Miller Electric SYNCROWAVE 250 Bedienungsanleitung

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

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.

YMarks 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. Stopengine 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

beforeservicing unless the procedure specifically

requires an energized unit.

3. Insulate yourself from ground by standing or

working on dry insulating mats big enough to

preventcontact with the ground.

4. Do not leave live unit unattended.

5. Whentesting 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

weldingpower 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

touchingany 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

duringservicing.

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

explodewhen 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

equipmentperform this installation.

2. The user is responsible for having a qualified

electrician promptly correct any interference

problemresulting 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

tightlyshut, keep spark gaps at correct setting, and

use grounding and shielding to minimize the

possibilityof 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. Keepall 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

startingto 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

ConsiderationsAbout 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

findingsbased on experiments at the cellular level and from studies

with animals and people which clearly establish that low frequency

magneticfields 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

interpretthe evidence in a single coherent framework. Even more

frustrating,it does not yet allow us to draw definite conclusions about

questionsof 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 +

22.1 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

U0= 80V I2310A 200A 155A

U222.4V 18V 16.2V

X 25% 60% 100%

5A/20.2V 310A/32.4V

U0= 80V I2310A 200A 155A

U232.4V 28V 26.2V

IP 21S

U1= 220 I1max = 117.2A I1Eff = 59A

50 Hz U1= 380 I1max = 72.2A I1Eff = 36A

U1= 415 I1max = 63.8A I1Eff = 32A

TM-353 Page 5Syncrowave 250

2-3. Symbols And Definitions

Some symbols are found only on CE products.

NOTE

AAmperes Panel–Local Gas Tungsten Arc

Welding (GTAW) Shielded Metal Arc

Welding (SMAW)

VVolts 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

U0Rated No Load

Voltage (Average) U1Primary Voltage U2Conventional Load

Voltage Line Connection

I1Primary Current I2Rated Welding

Current XDuty Cycle 11Single-Phase

Combined AC/DC

Power Source

IP Degree Of

Protection I1eff Maximum Effective

Supply Current I1max Rated Maximum

Supply Current Hz Hertz

Electrode Work Thickness Gauge Spark Gap

SSeconds

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

V220

V230

V260

V380

V415

V460

V520

V575

VKVA 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

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Hobart Welding Products

Hobart Welding Products Spool Gun DP 3035-10 Bedienungsanleitung

Elettro

Elettro HI-MIG 3000 SYNERGIC Bedienungsanleitung

WIA

WIA Weldmatic 270 CP132-2 Bedienungsanleitung

Sonics

Sonics H520T Bedienungsanleitung

Miller

Miller Big Blue 400D Bedienungsanleitung

NewArc

NewArc RT2000 Kurzanleitung

Hypertherm

Hypertherm powermax1000 Bedienungsanleitung