Miller Electric Syncrowave 500 Specifications

TM-353E
January 2001
Eff. w/Serial Number JJ339876
Processes
TIG (GTAW) Welding
Stick (SMAW) Welding
Description
Arc Welding Power Source
R
Syncrowave 250
60 Hz, 50 Hz
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www.MillerWelds.com
TABLE OF CONTENTS
1. Safety Precautions – Read Before Using . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1 Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2 Servicing Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3 EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
2
SECTION 2 – DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Warning Label Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Rating Label For CE Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
3
4
5
SECTION 3 – INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5. Dimensions And Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-6. Tipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-7. Weld Output Terminals And Selecting Cable Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-8. Remote 14 Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-9. 115 Volts AC Duplex Receptacle And Shielding Gas Connections . . . . . . . . . . . . . . . . . . . . . .
3-10.Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-11.Placing Jumper Links And Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
6
6
7
8
8
9
9
10
10
11
12
SECTION 4 – OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Output Selector Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Meters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Crater Time Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Spot Time Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. AC Balance Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Amperage Adjustment Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8. Output (Contactor) Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-9. Arc Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-10.Postflow Time Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-11.High Frequency Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-12.Preflow Time Control (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
13
14
14
15
15
16
17
17
18
18
19
19
SECTION 5 – THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20
SECTION 6 – TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Troubleshooting Circuit Diagram For Welding Power Source . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Waveforms For Section 6-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4. Control Board PC1 Testing Information (Use With Section 6-5) . . . . . . . . . . . . . . . . . . . . . . . .
6-5. Control Board PC1 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-6. Remote Board PC2 Testing Information (Use With Section 6-7) . . . . . . . . . . . . . . . . . . . . . . . .
6-7. Remote 14 Filter Board PC2 Test Point Values (Use With Section 6-2 And Section 6-6) . . . .
6-8. Meter Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-9. Input Voltage Labels And Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22
22
26
28
30
31
33
34
35
36
SECTION 7 – MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. Circuit Breaker CB1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-3. Fuses F1 And F2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-4. Adjusting Spark Gaps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
37
37
37
38
38
SECTION 8 – HIGH FREQUENCY (HF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1. Welding Processes Using HF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2. Sources Of HF Radiation From Incorrect Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-3. Correct Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
39
39
39
40
SECTION 9 – ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
41
SECTION 10 – PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
68
TM-353D
Declaration of Conformity For
European Community (CE) Products
NOTE
This information is provided for units with CE certification (see rating label on unit.)
Miller Electric Mfg. Co.
Manufacturer’s Name:
1635 W. Spencer Street
Appleton, WI 54914 USA
Manufacturer’s Address:
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:
Telephone:
Fax:
dec_con1 10/95
Mr. Luigi Vacchini, Managing Director
MILLER Europe S.P.A.
Via Privata Iseo
20098 San Giuliano
Milanese, Italy
39(02)98290-1
39(02)98281-552
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.
Y Marks a special safety message.
. Means NOTE; not safety related.
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.
1-2. Servicing Hazards
WARNING
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.
ELECTRIC SHOCK can kill.
HOT PARTS can cause severe burns.
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.
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
incorrect use of test equipment.
from
1. Turn Off welding power source and wire feeder or
stop engine before making or changing meter lead
connections.
7. Turn Off inverter, disconnect input power, and
discharge input capacitors according to
instructions in Maintenance Section before
touching any parts.
2. At least one meter lead should be a self-retaining
spring clip such as an alligator clamp.
STATIC ELECTRICITY can
parts on circuit boards.
HIGH-FREQUENCY RADIATION can
interfere with radio navigation, safety
services,
computers,
and
communications equipment.
damage
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.
Syncrowave 250
1. Do not touch hot parts bare handed.
3. Read instructions for test 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.
FLYING PIECES OF METAL or DIRT can
injure eyes.
4. Have the installation regularly checked and
maintained.
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.
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.
TM-353 Page 1
FALLING EQUIPMENT can cause
serious personal injury and equipment
damage.
MOVING PARTS can cause injury.
1. Use lifting eye to lift unit only, NOT running gear,
gas cylinders, or any other accessories.
OVERUSE can cause OVERHEATED
EQUIPMENT.
2. Use equipment of adequate capacity to lift unit.
MAGNETIC
CURRENTS
operation.
FIELDS FROM HIGH
can affect pacemaker
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.
1. Keep away from moving parts.
2. Keep away from pinch points such as drive rolls.
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.”
TM-353 Page 2
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.
Syncrowave 250
SECTION 2 – DEFINITIONS
2-1. Warning Label Definitions
Warning! Watch Out! There are
possible hazards as shown by the
symbols.
1
1.1
1.2
1.3
2
1
1.1
2.1
1.3
1.2
2.2
2.3
3
2
2.1
2.2
3.1
2.3
3.2
3
3.1
3.2
3.3
3.3
4
4.1
4
4.1
+
+
5
+
6
5
Electric shock from welding
electrode or wiring can kill.
Wear dry insulating gloves.
Do not touch electrode with
bare hand. Do not wear wet or
damaged gloves.
Protect yourself from electric
shock by insulating yourself
from work and ground.
Disconnect input plug or
power before working on
machine.
Breathing welding fumes can
be hazardous to your health.
Keep your head out of the
fumes.
Use forced ventilation or local
exhaust to remove the fumes.
Use ventilating fan to remove
fumes.
Welding sparks can cause
explosion or fire.
Keep flammables away from
welding. Don’t weld near
flammables.
Welding sparks can cause
fires. Have a fire extinguisher
nearby and have a watch
person ready to use it.
Do not weld on drums or any
closed containers.
Arc rays can burn eyes and
injure skin.
Wear hat and safety glasses.
Use ear protection and button
shirt collar. Use welding
helmet with correct shade of
filter. Wear complete body
protection.
Become trained and read the
instructions before working on
the machine or welding.
Do not remove or paint over
(cover) the label.
6
+
S-176 254-A
Syncrowave 250
TM-353 Page 3
2-2. Rating Label For CE Products
1
1
U0 = 80V
U0 = 80V
ISO/IEC 974-1
7A/10.2V
310A/22.4V
X
25%
60%
I2
310A 200A 155A
U2
22.4V
18V
100%
16.2V
5A/20.2V
310A/32.4V
X
25%
60%
I2
310A 200A 155A
U2
32.4V
28V
100%
26.2V
1
U1 = 220
50 Hz
U1 = 380
I1max = 117.2A I1Eff = 59A
U1 = 415
I1max = 63.8A I1Eff = 32A
I1max = 72.2A I1Eff = 36A
IP 21S
S-178 813-A
TM-353 Page 4
Syncrowave 250
2-3. Symbols And Definitions
NOTE
A
V
Some symbols are found only on CE products.
Amperes
Panel–Local
Gas Tungsten Arc
Welding (GTAW)
Shielded Metal Arc
Welding (SMAW)
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
Line Connection
U0
Rated No Load
Voltage (Average)
U1
Primary Voltage
U2
Conventional Load
Voltage
I1
Primary Current
I2
Rated Welding
Current
X
Duty Cycle
IP
Degree Of
Protection
I1eff
Maximum Effective
Supply Current
I1max
Rated Maximum
Supply Current
Electrode
S
Syncrowave 250
Work
Thickness Gauge
1
1
Hz
Single-Phase
Combined AC/DC
Power Source
Hertz
Spark Gap
Seconds
TM-353 Page 5
SECTION 3 – INSTALLATION
3-1. Specifications
Rated
Welding Output
NEMA Class II
(40) – 250
Amperes, 30 Volts
AC, 40% Duty
Cycle
Amperes Input at AC Balanced
Rated Load Output,
50/60 Hz, Single-Phase
PFC**
200 V
230 V
460 V
575 V
KVA
KW
No
PFC
106
(4.6*)
92
(4*)
46
(2*)
37
(1.6*)
21
(0.89*)
11.4
(0.68*)
With
PFC
76
66
33
26
15.2
11.4
Amp
Range
Max
OCV
IP
Rating
5–310 A
80 V
21
*While idling
**Power Factor Correction
Rated
Welding
Output
NEMA
Class I
(60) – 200
Amperes,
28 Volts
AC, 60%
Duty Cycle
Amperes Input at AC Balanced
Rated Load Output,
50/60 Hz, Single-Phase
PFC
**
200
V
220
V
230
V
260
V
380
V
415
V
460
V
520
V
575
V
KVA
KW
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*)
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*)
Amp
Range
Max
OCV
IP
Rating
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.
A. DC Mode
B. AC Mode
ssb1.1 10/91 – SB-116 199 / SB-116 200
TM-353 Page 6
Syncrowave 250
3-3. Duty Cycle And Overheating
Duty Cycle is percentage of 10 minutes 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 before welding.
Y Exceeding duty cycle can
damage unit and void
warranty.
40% Duty Cycle At 250 Amperes (60 Hz Models Only)
4 Minutes Welding
6 Minutes Resting
60% Duty Cycle At 200 Amperes
6 Minutes Welding
4 Minutes Resting
Overheating
A
0
15
Minutes
OR
Reduce Duty Cycle
duty1 4/95 / SB-116 198
Syncrowave 250
TM-353 Page 7
3-4. Selecting A Location
1
2
Lifting Eye
Lifting Forks
Use lifting eye or lifting forks to
move unit.
Movement
If using lifting forks, extend forks
beyond opposite side of unit.
1
3
4
OR
2
Location And Airflow
Rating Label (Non CE Models
Only)
Rating Label (CE Models
Only, See Section 2-2)
Use rating label to determine input
power needs. CE label located on
rear panel.
5
6
6
Plate Label (CE Models Only)
Line Disconnect Device
Locate unit near correct input power supply.
Y Special installation may be
required where gasoline or
volatile liquids are present –
see NEC Article 511 or CEC
Section 20.
3
4
18 in (460
mm)
5
18 in (460
mm)
ST-800 402 / ST-117 264-F
3-5. Dimensions And Weights
Dimensions
A
B
C
D
Height
30-3/4 in (781 mm)
Width
19-3/4 in (502 mm)
Length
27-1/2 in (698 mm)
A
27 in (686 mm)
B
26 in (661 mm)
C
25-1/4 in (642 mm)
D
1-1/2 in (38 mm)
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
E
F
Front
G
Weight
H 6 Holes
ST-154 792-B
355 lbs (161 kg)
TM-353 Page 8
Syncrowave 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
Weld Output
Terminals
Work
150 ft
(45 m)
200 ft
(60 m)
250 ft
(70 m)
300 ft
(90 m)
350 ft
(105 m)
400 ft
(120 m)
Welding
Amperes
10 – 60%
Duty
Cycle
60 – 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
500
2/0
3/0
4/0
2-2/0
2-3/0
2-4/0
3-3/0
3-3/0
10 – 100% Duty Cycle
Electrode
ST-154 795-C
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 distributor for the mm2 equivalent weld cable sizes.
S-0007-E
Syncrowave 250
TM-353 Page 9
3-8. Remote 14 Receptacle
Socket*
A
B
K
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.
D
Remote control circuit common.
E
0 to +10 volts dc input command signal from remote control.
K
Chassis common.
J
I
H
C L N
D M
G
E F
A
ST-154 795-C
*The remaining sockets are not used.
3-9. 115 Volts AC Duplex Receptacle And Shielding Gas Connections
Y Turn Off power before
connecting to receptacle.
1
115 V AC Receptacle
Receptacle is protected from overload by circuit breaker CB1 (see
Section 7-2).
5
4
6
2
3
Gas Valve In Fitting
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
6
Regulator/Flow Gauge
Flow Adjust
Typical flow rate is 20 cfh (cubic feet
per hour) (9.4 L/min)
7
1
High Frequency Control (see
Section 4-1)
7
3
2
Ref. ST-154 795-C / Ref. ST-157 858
TM-353 Page 10
Syncrowave 250
3-10. Electrical Service Guide
NOTE
All values calculated at 60% duty cycle.
Without Power Factor
Correction
60 Hertz Models
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
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
Min Input Conductor Size In AWG/Kcmil
Reference: 1996 National Electrical Code (NEC)
50 Hertz Models
S-0092-J
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
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
Min Input Conductor Size In AWG/Kcmil
Reference: 1996 National Electrical Code (NEC)
Syncrowave 250
S-0092-J
TM-353 Page 11
3-11. Placing Jumper Links And Connecting Input Power
Check input voltage available at
site.
1
200 VOLTS
L
230 VOLTS
L
460 VOLTS
L
L
L
Y Only make connections for
the voltages shown on the label 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 input voltages.
L
S-083 566-C
230 VOLTS
L
460 VOLTS
L
L
2
575 VOLTS
L
L
2
L
3
L
380 VOLTS
L
L
415 VOLTS
L
L
L
L
380 VOLTS
L
L
4
Reinstall side panel.
Y Special installation may be
required where gasoline or
volatile liquids are present –
see NEC Article 511 or CEC
Section 20.
L
S-047 672-A
1
Line Disconnect Device
Select type and size of overcurrent
protection using Section 3-10.
520 VOLTS
L
Input And Grounding
Conductors
Select size and length using
Section 3-10.
L
S-131 783-A
260 VOLTS
Jumper Links
Move jumper links to match input
voltage.
S-010 587-B
220 VOLTS
Jumper Link Label
Check label inside your unit–
only one label is on unit.
Connect GND/PE
Conductor First
GND/PE
Earth Ground
4
L1 (U)
L2 (V)
3
Connect GND/PE
Conductor First
Tools Needed:
3/8 in
3/8, 1/2, 7/16 in
ST-117 263-K
TM-353 Page 12
Syncrowave 250
SECTION 4 – OPERATION
4-1. Controls
1
7
8
2
9
Voltmeter
See Section 4-3.
3
6
Ammeter
See Section 4-3.
High Frequency Switch
See Section 4-11.
10
4
11
12
Output (Contactor) Switch
See Section 4-8.
5
5
13
Spot Time Switch And Control
(Optional)
See Section 4-5.
6
Preflow Time Control (Optional)
See Section 4-12.
4
3
7
AC Balance Control
See Section 4-6.
8
Crater Time Control And Switch
See Section 4-4.
14
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.
2
12 High Temperature Shutdown Light
(CE Models Only)
1
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.
15
Ref. ST-117 264-F / Ref. ST-154 795-C
Syncrowave 250
TM-353 Page 13
4-2. Output Selector Switch
1
Output Selector Switch
Y Do not use AC output in
damp areas, if movement is
confined, or if there is danger of falling. Use AC output
ONLY if required for the
welding process, and then
use a remote control.
1
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.
Ref. ST-181 675-A
4-3. Meters
1
1
2
Voltmeter
Voltmeter displays voltage at the
weld output terminals, but not necessarily the welding arc due to
cable resistance, poor connections, etc.
2
Ammeter
Ammeter displays weld amperage
output of unit.
TM-353 Page 14
Syncrowave 250
4-4. Crater Time Controls
1
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:
2
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.
4-5. Spot Time Controls
1
Spot Time Switch
Place switch in the ON position to
turn on spot weld circuitry.
2
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 doing Shielded Metal Arc Welding
(SMAW).
2
1
Spot Time Control
Use control to set time (0–5.7 seconds) for Gas Tungsten Arc
(GTAW) spot welds. Spot time begins at arc initiation. If the arc is broken 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.
Syncrowave 250
TM-353 Page 15
4-6. AC Balance Control
1
AC Balance Control
Balance Control (AC GTAW):
Control changes the AC output
square wave. Rotating the control
towards 10 provides deeper penetration. Rotating the control towards
0 provides more cleaning action of
the workpiece.
1
When the control is in the Balanced
position, the wave shape provides
equal penetration and cleaning
action.
Application:
When welding on oxide forming materials such as aluminum or magnesium, excess cleaning is not necessary. 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.
Setting
Output Waveforms
Balanced
3
50% Electrode
Positive
50% Electrode
Negative
More Penetration
10
More Cleaning
0
32% Electrode
Positive
Arc
Set control to 7 and adjust as necessary. Joint configuration, set-up,
process variables, and oxide thickness 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.
68% Electrode
Negative
55% Electrode
Positive
45% Electrode
Negative
Ref. S-0795-A
TM-353 Page 16
Syncrowave 250
4-7. Amperage Adjustment Controls
1
1
Amperage Adjustment Control
Use control to adjust amperage,
and preset amperage on ammeter
(see Section 4-3). This control may
be adjusted while welding.
For remote amperage control,
front panel control setting is the
maximum amperage available. For
example: If front panel control is set
to 200 A, the range of the remote
amperage control is 5 to 200 A.
For spot welding, use Amperage
Adjust control to select from 5–310
amps of peak amperage (see Section 4-5).
2
Amperage Control Switch
Use switch to select way of controlling amperage adjustment.
For front panel control, place switch
in the PANEL position.
2
For remote control, place switch in
REMOTE 14 position, and connect
remote control device (see Section
3-8).
4-8. Output (Contactor) Control Switch
Y Weld output terminals are
energized when Output
(Contactor) switch is On and
Power is On.
1
1
Output/Contactor Switch
Use switch to select way of controlling unit output.
For front panel control, place switch
in ON position.
When On is selected, HF and gas
control are disabled.
For remote control, place switch in
REMOTE 14 position, and connect
remote control device (see Section
3-8).
Syncrowave 250
TM-353 Page 17
4-9. Arc Controls
1
Arc Control (Dig)
For AC And DC SMAW Welding
1
When set at 0, short-circuit amperage at low arc voltage is the same
as normal welding amperage.
When setting is increased, shortcircuit amperage at low arc voltage
increases.
Set at 0 for GTAW welding.
2
2
Arc Control Switch
Place switch in the ON position to
turn on arc control circuitry. When
switch is in the OFF position, no additional amperage is available at
low arc voltages. 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 increasing amperage at low arc voltage, and reduces electrode sticking
while welding.
4-10. Postflow Time Control
1
1
Postflow Time Control
Use control to set length of time
(0–70 seconds) gas flows after
welding stops. It is important to set
enough time to allow gas to flow until after the tungsten and weld
puddle has cooled down.
Application:
Postflow is required to cool tungsten and weld, and to prevent contamination of tungsten and weld. Increase postflow time if tungsten or
weld are dark in appearance.
TM-353 Page 18
Syncrowave 250
4-11. High Frequency Controls
Y Place
High Frequency
switch in Off position before
using the shielded metal arc
welding (SMAW) process.
1
1
High Frequency Switch
START – (Up position) provides HF
for arc starting only. High frequency
turns on to help start arc when output is enabled. High frequency
turns off when arc is started, and
turns on whenever arc is broken to
help restart arc.
Application:
HF Start is used when the DCEN
GTAW process is required.
OFF – provides no HF. Use OFF for
SMAW (stick electrode) welding.
CONTINUOUS – (Down position)
provides HF continuously throughout the weld.
Application:
HF Continuous is used when the
AC GTAW process is required.
2
2
High Frequency Intensity
Control
Use control to change amount of
HF energy used to start and maintain the arc. Set as low as practical
to prevent interfering with electronic
equipment.
4-12. Preflow Time Control (Optional)
1
Preflow Time Control
Use control to set the length of time
(0–15 seconds) that gas flows before an arc is started.
Application:
Preflow is used to purge the immediate weld area of atmosphere. Preflow also aids in consistent arc
starting.
1
Syncrowave 250
TM-353 Page 19
SECTION 5 – THEORY OF OPERATION
1
Input Terminal Board TE1
2
1φ 2
1
Provides means for operation on
different input voltages.
Power Switch S1
1-Phase
Line
Input
3 Fan Motor FM
Power
Provides cooling of internal components.
Input
Terminal
Board TE1
Power
Switch
S1
AC
1φ 4
24
Background
Power
Source
Main
Transformer
T1
Provide on/off control of unit.
4
115 VAC
3
14
Fan
Motor
FM
Main Transformer T1
Circuit
Breaker
CB1
Supplies power to weld output circuit, various control circuits, main
control board PC1, and fan motor
FM.
5
115 VAC Duplex
Receptacle
RC2
Control Board PC1
115 VAC
1φ , 10 VAC
Synchronization
Signal
Also provides input connections for
switches S3, S5, S6, and S7.
Arc Control Switch S6 And
Control R2
6
Crater Time Switch S7 And
Control R11
8
7
Control
Board
PC1
7
Crater Time
Control
R11
Crater Time
Switch
S7
Thermostat TP1
If T1 overheats, TP1 opens stopping all weld output.
9
Arc Control
Switch
S6
Arc Control
R2
R11 selects crater time when S7 is
on, and Amperage Control switch
S5 is in Panel position.
SCR
Gating
Signals
5
6
R2 selects short-circuit amperage
when S6 is On, and High Frequency control R13 is Off.
7
Main
Rectifier
SR1
15
Controls weld output by changing
the SCR gate pulses (conduction
times) after comparing current
feedback to selected amperage
signal.
6
DC
23
Output (Contactor) Switch S3
Selects On or remote contactor
control.
9
16
8
Output
(Contactor)
Switch S3
17
10 AC Balance Control R3
AC Balance
Control
R3
11 Ammeter A1 And Voltmeter
V1
11♦
Display weld amperage and voltage while welding.
Ammeter
A1
12 Amperage Control Switch S5
And Adjustment Control R1
13 Remote 14 Filter Board
PC2/Remote 14 Receptacle
RC1
PC2 protects unit from high frequency, and RC1 connects remote
amperage and contactor controls to
power source.
14 Circuit Breaker CB1
Protects 115 volts ac duplex receptacle RC2 from overload.
TM-353 Page 20
Gas
Valve
GS1
10
Controls changes to ac output
square wave.
R1 selects weld output amperage
when S5 is in Panel.
Postflow
Timer
TD1
Thermostat
TP1
12
Amperage
Adjustment
Control R1
12
13
Amperage
Control
Switch S5
Remote 14
Filter Board
PC2
13
Remote
Amperage
Control
Syncrowave 250
15 115 Volts AC Duplex Receptacle RC2
28
26
25
30
Work Weld
Output
Terminal
Hall Device
HD1
Stabilizer
Z1
11♦
Voltmeter
V1
Output
Selector
Switch
S4
21
29
Line
Filter
FL1
Controls shielding gas and coolant
postflow time.
30
Electrode
Weld Output
Terminal
Provides shielding gas during the
weld cycle.
18 Preflow Timer TD3, Control
R12, And Switch S9
R12 selects time shielding gas
flows before arc starts. S9 is an integral part of R12 so that when R12
is turned past zero (0), TD3 is off.
19 Spot Timer TD2, Switch S8,
And Control R10
22
High
Frequency
Intensity
Control R13
Integrated
Rectifier
SR2
16 Postflow Timer TD1
17 Gas Valve GS1
High
Frequency
Coupling
Coil T3
27
Provides connection point for auxiliary equipment.
R10 selects time output is available
when spot welding. S8 selects Off
or spot welding with remote contactor control.
20 High Frequency Transformer
T2
21
Spark Gaps G
Capacitor
C4
Current Feedback
Voltage Feedback
Voltage Feedback
Steps up input voltage and charges
capacitor C4.
21 Spark Gaps G And High Frequency Coupling Coil T3
G provides path for C4 to discharge
into T3. T3 supplies high-frequency
to welding circuit.
20
High
Frequency
Transformer
T2
22 High Frequency Intensity
Control R13
Changes amount of HF energy
used to start and maintain the arc.
23 Main Rectifier SR1
18 ♦
19 ♦
Preflow
Timer
TD3
18♦
Preflow Time
Control
R12
Switch
S9
115 VAC
Spot
Timer
TD2
19 ♦
Spot Time
Control
R10
19 ♦
Spot Time
Switch
S8
AC Or DC Control
1φ Power
Weld Current Circuit
External Circuits
♦
Syncrowave 250
Changes the ac output from T1 to
full-wave rectified dc.
24 Background Power Source
Provides reduced weld output ripple 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 output polarity.
29 Integrated Rectifier SR2
Provides dc voltage feedback to
PC1.
30 Electrode And Work Weld
Output Terminals
Provide weld output.
Optional
TM-353 Page 21
SECTION 6 – TROUBLESHOOTING
6-1. Troubleshooting Table
. See Section 6-2 for test points and values and
Section 10 for parts location.
. Use MILLER Testing Booklet (Part No. 150 853)
when servicing this unit.
Trouble
Prior to Serial No. KG164875, no weld
output; unit completely inoperative –
Effective with Serial No. KG164875,
no weld output; unit completely inoperative; PL2 off.
Remedy
Be sure line disconnect switch is in the On position.
Replace building line fuse(s) or reset circuit breaker(s) if open.
Check for proper electrical input connections (see Section 3-11).
Check for proper jumper link position (see Section 3-11).
Check Power switch S1 and replace if necessary.
Prior to Serial No. KG164875, no weld
output; fan runs – Effective with Serial
No. KG164875, no weld output; fan
runs; PL2 on.
If using remote control, place Output (Contactor) switch S3 in Remote 14 position, and connect remote control to Remote 14 receptacle RC1 (see Sections 3-8 and Section 4-8). If remote is not being
used, place Output switch S3 in On position.
Check, repair or replace remote control device.
Allow a cooling period of approximately 15 minutes. If thermostats TP1 remain open, check continuity
and replace if necessary (see Section 3-3).
Check circuit breaker CB1, and reset if open (see Section 7-2).
Place Output Selector switch S4 in desired position (see Section 4-2).
Check optional preflow timer board TD3, and replace if necessary.
Check optional spot timer relay TD2 for proper connections and resistance. Replace TD2 if
necessary.
Check continuity of Spot Time switch S8. Check condition of contacts. Repair or replace S8 if necessary.
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. Replace HD1 if
necessary.
Unit provides only minimum weld
output.
Check position of Amperage Control switch S5 (see Section 4-7).
Increase Amperage Adjustment control R1 setting if a remote control is used (see Section 4-7).
Check, repair or replace remote control device.
Check resistance and connections of Amperage Adjustment control R1; R1 is 1000 ohms ±10%.
Replace R1 if necessary.
Check SCRs in main rectifier SR1, and replace if necessary. If any SCRs are replaced, Check capacitors C7 through C10 for a short or open, and check for proper connections. Replace C7 through C10
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. Replace HD1 if
necessary.
Unit provides only maximum weld
output.
Check Amperage Adjustment control R1 for proper connections and resistance; R1 is 1000 ohms
±10%. Replace R1 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. Replace HD1 if
necessary.
Check connections for continuity to shunt device on units with Serial No. prior to KB110695.
Check bypass capacitors C13, C14, C16, C17, C18, and C19 for broken leads, shorts, and leakage.
Replace if necessary.
TM-353 Page 22
Syncrowave 250
Trouble
Remedy
Check SCRs in main rectifier SR1, and replace if necessary. If any SCRs are replaced, Check capacitors C7 through C10 for a short or open, and check for proper connections. Replace C7 through C10
if necessary.
Check control board PC1 and connections, and replace if necessary.
Check connections to line filter FL1. Check input to PC1. Replace FL1 if necessary.
Erratic weld output.
Check for poor or improper input or output connections. See Sections 3-11 and 3-8.
Replace electrode.
Check torch assembly, and replace if necessary.
Check fuse F2 in rectifier SR3 circuit, and replace if necessary.
If Amperage Control switch S5 is in the Remote position check, repair, or replace remote amperage
control device if necessary.
Check connections for continuity to shunt device on units with Serial No. prior to KB110695.
Check Amperage Adjustment control R1 for proper connections and resistance; R1 is 1000 ohms
±10%. Replace R1 if necessary.
Check bypass capacitors C13, C14, C16, C17, C18, and C19 for broken leads, shorts, and leakage.
Replace if necessary.
Check SCRs in main rectifier SR1, and replace if necessary. If any SCRs are replaced, Check capacitors C7 through C10 for a short or open, and check for proper connections. Replace C7 through C10
if necessary.
Check control board PC1 and connections, and replace if necessary.
No or limited ac balance control.
Check AC Balance control R3 for proper connections and resistance; R3 is 5000 ohms ±10%.
Replace R3 if necessary.
Check control board PC1 and connections, and replace if necessary.
Check SCRs in main rectifier SR1, and replace if necessary. If any SCRs are replaced, Check capacitors 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 S5, S5 must be in Panel position (see Section 4-7).
Check control board PC1 and connections, and replace if necessary.
Crater fill time too long or does not
time out.
Check position of Crater control R11 (see Section 4-4).
Check resistance and connections of Crater control R11; R11 is 5 meg ohms ±10%. Replace R11 if
necessary.
Check control board PC1 and connections, and replace if necessary.
No arc control.
Place Arc Control switch S6 in the On position.
Place High Frequency switch S2 in the Off position.
Be sure arc voltage is below 24 volts (see Section 3-2. Volt-Ampere Curves).
Check position of Arc Control R2 (see Section 4-9).
Check fuse F1 in rectifier SR3 circuit, and replace if necessary.
Check resistance and connections of Arc control R2; R2 is 1000 ohms ±10%. Replace R1 if
necessary.
Check control board PC1 and connections, and replace if necessary.
Lack of high frequency at tungsten
electrode; difficulty in starting an arc.
Use proper size tungsten for welding application.
Use shortest possible cables (see Section 3-7).
Check cables and torch for cracked or deteriorated insulation or bad connections. Repair or replace
necessary parts.
Be sure to disconnect SMAW electrode cable from weld output terminal when GTAW welding.
Decrease gas flow setting.
Use properly prepared tungsten.
Increase setting of High Frequency Intensity control R13 (see Section 4-11).
Check spark gaps G, and readjust if necessary (see 7-4).
Syncrowave 250
TM-353 Page 23
Trouble
No high frequency at spark gaps G.
Remedy
Check position of High Frequency switch S2 (see Section 4-11).
Place Output (Contactor) switch S3 in Remote position and be sure remote control is connected to
Remote receptacle RC1 (see Section 3-8).
Check circuit breaker CB1, and reset if open (see Section 7-2).
Check fuse F1 in rectifier SR2 circuit, and replace if necessary.
Check coil voltage and connections of contactor control relay CR1. Check continuity of coil and condition of contacts. Replace CR1 if necessary.
Check coil voltage and connections of contactor control relay CR5. Check continuity of coil and condition of contacts. Replace CR5 if necessary.
Check spark gaps G, and readjust if necessary (see Section 7-4).
Check resistance and connections of High Frequency Intensity control R13; R13 is 1.5 ohms ±10%.
Replace R1 if necessary.
Check capacitor C4 for a short or open, and check for proper connections. Replace C4 if necessary.
Check transformer T2 for signs of winding failure. Check continuity across windings, and check for
proper connections. Check secondary voltages. Replace T2 if necessary.
Check coupling coil T3 for signs of winding failure. Check continuity across windings, and check for
proper connections. Replace T3 if necessary.
Check control board PC1 and connections, and replace if necessary.
No preflow time (optional).
Place Output (Contactor) switch S3 in Remote position and be sure remote control is connected to
Remote receptacle RC1 (see Section 3-8).
Check position of Preflow Time control R12.
Check continuity of Preflow Time switch S9. Check condition of contacts. Repair or replace S9 if necessary.
Remove jumper link 1 on terminal strip 1T.
Check optional preflow timer board TD3, 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 CR3. Check continuity of coil and condition of
contacts. Replace CR3 if necessary.
Check coil voltage and connections of control relay CR1. Check continuity of coil and condition of
contacts. Replace CR1 if necessary.
Postflow timer does not time out.
Check position of Postflow Time control setting (see Section 4-10).
Check Control relay CR5 contacts 2 and 5 for proper operation. Replace CR5 if necessary.
Check coil voltage and connections of gas valve GS1. Check continuity of coils. Replace GS1 if necessary.
Check input voltage and connections to Postflow timer board TD1. Check continuity of contacts. Replace TD1 if necessary.
Check control board PC1 and connections, and replace if necessary.
No postflow time.
Check position of Postflow Time control setting (see Section 4-10).
Place Output(Contactor) switch S3 in the Remote position, and connect a remote control to receptacle RC1 according to Section 3-8.
Check coil voltage and connections of control relay CR5. Check continuity of coil and condition of
contacts. Replace CR5 if necessary.
Check coil voltage and connections of gas valve GS1. Check continuity of coils. Replace GS1 if necessary.
Check input voltage and connections to Postflow timer board TD1. Check continuity of contacts. Replace TD1 if necessary.
Check control board PC1 and connections, and replace if necessary.
No gas flow.
Place Output(Contactor) switch S3 in the Remote position, and connect a remote control to receptacle RC1 according to Section 3-8.
Check circuit breaker CB1, and reset if open (see Section 7-2).
TM-353 Page 24
Syncrowave 250
Trouble
Remedy
Check Control relay CR2 contacts 4 and 7 for proper operation. Replace CR2 if necessary.
Check coil voltage and connections of gas valve GS1. Check continuity of coils. Replace GS1 if necessary.
No power output at 115 volts ac receptacle RC1; weld output available.
Check circuit breaker CB1, and reset if open (see Section 7-2).
Fan motor FM does not run; weld output available. Effective with Serial No.
KG164875, unit is equipped with FanOn-Demand, which only runs when
cooling is required.
Check and clear fan blade obstruction.
Check coil voltage and connections of fan motor FM, and replace if necessary.
Line fuse opens immediately when
solid-state contactor SR1 turns on in
DC mode only.
Check diode D1, and replace if necessary.
Check SCRs in main rectifier SR1, and replace if necessary. If any SCRs are replaced, Check capacitors C7 through C10 for a short or open, and check for proper connections. Replace C7 through C10
if necessary.
No control of weld output.
Check position of Amperage Control switch S5 (see Section 4-7).
Check resistance and connections of Amperage Adjustment control R1; R1 is 1000 ohms ±10%.
Replace R1 if necessary.
Check, repair or replace remote control device.
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. Replace HD1 if
necessary.
Check control board PC1 and connections, and replace if necessary.
Tungsten electrode oxidizing and not
remaining bright after conclusion of
weld.
Check position of Postflow Time control R12 (see Section 4-10).
Check and tighten 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 direction 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 control device.
Check Amperage Control switch S5 position (see Section 4-7). Check and replace S5 if necessary.
Check Output (Contactor) switch S3 position (see Section 4-8). Check and replace S3 if necessary.
Check position of jumper links 1 and 2 on terminal strip 1T according to Section 6-2.
Check coil voltage and connections of control relay CR2. Check continuity of coil and condition of
contacts. Replace CR2 if necessary.
Prior to Serial No. KF959379, check choke RFC1 connections. Check continuity of RFC1. Replace if
necessary. Effective with Serial No. KF959379 check remote 14 filter board PC2 (see Section 6-6).
Replace PC2 if necessary.
Check control board PC1 and connections, and replace if necessary.
Ammeter A1 not displaying correct
weld output amperage.
Calibrate ammeter as instructed in Section 6-8.
Check ammeter A1 voltage; +1 millivolts dc per 3 ampere of weld output. Replace A1 if necessary.
Check control board PC1 and connections, and replace if necessary.
Effective with Serial No. KB110695, check resistance and connections of hall device HD1; HD1 is
1600 ohms ±10% between pins 1 and 3 of plug PLG3. Check input and output voltages. Replace HD1
if necessary.
Voltmeter V1 not displaying correct arc
voltage.
Check connections for continuity to voltmeter V1. Replace V1 if necessary.
Electronic equipment in welding area
not working properly.
HF interference problem. Check for proper installation, and correct problem (see Section 8).
Syncrowave 250
TM-353 Page 25
6-2. Troubleshooting Circuit Diagram For Welding Power Source
Y Disable high frequency by placing High Frequency
switch S2 in Off position before testing unit.
R1
R1
R1
V3
V2
V25
V1
V11
V4
V5
R1
V10
V9
V6
V8
V7
Link 1
Link 2
V13
V12
V14
V17
TD1 begins to time out
when CR5 deenergizes
TD3 begins to time out
when CR4 energizes
V15
V16
CR2 energizes when
remote contactor
switch closes
See Figure 9-19
for PC3 circuit
CR3 energizes during spot time
when an arc is detected
CR4 energizes when remote contactor
switch closes
See Section 6-6
for PC2 data
TM-353 Page 26
See Section 3-8
for RC1
information
Syncrowave 250
Test Equipment Needed:
Voltage Readings
See Figure 10-1 for
HD1 location
No calibration available
for voltmeter V1
R1
V24
R1
V25
V23, B,
C, D, E
See Section 6-3
for waveforms
B, C, D, E
a)
Tolerance – ±10% unless
specified
b)
Reference – to circuit
common (lead 42) unless
noted
c)
Wiring Diagram
Section 10
V1
230 volts ac
V2
77 volts ac
V3
82.5 volts ac
V4
57 volts ac
V5, V6
115 volts ac
V7
24 volts ac
V8, V9
18 volts ac
V10
10 volts ac
V11
80 volts dc
V12. V13, V14
115 volts ac
R2
A A
see
V15, V16, V17
24 volts ac
V18
115 volts ac with S2
in Start or Continuous
V19
0 to +10 volts dc
with contactor on
R3
V22
V21
–
V20, V21
24 volts dc
V22
0-80 volts dc (rectified arc voltage)
V23
maximum 80 volts
ac/dc
V24
24 volts dc
V25
16.5 millivolts dc
per 1 ampere of
weld output
A
CR1 energizes
when open-circuit voltage
is present; denergizes
when an
arc is struck
A
V20
See Section 6-3
for waveform A
V18
See Section 6-8
for ammeter A1
calibration
V19
See also
Sections 6-4 and 6-5
for PC1 data
CR5 energizes when
contactor is on
Resistance Values
a)
Tolerance – ±10% unless specified
b)
Turn Off unit and disconnect input
power before checking resistance
R1
All values for T1, Z1, and T3 are less
than 1 ohm
R2
5.3 ohms
R3
6.1 K ohms
SC-188 161
Syncrowave 250
TM-353 Page 27
6-3. Waveforms For Section 6-2
Waveforms shown are for 60 Hertz models;
waveforms for 50 Hertz models are similar.
5 ms 1 V
5 ms 50 V
gnd
gnd
A. SR1 Gate Pulse With Respect To Cathode
At No Load
B. DC Open-Circuit Voltage With Amperage
Adjustment Control At Maximum
5 ms 20 V
5 ms 50 V
gnd
C. DC Output, 100 Amperes, 24 Volts DC
(Resistive Load)
TM-353 Page 28
gnd
D. AC Open-Circuit Voltage With Amperage
Adjustment Control At Maximum
Syncrowave 250
5 ms 50 V
gnd
E. AC Output, 100 Amperes, 24 Volts AC (Resistive Load)
Test Equipment Needed:
Syncrowave 250
TM-353 Page 29
6-4. Control Board PC1 Testing Information (Use With Section 6-5)
Y Disable 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
2
1
Control Board PC1
2
Receptacle RC51
3
Receptacle RC52
4
Receptacle RC53
5
Receptacle RC54
6
Receptacle RC55
3
4
6
5
Test Equipment Needed:
SB-178 976-A / ST-800 344-A
TM-353 Page 30
Syncrowave 250
6-5. Control Board PC1 Test Point Values
a) Tolerance
specified
PC1 Voltage Readings
–
±10% unless
b) Reference – to circuit common
(lead 42) unless noted
Receptacle
Pin
RC51
1
18 volts ac input
2
18 volts ac input
3
+10 volts dc output
4
Circuit common
5
Not used
6
Not used
1
Circuit common
2
+1 millivolt dc per 3 ampere of weld output
1
Gate pulse for SCR1 with respect to pin 2 (see Section 6-3)
2
Reference for gate pulse to SCR1
3
Gate pulse for SCR3 with respect to pin 4 (see Section 6-3)
4
Reference for gate pulse to SCR3
5
Gate pulse for SCR2 with respect to pin 6 (see Section 6-3)
6
Reference for gate pulse to SCR2
7
Gate pulse for SCR4 with respect to pin 8 (see Section 6-3)
8
Reference for gate pulse to SCR4
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 switch S7 in On position, or +10 volts dc with S7 in Off position
5
+10 volts dc output with Output (Contactor) switch S3 in On position
6
–24 volts dc
7
–24 volts dc with contactor on or off
8
0 to +10 volts dc input from min. to max. of Amperage Adjustment control R1 with contactor on
9
0 to +10 volts dc input from min. to max. of Amperage Adjustment control R1 with contactor on
10
Circuit common
11
+24 volts dc
12
0 volts during open-circuit voltage condition; +24 volts with arc on or contactor off
RC52
RC53
RC54
Syncrowave 250
Value
TM-353 Page 31
Receptacle
Pin
RC55
1
Circuit common
2
+1.65 volts dc per 100 amperes of weld output with respect to pin 1
3
–15 volts dc output
4
0 to +4 volts dc input from min. to max. of Arc Control R2 with Arc Control switch S6 On
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 max. of Arc Control R2 with Arc Control switch S6 Off
TM-353 Page 32
Value
Syncrowave 250
6-6. Remote Board PC2 Testing Information (Use With Section 6-7)
Y Disable 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.
1
3
Receptacle RC2
4
Receptacle RC3
4
3
2
Test Equipment Needed:
ST-157 960-B / ST-800 344-A
Syncrowave 250
TM-353 Page 33
6-7. Remote 14 Filter Board PC2 Test Point Values (Use With Section 6-2 And Section 6-6)
a) Tolerance
specified
PC2 Voltage Readings
Pin
RC1
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
D
Remote control circuit common
E
0 to +10 volts dc input command signal from remote control
K
Chassis common
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 volts dc input command signal from remote control
6
24 volts ac
1
Chassis common
RC3
TM-353 Page 34
±10% unless
b) Reference – to circuit common
(lead 42) unless noted
Receptacle
RC2
–
Value
Syncrowave 250
6-8. Meter Calibration
Be sure plugs are secure before
calibrating meter.
No calibration available for ammeter
offset, or for voltmeter V1.
1
Control Board PC1
2
Voltmeter V1
3
Ammeter A1
1
Top View
R19
2
3
Amperes
Adjust R19 for amperage gain to
match external calibrated meter
using load bank set at desired
load.
SB-130 690-D / ST-800 344-A
Syncrowave 250
TM-353 Page 35
6-9. Input Voltage Labels And Connections
1
Input Voltage Label And Connection Diagram – Only One
Label Is On Unit
2
Terminal Strip TE1
Test Equipment Needed:
2
1
ST-154 793-A / ST-114 947-A / ST-121 000-A / ST-131 735
TM-353 Page 36
Syncrowave 250
SECTION 7 – MAINTENANCE
7-1. Routine Maintenance
Y Disconnect power before maintaining.
3 Months
Clean And
Tighten
Weld
Terminals
Repair Or
Replace
Cracked
Weld
Cables
Replace
Unreadable
Labels
Adjust Spark
Gaps
Replace
Cracked
Parts
14-Pin Cord
Torch Cable
Gas Hose
6 Months
OR
Blow Out Or Vacuum
Inside,
During Heavy Service,
Clean Monthly
7-2. Circuit Breaker CB1
1
Circuit Breaker CB1
If CB1 opens, output to the 115 volts
ac duplex receptacle, high frequency, and gas flow stop. Press button
to reset breaker.
1
CB1
Ref. ST-154 795-C
Syncrowave 250
TM-353 Page 37
7-3. Fuses F1 And F2
1
Fuse F1 (See Parts List For
Rating)
Fuse F1 (between leads 50 and
150) protects wiring harness from
shorted SR2. If F1 opens, you may
experience problems with arc starting and arc performance in the DC
TIG mode.
1
2
2
Fuse F2 (See Parts List For
Rating)
Fuse F2 (between leads 22 and
149) protects wiring harness from
shorted SR3. If F2 opens, you may
experience problems with arc control, and no high frequency in start
high frequency.
Tools Needed:
3/8 in
7-4. Adjusting Spark Gaps
Y Turn Off power before
adjusting spark gaps.
4
4
Open access door.
1
Replace point if tungsten end disappears; do not clean or dress
tungsten.
3
3
2
Tungsten End Of Point
1
2
Spark Gap
Normal spark gap is 0.008 in (0.203
mm).
If adjustment is needed, proceed as
follows:
3
Adjustment Screws
Loosen screws. Place gauge of
proper thickness in spark gap.
4
Pressure Point
Apply slight pressure at point until
gauge is held firmly in gap. Tighten
screws to 12 in/lbs torque (overtightening will deform plastic base). Adjust other gap.
Close access door.
Tools Needed:
Ref. ST-154 795-C / Ref. S-0043
TM-353 Page 38
Syncrowave 250
SECTION 8 – HIGH FREQUENCY (HF)
8-1. Welding Processes Using HF
1
HF Voltage
GTAW – helps arc jump air gap
between torch and workpiece and/
or stabilize the arc.
SAW – helps arc reach workpiece
through flux granules.
2
1
2
1
Work
Work
Gas Tungsten Arc
Welding (GTAW)
Submerged Arc
Welding (SAW)
Flux
high_freq1 7/95 – S-0693
8-2. Sources Of HF Radiation From Incorrect Installation
Weld Zone
11, 12
50 ft
(15 m)
10
14
9
8
7
3
2
13
1
4
5
6
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
Syncrowave 250
5
6
Workpiece
Work Table
Sources Of Conduction Of HF
7
8
9
Input Power Cable
Line Disconnect Device
Input Supply Wiring
Sources Of Reradiation Of HF
10
11
12
13
14
Ungrounded Metal Objects
Lighting
Wiring
Water Pipes And Fixtures
External Phone And Power Lines
TM-353 Page 39
8-3. Correct Installation
Weld Zone
6
50 ft
(15 m)
50 ft
(15 m)
4
1
5
2
7
3
7
Ground All
Metal Objects
And All Wiring
In Welding Zone
Using #12 AWG
Wire
Nonmetal
Building
Ground
Workpiece
If Required
By Codes
8
7
7
10
Metal Building
9
Ref. S-0695 / Ref. S-0695
1
HF Source (Welder With Built-In HF Or
Separate HF Unit)
Ground metal machine case, work output
terminal, line disconnect device, input
supply, and worktable.
Electrically join (bond) all conduit sections
using copper straps or braided wire. Ground
conduit every 50 ft (15 m).
5
Water Pipes And Fixtures
8
Metal Building Panel Bonding Methods
Bolt or weld building panels together, install
copper straps or braided wire across seams,
and ground frame.
Ground water pipes every 50 ft (15 m).
9
A circle 50 ft (15 m) from centerpoint
between HF source and welding torch in all
directions.
6
Cover all windows and doorways with
grounded copper screen of not more than
1/4 in (6.4 mm) mesh.
3
7
2
Welding Zone And Centerpoint
Weld Output Cables
Keep cables short and close together.
4
Conduit Joint Bonding And Grounding
TM-353 Page 40
External Power Or Telephone Lines
Locate HF source at least 50 ft (15 m) away
from power and phone lines.
Grounding Rod
Consult the National Electrical Code for
specifications.
Windows And Doorways
10 Overhead Door Track
Ground the track.
Syncrowave 250
SECTION 9 – ELECTRICAL DIAGRAMS
. The circuits in this manual can be used for troubleshooting, but there might be minor circuit differences from your machine. Use circuit inside
machine case or contact distributor for more information.
The following is a list of all diagrams for models covered by this manual.
Model
Syncrowave 250
Serial Or Style Number
Circuit Diagram
Wiring Diagram
JJ339876 thru JJ351864
SC-114 914
D-116 884-B♦♦
JJ351865 thru JJ365633
SC-120 877
D-120 878-B♦♦
JJ365634 thru JJ503983
SC-121 280
D-121 281-D♦♦
JJ503984 thru JK572897
SC-124 314
D-124 307-C♦♦
JK572898 thru JK617846
SC-124 785-B
D-124 786-B♦♦
JK617847 thru JK682713
SC-124 785-B
D-129 200-B♦♦
JK682714 thru JK690986
SC-124 785-B
D-130 576-B♦♦
JK690987 thru KA806712
SC-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♦♦
KH526231 and following
SC-188 161-A
SD-188162-A
JJ339876 thru JJ399987
D-118 765♦♦
JJ399988 thru JK682713
D-122 270♦♦
JK682714 thru KA797306
D-130 691-A♦♦
KA797307 thru KG062109
D-135 253♦♦
KG062110 thru KH508254
SD-178 975♦♦
KH508255 and following
SD-187644
RFC Circuit Board PC2
JJ365634 thru KB010829
SA-121 282
Remote 14 Filter Board PC2
KF959379 and following
SA-158 763
Circuit Board PC3♦
JJ351865 and following
SA-120 872
Timer TD1
JJ339876 and following
SA-044 725-C
Timer TD3♦
JJ339876 and following
SA-045 288-D
Circuit Board PC1
♦ Optional
♦♦ Not included in this manual
Syncrowave 250
TM-353 Page 41
SC-114 914
Figure 9-1. Circuit Diagram For Syncrowave 250 Effective With Serial No. JJ339876 Thru JJ351864
TM-353 Page 42
Syncrowave 250
SC-120 877
Figure 9-2. Circuit Diagram For Syncrowave 250 Effective With Serial No. JJ351865 Thru JJ365633
Syncrowave 250
TM-353 Page 43
SC-121 280
Figure 9-3. Circuit Diagram For Syncrowave 250 Effective With Serial No. JJ365634 Thru JJ503983
TM-353 Page 44
Syncrowave 250
SC-124 314
Figure 9-4. Circuit Diagram For Syncrowave 250 Effective With Serial No. JJ503984 Thru JK572897
Syncrowave 250
TM-353 Page 45
SC-124 785-B
Figure 9-5. Circuit Diagram For Syncrowave 250 Effective With Serial No. JK572898 Thru JK690986
TM-353 Page 46
Syncrowave 250
SC-132 697-A
Figure 9-6. Circuit Diagram For Syncrowave 250 Effective With Serial No. JK690987 Thru KA806712
Syncrowave 250
TM-353 Page 47
SC-137 431
Figure 9-7. Circuit Diagram For Syncrowave 250 Effective With Serial No. KA806713 Thru KA877024
TM-353 Page 48
Syncrowave 250
SC-135 581
Figure 9-8. Circuit Diagram For Syncrowave 250 Effective With Serial No. KA877025 Thru KB010829
Syncrowave 250
TM-353 Page 49
SC-142 524
Figure 9-9. Circuit Diagram For Syncrowave 250 Effective With Serial No. KB010830 Thru KB110694
TM-353 Page 50
Syncrowave 250
SC-148 144
Figure 9-10. Circuit Diagram For Syncrowave 250 Effective With Serial No. KB110695 Thru KC252675
Syncrowave 250
TM-353 Page 51
SC-154 649-C
Figure 9-11. Circuit Diagram For Syncrowave 250 Effective With Serial No. KC252676 Thru KG029204
TM-353 Page 52
Syncrowave 250
SC-178 835
Figure 9-12. Circuit Diagram For Syncrowave 250 Effective With Serial No. KG029205 Thru KG062109
Syncrowave 250
TM-353 Page 53
SC-179 303-A
Figure 9-13. Circuit Diagram For Syncrowave 250 Effective With Serial No. KG062110 Thru KG170300
TM-353 Page 54
Syncrowave 250
SC-181 109-E
Figure 9-14. Circuit Diagram For Syncrowave 250 Effective With Serial No. KG170301 Thru KH526230
Syncrowave 250
TM-353 Page 55
SC-188 161-A
Figure 9-15. Circuit Diagram For Syncrowave 250 Effective With Serial No. KH526231 And Following
TM-353 Page 56
Syncrowave 250
Notes
Syncrowave 250
TM-353 Page 57
Figure 9-16. Wiring Diagram For Syncrowave 250 Effective With Serial No. KH526231 And Following
TM-353 Page 58
Syncrowave 250
SD-188 162-A
Syncrowave 250
TM-353 Page 59
Figure 9-17. Circuit Diagram For Control Board PC1 Effective With
Serial No. KH508255 And Following (Part 1 Of 2)
TM-353 Page 60
Syncrowave 250
SD-187 644 (1 of 2)
Syncrowave 250
TM-353 Page 61
Figure 9-18. Circuit Diagram For Control Board PC1 Effective With
Serial No. KH508255 And Following (Part 2 Of 2)
TM-353 Page 62
Syncrowave 250
SD-187 644 (2 of 2)
Syncrowave 250
TM-353 Page 63
SA-121 282
Figure 9-19. Circuit Diagram For RFC Board PC2 Effective With Serial No. JJ365634 Thru KB010829
SA-158 763
Figure 9-20. Circuit Diagram For Remote 14 Filter Board PC2
Effective With Serial No. KF959379 And Following
SA-120 872
Figure 9-21. Circuit Diagram For Optional Snubber Board PC3
Effective With Serial No. JJ351865 And Following
TM-353 Page 64
Syncrowave 250
SA-044 725-C
Figure 9-23. Circuit Diagram For Postflow Timer Board TD1
Effective With Serial No. JJ339876 And Following
SA-045 288-D
Figure 9-22. Circuit Diagram For Optional Preflow Timer Board TD3
Effective With Serial No. JJ339876 And Following
Syncrowave 250
TM-353 Page 65
Notes
TM-353 Page 66
Syncrowave 250
TM-353E
January 2001
Eff. w/Serial Number JJ339876
Processes
TIG (GTAW) Welding
Stick (SMAW) Welding
Description
Arc Welding Power Source
R
Syncrowave 250
60 Hz, 50 Hz
Visit our website at
www.MillerWelds.com
16
23
29–Fig.10-2
1
28
2–Fig.10-3
5
6
27
3
4
7–Fig.10-5
8
26
25
9
24
10
22
11
12
15
14
31
30
13
21
20
19
18
17–Fig.10-4
SECTION 10 – PARTS LIST
. Hardware is common and
not available unless listed.
TM-353 Page 68
ST-120 135-R
Figure 10-1. Main Assembly
Syncrowave 250
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 10-1. Main Assembly
. 1 . . . . . . . . . . . . . 114 741
. 1 . . . . . . . . . . . . . 182 605
. 2 . . . . SR1 . . . . 181 106
. 3 . . . . . S4 . . . . 112 630
. 3 . . . . . S4 . . . . 133 061
. . . . . . PLG10 . . 164 899
. . . . . . PLG11 . . . 168 809
. . . . . . . C13 . . . . 155 082
. . . . . . . C13 . . . . 132 433
. 4 . . . . . . . . . . . . . 057 357
. 5 . . . . . . . . . . . . . 010 494
. 6 . . . . . . . . . . . . . 110 375
. 6 . . . . . . . . . . . . . 134 201
. 7 . . . . . . . . . . . . . Fig 10-4
. 8 . . . . . . . . . . . . . 083 147
. 9 . . . . . . . . . . . . . 114 754
. 9 . . . . . . . . . . . . . 181 101
10 . . . . . . . . . . . . 026 627
11 . . . . . . . . . . . . 070 026
12 . . . PC1 . . . . 117 981
12 . . . PC1 . . . . 138 058
12 . . . PC1 . . . . 180 014
12 . . . PC1 . . . . 187 642
. . . . . . PLG51 . . 115 093
. . . . . . PLG54 . . 130 203
. . . . . . PLG55 . . 115 091
13 . . . R14 . . . . 138 105
13 . . . FL1 . . . . 084 171
14 . . . HD1 . . . . 156 313
. . . . . . PLG3 . . . 130 204
15 . . . . . . . . . . . . 073 756
16 . . . . Z1 . . . . 114 826
17 . . . . . . . . . . . . Fig 10-4
. . . . . . . . . . . . . . . . 109 035
18 . . C11,12 . . 111 634
. . . . . . . . . . . . . . . . 172 078
19 . . . TE1 . . . . 034 587
. . . . . . . . . . . . . . . . 601 835
. . . . . . . . . . . . . . . . 601 836
. . . . . . . . . . . . . . . . 010 915
. . . . . . . . . . . . . . . . 083 426
. . . . . . . . . . . . . . . . 038 888
. . . . . . . . . . . . . . . . 010 913
. . . . . . . . . . . . . . . . 038 887
. . . . . . . . . . . . . . . . 038 618
20 . . . . . . . . . . . +114 751
20 . . . . . . . . . . . +181 097
20 . . . . . . . . . . . +182 606
21 . . . . T1 . . . . 115 097
21 . . . . T1 . . . . 138 171
21 . . . . T1 . . . . 180 674
21 . . . . T1 . . . . 138 175
21 . . . . T1 . . . . 180 673
21 . . . . T1 . . . . 121 161
21 . . . . T1 . . . . 138 172
21 . . . . T1 . . . . 180 672
21 . . . . T1 . . . . 191 887
. . . . . . . TP1 . . . . 020 520
. . . . . . . TP2 . . . . 168 891
Syncrowave 250
. . COVER, top (Prior to KG170301) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . COVER, top (Eff w/KG170301) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . RECTIFIER, si diode (Fig 10-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . SWITCH, plrty/changeover (Prior to KA759476) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . SWITCH, plrty/changeover (Eff w/KA759476) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . CAPACITOR, cer disc. .003 200VAC (Prior to JK690987) . . . . . . . . . . . . . . . . . 1
. . CAPACITOR, cer disc. .05uf 500VDC (Eff w/JK690987) . . . . . . . . . . . . . . . . . . . 1
. . BUSHING, snap-in nyl .937 ID x 1.125mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . BUSHING, snap-in nyl 1.375 ID x1.750mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . STAND-OFF SUPPORT, PC card No. 6 screw (Prior to KG170301) . . . . . . . . 3
. . STAND-OFF SUPPORT, PC card No. 6 screw (Eff w/KG170301) . . . . . . . . . . 3
. . PANEL, mtg components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . GROMMET, screw No. 8/10 panel hole .312sq .500 high . . . . . . . . . . . . . . . . . . 4
. . FRAME, lifting (Prior to KG170301) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . FRAME, lifting (Eff w/KG170301) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . GASKET, lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . STAND-OFF, 6-32 x .437 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . CIRCUIT CARD, control (Prior to JJ389988) (Fig 10-5) . . . . . . . . . . . . . . . . . . . . 1
. . CIRCUIT CARD, control (Eff w/JJ389988 thru KB110694) (Fig 10-5) . . . . . . . . 1
. . CIRCUIT CARD, control (Eff w/ KB110695 thru KG060803) . . . . . . . . . . . . . . . . 1
. . CIRCUIT CARD, control (Eff w/KG060804) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . CONNECTOR PLUG & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . CONNECTOR PLUG & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . CONNECTOR PLUG & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . RESISTOR, (Eff w/KB110695 thru KG062110) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . FILTER, line power 115/250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . TRANSDUCER, current 300A (Eff w/KB110695) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . CONNECTOR & SOCKETS, (Eff w/KB110695) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . STAND-OFF, 6-32 x .625 lg (Eff w/KB110695) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . REACTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . PANEL, rear w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . LABEL, warning electric shock can kill etc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . BRACKET, mtg primary board (Eff w/KE727074) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . TERMINAL ASSEMBLY, pri (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . NUT, brs hex 10-32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
. . . . NUT, brs hex .250-20 jam hvy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . WASHER, flat brs .250 ID x .625 OD x .031thk . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . TERMINAL BOARD, primary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . STUD, primary board brs .250-20 x 1.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . WASHER, flat brs .218 ID x 460 OD x .031thk . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . . STUD, primary board brs 10-32 x 1.375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . . LINK, jumper term bd pri . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . PANEL, side (Prior to KG170301) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . PANEL, side (Eff w/KG170301 thru KG181270) . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . PANEL, side (Eff w/KG181271 and on) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . TRANSFORMER, pwr main 200/230/460 (Prior to KA877025) . . . . . . . . . . . . . 1
. . TRANSFORMER, pwr main 200/230/460 (Eff w/KA877025 thru KG082621) . 1
. . TRANSFORMER, pwr main 200/230/460 (Eff w/KG082622) . . . . . . . . . . . . . . . 1
. . TRANSFORMER, pwr main (220/380/415 (Prior to KG082622) . . . . . . . . . . . . 1
. . TRANSFORMER, pwr main 220/380/415 (Eff w/KG082622) . . . . . . . . . . . . . . . 1
. . TRANSFORMER, pwr main 230/460/575 (Prior to KA877025) . . . . . . . . . . . . . 1
. . TRANSFORMER, pwr main 230/460/575 (Eff w/KA877025 thru KG082621) . 1
. . TRANSFORMER, pwr main 230/460/575 (Eff w/KG082622) . . . . . . . . . . . . . . . 1
. . TRANSFORMER, pwr main 260/380/520 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . THERMOSTAT, NC (included w/transformer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . THERMOSTAT, NC (Eff w/KG170301) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
TM-353 Page 69
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 10-1. Main Assembly (Continued)
22 . . . . . . . . . . . .
22 . . . . . . . . . . . .
22 . . . . . . . . . . . .
23 . . . . . . . . . . . .
24 . . . . . . . . . . . .
25 . . . . . . . . . . . .
26 . . . . C2 . . . .
27 . . . . R5 . . . .
28 . . . . . . . . . . . .
29 . . . . . . . . . . . .
30 . . . . . . . . . . . .
31 . . . F1,2 . . . .
................
................
114 755
170 748
171 677
157 196
010 199
108 105
031 668
117 803
114 722
Fig 10-2
098 376
085 874
092 368
130 764
..
..
..
..
..
..
..
..
..
..
..
..
..
..
BASE, (Prior to KE727074) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BASE, (Eff w/KE727074 thru KF959176) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BASE, (Eff w/KF959177) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSULATOR, upright (Eff w/KC307050) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TUBING, stl .500 OD x 17ga x 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLAMP, capacitor 2.500dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAPACITOR, elctlt 4000uf 100VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RESISTOR, WW fxd 10W 1K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRACKET, mtg rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PANEL, front w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUSE, holder (Eff w/KH526231) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUSE, mintr gl slo-blo 10A (Eff w/KH526231) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TUBING, stl .250 ID x 16ga x 3 (Prior to JK682714) . . . . . . . . . . . . . . . . . . . . . .
TUBING, stl .250 ID x 16ga wall x 1.500 (Eff w/JK682714) . . . . . . . . . . . . . . . .
1
1
1
1
2
1
1
1
2
1
1
1
1
1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
TM-353 Page 70
Syncrowave 250
8
9
10
2
4
1
5
6
7
3
4
12
13
Includes
Item 26
11
14
29
28
27
15
1
16
26
25
24
23
17
22
18
Figure 10-6
19
21
20
ST-120 088-G
Figure 10-2. Panel, Front w/Components
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 10-2. Panel, Front w/Components (Fig 10-1 Item 29)
. . . 1 . . . . . . . . . . . . . 097 922 . . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 2 . . . . . . . . . . . . . . . . . . . . . . . . NAMEPLATE, (order by model & serial number) . . . . . . . . . . . . . . . . . . . . .
. . . 3 . . . . . . . . . . . . . 109 013 . . BUSHING, snap-in nyl .375 ID x .562mtg hole . . . . . . . . . . . . . . . . . . . . . . .
. . . 4 . . . . S6,7 . . . 089 085 . . SWITCH, tgl SPST 20A 125VAC (Prior to KF988252) . . . . . . . . . . . . . . . .
. . . 4 . . . . S6,7 . . . 176 882 . . SWITCH, tgl SPST 20A 125VAC (Eff w/KF988252) . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 107 983 . . BLANK, snap-in nyl .500mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 057 359 . . BLANK, snap-in nyl .375mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 5 . . . . . R3 . . . . 030 109 . . POTENTIOMETER, C sltd sft 1/T 2W 5000 ohm . . . . . . . . . . . . . . . . . . . .
. . . 6 . . . . . R11 . . . 030 684 . . POTENTIOMETER, C sltd sft 1/T 2W 5 meg ohm . . . . . . . . . . . . . . . . . . .
. . . 7 . . . . R1,2 . . . 035 897 . . POTENTIOMETER, C sltd sft 1/T 2W 1000 ohm . . . . . . . . . . . . . . . . . . . .
. . . 8 . . . . . S5 . . . . . 011 609 . . SWITCH, tgl SPDT 15A 125VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 9 . . . . . S3 . . . . 052 769 . . SWITCH, tgl 4PDT 15A 125VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 10 . . . . . S2 . . . . . 011 610 . . SWITCH, tgl SPDT 15A 125VAC (Prior to JJ503984) . . . . . . . . . . . . . . . . .
. . . 10 . . . . . S2 . . . . 088 409 . . SWITCH, tgl 2PDT 15A 125VAC (Eff w/JJ503984) . . . . . . . . . . . . . . . . . . .
. . . 11 . . . . TD1 . . . 052 192 . . TIMER, delay on make - postflow (consisting of) . . . . . . . . . . . . . . . . . . . . .
. . . 12 . . . . . . . . . . . . . 039 449 . . . . BRACKET, mtg - circuit card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Syncrowave 250
3
1
1
2
2
1
2
1
1
2
1
1
1
1
1
1
TM-353 Page 71
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 10-2. Panel, Front w/ Components (Continued)
. . . 13 . . . . . . . . . . . . . 044 723 . . . . CIRCUIT CARD, postflow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 14 . . . . . S1 . . . . 045 834 . . SWITCH, tgl DPST 60A 600VAC (Prior to KA759476) . . . . . . . . . . . . . . . .
. . . 14 . . . . . S1 . . . . 128 757 . . SWITCH, tgl DPST 60A 600VAC (Eff w/KA759476) . . . . . . . . . . . . . . . . . .
. . . 15 . . . . . . . . . . . . . 106 398 . . PIN, spring CS .156 x .625 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 16 . . . . . . . . . . . . . . 114 721 . . SHAFT, extension switch (Prior to KA759476) . . . . . . . . . . . . . . . . . . . . . . .
. . . 16 . . . . . . . . . . . . . 133 276 . . EXTENSION, handle switch (Eff w/KA759476 thru KF959378) . . . . . . . .
. . . 16 . . . . . . . . . . . . . 171 420 . . EXTENSION, handle switch (Eff w/KF959379) . . . . . . . . . . . . . . . . . . . . . .
. . . 17 . . . . . . . . . . . . . 164 481 . . PANEL, front (Prior to KF959379) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 17 . . . . . . . . . . . . . 169 476 . . PANEL, front (Eff w/KF959379 thru KG170300) . . . . . . . . . . . . . . . . . . . . .
. . . 17 . . . . . . . . . . . . . 181 096 . . PANEL, front (Eff w/KG170301) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 18 . . . . . . . . . . . . . . . . . . . . . . . . CONTROL PANEL, lower front (Fig 10-6) . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 19 . . . . . . . . . . . . . 128 230 . . LABEL, warning electric shock etc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 19 . . . . . . . . . . . . . 134 327 . . LABEL, warning electric shock etc CE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 20 . . . . . . . . . . . . +114 759 . . DOOR, access front (Prior to KG170301) . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 20 . . . . . . . . . . . . +181 589 . . DOOR, access front (Eff w/KG170301) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 605 583 . . CATCH, spring loaded door (Prior to KG170301) . . . . . . . . . . . . . . . . . . . .
. . . 21 . . . . . . . . . . . . . 134 327 . . LABEL, warning general precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 21 . . . . . . . . . . . . . 176 254 . . LABEL, warning general precautionary CE . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 22 . . . . . PL2 . . . 157 958 . . LIGHT, ind wht lens 28V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 23 . . . . . PL1 . . . 155 500 . . LED, yellow (50 Hz model) (Eff w/ KG060803) . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . PLG5 . . . 135 635 . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . PLG6 . . . 131 054 . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 24 . . . . . . . . . . . . . 010 647 . . PIN, spring CS .156 x 1.250 (Prior to KF959379) . . . . . . . . . . . . . . . . . . . .
. . . 24 . . . . . . . . . . . . . 169 136 . . PIN, handle (Eff w/KF959379) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 25 . . . . . . . . . . . . . 098 279 . . HANDLE, plrty/changeover switch (Prior to KF959379) . . . . . . . . . . . . . . .
. . . 25 . . . . . . . . . . . . . 169 135 . . HANDLE, switch (Eff w/KF959379) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 26 . . . . . . . . . . . . . 052 370 . . . . KNOB, indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 27 . . . . . . . . . . . . . 097 924 . . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 28 . . . . . . . . . . . . ♦115 920 . . METER, amp AC/DC 100MV 0-300 scale . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 29 . . . . . . . . . . . . ♦004 189 . . METER, volt AC/DC 0–100 scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
♦OPTIONAL
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
TM-353 Page 72
Syncrowave 250
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 10-3. Rectifier, Si Diode (Fig 10-1 Item 2)
. . . 1 . . . . C7-10 . . 031 689
. . . 2 . . . . . . . . . . . . . 083 884
. . . 2 . . . . . . . . . . . . . 166 667
. . . 3 . . . . . D1 . . . . 037 956
. . . 4 . . . . TP3 . . . 168 898
. . . 5 . . . SCR1-4 . . . 115 114
. . . 6 . . . . . . . . . . . . . 176 645
. . . 6 . . . . . . . . . . . . . 173 714
. . . . . . . . . . . . . . . . . . . 028 516
. . . . . . . . . PLG53 . . . 115 092
..
..
..
..
..
..
..
..
..
..
CAPACITOR, rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLAMP, thyristor rectifier (Prior to KG023560) . . . . . . . . . . . . . . . . . . . . . . .
CLAMP, spring rectifier (Eff w/KG023560) . . . . . . . . . . . . . . . . . . . . . . . . . .
DIODE, rect 275A 300V SP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
THERMOSTAT, NC open 125°C (Eff w/KG170301) . . . . . . . . . . . . . . . . . .
THYRISTOR, SCR 300A 300V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLAMP, thyristor w/o thermostat (Eff w/KG023560) . . . . . . . . . . . . . . . . . .
CLAMP, thyristor with thermostat (Eff w/KG170030) . . . . . . . . . . . . . . . . . .
PIN, spring CS .125 x .250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
2
2
1
1
4
2
2
2
1
3
2
4
1
2
5
ST-120 205-A
6
5
Figure 10-3. Rectifier, Si Diode
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 10-4. Panel, Rear w/Components (Fig 10-1 Item 17)
. . . 1 . . . . . R4 . . . . 186 949
. . . 2 . . . . . . . . . . . . . 032 604
. . . 2 . . . . . . . . . . . . . 180 165
. . . 3 . . . . . . . . . . . . . . 114 752
. . . 3 . . . . . . . . . . . . . 181 099
. . . 4 . . . . . . . . . . . . . 131 361
. . . 4 . . . . . . . . . . . . . 173 283
. . . 5 . . . . . . . . . . . . . 124 274
. . . 6 . . . . . FM . . . . . 116 190
. . . . . . . . . . . . . . . . . . . 026 947
. . . . . . . . . . Shunt . . . . 114 723
. . . . . . . . . . . . . . . . . . . 176 272
..
..
..
..
..
..
..
..
..
..
..
..
RESISTOR, WW fxd 175W 20 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BLADE, fan 14 in 3 wing 19deg .375 bore CCW (Prior to KG198783) . . .
BLADE, fan 14 in 3 wing 19deg .375 bore CCW (Eff w/KG198783) . . . . .
PANEL, rear (Prior to KG170301) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PANEL, rear (Eff w/KG170301) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHAMBER, plenum 14 in (Prior to KG128812) . . . . . . . . . . . . . . . . . . . . . .
CHAMBER, plenum 14 in (Eff w/KG128812) (50 Hz only) . . . . . . . . . . . . .
BRACKET, mtg fan motor (Eff w/KG128812) . . . . . . . . . . . . . . . . . . . . . . . .
MOTOR, 1/12 hp 230V 1550 RPM 50/60Hz 1.5A . . . . . . . . . . . . . . . . . . . .
STAND-OFF, insul .250-20 x 1.000 lg (Prior to KB110695) . . . . . . . . . . . .
SHUNT, (Prior to KB110695) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONNECTOR, clamp cable (50 Hz model) (Eff w/KG060803) . . . . . . . . .
2
1
1
1
1
1
1
1
1
1
2
1
1
3
1
4
6
5
ST-120 089-F
Figure 10-4. Panel, Rear w/Components
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
Syncrowave 250
TM-353 Page 73
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 10-5. Panel, Mtg Components (Fig 10-1 Item 7)
. . 1 . . . . . R7 . . . . . 186 468
. . 2 . . . . . . . . . . . . . . . 117 721
. . 3 . . . CR2,6 . . . . . 110 386
. . 4 . . . . . 2T . . . . . 072 253
. . 5 . . . SR2,3 . . . . 035 704
. . 6 . . . SN1,2 . . . . . 118 625
. . 7 . . . . . R6 . . . . . . 117 803
. . 8 . . . . C20 . . . . . . 119 834
. . 9 . . . . . 1T . . . . . . 117 372
. . . . . . . . . . . . . . . . . . . 108 023
. . 10 . . . CR5 . . . . . 000 770
. . 11 . . . CR1 . . . . . 052 964
..
..
..
..
..
..
..
..
..
..
..
..
RESISTOR, WW fxd 100W 50 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PANEL, mtg relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RELAY, encl 24VAC DPDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STUD, single connection 10-32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RECTIFIER, integ 40A 800V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SNUBBER, poly metal film .5uf 200VDC 100 ohm . . . . . . . . . . . . . . . . . . .
RESISTOR, WW fxd 10W 1K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAPACITOR, cer disc .05uf 500V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BLOCK, term 10A 15P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LINK, jumper term blk 10A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RELAY, encl 24VDC 3PDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RELAY, encl 24VDC DPDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
2
1
2
2
1
1
1
3
1
1
1
2
11
3
6
10
3
4
5
6
9
8
7
ST-120 090-F
Figure 10-5. Panel, Mtg Components
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
TM-353 Page 74
Syncrowave 250
15
14
17
5
16
13
3
6
2
4
7
11
8
1
9
10
18
23
22
19
21
20
ST-120 003-P
Figure 10-6. Control Panel, Lower Front
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 10-6. Control Panel, Lower Front (Fig 10-2 Item 18)
. . . . . . . . . . . . . . . . . . . . 116 477
. . . . . . . . . . . . . . . . . . . 124 647
. . . . . . . . . . . . . . . . . . . 131 217
. . . . . . . . . . . . . . . . . . . 132 430
. . . . . . . . . . . . . . . . . . . 137 516
. . . . . . . . . . . . . . . . . . . 147 793
. . . . . . . . . . . . . . . . . . . 174 067
. . . . . . . . . . . . . . . . . . . 181 108
. . . 1 . . . . . . . . . . . . . . 114 742
. . . 1 . . . . . . . . . . . . . 124 784
. . . 1 . . . . . . . . . . . . . 130 582
. . . 1 . . . . . . . . . . . . . 147 795
. . . 1 . . . . . . . . . . . . . 171 652
. . . 2 . . . . R25 . . . 137 429
Syncrowave 250
..
..
..
..
..
..
..
..
..
..
..
..
..
..
CONTROL PANEL, lower (Prior to JK572898) . . . . . . . . . . . . . . . . . . . . . . .
CONTROL PANEL, lower (Eff w/JK572898 thru JK682712) . . . . . . . . . . .
CONTROL PANEL, lower (Eff w/JK682714 thru JK690986) . . . . . . . . . . .
CONTROL PANEL, lower (Eff w/JK690987 thru KA806713) . . . . . . . . . . .
CONTROL PANEL, lower (Eff w/KA806713 thru KA877024) . . . . . . . . . .
CONTROL PANEL, lower (Eff w/KA877025 thru KF959378) . . . . . . . . . . .
CONTROL PANEL, lower (Eff w/KF959379 thru KG170300) . . . . . . . . . .
CONTROL PANEL, lower (Eff w/KG170301) . . . . . . . . . . . . . . . . . . . . . . . .
PANEL, lower front (Prior to JK572898) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PANEL, lower front (Eff w/JK572898 thru JK690986) . . . . . . . . . . . . . . . . .
PANEL, lower front (Eff w/JK690987 thru KB093120) . . . . . . . . . . . . . . . . .
PANEL, lower front (Eff w/KB093121 thru KF959176) . . . . . . . . . . . . . . . .
PANEL, lower front (Eff w/KF959177) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RESISTOR, C 2W 3.3K ohm (Eff w/KA806713) . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
1
1
1
1
1
1
TM-353 Page 75
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 10-6. Control Panel, Lower Front (Continued)
... 3 .............
. . . 3 . . . . C14 . . .
. . . 3 . . . . C14 . . .
...................
CAPACITOR ASSEMBLY, (Eff w/JK537589 thru JK690986) . . . . . . . . . . .
CAPACITOR, (Prior to JK537589) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAPACITOR, (Eff w/JK690987) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 4 . . 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
. . . 5 . . . . . C6 . . . . 164 290 . . CAPACITOR, polyp film 3.5uf 600VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 6 . . . . PLG3 . . . 131 204 . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 7 . . . . RC2 . . . 604 176 . . RECEPTACLE, straight duplex grd 2P3W 15A 125V . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 073 690 . . CAP, straight P & S 2P3W 5266 DF
. . . 8 . . . . C15 . . . 170 920 . . CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 9 . . . . CB1 . . . 093 995 . . CIRCUIT BREAKER, man reset 1P 15A 250V . . . . . . . . . . . . . . . . . . . . . . .
. . . 10 . . . . R13 . . . 605 828 . . RHEOSTAT, WW 50W 1.5 ohm (Prior to KG170301) . . . . . . . . . . . . . . . . .
. . . 10 . . . . R13 . . . 174 037 . . RHEOSTAT, WW 50W 1.5 ohm (Eff w/KG170301 thru LA292998) . . . . .
. . . 10 . . . . R13 . . . 198 547 . . RHEOSTAT, WW 25W 1.5 ohm (Eff w/LA292999) . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 010 493 . . BUSHING, snap-in nyl .625 ID x .875 mtg hole . . . . . . . . . . . . . . . . . . . . . .
. . . 11 . . . . . . G . ♦♦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) . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 11 . . . . . . G . ♦♦203 419 . . SPARK GAP ASSEMBLY SERVICE KIT (for units prior to LA337284)) .
. . . 11 . . . . . . G . ♦♦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 . . . . . . . . . . . . . . . . . . . . . . .
. . . 12 . . . . . . . . . . . . . 097 712 . . STRIP, insulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 13 . . . . . . . . . . . . . 174 070 . . BRACKET, mtg components (Eff w/KG959379) . . . . . . . . . . . . . . . . . . . . . .
. . . 14 . . . . . C3 . . . . 106 935 . . CAPACITOR, polyp film 10uf 250VAC (Prior to KK001554) . . . . . . . . . . . .
. . . 14 . . . . . C3 . . . . 191 944 . . CAPACITOR, polyp film 10uf 250VAC (Eff w/KK001554) . . . . . . . . . . . . . .
. . . 15 . . . . . R8 . . . . 083 784 . . RESISTOR, WW fxd 100W 10 ohm (Prior to KG170301) . . . . . . . . . . . . .
. . . 15 . . . . . R8 . . . . 181 107 . . RESISTOR ASSEMBLY w/LEADS, (Eff w/KG170301) . . . . . . . . . . . . . . . .
. . . 16 . . . . . C4 . . . . 096 761 . . CAPACITOR, mica .002uf 10000V (CE Models Only) . . . . . . . . . . . . . . . .
. . . 16 . . . . . C4 . . . . 096 761 . . CAPACITOR, mica .002uf 10000V
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Prior to KK001554 for nonCE Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 16 . . . . . C4 . . . . 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) . . . . . . .
. . . 17 . . . . . T2 . . . . 074 398 . . TRANSFORMER, high voltage 115V pri 3600V sec 30mA . . . . . . . . . . . .
TM-353 Page 76
126 750
098 566
132 433
121 270
..
..
..
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1
1
3
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
4
1
1
1
4
4
2
1
1
1
1
1
1
1
1
1
1
1
2
2
1
Syncrowave 250
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 10-6. Control Panel, Lower Front (Fig 10-2 Item 18) (Continued)
. . . 18 . . . . . T3 . . . . . 115 967
. . . 18 . . . . . T3 . . . . 124 650
. . . 18 . . . . . T3 . . . . 174 692
. . . . . . . . . . . R9 . . . . 030 603
. . . 19 . . . . Work
Electrode . 039 047
. . . . . . . . . . . . . . . . . . . 601 976
. . . . . . . . . . . . . . . . . . . 039 049
. . . . . . . . . . . . . . . . . . . 601 880
. . . . . . . . . . . . . . . . . . . 039 044
. . . . . . . . . . . . . . . . . . . 601 879
. . . 20 . . . . GS1 . . . 174 036
. . . . . . . . . . . . . . . . . . . 010 296
. . . . . . . . . . . . . . . . . . . 035 601
. . . . . . . . . . PLG4 . . . 131 203
. . . 21 . . . . . . . . . . . . . 174 038
. . . 22 . . . . . . . . . . . . . 097 922
. . . 23 . . . . . . . . . . . . . 010 357
. . . 24 . . . . . . . . . . . . . 605 742
..
..
..
..
COIL, HF coupling (Prior to JK572898) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COIL, HF coupling (Eff w/JK572898 thru KF959378) . . . . . . . . . . . . . . . . .
COIL, HF coupling (Eff w/KF959379) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RESISTOR, WW fxd 10W 10K ohm (Prior to KA877025) . . . . . . . . . . . . .
1
1
1
1
. . TERMINAL, power output (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . SCREW, stl hexhd .500-13 x 1.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . TERMINAL BOARD, red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . NUT, stl hex jam .500 -13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . BUS BAR, term bd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . NUT, stl hex full fnsh .500-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . VALVE, w/fittings & leads (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . FITTING, hose brs elbow M 1/4NPT x .625-18 . . . . . . . . . . . . . . . . . . . . .
. . . . VALVE, 115VAC 2 way 1/4 IPS port 1/8 orf . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PANEL, door access HF (Eff w/KF959379) . . . . . . . . . . . . . . . . . . . . . . . . .
. . KNOB, pointer (Eff w/JK572898) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SPEED NUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CLIP, mtg resistor .500 ID core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
1
1
1
1
1
1
2
1
1
1
1
1
2
*Recommended Spare Parts
♦♦Effective with Serial No.LA337284, Spark Gap Assembly 020 623 consisting of: Base 095 621, Holder 020 622,
and Points 020 603, is no longer available. If replacement parts are needed for any units with a Serial No. prior to
LA337284, you must first order and install Spark Gap Assembly Service Kit 203 419. To replace spark gap parts in
units with Serial No. LA337284 and following, or for units with Spark Gap Assembly Service Kit 203 419 installed, order
appropriate spark gap parts listed above as, eff/w Serial No. LA337284.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
Syncrowave 250
TM-353 Page 77
Eff w/KE558763 the Water Valve Option (042 138) is no longer available
and all other options are available as Field Options only.
Dia.
Mkgs.
Part
No.
Description
Quantity
Optional Equipment
. . . . . . . . . . . . . . . . . . . . . . 042 138
. . . . . . . . WSI . . . . . . . . . 035 601
. . . . . . . . . . . . . . . . . . . . . . 010 295
. . . . . . . . . . . . . . . . . . . . . . 116 201
. . . . . . . . . . . . . . . . . . . . . . 042 140
. . . . . . . . . A . . . . . . . . . . 115 920
. . . . . . . . . V . . . . . . . . . . 004 189
. . . . . . . . . . . . . . . . . . . . . . 131 054
. . . . . . . . . . . . . . . . . . . . . . 113 746
. . . . . . . . . . . . . . . . . . . . . . 042 142
. . . . . . . CR3 . . . . . . . . . 006 393
. . . RFC,VR1/PC3 . . . . . 120 875
. . . . . . . . R10 . . . . . . . . . 030 108
. . . . . . . . S8 . . . . . . . . . . . 011 611
. . . . . . . . TD2 . . . . . . . . . 047 133
. . . . . . . . . . . . . . . . . . . . . . 097 922
. . . . . . . . . . . . . . . . . . . . . . 042 144
. . . . . . . CR4 . . . . . . . . . 006 393
. . . . . . R12,S9 . . . . . . . . 115 862
. . . . . . . . TD3 . . . . . . . . . 116 476
. . . . . . . . . . . . . . . . . . . . . . 115 856
. . . . . . . . A50 . . . . . . . . . 008 971
. . . . . . . . C50 . . . . . . . . . 039 482
. . . . . . . . C51 . . . . . . . . . 091 378
. . . . . . . . C52 . . . . . . . . . 039 481
. . . . . . . . C53 . . . . . . . . . 031 677
. . . . . . . . C54 . . . . . . . . . 166 199
. . . . . . . CR50 . . . . . . . . 039 486
. . . . . . D50,51 . . . . . . . . 026 202
. . . . . . . . Q50 . . . . . . . . . 000 088
. . . . . . . . R50 . . . . . . . . . 074 121
. . . . . . . . R52 . . . . . . . . . 108 432
. . . . . . . . R53 . . . . . . . . . 000 342
. . . . . . . . R54 . . . . . . . . . 093 030
. . . . . . . . R55 . . . . . . . . . 028 273
. . . . . . . . R56 . . . . . . . . . 093 037
. . . . . . . . R57 . . . . . . . . . 605 919
. . . . . . . . . . . . . . . . . . . . . . 039 449
. . . . . . . . . . . . . . . . . . . . . . 097 922
. . . . . . . . . . . . . . . . . . . . . . 042 353
. . . . . . . . C1 . . . . . . . . . . 125 781
. . . . . . . . . . . . . . . . . . . . . . 129 201
TM-353 Page 78
. . WATER VALVE, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . VALVE, 115VAC 2 way 1/4 IPS port 1/8 orf . . . . . . . . . . . . . . . . . . . . .
. . . . FITTING, pipe brs elbow M 1/4NPT x .625-18 . . . . . . . . . . . . . . . . . .
. . . . BRACKET, mtg valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . METER KIT, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . METER, amp AC/DC 100MV 0-300 scale . . . . . . . . . . . . . . . . . . . . . .
. . . . METER, volt AC/DC 0-100 scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . .
. . . . . . CONNECTOR, rect skt 24-18ga Molex 39-00-0038 . . . . . . . . . . . .
. . SPOT TIMER, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . RELAY, encl 24VAC DPDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CIRCUIT CARD, snubber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . POTENTIOMETER, C sltd sft 1/T 2W 100K ohm . . . . . . . . . . . . . . .
. . . . SWITCH, tgl DPDT 15A 125V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . RELAY, delay adj 120VAC DPDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PRE-FLOW TIMER, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . RELAY, encl 24VAC DPDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . POTENTIOMETER, C sltd sft 1/T .50W 500K ohm . . . . . . . . . . . . . .
. . . . TIMER, delay on make - preflow (consisting of) . . . . . . . . . . . . . . . . .
. . . . . . CIRCUIT CARD, preflow (consisting of) . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . IC, linear 741 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . CAPACITOR, elctlt 100uf 35VDC . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . CAPACITOR, tantlm 33uf 35VDC . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . CAPACITOR, elctlt 3.3uf 50VDC . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . CAPACITOR, elctlt 5.6uf 35VDC . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . CAPACITOR, cer disc .05uf 500VDC . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . RELAY, encl 24VDC SPDT 2.5A . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . DIODE, rect 1A 400V SP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . TRANSISTOR, NPN 800mA 400V . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . RESISTOR, C 2W 3.3K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . RESISTOR, MF .25W 2.21K ohm . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . POTENTIOMETER, cermet trmr 1/T .5W 5K ohm . . . . . . . . . . .
. . . . . . . . RESISTOR, MF .25W 15K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . RESISTOR, C .5W 2.7K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . RESISTOR, MF .25W 47.5K ohm . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . RESISTOR, C .25W 47 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . BRACKET, mtg circuit card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . POWER FACTOR CORRECTION, (consisting of) . . . . . . . . . . . . . . . .
. . . . CAPACITOR, polyp film 150uf 250VAC . . . . . . . . . . . . . . . . . . . . . . . .
. . . . BRACKET, mtg capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
2
1
1
1
1
1
8
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
4
2
Syncrowave 250
Call
1-800-4-AMILLER
for your local
Miller distributor.
Miller Electric Mfg. Co.
An Illinois Tool Works Company
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
PRINTED IN USA
 1998 Miller Electric Mfg. Co.