Miller Electric SYNCROWAVE 250 Page 80 Technical Manual Download

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TM-353 Page 76

Syncrowave 250

Figure 10-6. Control Panel, Lower Front (Continued)

Description

Quantity

Part

No.

Dia.

Mkgs.

Item

No.

126 750

CAPACITOR ASSEMBLY, (Eff w/JK537589 thru JK690986)

. . .

. . . . . . . . . . . . .

. .

. . . . . . . . . . .

C14

098 566

CAPACITOR, (Prior to JK537589)

. . .

. . . .

. . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C14

132 433

CAPACITOR, (Eff w/JK690987)

. . .

. . . .

. . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

121 270

RECEPTACLE/CAPACITOR,w/leads (Prior to JK682714)

. . . . . . . . . . . . . . . . . . .

. .

(consisting of)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RC2

035 523

CONNECTOR, circ 5skt rcpt Amphenol MS-3102A-16S-8S

. . . . . . . . . .

. . .

. . . .

. . . . . . . . .

C16-19

119 856

CAPACITOR

. . . . . . . . .

. . .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PC2/RFC1

121 273

CIRCUIT CARD, snubber

. . . . . . .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

039 273

CONNECTOR, circ 5 pin size 16S plug Amphenol MS-3106A-16S-8P

. . . . . . . . . . . . . . . . . . .

. .

039 685

CONNECTOR, circ clamp str rlf size 16 Amphenol 97-3057-8

. . . . . . . . . . . . . . . . . . .

. .

142 523

CONNECTOR/CAPACITOR, w/leads (Eff w/JK674521 thru

. . . . . . . . . . . . . . . . . . .

. .

KF959378) (consisting of)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RC2

143 976

CONNECTOR w/SOCKETS

. . . . . . . . . .

. . .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C16

143 899

LEAD ASSY, elect

. . . . . . . . . .

. . .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C17

143 897

LEAD ASSY, elect

. . . . . . . . . .

. . .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C18

143 898

LEAD ASSY, elect

. . . . . . . . . .

. . .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C19

143 900

LEAD ASSY, elect

. . . . . . . . . .

. . .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RFC1/PC2

142 522

CHOKE

. . . . . . .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PC2/RC1

157 959

CIRCUIT CARD ASSEMBLY, (Eff w/KF959379) (consisting of)

. . .

. .

. . . . . . . .

PLG21

153 501

CONNECTOR & SOCKETS

. . . . . . . . .

. .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

134 734

CONNECTOR, circ 14 pin size 20 plug Amp 213571-2

. . . . . . . . . . . . . . . . . . .

. .

079 534

CONNECTOR, circ skt push-in 14-18ga Amp 66358-6

. . . . . . . . . . . . . . . . . . .

. .

079 739

CONNECTOR, circ clamp str rlf size 17-20 Amp 206322-2

. . . . . . . . . . . . . . . . . . .

. .

164 290

CAPACITOR, polyp film 3.5uf 600VDC

. . .

. . . . .

. . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG3

131 204

CONNECTOR & SOCKETS

. . .

. . . .

. . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RC2

604 176

RECEPTACLE, straight duplex grd 2P3W 15A 125V

. . .

. . . .

. . .

. .

. . . . . . . . . . . . . . . . .

073 690

CAP, straight P & S 2P3W 5266 DF

. . . . . . . . . . . . . . . . . . .

. .

C15

170 920

CAPACITOR

. . .

. . . .

. . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CB1

093 995

CIRCUIT BREAKER, man reset 1P 15A 250V

. . .

. . . .

. . .

. .

. . . . . . . . . . . . . . . . . . . . . . .

R13

605 828

RHEOSTAT, WW 50W 1.5 ohm (Prior to KG170301)

. . .

. . . .

. . .

. .

. . . . . . . . . . . . . . . . .

R13

174 037

RHEOSTAT, WW 50W 1.5 ohm (Eff w/KG170301 thru LA292998)

. . .

. . . .

. . .

. .

. . . . .

R13

198 547

RHEOSTAT, WW 25W 1.5 ohm (Eff w/LA292999)

. . .

. . . .

. . .

. .

. . . . . . . . . . . . . . . . . . .

010 493

BUSHING, snap-in nyl .625 ID x .875 mtg hole

. . . . . . . . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . .

♦♦

020 623

SPARK GAP ASSEMBLY (Prior to LA337284)

. . .

. . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . .

♦♦

095 621

BASE, spark gap (Prior to LA337284)

. . . . . . . . . . . . . . . .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦♦

020 622

HOLDER, points (Prior to LA337284)

. . . . . . . . . . . . . . . .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦♦

*020 603

POINT, spark gap (Prior to LA337284)

. . . . . . . . . . . . . . . .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . .

♦♦

203 419

SPARK GAP ASSEMBLY SERVICE KIT (for units prior to LA337284))

. . .

. . . . . .

. .

♦♦

199 854

SPARK GAP ASSEMBLY (Eff w/LA337284)

. . .

. . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . .

♦♦

199 855

BASE, spark gap (Eff w/LA337284)

. . . . . . . . . . . . . . . .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦♦

199 856

HOLDER, points (Eff w/LA337284)

. . . . . . . . . . . . . . . .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦♦

*196 455

POINT, spark gap (Eff w/LA337284)

. . . . . . . . . . . . . . . .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

088 731

BUSHING, snap-in nyl .375 ID x .500mtg hole

. . . . . . . . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . .

097 712

STRIP, insulator

. . .

. . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

174 070

BRACKET, mtg components (Eff w/KG959379)

. . .

. . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . .

106 935

CAPACITOR, polyp film 10uf 250VAC (Prior to KK001554)

. . .

. . . . .

. . . .

. .

. . . . . . . . . . . .

191 944

CAPACITOR, polyp film 10uf 250VAC (Eff w/KK001554)

. . .

. . . . .

. . . .

. .

. . . . . . . . . . . . . .

083 784

RESISTOR, WW fxd 100W 10 ohm (Prior to KG170301)

. . .

. . . . .

. . . .

. .

. . . . . . . . . . . . .

181 107

RESISTOR ASSEMBLY w/LEADS, (Eff w/KG170301)

. . .

. . . . .

. . . .

. .

. . . . . . . . . . . . . . . .

096 761

CAPACITOR, mica .002uf 10000V (CE Models Only)

. . .

. . . . .

. . . .

. .

. . . . . . . . . . . . . . . .

096 761

CAPACITOR, mica .002uf 10000V

. . .

. . . . .

. . . .

. .

(Prior to KK001554 for nonCE Models)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

201 197

CAPACITOR, polyp met film .002uf 10000VDC/4400VAC pnl mtg

. . .

. . . . .

. . . .

. .

(Eff w/KK001554 for nonCE Models)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

000 681

STRIP, mtg HF coil (Prior to JK572898)

. . . . . . . . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

124 649

STRIP, mtg HF coil (Eff w/JK572898)

. . . . . . . . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

000 682

TUBING, fiber vulc .250 ID x .312 OD x .812 (Prior to JK572898)

. . . . . . . . . . . . . . . . . . .

. .

. . . . . .

125 949

TUBING, fiber vulc .250 ID x .312 OD x 1.125 (Eff w/JK572898)

. . . . . . . . . . . . . . . . . . .

. .

. . . . . . .

074 398

TRANSFORMER, high voltage 115V pri 3600V sec 30mA

. . .

. . . . .

. . . .

. .

. . . . . . . . . . . .

Summary of Contents for SYNCROWAVE 250

Page 1: ...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 ...

Page 2: ...ent 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 Informa...

Page 3: ...EC 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 ...

Page 4: ......

Page 5: ...e 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 servicin...

Page 6: ...l 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 frequen...

Page 7: ... 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 o...

Page 8: ...A ISO IEC 974 1 X 25 60 100 7A 10 2V 310A 22 4V U0 80V I2 310A 200A 155A U2 22 4V 18V 16 2V X 25 60 100 5A 20 2V 310A 32 4V U0 80V I2 310A 200A 155A U2 32 4V 28V 26 2V IP 21S U1 220 I1max 117 2A I1Eff 59A 1 1 1 50 Hz U1 380 I1max 72 2A I1Eff 36A U1 415 I1max 63 8A I1Eff 32A ...

Page 9: ...uency 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 U0 Rated No Load Voltage Average U1 Primary Voltage U2 Conventional Load Voltage Line Connection I1 Primary Current I2 Rated Welding Current X Duty Cycle ...

Page 10: ...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 Cor...

Page 11: ... 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 Am...

Page 12: ...e 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 ...

Page 13: ...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...

Page 14: ...ining 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 ...

Page 15: ...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...

Page 16: ... 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 L L 460 VOLTS L L S...

Page 17: ... 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 ...

Page 18: ...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 tio...

Page 19: ...ontrols 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 Tungs...

Page 20: ...leaning 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 increas...

Page 21: ...perage see Sec tion 4 5 2 Amperage Control Switch Use switch to select way of control ling amperage adjustment For front panel control place switch in the PANEL position For remote control place switch in REMOTE 14 position and connect remote control device see Section 3 8 1 2 4 8 Output Contactor Control Switch Y Weld output terminals are energized when Output Contactor switch is On and Power is ...

Page 22: ... Place switch in the OFF position while performing Gas Tungsten Arc Welding GTAW Application Control helps arc starting or making vertical or overhead welds by in creasing amperage at low arc volt age and reduces electrode sticking while welding 2 1 4 10 Postflow Time Control 1 Postflow Time Control Use control to set length of time 0 70 seconds gas flows after welding stops It is important to set...

Page 23: ...ired OFF provides no HF Use OFF for SMAW stick electrode welding CONTINUOUS Down position provides HF continuously through out the weld Application HF Continuous is used when the AC GTAW process is required 2 High Frequency Intensity Control Use control to change amount of HF energy used to start and main tain the arc Set as low as practical to prevent interfering with electronic equipment 1 2 4 1...

Page 24: ...Control R3 Controls changes to ac output square wave 11 Ammeter A1 And Voltmeter V1 Display weld amperage and volt age while welding 12 Amperage Control Switch S5 And Adjustment Control R1 R1 selects weld output amperage when S5 is in Panel 13 Remote 14 Filter Board PC2 Remote 14 Receptacle RC1 PC2 protects unit from high fre quency and RC1 connects remote amperageand contactor controls to power s...

Page 25: ...ain Rectifier SR1 Changes the ac output from T1 to full wave rectified dc 24 Background Power Source Provides reduced weld output rip ple at low weld output levels 25 Stabilizer Z1 Smooths dc welding current 26 Hall Device HD1 Provides current feedback signal to PC1 through line filter FL1 27 Line Filter FL1 Filters current feedback signal 28 Output Selector Switch S4 Provides either AC or DC and ...

Page 26: ...contacts Repair or replace S8 if neces sary Check SR1 and replace necessary components If components are replaced check capacitors C7 thru C10 Replace capacitor s if necessary Check control board PC1 and connections and replace if necessary Effective with Serial No KB110695 check resistance and connections of HD1 HD1 is 1600 ohms 10 between pins 1 and 3 of plug PLG3 Check input and output voltages...

Page 27: ...if necessary If any SCRs are replaced Check capac itors C7 through C10 for a short or open and check for proper connections Replace C7 through C10 if necessary No crater fill time Check position of Crater switch S7 see Section 4 4 Check position of Crater control R11 see Section 4 4 Be sure arc voltage is below 24 volts see Section 3 2 Volt Ampere Curves Check position of Amperage Control switch S...

Page 28: ...3 and replace if necessary Optional spot timer relay TD2 does not time out Place Spot Time switch S8 in the On position Remove jumper link 2 from terminal strip 1T Place Spot Time control R10 in desired position Check coil voltage and connections of spot timer relay TD2 Check continuity of coil and condition of contacts Replace TD2 if necessary Check coil voltage and connections of control relay C...

Page 29: ...hten all gas fittings if necessary Increase gas flow setting Shield weld zone from drafts Properly prepare tungsten Place High Frequency switch S2 in Start or Continuous position Wandering arc poor control of direc tion of arc Use proper size tungsten for welding application Properly prepare tungsten Controls connected to Remote 14 receptacle RC1 do not work properly Check repair or replace remote...

Page 30: ...V6 V13 V14 V15 V16 Link 1 Link 2 V7 V8 V9 V10 V11 V17 V12 R1 R1 See Section 3 8 for RC1 information TD1 begins to time out when CR5 deenergizes TD3 begins to time out when CR4 energizes See Figure 9 19 for PC3 circuit CR3 energizes during spot time when an arc is detected CR4 energizes when remote contactor switch closes CR2 energizes when remote contactor switch closes See Section 6 6 for PC2 dat...

Page 31: ...lts ac V8 V9 18 volts ac V10 10 volts ac V11 80 volts dc V12 V13 V14 115 volts ac V15 V16 V17 24 volts ac V18 115 volts ac with S2 in Start or Con tinuous V19 0 to 10 volts dc with contactor on V20 V21 24 volts dc V22 0 80 volts dc rec tified arc voltage V23 maximum 80 volts ac dc V24 24 volts dc V25 16 5 millivolts dc per 1 ampere of weld output CR1 energizes when open circuit voltage is present ...

Page 32: ...rtz models are similar 5 ms 1 V A SR1 Gate Pulse With Respect To Cathode At No Load 5 ms 50 V B DC Open Circuit Voltage With Amperage Adjustment Control At Maximum 5 ms 20 V C DC Output 100 Amperes 24 Volts DC Resistive Load 5 ms 50 V D AC Open Circuit Voltage With Amperage Adjustment Control At Maximum gnd gnd gnd gnd ...

Page 33: ...TM 353 Page 29 Syncrowave 250 Test Equipment Needed 5 ms 50 V E AC Output 100 Amperes 24 Volts AC Re sistive Load gnd ...

Page 34: ...able high frequency by placing High Frequency switch S2 in Off position before testing unit Be sure plugs are secure before testing See Section 6 5 for specific values during testing 1 Control Board PC1 2 Receptacle RC51 3 Receptacle RC52 4 Receptacle RC53 5 Receptacle RC54 6 Receptacle RC55 Test Equipment Needed 1 2 3 4 5 6 ...

Page 35: ...t to pin 8 see Section 6 3 8 Reference for gate pulse to SCR4 RC54 1 Not used 2 0 to 10 volts dc input from min to max of Amperage Adjustment control R1 with Amperage Control switch S5 in Panel position and contactor on 3 0 volts with Output Contactor switch S3 in On position or 7 8 volts dc with S3 in Remote position 4 0 to 10 volts dc input from min to max of Crater Control R11 with Crater Fill ...

Page 36: ... 5 10 volts ac input for synchronization 6 5 8 volts dc output 7 15 volts dc input from Max Penetration setting of AC Balance control R3 to 5 8 volts dc input at Max Cleaning setting of R3 8 0 to 80 volts dc voltage feedback signal rectified arc voltage with respect to pin 9 9 0 to 80 volts dc voltage feedback signal rectified arc voltage with respect to pin 8 10 0 to 4 volts dc input from min to ...

Page 37: ...high frequency by placing High Frequency switch S2 in Off position before testing unit Be sure plugs are secure before testing See Section 6 7 for specific values during testing 1 Remote 14 Filter Board PC2 2 Remote 14 receptacle RC1 See Section 3 8 for information 3 Receptacle RC2 4 Receptacle RC3 Test Equipment Needed 2 3 1 4 ...

Page 38: ... completes 24 volts ac contactor control circuit C Command reference 0 to 10 volts dc output to remote control D Remote control circuit common E 0 to 10 volts dc input command signal from remote control K Chassis common RC2 1 Command reference 0 to 10 volts dc output to remote control 3 Contact closure to A completes 24 volts ac contactor control circuit 4 Remote control circuit common 5 0 to 10 v...

Page 39: ...ure plugs are secure before calibratingmeter 1 Control Board PC1 2 Voltmeter V1 3 Ammeter A1 Top View R19 Amperes No calibration available for ammeter offset or for voltmeter V1 1 2 3 Adjust R19 for amperage gain to match external calibrated meter using load bank set at desired load ...

Page 40: ...rowave 250 6 9 Input Voltage Labels And Connections ST 154 793 A ST 114 947 A ST 121 000 A ST 131 735 1 Input Voltage Label And Con nection Diagram Only One Label Is On Unit 2 Terminal Strip TE1 Test Equipment Needed 1 2 ...

Page 41: ...nals Repair Or Replace Cracked Weld Cables Adjust Spark Gaps Replace Cracked Parts 14 Pin Cord Gas Hose Torch Cable 6 Months OR Blow Out Or Vacuum Inside During Heavy Service Clean Monthly 7 2 Circuit Breaker CB1 Ref ST 154 795 C 1 Circuit Breaker CB1 If CB1 opens output to the 115 volts ac duplex receptacle high frequen cy and gas flow stop Press button to reset breaker 1 CB1 ...

Page 42: ...in start high frequency Tools Needed 1 2 3 8 in 7 4 Adjusting Spark Gaps Ref ST 154 795 C Ref S 0043 Tools Needed 1 4 3 4 3 2 Y Turn Off power before adjusting spark gaps Open access door 1 Tungsten End Of Point Replace point if tungsten end dis appears do not clean or dress tungsten 2 Spark Gap Normal spark gap is 0 008 in 0 203 mm If adjustment is needed proceed as follows 3 Adjustment Screws Lo...

Page 43: ...AW Work Work 50 ft 15 m S 0694 Sources Of Direct HF Radiation 1 HF source welding power source with built in HF or separate HF unit 2 Weld Cables 3 Torch 4 Work Clamp 5 Workpiece 6 Work Table Sources Of Conduction Of HF 7 Input Power Cable 8 Line Disconnect Device 9 Input Supply Wiring Sources Of Reradiation Of HF 10 Ungrounded Metal Objects 11 Lighting 12 Wiring 13 Water Pipes And Fixtures 14 Ext...

Page 44: ...And Fixtures Ground water pipes every 50 ft 15 m 6 External Power Or Telephone Lines Locate HF source at least 50 ft 15 m away from power and phone lines 7 Grounding Rod Consult the National Electrical Code for specifications 8 Metal Building Panel Bonding Methods Bolt or weld building panels together install copper straps or braided wire across seams and ground frame 9 Windows And Doorways Cover ...

Page 45: ... 132 697 A D 132 431 D KA806713 thru KA877024 SC 137 431 D 137 430 A KA877025 thru KB010829 SC 135 581 D 135 734 A KB010830 thru KB110694 SC 142 524 D 142 525 A KB110695 thru KC252675 SC 148 144 D 148 145 A KC252676 thru KG029204 SC 154 649 C D 154 648 E KG029205 thru KG062109 SC 178 835 D 174 039 A KG062110 thru KG170300 SC 179 303 A D 179 305 A KG170301 thru KH526230 SC 181 109 E SD 181 110 F KH...

Page 46: ...TM 353 Page 42 Syncrowave 250 SC 114 914 Figure 9 1 Circuit Diagram For Syncrowave 250 Effective With Serial No JJ339876 Thru JJ351864 ...

Page 47: ...TM 353 Page 43 Syncrowave 250 Figure 9 2 Circuit Diagram For Syncrowave 250 Effective With Serial No JJ351865 Thru JJ365633 SC 120 877 ...

Page 48: ...TM 353 Page 44 Syncrowave 250 SC 121 280 Figure 9 3 Circuit Diagram For Syncrowave 250 Effective With Serial No JJ365634 Thru JJ503983 ...

Page 49: ...TM 353 Page 45 Syncrowave 250 Figure 9 4 Circuit Diagram For Syncrowave 250 Effective With Serial No JJ503984 Thru JK572897 SC 124 314 ...

Page 50: ...TM 353 Page 46 Syncrowave 250 SC 124 785 B Figure 9 5 Circuit Diagram For Syncrowave 250 Effective With Serial No JK572898 Thru JK690986 ...

Page 51: ...TM 353 Page 47 Syncrowave 250 Figure 9 6 Circuit Diagram For Syncrowave 250 Effective With Serial No JK690987 Thru KA806712 SC 132 697 A ...

Page 52: ...TM 353 Page 48 Syncrowave 250 Figure 9 7 Circuit Diagram For Syncrowave 250 Effective With Serial No KA806713 Thru KA877024 SC 137 431 ...

Page 53: ...TM 353 Page 49 Syncrowave 250 Figure 9 8 Circuit Diagram For Syncrowave 250 Effective With Serial No KA877025 Thru KB010829 SC 135 581 ...

Page 54: ...TM 353 Page 50 Syncrowave 250 Figure 9 9 Circuit Diagram For Syncrowave 250 Effective With Serial No KB010830 Thru KB110694 SC 142 524 ...

Page 55: ...TM 353 Page 51 Syncrowave 250 Figure 9 10 Circuit Diagram For Syncrowave 250 Effective With Serial No KB110695 Thru KC252675 SC 148 144 ...

Page 56: ...TM 353 Page 52 Syncrowave 250 Figure 9 11 Circuit Diagram For Syncrowave 250 Effective With Serial No KC252676 Thru KG029204 SC 154 649 C ...

Page 57: ...TM 353 Page 53 Syncrowave 250 Figure 9 12 Circuit Diagram For Syncrowave 250 Effective With Serial No KG029205 Thru KG062109 SC 178 835 ...

Page 58: ...TM 353 Page 54 Syncrowave 250 Figure 9 13 Circuit Diagram For Syncrowave 250 Effective With Serial No KG062110 Thru KG170300 SC 179 303 A ...

Page 59: ...TM 353 Page 55 Syncrowave 250 Figure 9 14 Circuit Diagram For Syncrowave 250 Effective With Serial No KG170301 Thru KH526230 SC 181 109 E ...

Page 60: ...TM 353 Page 56 Syncrowave 250 SC 188 161 A Figure 9 15 Circuit Diagram For Syncrowave 250 Effective With Serial No KH526231 And Following ...

Page 61: ...TM 353 Page 57 Syncrowave 250 Notes ...

Page 62: ...TM 353 Page 58 Syncrowave 250 Figure 9 16 Wiring Diagram For Syncrowave 250 Effective With Serial No KH526231 And Following ...

Page 63: ...TM 353 Page 59 Syncrowave 250 SD 188 162 A ...

Page 64: ...TM 353 Page 60 Syncrowave 250 Figure 9 17 Circuit Diagram For Control Board PC1 Effective With Serial No KH508255 And Following Part 1 Of 2 ...

Page 65: ...TM 353 Page 61 Syncrowave 250 SD 187 644 1 of 2 ...

Page 66: ...TM 353 Page 62 Syncrowave 250 Figure 9 18 Circuit Diagram For Control Board PC1 Effective With Serial No KH508255 And Following Part 2 Of 2 ...

Page 67: ...TM 353 Page 63 Syncrowave 250 SD 187 644 2 of 2 ...

Page 68: ...e With Serial No JJ365634 Thru KB010829 Figure 9 20 Circuit Diagram For Remote 14 Filter Board PC2 Effective With Serial No KF959379 And Following SA 120 872 SA 121 282 Figure 9 21 Circuit Diagram For Optional Snubber Board PC3 Effective With Serial No JJ351865 And Following SA 158 763 ...

Page 69: ... 288 D Figure 9 22 Circuit Diagram For Optional Preflow Timer Board TD3 Effective With Serial No JJ339876 And Following SA 044 725 C Figure 9 23 Circuit Diagram For Postflow Timer Board TD1 Effective With Serial No JJ339876 And Following ...

Page 70: ...TM 353 Page 66 Syncrowave 250 Notes ...

Page 71: ...Syncrowave 250 Processes 60 Hz 50 Hz R TM 353E January 2001 Eff w Serial Number JJ339876 Description TIG GTAW Welding Stick SMAW Welding Arc Welding Power Source Visit our website at www MillerWelds com ...

Page 72: ...SECTION 10 PARTS LIST Figure 10 1 Main Assembly ST 120 135 R Hardware is common and not available unless listed 1 2 Fig 10 3 3 4 5 6 7 Fig 10 5 8 9 10 11 12 13 30 31 14 15 16 17 Fig 10 4 18 19 20 21 22 23 24 25 26 27 28 29 Fig 10 2 ...

Page 73: ...5 thru KG062110 1 13 FL1 084 171 FILTER line power 115 250V 1 14 HD1 156 313 TRANSDUCER current 300A Eff w KB110695 1 PLG3 130 204 CONNECTOR SOCKETS Eff w KB110695 1 15 073 756 STAND OFF 6 32 x 625 lg Eff w KB110695 2 16 Z1 114 826 REACTOR 1 17 Fig 10 4 PANEL rear w components 1 109 035 LABEL warning electric shock can kill etc 1 18 C11 12 111 634 CAPACITOR 1 172 078 BRACKET mtg primary board Eff ...

Page 74: ... C2 031 668 CAPACITOR elctlt 4000uf 100VDC 1 27 R5 117 803 RESISTOR WW fxd 10W 1K ohm 1 28 114 722 BRACKET mtg rectifier 2 29 Fig 10 2 PANEL front w components 1 30 098 376 FUSE holder Eff w KH526231 1 31 F1 2 085 874 FUSE mintr gl slo blo 10A Eff w KH526231 1 092 368 TUBING stl 250 ID x 16ga x 3 Prior to JK682714 1 130 764 TUBING stl 250 ID x 16ga wall x 1 500 Eff w JK682714 1 When ordering a com...

Page 75: ... 20A 125VAC Prior to KF988252 2 4 S6 7 176 882 SWITCH tgl SPST 20A 125VAC Eff w KF988252 2 107 983 BLANK snap in nyl 500mtg hole 1 057 359 BLANK snap in nyl 375mtg hole 2 5 R3 030 109 POTENTIOMETER C sltd sft 1 T 2W 5000 ohm 1 6 R11 030 684 POTENTIOMETER C sltd sft 1 T 2W 5 meg ohm 1 7 R1 2 035 897 POTENTIOMETER C sltd sft 1 T 2W 1000 ohm 2 8 S5 011 609 SWITCH tgl SPDT 15A 125VAC 1 9 S3 052 769 SW...

Page 76: ... etc CE 1 20 114 759 DOOR access front Prior to KG170301 1 20 181 589 DOOR access front Eff w KG170301 1 605 583 CATCH spring loaded door Prior to KG170301 1 21 134 327 LABEL warning general precautionary 1 21 176 254 LABEL warning general precautionary CE 1 22 PL2 157 958 LIGHT ind wht lens 28V 1 23 PL1 155 500 LED yellow 50 Hz model Eff w KG060803 1 PLG5 135 635 CONNECTOR SOCKETS 1 PLG6 131 054 ...

Page 77: ... Panel Rear w Components Fig 10 1 Item 17 Description Quantity Part No Dia Mkgs Item No 1 R4 186 949 RESISTOR WW fxd 175W 20 ohm 1 2 032 604 BLADE fan 14 in 3 wing 19deg 375 bore CCW Prior to KG198783 1 2 180 165 BLADE fan 14 in 3 wing 19deg 375 bore CCW Eff w KG198783 1 3 114 752 PANEL rear Prior to KG170301 1 3 181 099 PANEL rear Eff w KG170301 1 4 131 361 CHAMBER plenum 14 in Prior to KG128812 ...

Page 78: ...SR2 3 035 704 RECTIFIER integ 40A 800V 2 6 SN1 2 118 625 SNUBBER poly metal film 5uf 200VDC 100 ohm 2 7 R6 117 803 RESISTOR WW fxd 10W 1K ohm 1 8 C20 119 834 CAPACITOR cer disc 05uf 500V 1 9 1T 117 372 BLOCK term 10A 15P 1 108 023 LINK jumper term blk 10A 3 10 CR5 000 770 RELAY encl 24VDC 3PDT 1 11 CR1 052 964 RELAY encl 24VDC DPDT 1 ST 120 090 F 1 2 3 4 6 7 8 9 10 3 11 5 6 Figure 10 5 Panel Mtg C...

Page 79: ... 132 430 CONTROL PANEL lower Eff w JK690987 thru KA806713 1 137 516 CONTROL PANEL lower Eff w KA806713 thru KA877024 1 147 793 CONTROL PANEL lower Eff w KA877025 thru KF959378 1 174 067 CONTROL PANEL lower Eff w KF959379 thru KG170300 1 181 108 CONTROL PANEL lower Eff w KG170301 1 1 114 742 PANEL lower front Prior to JK572898 1 1 124 784 PANEL lower front Eff w JK572898 thru JK690986 1 1 130 582 P...

Page 80: ...t 1P 15A 250V 1 10 R13 605 828 RHEOSTAT WW 50W 1 5 ohm Prior to KG170301 1 10 R13 174 037 RHEOSTAT WW 50W 1 5 ohm Eff w KG170301 thru LA292998 1 10 R13 198 547 RHEOSTAT WW 25W 1 5 ohm Eff w LA292999 1 010 493 BUSHING snap in nyl 625 ID x 875 mtg hole 1 11 G 020 623 SPARK GAP ASSEMBLY Prior to LA337284 1 095 621 BASE spark gap Prior to LA337284 1 020 622 HOLDER points Prior to LA337284 4 020 603 PO...

Page 81: ...bow M 1 4NPT x 625 18 2 035 601 VALVE 115VAC 2 way 1 4 IPS port 1 8 orf 1 PLG4 131 203 CONNECTOR SOCKETS 1 21 174 038 PANEL door access HF Eff w KF959379 1 22 097 922 KNOB pointer Eff w JK572898 1 23 010 357 SPEED NUT 1 24 605 742 CLIP mtg resistor 500 ID core 2 Recommended Spare Parts Effective with Serial No LA337284 Spark Gap Assembly 020 623 consisting of Base 095 621 Holder 020 622 and Points...

Page 82: ...r 1 042 144 PRE FLOW TIMER consisting of 1 CR4 006 393 RELAY encl 24VAC DPDT 1 R12 S9 115 862 POTENTIOMETER C sltd sft 1 T 50W 500K ohm 1 TD3 116 476 TIMER delay on make preflow consisting of 1 115 856 CIRCUIT CARD preflow consisting of 1 A50 008 971 IC linear 741 1 C50 039 482 CAPACITOR elctlt 100uf 35VDC 1 C51 091 378 CAPACITOR tantlm 33uf 35VDC 1 C52 039 481 CAPACITOR elctlt 3 3uf 50VDC 1 C53 0...

Page 83: ......

Page 84: ...ny 1635 West Spencer Street Appleton WI 54914 USA International Headquarters USA Phone 920 735 4505 USA Canada FAX 920 735 4134 International FAX 920 735 4125 European Headquarters United Kingdom Phone 44 0 1204 593493 FAX 44 0 1204 598066 Call 1 800 4 A MILLER for your local Miller distribu tor ...

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