trigger is held more than 3 seconds, operation reverts to Remote Trigger (Standard) mode (see previous page).

  • Page 38: 4T Momentary, And Mini Logoic Trigger Operation (Requires Optional Sequence Controls)

    4-6. 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 4-13), 4T trigger current and final current without breaking Use 4T trigger method when the functions method is available.
  • Page 39 Mini Logic Operation If unit is equipped with optional Sequence from the initial amps level to the main weld the welding power source. Controls (see Section 4-13), Mini Logic op- amps level by pressing and releasing the Application: This ability to change amper- eration is available.

  • Page 40: Reconfiguring Trigger Hold For 4T And Mini Logic Control

    4-7. 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 Front Panel display [SEL] [H−2].
  • Page 41 (CE Nameplate) Front Panel = 4T Momentary = Mini Logic = 4T (See Section 4-6) (See Section 4-6) (See Section 4-6) H‐4E OM-363 Page 35...

  • Page 42: Selecting Tig Starting Characteristics Using Syncro-Startt Technology

    4-8. Selecting TIG Starting Characteristics Using Syncro-Startt Technology Use this function to select desired TIG start- turn On power. Hold button for approximately Press torch trigger or turn Off power to save ing characteristics. 7 seconds (or until software version number_ setting.
  • Page 43 (CE Nameplate) OM-363 Page 37...

  • Page 44: Start Mode

    4-9. Start Mode (CE Nameplate) 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. whenever arc is broken to help restart arc.

  • Page 45: Balance/Dig Control

    4-10. Balance/DIG Control Balance/DIG Control (CE Nameplate) Balance Control (AC GTAW): Control changes the AC output square wave. Rotating the control towards 10 provides deeper pene- 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.

  • Page 46: Preflow Time Control

    4-11. Preflow Time Control 00.4 Use control to set length of time (0.2, 0.4, 0.6, Turn power off. Push and hold Process Con- time, press and release Process Control but- 0.8, 1.0, 1.5, 2.0, 2.5, 3.0, 3.5, 4.0, 4.5, 5.0 trol button and turn On power.
  • Page 47 (CE Nameplate) 00.4 OM-363 Page 41...

  • Page 48: Pulse Controls (Standard On 350 Lx Models, Optional On 250 Dx Models)

    4-12. Pulse Controls (Standard On 350 LX Models, Optional On 250 DX Models) On/Off Control Use control to turn pulse function On and Off. Background Amps Use Background Amps control to set the low pulse of the weld amper- age, which cools the weld puddle and affects overall heat input.

  • Page 49: Sequence Controls (Optional)

    4-13. Sequence Controls (Optional) Initial Time Control See Section 4-14. Initial Amperage Control See Section 4-14. Final Slope Control See Section 4-15. Final Amperage Control See Section 4-15. Spot Time Control See Section 4-16. (CE Nameplate) OM-363 Page 43...

  • Page 50: Initial Time Control And Initial Amperage Control

    4-14. Initial Time Control And Initial Amperage Control Initial Time Control Indicator light is on when Initial Time control function is active. (CE Nameplate) NOTE: Initial Sequence control function is inactive when Spot Time function is active. Use control to select 0−15 seconds of start time.

  • Page 51: Final Slope Control And Final Amperage Control

    4-15. Final Slope Control And Final Amperage Control Final Slope Control Indicator light is on when Final Slope control function is active. (CE Nameplate) Note: 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 using a remote current control.

  • Page 52: Timer/Cycle Counter

    4-17. Timer/Cycle Counter 1 2 3 4 5 6 1 2 3 (CE Nameplate) 4 5 6 Amperage Control software number and revision for the first seconds, and are read as 1, 234 hours seven seconds. It will then show arc time and 56 minutes.

  • Page 53: Resetting Unit To Factory Default Settings (All Models)

    4-18. Resetting Unit To Factory Default Settings (All Models) (CE Nameplate) Process Control Power Switch Output, and Start controls and turn On pow- er. Hold switch pads for approximately 7 Amperage Control To reset all welding power source functions seconds (or until software version number Output Control to original factory settings, turn power off.

  • Page 54: Section 5 − Maintenance

    SECTION 5 − MAINTENANCE 5-1. Routine Welding Power Source Maintenance 5-2. Routine Maintenance Disconnect power before maintaining. Maintain more often during severe conditions. Δ = Repair n = Check Z = Change ~ = Clean l = Replace * To be done by Factory Authorized Service Agent Every Months ~ Weld Terminals...

  • Page 55: Adjusting Spark Gaps

    5-4. Adjusting Spark Gaps Turn Off welding power source and disconnect and lockout/tagout input power before adjusting spark gaps. Remove right side panel.. 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 56: Section 6 − Troubleshooting

    SECTION 6 − TROUBLESHOOTING 6-1. Voltmeter/Ammeter Help Displays 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. the rectifier assembly of the unit.

  • Page 57: Troubleshooting The Welding Power Source

    6-2. 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. Refer to Section 6-1 for any Help (HLP) message displayed on voltmeter/ammeter.

  • Page 58: Routine Maintenance For Optional Cooler

    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) 6-4. Troubleshooting The Optional Cooler Trouble Remedy Coolant system does not work. Be sure input power cord is plugged in to energized receptacle.

  • Page 59: Coolant Maintenance And Oiling Motor

    6-5. Coolant Maintenance And Oiling Motor 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. If replacing hoses, use hoses compatible with ethylene gly- col, such as Buna-n, Neo- prene, or Hypalon.

  • Page 60: Section 7 − Electrical Diagram

    SECTION 7 − ELECTRICAL DIAGRAM 231 394-B Figure 7-1. Circuit Diagram For 250 DX Models OM-363 Page 54...
  • Page 61 Figure 7-2. Circuit Diagram For 350 LX Models 231 395-B OM-363 Page 55...
  • Page 62 225 650-A Figure 7-3. Circuit Diagram For Optional Cooler OM-363 Page 56...

  • Page 63: Section 8 − High Frequency

    SECTION 8 − HIGH FREQUENCY 8-1. 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 12/96 − S-0693 8-2. Incorrect Installation Weld Zone 11, 12 50 ft (15 m) Sources of Direct High-Frequency...

  • Page 64: Correct Installation

    8-3. Correct Installation 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 codes. Nonmetal Building Metal Building Ref. S-0695 / Ref. S-0695 High-Frequency Source (welding Conduit Joint Bonding and Grounding Metal Building Requirements...

  • Page 65: Section 9 − Selecting And Preparing A Tungsten For Dc Or Ac Welding

    SECTION 9 − SELECTING AND PREPARING A TUNGSTEN FOR DC OR AC WELDING gtaw_Phase_2007−04 Whenever possible and practical, use DC weld output instead of AC weld output. 9-1. Selecting Tungsten Electrode ( Wear Clean gloves To Prevent Contamination Of Tungsten ♦...

  • Page 66: Section 10 − Guidelines For Tig Welding (Gtaw)

    SECTION 10 − GUIDELINES FOR TIG WELDING (GTAW) 2007−04 10-1. Positioning The Torch Grinding the tungsten elec- trode produces dust and fly- ing sparks which can cause injury and start fires. Use lo- cal exhaust (forced ventila- tion) at the grinder or wear an approved respirator.

  • Page 67: Torch Movement During Welding

    10-2. Torch Movement During Welding Tungsten Without Filler Rod ° Welding direction Form pool Tilt torch Move torch to front of pool. Repeat process. Tungsten With Filler Rod ° ° Welding direction Form pool Tilt torch Add filler metal Remove rod Move torch to front of pool.

  • Page 68: Positioning Torch Tungsten For Various Weld Joints

    10-3. Positioning Torch Tungsten For Various Weld Joints ° Butt Weld And Stringer Bead ° ° ° “T” Joint ° ° ° ° Lap Joint ° ° ° ° Corner Joint ° ° ST-162 003 / S-0792 OM-363 Page 62...
  • Page 69 Notes OM-363 Page 63...

  • Page 70: Section 11 − Parts List

    SECTION 11 − PARTS LIST Hardware is common and not available unless listed. 350 LX Model Illustrated Figure 11-1. Main Assembly OM-363 Page 64...
  • Page 71 350 LX Model Illustrated 803 804-L OM-363 Page 65...
  • Page 72 Item Dia. Part Quantity Mkgs. Description Model Figure 11-1. Main Assembly ... . . 211 038 BASE, ASSY ........... . .
  • Page 73 199 479 LABEL, MILLER ..........
  • Page 74 Item Dia. Part Quantity Mkgs. Description Model Figure 11-1. Main Assembly (continued) ♦♦ 195 345 CIRCUIT CARD ASSY, SEQUENCER (INCLUDES) ..... .
  • Page 75 Hardware is common and not available unless listed. 803 775-A Figure 11-2. Panel, Lower Dinse Connector Assembly Item Dia. Part Mkgs. Description Quantity 220 509 Figure 11-2. Panel, Lower Dinse Connector Assy (Figure 11-1 Item 21) ... . . 213 109 PANEL, LOWER DINSE CONN .
  • Page 76 Hardware is common and not available unless listed. Ref. 803 725-C Figure 11-3. Optional Running Gear Item Dia. Part Mkgs. Description Quantity Figure 11-3. Running Gear (Optional) (Figure 11-1 Item 104) ... . . 218 134 HANDLE, LH .
  • Page 77 Hardware is common and not available unless listed. 805 016-C Figure 11-4. Factory Optional Running Gear For CS Cooler Item Dia. Part Mkgs. Description Quantity Figure 11-3. Factory Optional Running Gear For Models CS Cooler ... . . 218 134 HANDLE, LH .

  • Page 78: Section 12 − Parts List For Optional Cooler

    SECTION 12 − PARTS LIST FOR OPTIONAL COOLER Hardware is common and not available unless listed. 804 995-A Figure 12-1. Main Assembly OM-363 Page 72...
  • Page 79 Item Dia. Part Mkgs. Description Quantity Figure 12-1. Main Assembly ... . . 213 072 Fan, Muffin 115 V 60 Hz 3400 RPM 6.378 Mtg Holes ....
  • Page 80 Notes...
  • Page 81 Effective January 1, 2008 (Equipment with a serial number preface of LJ 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...

  • Page 82: 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. © PRINTED IN USA 2008 Miller Electric Mfg. Co. 2008−01...

This manual is also suitable for:

Syncrowave 350 lx907408907409

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