Miller Electric Syncrowave 500 Page 37 Owner'S Manual Download | Manualshive

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OM-350 Page 33

8-2.

Torch Movement During Welding

ST-162 002-B

Tungsten Without Filler Rod

Tungsten With Filler Rod

Form pool

Tilt torch

Move torch to front

of pool. Repeat process.

75

°

75

°

Welding direction

Form pool

Tilt torch

Add filler metal

Move torch to front

of pool. Repeat process.

Remove rod

Welding direction

15

°

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Summary of Contents for Syncrowave 500

Page 1: ...Syncrowave 500 Processes Description R TIG GTAW Welding Stick SMAW Welding Arc Welding Power Source OM 350 000 739AB December 2001 Visit our website at www MillerWelds com...

Page 2: ...alue established in 1929 This Owner s Manual is designed to help you get the most out of your Miller products Please take time to read the Safety precautions They will help you protect yourself agains...

Page 3: ...ATION 17 3 1 Controls 17 3 2 Work Clamp 18 3 3 AC DC And Polarity Switches 18 3 4 Amperage Voltage Controls 19 3 5 Start Amperage Controls 19 3 6 Output Contactor Switch 20 3 7 AC Balance Control 20 3...

Page 4: ......

Page 5: ...that cord plug is connected to a properly grounded receptacle outlet D When making input connections attach proper grounding conduc tor first double check connections D Frequently inspect input power...

Page 6: ...lding wire at contact tip when not in use D Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap D Remove any combustibles such as a butane light...

Page 7: ...intained D 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 ARC WELDING can cause...

Page 8: ...a human health hazard However studies are still going forth and evidence continues to be examined Until the final conclusions of the research are reached you may wish to minimize your exposure to ele...

Page 9: ...ation est bien raccord la borne de terre du sectionneur ou que la fiche du cordon est raccord e une prise correctement mise la terre D En effectuant les raccordements d entr e fixer d abord le conduct...

Page 10: ...des v tements de protection d pourvus d huile tels que des gants en cuir une chemise en mat riau lourd des pantalons sans re vers des chaussures hautes et un couvre chef D Avant de souder retirer tou...

Page 11: ...rements et dispositifs de protection LE RAYONNEMENT HAUTE FR QUENCE H F risque de provoquer des interf rences D Le rayonnement haute frequence peut provoquer des interf rences avec les quipements de r...

Page 12: ...hamps magn tiques basse fr quence Le courant de soudage pendant son passage dans les c bles de sou dage causera des champs lectromagn tiques Il y a eu et il y a encore un certain souci propos de tels...

Page 13: ...min utes that unit can weld at rated load without overheating If unit overheats thermostat s opens output stops and cooling fan runs Wait fifteen minutes for unit to cool Reduce amperage or voltage or...

Page 14: ...r Work Welding GTAW Work Source With HF Off Power Source With HF On 2 5 Selecting A Location And Moving Welding Power Source ssb9 1 5 94 ST 800 402 ST 127 872 A 1 Lifting Eye 2 Lifting Forks Use lifti...

Page 15: ...ctrode Holder 4 GTAW Torch Install according to manufacturer s instructions 5 Work Clamp Install onto work cable 10 ft 3 m 1 Total Cable Length In Weld Circuit 20 ft 6 m 10 ft 3 m For Example 2 5 2 4...

Page 16: ...2 Cylinder Valve Remove cap stand to side of valve and open valve slightly Gas flow blows dust and dirt from valve Close valve 3 Cylinder 4 Regulator Flowmeter Install so face is vertical 5 Gas Hose C...

Page 17: ...Turn Off power before con necting to weld output termi nals 1 Work Weld Output Terminal 2 Electrode Weld Output Terminal 3 Torch Cable Adapter Adapter connects power and water to torch and cooling sys...

Page 18: ...ceptacle align keyway insert plug and tighten threaded collar 3 4 A J B K I C L N H D M G E F 1 2 OR 2 14 Remote 14 Socket Information A 24 volts ac B Contact closure to A completes 24 volts ac contac...

Page 19: ...Voltage Jumper Links Move links to match input voltage For example use 230 volts position when 230 volts input power is avail able Reinstall side panel or go on to Sec tion 2 17 1 Tools Needed S 048 6...

Page 20: ...Input Conductors 3 Grounding Conductor Select size and length using Sec tion 2 16 Conductor rating must comply with national state and local electrical codes Use lugs of proper amperage capacity and c...

Page 21: ...n damage hearing Wear welding helmet with correct shade of filter Wear correct eye ear and body protection MOVING PARTS can cause injury Keep away from moving parts Keep all doors panels covers and gu...

Page 22: ...remove slag after welding sb4 1 2 93 Tools Needed 1 3 3 AC DC And Polarity Switches Ref ST 116 740 A 1 AC DC Switch Use switch to select type of weld output 2 Polarity Switch Use switch to select eit...

Page 23: ...ote Hand Control 5 Remote Foot Control See example below 1 Set Switch Adjust Remote Control Set Desired Maximum Amperage 3 4 5 2 Example Of Front Panel Amperage Control In Example Min 25 A AC Max 300...

Page 24: ...A 1 AC Balance Control Use control to change the ac output square wave Turn control towards 10 to obtain deeper penetration Turn control to wards 0 to obtain more cleaning ac tion of the workpiece Th...

Page 25: ...for arc starting only Continuous provides HF continu ously throughout the weld 2 High Frequency Intensity Control see Section 2 9 Use control to change amount of HF energy used to start and main tain...

Page 26: ...d amperage output of unit 2 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 1 3 12 Power Switch 1...

Page 27: ...14 Sequence Of Gas Tungsten Arc Welding GTAW Turn On Shielding Gas ssb8 1 12 92 Install Connect Equipment Select Tungsten See Section 7 1 Insert Tungsten Into Torch Put On Personal Safety Equipment Se...

Page 28: ...C 5 32 in Tools Needed 0 012 in 0 305 mm 1 4 3 4 3 2 Y Turn Off power before ad justing spark gaps Remove cover plate 1 Tungsten End Of Point Replace point if tungsten end dis appears do not clean or...

Page 29: ...HD1 No AC Balance Control Have Factory Authorized Service Station Service Distributor check and replace AC Balance Control if necessary and check control board PC1 see Section 3 7 No control of weld o...

Page 30: ...OM 350 Page 26 SECTION 5 ELECTRICAL DIAGRAM Figure 5 1 Circuit Diagram For Welding Power Source...

Page 31: ...OM 350 Page 27 SD 202 703 A...

Page 32: ...f Direct High Frequency Radiation 1 High Frequency 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...

Page 33: ...and Fixtures Ground water pipes every 50 ft 15 m 7 External Power or Telephone Lines Locate high frequency source at least 50 ft 15 m away from power and phone lines 8 Grounding Rod Consult the Nation...

Page 34: ...1 8 250 400 25 40 225 360 160 250 5 32 400 500 40 55 300 450 200 320 3 16 500 750 55 80 400 500 290 390 1 4 750 1000 80 125 600 800 340 525 Pure Tungsten Green Band 010 Up to 15 Up to 15 Up to 10 020...

Page 35: ...on fine grit hard abrasive wheel before weld ing Do not use wheel for other jobs or tungsten can become contami nated causing lower weld quality 3 Ideal Tungsten Preparation Stable Arc 2 1 2 Times Ele...

Page 36: ...rch 4 Filler Rod If Applicable 5 Gas Cup 6 Tungsten Electrode Select and prepare tungsten according to Sections 7 1 and 7 2 Guidelines The inside diameter of the gas cup should be at least three times...

Page 37: ...2 B Tungsten Without Filler Rod Tungsten With Filler Rod Form pool Tilt torch Move torch to front of pool Repeat process 75 75 Welding direction Form pool Tilt torch Add filler metal Move torch to fro...

Page 38: ...OM 350 Page 34 8 3 Positioning Torch Tungsten For Various Weld Joints ST 162 003 S 0792 75 70 90 20 20 10 15 75 20 40 30 15 75 90 15 Butt Weld And Stringer Bead T Joint Lap Joint Corner Joint...

Page 39: ...OM 350 Page 35 Notes...

Page 40: ...ge 36 SECTION 9 PARTS LIST ST 127 627 C 1 2 3 4 5 6 Fig 9 4 7 Fig 9 5 8 9 10 12 13 15 16 11 14 17 18 19 20 Fig 9 6 Fig 9 2 9 3 21 22 Hardware is common and not available unless listed Figure 9 1 Main...

Page 41: ...230 460 consisting of 1 12 139 543 COIL pri sec RH 1 13 139 542 COIL pri sec LH 1 11 T1 145 267 TRANSFORMER pwr main 230 460 575 consisting of 1 12 139 545 COIL pri sec RH 1 13 139 544 COIL pri sec LH...

Page 42: ...ge 38 1 5 6 7 8 9 11 12 13 14 15 10 16 10 17 18 19 20 21 22 23 24 25 22 29 7 30 31 32 ST 127 629 B 26 27 28 Hardware is common and not available unless listed Figure 9 2 Panel Front Lower Section w Co...

Page 43: ...SING term plug 14cont Amp 213571 2 134 731 TERMINAL male 1 pin 18 14 wire Amp 213603 1 079 739 CLAMP cable strain relief sz 17 Amp 206322 2 20 RC1 604 176 RECEPTACLE str dx grd 2P3W 15A 125V 1 073 690...

Page 44: ...el Front Upper Section w Components ST 127 628 A 1 Fig 9 7 2 3 4 5 4 6 4 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 24 22 25 23 26 27 28 Fig 9 11 29 30 31 32 33 34 35 36 37 38 39 Hardware is common and...

Page 45: ...blk 20A 4 20 1T 038 833 BLOCK term 20A 13P 1 107 794 ENCLOSURE circuit card consisting of 1 21 188 531 ENCLOSURE circuit card 1 22 188 534 GUIDE circuit card 4 23 188 532 PANEL encl circuit card 1 24...

Page 46: ...sembly Pri 1 2 4 1 2 3 4 5 1 6 1 5 3 Hardware is common and not available unless listed Description Quantity Part No Item No 059 095 Figure 9 5 Terminal Assembly Pri Fig 9 1 Item 7 1 601 838 NUT brs h...

Page 47: ...250VAC 2 11 C14 17 096 761 CAPACITOR mica 002uf 10000VDC 2 12 010 885 STRIP conductor 4 13 111 181 LINK connecting 1 14 199 854 SPARK GAP ASSEMBLY consisting of 1 15 199 856 HOLDER points 4 16 G 196 4...

Page 48: ...086 SPACER polarity switch 2 10 S7 059 082 CONTACTOR BOARD ASSEMBLY switch polarity Fig 9 10 1 11 004 696 BRACKET mtg switch 2 12 004 267 LINK jumper switch ac dc 1 13 080 346 LINK jumper switch 1 14...

Page 49: ...able switch consisting of 1 14 011 645 CONTACT ASSEMBLY movable switch consisting of 1 15 011 075 SPRING pressure contact switch 1 16 011 953 CONTACT switch 2 17 011 074 SPRING pressure contact switch...

Page 50: ...g of 1 13 011 645 CONTACT ASSEMBLY movable switch consisting of 2 14 011 075 SPRING pressure contact switch 1 15 011 953 CONTACT switch 2 16 011 074 SPRING pressure contact switch 1 17 011 080 SPACER...

Page 51: ...SSEMBLY movable switch consisting of 1 12 011 645 CONTACT ASSEMBLY movable switch consisting of 2 13 011 075 SPRING pressure contact switch 1 14 011 953 CONTACT switch 2 15 011 074 SPRING pressure con...

Page 52: ...SCR 700A 300V 4 5 010 311 CLAMP nyl 750 clamp dia x 500 wide 4 6 C7 10 R3 6 044 463 SUPPRESSOR 5uf 200V 4 7 D1 023 178 DIODE rect 275A 300V RP 2 ST 127 636 A 1 2 3 4 3 1 5 6 7 Hardware is common and...

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Page 55: ...tting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers Miller s True Blue Limited Warranty shall not apply to 1 Consumable components such as contact...

Page 56: ...complete and retain with your personal records Always provide Model Name and Serial Style Number Call 1 800 4 A Miller or see our website at www MillerWelds com to locate a DISTRIBUTOR or SERVICE AGEN...

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