Issued Dec. 2006 • Index No. AD/4.2

Syncrowave

® 250 DX/350 LX

TIG/Stick Welding

Power Source

Quick

Specs

Industrial Applications

Precision Metal Fabrication

Maintenance and Repair

Light and Heavy Manufacturing

Aerospace

Shipbuilding

Tube and Pipe

Automotive

Vocational

Processes

TIG (GTAW)

Stick (SMAW)

Pulsed TIG (GTAW-P) (Optional)

Input Power

Requires 1-Phase Power

Amperage Range

250: 3 – 310 350: 3 – 400

Max. Open-Circuit Voltage

80 VDC

Rated Output

250: 250 A at 30 VAC, 40% Duty Cycle

200 A at 28 VAC, 60% Duty Cycle

350: 350 A at 34 VAC, 40% Duty Cycle

300 A at 32 VAC, 60% Duty Cycle

Weight

250: 378 lb (172 kg) 350: 496 lb (225 kg)

The Power of Blue .

®

See page 2 for additional features

Syncrowave 350 LX TIGRunner ® with Torch Package

3X

Syncrowave 250 DX

TIGRunner ® 3X Package

The balance control is adjustable to provide additional oxide removal (more cleaning) or less cleaning based on the condition of the material being welded. See pg 2 for more information on this feature.

Syncro Start allows the choice of Soft, Standard or Hot TIG starts based on the application, lead lengths and tungsten size.

Dual inline high-frequency points provide intense high frequency for arc starting and stabilization. Internal machine components are protected from HF interference with additional grounding and filtering for extended product life.

Digital welding meters display both amperage and voltage for viewing of the actual and preset values for greater accuracy and repeatability in your welding procedure.

Last procedure recall simplifies changing your

Syncrowave back and forth from aluminum TIG to stainless TIG to stick welding. One switch makes all the control panel changes.

Power source is warranted for 3 years, parts and labor.

Original main power rectifier parts are warranted for 5 years.

Miller Electric Mfg. Co.

An Illinois Tool Works Company

1635 West Spencer Street

Appleton, WI 54914 USA

International Headquarters

Phone: 920-735-4505

USA FAX: 920-735-4134

Canadian FAX: 920-735-4169

International FAX: 920-735-4125

Web Site www.MillerWelds.com

2

Additional Features

Pulse TIG Control lowers the heat input into the part and reduces warping and distortion

(optional on 250DX models).

TIGRunner System Packages with NEW

CoolRunner ™ 3X cooler. A 3-gallon cooling system equipped with a visual flow indicator ensures that the coolant is flowing. An external coolant filter stops foreign objects from entering the water cooled torch cable for better flow and longer life. Extended cooling capacity ensures maximum productivity. 3-year cooler warranty.

Stick welding features such as Adaptive Hot

Start ™ provide good arc strikes without sticking.

Once welding, the DIG control makes dynamic adjustments to the welder to ensure smooth

E7018 and deep penetration E6010.

Tilted operator interface and built-in consumable

drawer provide added convenience to your welding experience.

Arc timer/cycle counter records actual welding time and number of arc starts. Great for estimating job costs.

Squarewave Technology developed and patented by Miller Electric in 1976. Squarewave technology was developed to improve your weld quality and make TIG welding easier. Miller

Squarewave technology provides arc stability when welding aluminum, prevents arc rectification and eliminates tungsten erosion.

Welding Aluminum?

Oxides that form on aluminum melt at temperatures over 3700° F. The aluminum material that is located under this layer of oxide melts at 1200° F. The Syncrowave’s

AC Squarewave welding current automatically removes the layer of oxide which is necessary for producing high quality welds.

Do you have power fluctuations?

The Syncrowave compensates for power fluctuation without changing your welding parameters. Line voltage compensation works on fluctuating power +/- 10%.

AC Output: Balance Control

AC Balance

3

2

1

4

5

6

0 10

Balanced

7

8

9

Medium bead

4

5

6

2

3

1

0 10

Max.

Penetration

9

7

8

Narrower bead for fillet welds

3

2

1

4

5

6

0

Max.

10

Cleaning

7

8

9

Wide bead

Bead

Cleaning

Narrow bead, with no visible cleaning

Bead

No Visible Cleaning

Wider bead and cleaning action

Bead

Cleaning

Balanced Wave Function

Balanced Wave

50%

Electrode

Positive

50%

Electrode

Negative

More Heat into Work

32%

Electrode

Positive

68%

Electrode

Negative

Greatest Cleaning Action

55%

Electrode

Positive

45%

Electrode

Negative

Specifications

(Subject to change without notice.)

Model

Syncrowave 250

Syncrowave

250 CE

220/400/440/520

Syncrowave 350

All Models

Input

Power

60 Hz,

1-Phase

50 Hz,

1-Phase

Welding

Amp Range

3 – 310 A

50 or

60 Hz,

1-Phase

50 or

60 Hz,

1-Phase

3 – 400 A

Max

OCV

80 V

Rated Output

250 A at 30 V,

40% Duty Cycle

225 A at 29 V,

40% Duty Cycle

250 A at 30 V,

40% Duty Cycle

80 V 350 A at 34 V,

40% Duty Cycle

Amps Input at AC Balance, Rated Load

200V 220V 230V 400V 440V 460V 520V 575V KVA KW

88 — 77 — — 38 — 31 18 9

101

—

146

—

100

88

—

120 128

—

55

66

—

50

60

44

—

65

—

42

51

35

—

50

20

22

30

10

12

14

Dimensions

H: 36-1/4 in (921 mm)

W:22-1/2 in (572 mm)

D: 25 in (635 mm) with TIGRunner ®

H: 52-1/2 in (1334 mm)

W:22-1/2 in (572 mm)

D: 38 in (975 mm)

H: 36-1/4 in (921 mm)

W:22-1/2 in (572 mm)

D: 25 in (635 mm)

Weight

378 lb

(172 kg)

525 lb

(238 kg)

378 lb

(172 kg)

H: 36-1/4 in (921 mm)

W:22-1/2 in (572 mm)

D: 25 in (635 mm) with TIGRunner ®

H: 52-1/2 in (1334 mm)

W:22-1/2 in (572 mm)

D: 38 in (975 mm)

496 lb

(225 kg)

643 lb

(290 kg)

* See pg 6 for power factor correction kit.

Certified to both the Canadian and U.S. Standards for welding equipment.

Performance Data

500

450

400

350

300

250

200

150

100

Syncrowave 350 LX

Syncrowave 250 DX

DUTY CYCLE CHART

RATED OUTPUT

50

10 20 30

% DUTY CYCLE

40 50 60 70 80 90 100

3

4

6

7

8

1

2

3

4

5

Control Panels

Common Bottom Panel

1. Voltmeter Display

2. Start Mode Control

(Lift-Arc, HF Start, HF Continuous)

3. Output Control

4. Amperage Control (Panel/Remote)

5. Process Control (Stick/TIG)

6. Balance/Dig Control (0 – 10)

7. Postflow Time Control (0 – 50 sec)

8. Ammeter Display

9. Pulser Control*

10. Background Amps Control (0 – 100%)*

11. Pulse-Per-Second Control (0.25 – 10 Hz)*

12. Peak Time Control (5 – 95%)*

13. Spot Time Control (0 – 5 sec)*

14. Final Slope Control (0 – 25 sec)*

15. Initial Time Control (0 – 15 sec)*

16. Final Amperage Control (0 – 100%)*

17. Initial Amperage Control (3 – 310/400 A)*

18. Amperage Adjustment Control (3 – 310/400 A)

19. Power Switch (On/Off)

20. Output Selector Switch (AC/DC-/DC+)

*Optional Pulser for 250 DX

**Optional Sequencer

15

16

17

18

9

10

11

12

13

14

Pulser*

Module

Sequencer**

Module

19

20

Packages

Syncrowave

®

Power Sources

Syncrowave ® 250 DX

#907 194 (200/230/460 VAC)

#907 195 (230/460/575 VAC)

#907 197 (220/400/440/520 VAC) CE

Syncrowave ® 350 LX

#907 198 (200/230/460 VAC)

#907 199 (230/460/575 VAC)

#907 200 (220/400/440/520 VAC) CE

Packages include: International-style connection kit (#195 303). Primary cord not included.

Syncrowave 250 DX

Syncrowave 250 DX

TIGRunner

250 A Water-Cooled Torch Kit for Syncrowave 250 DX TIGRunner

Syncrowave 350 LX

Syncrowave 350 LX

TIGRunner

300 A Water-Cooled Torch Kit for Syncrowave 350 LX TIGRunner

TIGRunner

®

Packages

Syncrowave ® 250 DX TIGRunner ® 3X

#907 194-03-2 (200/230/460 VAC)

#907 195-03-2 (230/460/575 VAC)

Syncrowave ® 350 LX TIGRunner ® 3X

#907 198-03-2 (200/230/460 VAC)

#907 199-03-2 (230/460/575 VAC)

Completely assembled. Packages include:

Syncrowave, Coolmate ™ 3X cooler, No. 37 running gear, RFCS-14 HD remote foot control, and international-style connection kit (#195 303). Primary cord not included.

TIG coolant (#043 810) required.

TIGRunner

®

Packages with Torch

Syncrowave ® 250 DX TIGRunner ® 3X with Torch Kit

#907 194-04-1 (200/230/460 VAC)

#907 195-04-1 (230/460/575 VAC)

Syncrowave ® 350 LX TIGRunner ® 3X with Torch Kit

#907 198-04-1 (200/230/460 VAC)

#907 199-04-1 (230/460/575 VAC)

Completely assembled. Packages include:

Syncrowave, Coolmate ™ 3X cooler, No. 37 running gear, RFCS-14 HD remote foot control, torch kit (see kits to left) and international-style connection kit

(#195 303). Primary cord not included.

TIG coolant (#043 810) required.

5

Genuine Miller Options

Field Options

Sequencer Module #195 345 Field Kit

Provides a starting current higher or lower than the welding current. Provides final slope and final current for trailing the weld. Provides a spot timer for TIG spot application.

Pulser Module

#195 344 Field Kit for Syncrowave 250 DX

For welding of thin materials. Provides a heating and cooling effect of the weld puddle to reduce heat input and control distortion of the material. Provides 0.25 to

10 pulses per second.

Power Factor Correction Kit

#194 692 Field Kit for Syncrowave 250 DX

#043 757 Field Kit for Syncrowave 350 LX

Reduces primary amperage draw by approximately 25% allowing the use of smaller breakers/fuses and smaller primary cord. Power Factor does not reduce the power consumption/electrical bill.

Genuine Miller Accessories

No. 37 Running Gear #195 282

Includes two 10 in (254 mm) wheels, two

5 in (127 mm) casters, two-compartment rack (for gas cylinder(s) or Coolmate V3 coolant system), and handles. Provides excellent mobility and easy to install.

Protective Cover #195 320

Heavy-duty, water- and mildew-resistant.

Protects and maintains the finish of the welder.

Remote Controls and Switches

RCCS-14 Remote Contactor and

Current Control #043 688 14-pin plug

For all Miller solid-state power sources after serial number JK674521. North/south rotary-motion fingertip control fastens to

TIG torch using two Velcro ® straps. Great for applications that require a finer amperage control. Includes 26.5 ft (8 m) control cord.

RFCS-14 HD Foot Control #194 744

For all Miller solid-state power sources after serial number JK674521. This new design increases stability with a larger base, and durability with a heavier cord.

Maximum flexibility is accomplished with a reconfigurable cord that can exit the front, back or either side of the pedal. Foot pedal provides remote current and contactor control. Includes 20 ft (6 m) cord and

14-pin plug.

RHC-14 Hand Control

#129 340

Miniature hand control for remote current and contactor control.

Dimensions:

4 x 4 x 3-1/4 in

(102 x 102 x 83 mm). Includes 20 ft (6 m) cord and 14-pin plug.

RMLS-14 Switch #129 337

For all Miller solid-state power sources after serial number JK674521. Momentaryand maintained-contact rocker switch for contactor control. Push forward for maintained contact and backward for momentary contact. Includes 26.5 ft (8 m) cord and 14-pin plug.

RMS-14 On/Off Control #187 208

For all Miller solid-state power sources after serial number JK674521. Momentarycontact switch for contactor control.

Rubber-covered pushbutton dome switch ideal for repetitive on-off applications.

Includes 26.5 ft (8 m) cord and 14-pin plug.

Extension Cords for 14-Pin Remote Controls

#122 973 25 ft (7.6 m)

#122 974 50 ft (15.2 m)

#122 975 75 ft (23 m)

Gas Tungsten Arc (TIG) Welding Book

#170 555

To order this item, distributors can call the Miller Literature Distribution Center at

1-920-735-4356, or FAX 1-920-735-4011.

86 pages — 8-1/2 x 11 in. A comprehensive text on all aspects of the GTAW process.

Filled with figures and tables to illustrate process technique and equipment setup.

Glossary of TIG terms also provided.

TIG Training CD #196 567

Designed for anyone who’s looking to better understand the TIG process. Easy to understand instruction, proven teaching steps, and expert advice help to create a more effective academic approach to training.

Subject areas covered include system components, process fundamentals, electrical theory, safety, power source operation.

Video – GTAW Setup Procedures #108 241

To order this item, distributors can call the Miller Literature Distribution Center at

1-920-735-4356, or FAX 1-920-735-4011.

13:00 minutes. A detailed demonstration on preparing your equipment for TIG welding. Uses a Syncrowave 250 power source, but topics fit any TIG setup including air-or water-cooled systems.

In-depth discussion of tungstens and gases.

6

Genuine Miller Accessories

(continued)

TIG Welding Gloves

#227 813 Small

#227 814 Medium

#227 815 Large

#227 816 X-Large

Designed to meet the specific requirements highquality TIG welding demands.

Made from soft grain goatskin. Sewn with

Kevlar ® thread.

TIG (GTAW) Torch Adapters

Water-Cooled Dinse #195 377

Used to adapt a 250 or 350 A water-cooled torch to an International-style connector.

Air-Cooled Dinse #195 379

Used to adapt a 1-piece 200 amp air-cooled torch to an International-style connector.

Tungsten

Items below are available in pkgs of 10, 7 in length

2% Ceriated (orange) for AC/DC applications

#WC040X7 .040 in, 10– 80 A

#WC116X7 1/16 in, 70– 150 A

#WC332X7 3/32 in, 140– 250 A

#WC018X7 1/8 in, 225– 400 A

#WC532X7 5/32 in, 300– 500 A

1.5% Lanthanum (gold) for AC/DC applications

#WL040X7 .040 in, 10– 80 A

#WL116X7 1/16 in, 70– 150 A

#WL332X7 3/32 in, 140– 250 A

#WL018X7 1/8 in, 225– 400 A

#WL532X7 5/32 in, 300– 500 A

Pure (green) for AC applications only

#WP040X7 .040 in, 10– 80 A

#WP116X7 1/16 in, 70– 150 A

#WP332X7 3/32 in, 140– 250 A

#WP018X7 1/8 in, 225– 400 A

#WP532X7 5/32 in, 300– 500 A

2% Thoriated (red) for DC applications only

#WT040X7 .040 in, 10– 80 A

#WT116X7 1/16 in, 70– 150 A

#WT332X7 3/32 in, 140– 250 A

#WT018X7 1/8 in, 225– 400 A

#WT532X7 5/32 in, 300– 500 A

Torch Kits

Water Coolant Systems

For more information, see the Miller Coolant

Systems literature sheet, Index No. AY/7.2.

Coolmate ™ V3

#043 009 115 VAC

#043 009-01-2 115 VAC, CE

For use with water-cooled torches rated up to 500 amps. Vertical design conveniently mounts to Miller cylinder rack in place of one cylinder. 3-gallon capacity.

Does NOT include wheels.

CoolRunner ™ 3X #043 994 115 VAC

Provides the perfect solution for industrial, water-cooled TIG applications.

For water-cooled TIG torches rated up to

500 amps. 3-gallon capacity.

TIG Coolant

#043 810

4 gallons of pre-mixed low-conductivity coolant. Miller coolant contains ethylene glycol and deionized water to protect from freezing and boiling -37˚ to 227˚F (-38˚ to 108˚C).

Coolant contains 2.4% algae growth inhibitor.

250 A Water-Cooled Torch Kit #300 185

Recommended for Syncrowave 250 DX

25 ft (7.6 m) Weldcraft ® WP20 torch

Torch cable cover

AK4C torch accessory kit includes shielding cups, collets, collet bodies and

2% cerium tungsten electrodes (1/16,

3/32 and 1/8 in)

Smith ® regulator/flowmeter HM2051A-580

12 ft (3.7 m) rubber gas hose (regulator to machine)

Water-cooled Dinse torch adapter

12 ft (3.7 m) 1/0 weld lead with clamp

(work or ground lead) and Dinse connector

300 A Water-Cooled Torch Kit #300 183

Recommended for Syncrowave 350 LX

25 ft (7.6 m) Weldcraft ® CS310 torch

Torch cable cover

CS310AKC torch accessory kit includes shielding cups, collets, collet bodies and

2% cerium tungsten electrodes (1/16,

3/32 and 1/8 in)

Smith ® regulator/flowmeter HM2051A-580

12 ft (3.7 m) rubber gas hose (regulator to machine)

Water-cooled Dinse torch adapter

12 ft (3.7 m) 1/0 weld lead with clamp

(work or ground lead) and Dinse connector

400 A Water-Cooled Torch Kit #300 186

25 ft (7.6 m) Weldcraft ® WP18SC torch

Torch cable cover

AK18C torch accessory kit includes shielding cups, collets, collet bodies and

2% cerium tungsten electrodes (3/32,

1/8 and 5/32 in)

Smith ® regulator/flowmeter H1954D-580

12 ft (3.7 m) rubber gas hose (regulator to machine)

Water-cooled thread lock torch adapters

12 ft (3.7 m) 4/0 weld lead with clamp

(work or ground lead)

7

Ordering Information

Equipment and Options Stock No.

Description

Syncrowave

Syncrowave

®

®

Pulser Module

250 DX

350 LX

Sequencer Module

Power Factor Correction Kit

#907 194

#907 195

200/230/460 V, 50/60 Hz, Standard Model

230/460/575 V, 50/60 Hz, Standard Model

#907 197 220/400/440/520 V, 50/60 Hz, CE, Standard Model

#907 194-03-2 200/230/460 V, Syncrowave 250 DX TIGRunner ® 3X

#907 194-04-1 200/230/460 V, Syncrowave 250 DX TIGRunner ® 3X with torch

#907 195-03-2 230/460/575 V, Syncrowave 250 DX TIGRunner ® 3X

#907 195-04-1 230/460/575 V, Syncrowave 250 DX TIGRunner ® 3X with torch

#907 198

#907 199

200/230/460 V, 50/60 Hz, Standard Model

230/460/575 V, 50/60 Hz, Standard Model

#907 200 220/400/440/520 V, 50/60 Hz, CE

#907 198-03-2 200/230/460 V, Syncrowave 350 LX TIGRunner ® 3X

#907 198-04-1 200/230/460 V, Syncrowave 350 LX TIGRunner ® 3X with torch

#907 199-03-2 230/460/575 V, 50/60 Hz, Syncrowave 350 LX TIGRunner ® 3X

#907 199-04-1 230/460/575 V, 50/60 Hz, Syncrowave 350 LX TIGRunner ® 3X with torch

#195 345

#195 344

#194 692

#043 757

Field

Field. For Syncrowave 250 DX

Field. For Syncrowave 250 DX

Field. For Syncrowave 350 LX

TIG Torch Kits

Weldcraft ® 250 A Water-Cooled Torch Kit #300 185

Weldcraft ® 300 A Water-Cooled Torch Kit #300 183

Weldcraft ® 400 A Water-Cooled Torch Kit #300 186

Consumables and Tungsten

Gas Cylinder, Hose and Fittings

See page 7. Recommended for Syncrowave 250 DX TIGRunner 3X

See page 7. Recommended for Syncrowave 350 LX TIGRunner 3X

See page 7

Distributor: See Miller Parts Catalog

Remote Controls

RCCS-14

RFCS-14 HD

RHC-14

RMLS-14

RMS-14

Extension Cords

#043 688

#194 744

#129 340

#129 337

#187 208

#122 973

#122 974

#122 975

Accessories

No. 37 Running Gear

Protective Cover

Gas Tungsten Arc (TIG) Welding Book

TIG Training CD

Video – GTAW Setup Procedures

#195 282

#195 320

#170 555

#196 567

#108 241

Torch Adapters #195 377

Supplied with power source and torch kits #195 379

Cable Connectors

Dinse Connector 50 mm (1 male) #042 418

Dinse Connector 50 mm (1 male, 1 female) #042 419

Tweco Terminal Adapter

Cam-Lok Terminal Adapter

#042 465

#042 466

TIG Coolant

Water Coolant Systems

#043 810

Miscellaneous

Stick Electrodes

Welding and Work Cables

Helmets

TIG Welding Gloves

North/south fingertip control

Heavy-duty foot control

Hand control

Momentary/maintained rocker switch

Momentary rubber dome switch

25 ft (7.6 m)

50 ft (15.2 m)

75 ft (22.9 m)

Contact your distributor

Contact your distributor

Adapts 250 or 350 A water-cooled torch to international-style connector

Adapts 1-pc.200 A air-cooled torch to international-style connector

Supplied with power source and torch kits

Used to connect weld lead to Dinse terminal machine

Used to extend weld cables

Male Dinse to female Tweco

Male Dinse to female Cam-Lok

Case of four 1-gallon bottles

See page 7

See page 7

Date: Total Quoted Price:

Distributed by:

Qty.

Price

Litho in USA