Miller Electric SYNCROWAVE 250 User 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 Values (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

dec_con1 10/95

Declaration of Conformity For

European Community (CE) Products

This information is provided for units with CE certification (see rating label on unit.)

NOTE

Manufacturer’s Name: Miller Electric Mfg. Co.

Manufacturer’s Address: 1635 W. Spencer Street

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

TM-353 Page 1Syncrowave 250

SECTION 1 – SAFETY PRECAUTIONS FOR SERVICING

safety_stm1 4/95

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 ELECTRIC SHOCK, MOVING PARTS,

and HOT PARTS 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

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.

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.

WARNING

TM-353 Page 2 Syncrowave 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.

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.

1-3. EMF Information

Considerations About Welding And The Effects Of Low Frequency

Electric And Magnetic 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, it 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 3Syncrowave 250

SECTION 2 – DEFINITIONS

2-1. Warning Label Definitions

S-176 254-A

1 1.1 1.2

1.3

3 3.1 3.2 3.3

4 4.1

+

2

2.1

2.2

+

5 6

+

2.3

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.

TM-353 Page 4 Syncrowave 250

2-2. Rating Label For CE Products

S-178 813-A

ISO/IEC 974-1

X 25% 60% 100%

7A/10.2V 310A/22.4V

U

0

= 80V

I

2

310A 200A 155A

U

2

22.4V 18V 16.2V

X 25% 60% 100%

5A/20.2V 310A/32.4V

U

0

= 80V

I

2

310A 200A 155A

U

2

32.4V 28V 26.2V

IP 21S

U

1

= 220 I

1max

= 117.2A I

1Eff

= 59A

1

50 Hz

U

1

= 380 I

1max

= 72.2A I

1Eff

= 36A

U

1

= 415 I

1max

= 63.8A I

1Eff

= 32A

TM-353 Page 5Syncrowave 250

2-3. Symbols And Definitions

Some symbols are found only on CE products.

NOTE

A

Amperes Panel–Local

Gas Tungsten Arc

Welding (GTAW)

Shielded Metal Arc

Welding (SMAW)

V

Volts

Do Not Switch

While Welding

Arc Force (DIG) Spot Timer

Output Circuit Breaker Remote Temperature

Protective Earth

(Ground)

Alternating Current

High Frequency -

Start

Input

Postflow Timer Preflow Timer

High Frequency -

Continuous

High Frequency

Gas (Supply) Gas Input Gas Output

Increase/Decrease

Of Quantity

On Off Percent Direct Current

Balance Control Maximum Cleaning

Maximum

Penetration

Electrode Positive

Electrode

Negative

Crater Time Meter Single-Phase

U

0

Rated No Load

Voltage (Average)

U

1

Primary Voltage

U

2

Conventional Load

Voltage

Line Connection

I

1

Primary Current

I

2

Rated Welding

Current

X

Duty Cycle

1

Single-Phase

Combined AC/DC

Power Source

IP

Degree Of

Protection

I

1eff

Maximum Effective

Supply Current

I

1max

Rated Maximum

Supply Current

Hz

Hertz

Electrode Work Thickness Gauge Spark Gap

S

Seconds

TM-353 Page 6 Syncrowave 250

SECTION 3 – INSTALLATION

3-1. Specifications

Amperes Input at AC Balanced

Rated Load Output,

50/60 Hz, Single-Phase

Rated

Welding Output

PFC**

200 V 230 V 460 V 575 V

KVA KW

Amp

Range

Max

OCV

IP

Rating

NEMA Class II

(40) – 250

No

PFC

106

(4.6*)

92

(4*)

46

(2*)

37

(1.6*)

21

(0.89*)

11.4

(0.68*)

Amperes, 30 Volts

AC, 40% Duty

Cycle

With

PFC

76 66 33 26 15.2 11.4

5–310 A 80 V 21

*While idling

**Power Factor Correction

Rated

Amperes Input at AC Balanced

Rated Load Output,

50/60 Hz, Single-Phase

Rated

Welding

Output

PFC

**

200

V

220

V

230

V

260

V

380

V

415

V

460

V

520

V

575

V

KVA KW

Amp

Range

Max

OCV

IP

Rating

NEMA

Class I

(60) – 200

No

PFC

85

(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*)

8.3

(0.7*)

Amperes,

28 Volts

AC, 60%

Duty Cycle

With

PFC

55

(57*)

64

(51*)

48

(49*)

48

(49*)

37

(30*)

34

(27*)

24

(25*)

48

(49*)

19

(20*)

11

(11*)

8.3

(0.6*)

5–310 A 80 V 21

*While idling

**Power Factor Correction

3-2. 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.

ssb1.1 10/91 – SB-116 199 / SB-116 200

A. DC Mode

B. AC Mode

TM-353 Page 7Syncrowave 250

3-3. Duty Cycle And Overheating

4 Minutes Welding 6 Minutes Resting

6 Minutes Welding 4 Minutes Resting

Duty Cycle is percentage of 10 min-

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 be-

fore welding.

Y Exceeding duty cycle can

damage unit and void

warranty.

40% Duty Cycle At 250 Amperes (60 Hz Models Only)

Overheating

0

15

A

OR

Reduce Duty Cycle

Minutes

duty1 4/95 / SB-116 198

60% Duty Cycle At 200 Amperes

TM-353 Page 8 Syncrowave 250

3-4. Selecting A Location

1 Lifting Eye

2 Lifting Forks

Use lifting eye or lifting forks to

move unit.

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 20.

1

2

Movement

ST-800 402 / ST-117 264-F

6

18 in (460

mm)

Location And Airflow

OR

18 in (460

mm)

3

5

4

3-5. Dimensions And Weights

Dimensions

A

Height 30-3/4 in (781 mm)

B

C

Width 19-3/4 in (502 mm)

E

D

Length 27-1/2 in (698 mm)

A 27 in (686 mm)

B 26 in (661 mm)

F

C 25-1/4 in (642 mm)

F

Front

D 1-1/2 in (38 mm)

G

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

Weight

ST-154 792-B

355 lbs (161 kg)

TM-353 Page 9Syncrowave 250

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

100 ft (30 m) Or Less

150 ft

(45 m)

200 ft

(60 m)

250 ft

(70 m)

300 ft

(90 m)

350 ft

(105 m)

400 ft

(120 m)

Weld Output

Terminals

Welding

Amperes

10 – 60%

Duty

Cycle

60 – 100%

Duty

Cycle

10 – 100% Duty Cycle

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

350 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0 2-4/0

400 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 2-4/0

ElectrodeWork

ST-154 795-C

500 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 3-3/0 3-3/0

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 dis-

tributor for the mm

2

equivalent weld cable sizes. S-0007-E

TM-353 Page 10 Syncrowave 250

3-8. Remote 14 Receptacle

Socket* Socket Information

A 24 volts ac.

B Contact closure to A completes 24 volts ac contactor control

circuit.

C Command reference; 0 to +10 volts dc output to remote control.

AJ

B

K

I

D Remote control circuit common.

C

L

NH

D

M

G

F

A

E 0 to +10 volts dc input command signal from remote control.

E

F

ST-154 795-C

K Chassis common.

*The remaining sockets are not used.

3-9. 115 Volts AC Duplex Receptacle And Shielding Gas Connections

Ref. ST-154 795-C / Ref. ST-157 858

Y Turn Off power before

connecting to receptacle.

1 115 V AC Receptacle

Receptacle is protected from over-

load 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)

4

5

6

1 7

3 2

TM-353 Page 11Syncrowave 250

3-10. Electrical Service Guide

All values calculated at 60% duty cycle.

NOTE

60 Hertz Models

Without Power Factor

Correction

With Power Factor Correction

Input Voltage

200 230 460 575 200 230 460 575

Input Amperes At Rated Output

85 74 37 30 55 48 24 19

Max Recommended Standard Fuse Or Circuit

Breaker Rating In Amperes

125 110 60 45 80 70 35 30

Min Input Conductor Size In AWG/Kcmil

4 6 10 10 8 8 12 14

Max Recommended Input Conductor Length

In Feet (Meters)

173

(53)

158

(48)

291

(89)

455

(139)

86

(26)

114

(35)

186

(58)

189

(48)

Min Grounding Conductor Size In AWG/Kcmil

6 6 10 10 8 8 12 14

Reference: 1996 National Electrical Code (NEC) S-0092-J

50 Hertz Models Without Power Factor Correction

With Power Factor

Correction

Input Voltage

220 260 380 415 520 220 380 415

Input Amperes At Rated Output

77 65 45 41 33 64 37 34

Max Recommended Standard Fuse Or Circuit

Breaker Rating In Amperes

125 100 70 60 50 90 60 50

Min Input Conductor Size In AWG/Kcmil

6 6 8 8 10 6 10 10

Max Recommended Input Conductor Length

In Feet (Meters)

145

(44)

202

(62)

291

(89)

347

(106)

372

(113)

145

(44)

291

(89)

347

(106)

Min Grounding Conductor Size In AWG/Kcmil

6 8 8 10 10 6 8 10

Reference: 1996 National Electrical Code (NEC) S-0092-J

TM-353 Page 12 Syncrowave 250

1

3-11. Placing Jumper Links And Connecting Input Power

ST-117 263-K

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 la-

bel inside your unit. Do not

make connections for any

other voltages. If jumper link

label is missing from inside

unit, check rating label (see

Section 3-4) for allowable in-

put 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 20.

3/8 in

3/8, 1/2, 7/16 in

Tools Needed:

230 VOLTS

LL

460 VOLTS

LL

S-010 587-B

575 VOLTS

LL

230 VOLTS 460 VOLTS200 VOLTS

LL LL LL

S-083 566-C

2

L1 (U)

L2 (V)

GND/PE

Earth Ground

4

3

220 VOLTS

LL

380 VOLTS

LL

S-131 783-A

415 VOLTS

LL

Connect GND/PE

Conductor First

Connect GND/PE

Conductor First

S-047 672-A

260 VOLTS

LL

380 VOLTS

LL

520 VOLTS

LL

TM-353 Page 13Syncrowave 250

SECTION 4 – OPERATION

4-1. Controls

Ref. ST-117 264-F / Ref. ST-154 795-C

15

14

13

12

11

10

9

87

6

5

4

3

2

1

1 Ammeter

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.

TM-353 Page 14 Syncrowave 250

4-2. Output Selector Switch

Ref. ST-181 675-A

1 Output Selector Switch

Y 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.

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.

1

4-3. Meters

1 Voltmeter

Voltmeter displays voltage at the

weld output terminals, but not nec-

essarily the welding arc due to

cable resistance, poor connec-

tions, etc.

2 Ammeter

Ammeter displays weld amperage

output of unit.

1 2

TM-353 Page 15Syncrowave 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

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.

2

1

4-5. Spot Time Controls

1 Spot Time Switch

Place switch in the ON position to

turn on spot weld circuitry.

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 do-

ing Shielded Metal Arc Welding

(SMAW).

2 Spot Time Control

Use control to set time (0–5.7 sec-

onds) for Gas Tungsten Arc

(GTAW) spot welds. Spot time be-

gins at arc initiation. If the arc is bro-

ken 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.

1

2

TM-353 Page 16 Syncrowave 250

4-6. AC Balance Control

Ref. S-0795-A

1 AC Balance Control

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.

Application:

When welding on oxide forming ma-

terials such as aluminum or magne-

sium, excess cleaning is not neces-

sary. 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 nec-

essary. Joint configuration, set-up,

process variables, and oxide thick-

ness 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.

Balanced

3

10

0

More Penetration

More Cleaning

50% Electrode

Positive

50% Electrode

Negative

32% Electrode

Positive

68% Electrode

Negative

55% Electrode

Positive

45% Electrode

Negative

Output Waveforms ArcSetting

1

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