Miller Electric 350 User manual

Miller Electric 350 User manual
Syncrowave 250 DX/350 LX
®
Quick
Specs
Industrial Applications
Processes
Precision Metal Fabrication
Maintenance and Repair
Light and Heavy Manufacturing
Aerospace
Shipbuilding
Tube and Pipe
Automotive
Vocational
TIG (GTAW)
Stick (SMAW)
Pulsed TIG (GTAW-P) (Optional)
Issued Dec. 2006 • Index No. AD/4.2
TIG/Stick Welding
Power Source
Input Power Requires 1-Phase Power
Amperage Range 250: 3 – 310 350: 3 – 400
Max. Open-Circuit Voltage 80 VDC
Rated Output 250: 250 A at 30 VAC, 40% Duty Cycle
200 A at 28 VAC, 60% Duty Cycle
350: 350 A at 34 VAC, 40% Duty Cycle
300 A at 32 VAC, 60% Duty Cycle
Weight
250: 378 lb (172 kg) 350: 496 lb (225 kg)
The Power of Blue .
®
See page 2 for
additional features
Syncrowave 350 LX TIGRunner ® 3X
with Torch Package
Syncrowave 250 DX
TIGRunner ® 3X Package
The balance control is adjustable to provide
additional oxide removal (more cleaning) or less
cleaning based on the condition of the material
being welded. See pg 2 for more information on
this feature.
Dual inline high-frequency points provide
intense high frequency for arc starting and
stabilization. Internal machine components are
protected from HF interference with additional
grounding and filtering for extended product life.
Syncro Start allows the choice of Soft, Standard
or Hot TIG starts based on the application, lead
lengths and tungsten size.
Digital welding meters display both amperage
and voltage for viewing of the actual and preset
values for greater accuracy and repeatability in
your welding procedure.
Last procedure recall simplifies changing your
Syncrowave back and forth from aluminum TIG
to stainless TIG to stick welding. One switch
makes all the control panel changes.
Power source is warranted for 3 years, parts and labor.
Original main power rectifier parts are warranted for 5 years.
Miller Electric Mfg. Co.
International Headquarters
Web Site
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Phone: 920-735-4505
USA FAX: 920-735-4134
Canadian FAX: 920-735-4169
International FAX: 920-735-4125
www.MillerWelds.com
Additional Features
Pulse TIG Control lowers the heat input into
the part and reduces warping and distortion
(optional on 250DX models).
TIGRunner System Packages with NEW
CoolRunner™ 3X cooler. A 3-gallon cooling
system equipped with a visual flow indicator
ensures that the coolant is flowing. An external
coolant filter stops foreign objects from entering
the water cooled torch cable for better flow and
longer life. Extended cooling capacity ensures
maximum productivity. 3-year cooler warranty.
Stick welding features such as Adaptive Hot
Start™ provide good arc strikes without sticking.
Once welding, the DIG control makes dynamic
adjustments to the welder to ensure smooth
E7018 and deep penetration E6010.
Tilted operator interface and built-in consumable
drawer provide added convenience to your
welding experience.
Squarewave Technology developed and
patented by Miller Electric in 1976. Squarewave
technology was developed to improve your weld
quality and make TIG welding easier. Miller
Squarewave technology provides arc stability
when welding aluminum, prevents arc
rectification and eliminates tungsten erosion.
Welding Aluminum?
Oxides that form on aluminum melt at
temperatures over 3700° F. The aluminum
material that is located under this layer of
oxide melts at 1200° F. The Syncrowave’s
AC Squarewave welding current automatically
removes the layer of oxide which is necessary
for producing high quality welds.
Do you have power fluctuations?
The Syncrowave compensates for power
fluctuation without changing your welding
parameters. Line voltage compensation
works on fluctuating power +/- 10%.
Arc timer/cycle counter records actual welding
time and number of arc starts. Great for estimating
job costs.
AC Output: Balance Control
AC Balance
4
5
Balanced Wave Function
Balanced Wave
6
3
7
2
Medium bead
8
Bead
9
1
0
5
Cleaning
6
3
7
2
8
Narrower bead
for fillet welds
0
Bead
5
68%
Electrode
Negative
No Visible Cleaning
Wider bead and
cleaning action
6
3
7
2
Greatest Cleaning Action
Wide bead
8
9
1
0
32%
Electrode
Positive
10
Max.
Penetration
Bead
10
Max.
Cleaning
2
More Heat into Work
Narrow bead, with no
visible cleaning
9
1
4
50%
Electrode
Negative
10
Balanced
4
50%
Electrode
Positive
Cleaning
55%
Electrode
Positive
45%
Electrode
Negative
Specifications
Input
Power
Model
(Subject to change without notice.)
Max
Welding
Amp Range OCV
Rated Output
Amps Input at AC Balance, Rated Load
200V 220V 230V 400V 440V 460V 520V 575V KVA KW Dimensions
80 V 250 A at 30 V,
40% Duty Cycle
88
—
77
—
—
38
—
31
18
50 Hz,
1-Phase
225 A at 29 V,
40% Duty Cycle
101
—
88
—
—
44
—
35
20 10
Syncrowave
250 CE
220/400/440/520
50 or
60 Hz,
1-Phase
250 A at 30 V,
40% Duty Cycle
—
Syncrowave 350
All Models
3 – 400 A
50 or
60 Hz,
1-Phase
80 V 350 A at 34 V,
40% Duty Cycle
146
Syncrowave 250
3 – 310 A
60 Hz,
1-Phase
9
Weight
H: 36-1/4 in (921 mm)
W:22-1/2 in (572 mm)
D: 25 in (635 mm)
378 lb
(172 kg)
with TIGRunner®
H: 52-1/2 in (1334 mm) 525 lb
W:22-1/2 in (572 mm) (238 kg)
D: 38 in (975 mm)
—
55
50
—
42
—
22 12
H: 36-1/4 in (921 mm)
W:22-1/2 in (572 mm)
D: 25 in (635 mm)
378 lb
(172 kg)
120 128
66
60
65
51
50
30 14
H: 36-1/4 in (921 mm)
W:22-1/2 in (572 mm)
D: 25 in (635 mm)
496 lb
(225 kg)
100
with TIGRunner®
H: 52-1/2 in (1334 mm) 643 lb
W:22-1/2 in (572 mm) (290 kg)
D: 38 in (975 mm)
*See pg 6 for power factor correction kit.
Certified to both the Canadian and U.S. Standards for welding equipment.
Performance Data
DUTY CYCLE CHART
RATED OUTPUT
500
450
400
350
Syncrowave 350 LX
WELDING AMPERES
300
Syncrowave 250 DX
250
200
150
100
50
10
20
30
40
50
60
70
80
90
100
% DUTY CYCLE
3
Control Panels
9
10
11
1
12
2
3
4
13
14
5
15
16
6
17
7
8
18
Common Bottom Panel
19
20
1. Voltmeter Display
2. Start Mode Control
(Lift-Arc, HF Start, HF Continuous)
3. Output Control
4. Amperage Control (Panel/Remote)
5. Process Control (Stick/TIG)
6. Balance/Dig Control (0 – 10)
7. Postflow Time Control (0 – 50 sec)
8. Ammeter Display
9. Pulser Control*
10. Background Amps Control (0 – 100%)*
11. Pulse-Per-Second Control (0.25 – 10 Hz)*
4
Pulser*
Module
12.
13.
14.
15.
16.
17.
18.
19.
20.
Peak Time Control (5 – 95%)*
Spot Time Control (0 – 5 sec)*
Final Slope Control (0 – 25 sec)*
Initial Time Control (0 – 15 sec)*
Final Amperage Control (0 – 100%)*
Initial Amperage Control (3 – 310/400 A)*
Amperage Adjustment Control (3 – 310/400 A)
Power Switch (On/Off)
Output Selector Switch (AC/DC-/DC+)
*Optional Pulser for 250 DX
**Optional Sequencer
Sequencer**
Module
Packages
Syncrowave Power Sources
®
Syncrowave® 250 DX
#907 194 (200/230/460 VAC)
#907 195 (230/460/575 VAC)
#907 197 (220/400/440/520 VAC) CE
Syncrowave® 350 LX
#907 198 (200/230/460 VAC)
#907 199 (230/460/575 VAC)
#907 200 (220/400/440/520 VAC) CE
Packages include: International-style
connection kit (#195 303). Primary cord
not included.
Syncrowave 250 DX
Syncrowave 350 LX
TIGRunner Packages
®
Syncrowave® 250 DX TIGRunner® 3X
#907 194-03-2 (200/230/460 VAC)
#907 195-03-2 (230/460/575 VAC)
Syncrowave® 350 LX TIGRunner® 3X
#907 198-03-2 (200/230/460 VAC)
#907 199-03-2 (230/460/575 VAC)
Completely assembled. Packages include:
Syncrowave, Coolmate™ 3X cooler, No. 37
running gear, RFCS-14 HD remote foot
control, and international-style connection
kit (#195 303). Primary cord not included.
TIG coolant (#043 810) required.
Syncrowave 250 DX
TIGRunner
TIGRunner Packages with Torch
®
Syncrowave 350 LX
TIGRunner
Syncrowave® 250 DX TIGRunner® 3X
with Torch Kit
#907 194-04-1 (200/230/460 VAC)
#907 195-04-1 (230/460/575 VAC)
Syncrowave® 350 LX TIGRunner® 3X
with Torch Kit
#907 198-04-1 (200/230/460 VAC)
#907 199-04-1 (230/460/575 VAC)
250 A Water-Cooled Torch Kit
for Syncrowave 250 DX TIGRunner
300 A Water-Cooled Torch Kit
for Syncrowave 350 LX TIGRunner
Completely assembled. Packages include:
Syncrowave, Coolmate™ 3X cooler, No. 37
running gear, RFCS-14 HD remote foot
control, torch kit (see kits to left) and
international-style connection kit
(#195 303). Primary cord not included.
TIG coolant (#043 810) required.
5
Genuine Miller Options
Field Options
Sequencer Module #195 345 Field Kit
Provides a starting current higher or lower
than the welding current. Provides final slope
and final current for trailing the weld. Provides
a spot timer for TIG spot application.
Pulser Module
#195 344 Field Kit for Syncrowave 250 DX
For welding of thin materials. Provides a
heating and cooling effect of the weld
puddle to reduce heat input and control
distortion of the material. Provides 0.25 to
10 pulses per second.
Power Factor Correction Kit
#194 692 Field Kit for Syncrowave 250 DX
#043 757 Field Kit for Syncrowave 350 LX
Reduces primary amperage draw by
approximately 25% allowing the use of
smaller breakers/fuses and smaller primary
cord. Power Factor does not reduce the
power consumption/electrical bill.
Genuine Miller Accessories
No. 37 Running Gear #195 282
Includes two 10 in (254 mm) wheels, two
5 in (127 mm) casters, two-compartment
rack (for gas cylinder(s) or Coolmate V3
coolant system), and handles. Provides
excellent mobility and easy to install.
Protective Cover #195 320
Heavy-duty, water- and mildew-resistant.
Protects and maintains the finish of
the welder.
Remote Controls and Switches
RCCS-14 Remote Contactor and
Current Control #043 688 14-pin plug
For all Miller solid-state power sources
after serial number JK674521. North/south
rotary-motion fingertip control fastens to
TIG torch using two Velcro® straps. Great for
applications that require a finer amperage
control. Includes 26.5 ft (8 m) control cord.
6
RFCS-14 HD Foot Control #194 744
For all Miller solid-state power sources
after serial number JK674521. This new
design increases stability with a larger
base, and durability with a heavier cord.
Maximum flexibility is accomplished with a
reconfigurable cord that can exit the front,
back or either side of the pedal. Foot pedal
provides remote current and contactor
control. Includes 20 ft (6 m) cord and
14-pin plug.
RHC-14 Hand Control
#129 340
Miniature hand control
for remote current and
contactor control.
Dimensions:
4 x 4 x 3-1/4 in
(102 x 102 x 83 mm). Includes 20 ft (6 m)
cord and 14-pin plug.
RMLS-14 Switch #129 337
For all Miller solid-state power sources
after serial number JK674521. Momentaryand maintained-contact rocker switch for
contactor control. Push forward for
maintained contact and backward for
momentary contact. Includes 26.5 ft (8 m)
cord and 14-pin plug.
RMS-14 On/Off Control #187 208
For all Miller solid-state power sources
after serial number JK674521. Momentarycontact switch for contactor control.
Rubber-covered pushbutton dome switch
ideal for repetitive on-off applications.
Includes 26.5 ft (8 m) cord and 14-pin plug.
Extension Cords for 14-Pin Remote Controls
#122 973 25 ft (7.6 m)
#122 974 50 ft (15.2 m)
#122 975 75 ft (23 m)
Gas Tungsten Arc (TIG) Welding Book
#170 555
To order this item, distributors can call
the Miller Literature Distribution Center at
1-920-735-4356, or FAX 1-920-735-4011.
86 pages — 8-1/2 x 11 in. A comprehensive
text on all aspects of the GTAW process.
Filled with figures and tables to illustrate
process technique and equipment setup.
Glossary of TIG terms also provided.
TIG Training CD #196 567
Designed for anyone who’s looking to
better understand the TIG process. Easy
to understand instruction, proven teaching
steps, and expert advice help to create a
more effective academic approach to training.
Subject areas covered include system
components, process fundamentals, electrical
theory, safety, power source operation.
Video – GTAW Setup Procedures #108 241
To order this item, distributors can call
the Miller Literature Distribution Center at
1-920-735-4356, or FAX 1-920-735-4011.
13:00 minutes. A detailed demonstration
on preparing your equipment for TIG
welding. Uses a Syncrowave 250 power
source, but topics fit any TIG setup
including air-or water-cooled systems.
In-depth discussion of tungstens and gases.
Genuine Miller Accessories
TIG Welding Gloves
#227 813 Small
#227 814 Medium
#227 815 Large
#227 816 X-Large
Designed to meet the
specific requirements highquality TIG welding demands.
Made from soft grain goatskin. Sewn with
Kevlar® thread.
TIG (GTAW) Torch Adapters
Water-Cooled Dinse #195 377
Used to adapt a 250 or 350 A water-cooled
torch to an International-style connector.
Air-Cooled Dinse #195 379
Used to adapt a 1-piece 200 amp air-cooled
torch to an International-style connector.
(continued)
Tungsten
Water Coolant Systems
Items below are available in pkgs of 10, 7 in length
For more information, see the Miller Coolant
Systems literature sheet, Index No. AY/7.2.
2% Ceriated (orange) for AC/DC applications
#WC040X7 .040 in, 10– 80 A
#WC116X7 1/16 in, 70– 150 A
#WC332X7 3/32 in, 140– 250 A
#WC018X7 1/8 in, 225– 400 A
#WC532X7 5/32 in, 300– 500 A
1.5% Lanthanum (gold) for AC/DC applications
#WL040X7 .040 in, 10– 80 A
#WL116X7 1/16 in, 70– 150 A
#WL332X7 3/32 in, 140– 250 A
#WL018X7 1/8 in, 225– 400 A
#WL532X7 5/32 in, 300– 500 A
Pure (green) for AC applications only
#WP040X7 .040 in, 10– 80 A
#WP116X7 1/16 in, 70– 150 A
#WP332X7 3/32 in, 140– 250 A
#WP018X7 1/8 in, 225– 400 A
#WP532X7 5/32 in, 300– 500 A
2% Thoriated (red) for DC applications only
#WT040X7 .040 in, 10– 80 A
#WT116X7 1/16 in, 70– 150 A
#WT332X7 3/32 in, 140– 250 A
#WT018X7 1/8 in, 225– 400 A
#WT532X7 5/32 in, 300– 500 A
Torch Kits
250 A Water-Cooled Torch Kit #300 185
300 A Water-Cooled Torch Kit #300 183
Recommended for Syncrowave 250 DX
Recommended for Syncrowave 350 LX
25 ft (7.6 m) Weldcraft® WP20 torch
Torch cable cover
AK4C torch accessory kit includes
shielding cups, collets, collet bodies and
2% cerium tungsten electrodes (1/16,
3/32 and 1/8 in)
Smith® regulator/flowmeter HM2051A-580
12 ft (3.7 m) rubber gas hose (regulator
to machine)
Water-cooled Dinse torch adapter
12 ft (3.7 m) 1/0 weld lead with clamp
(work or ground lead) and Dinse connector
25 ft (7.6 m) Weldcraft® CS310 torch
Torch cable cover
CS310AKC torch accessory kit includes
shielding cups, collets, collet bodies and
2% cerium tungsten electrodes (1/16,
3/32 and 1/8 in)
Smith® regulator/flowmeter HM2051A-580
12 ft (3.7 m) rubber gas hose (regulator
to machine)
Water-cooled Dinse torch adapter
12 ft (3.7 m) 1/0 weld lead with clamp
(work or ground lead) and Dinse connector
Coolmate™ V3
#043 009 115 VAC
#043 009-01-2 115 VAC, CE
For use with water-cooled
torches rated up to 500
amps. Vertical design
conveniently mounts to Miller
cylinder rack in place of one
cylinder. 3-gallon capacity.
Does NOT
include wheels.
CoolRunner™ 3X #043 994 115 VAC
Provides the perfect solution for
industrial, water-cooled TIG applications.
For water-cooled TIG torches rated up to
500 amps. 3-gallon capacity.
TIG Coolant
#043 810
4 gallons of pre-mixed
low-conductivity
coolant. Miller coolant
contains ethylene glycol
and deionized water to protect from freezing
and boiling -37˚ to 227˚F (-38˚ to 108˚C).
Coolant contains 2.4% algae growth inhibitor.
400 A Water-Cooled Torch Kit #300 186
25 ft (7.6 m) Weldcraft® WP18SC torch
Torch cable cover
AK18C torch accessory kit includes
shielding cups, collets, collet bodies and
2% cerium tungsten electrodes (3/32,
1/8 and 5/32 in)
Smith® regulator/flowmeter H1954D-580
12 ft (3.7 m) rubber gas hose (regulator
to machine)
Water-cooled thread lock torch adapters
12 ft (3.7 m) 4/0 weld lead with clamp
(work or ground lead)
7
Ordering Information
Equipment and Options
Stock No.
Description
Syncrowave® 250 DX
#907 194
#907 195
#907 197
#907 194-03-2
#907 194-04-1
#907 195-03-2
#907 195-04-1
200/230/460 V, 50/60 Hz, Standard Model
230/460/575 V, 50/60 Hz, Standard Model
220/400/440/520 V, 50/60 Hz, CE, Standard Model
200/230/460 V, Syncrowave 250 DX TIGRunner ® 3X
200/230/460 V, Syncrowave 250 DX TIGRunner ® 3X with torch
230/460/575 V, Syncrowave 250 DX TIGRunner ® 3X
230/460/575 V, Syncrowave 250 DX TIGRunner ® 3X with torch
Syncrowave® 350 LX
#907 198
#907 199
#907 200
#907 198-03-2
#907 198-04-1
#907 199-03-2
#907 199-04-1
200/230/460 V, 50/60 Hz, Standard Model
230/460/575 V, 50/60 Hz, Standard Model
220/400/440/520 V, 50/60 Hz, CE
200/230/460 V, Syncrowave 350 LX TIGRunner ® 3X
200/230/460 V, Syncrowave 350 LX TIGRunner ® 3X with torch
230/460/575 V, 50/60 Hz, Syncrowave 350 LX TIGRunner ® 3X
230/460/575 V, 50/60 Hz, Syncrowave 350 LX TIGRunner ® 3X with torch
Sequencer Module
Pulser Module
Power Factor Correction Kit
#195 345
#195 344
#194 692
#043 757
Field
Field. For Syncrowave 250 DX
Field. For Syncrowave 250 DX
Field. For Syncrowave 350 LX
#300 185
#300 183
#300 186
See page 7. Recommended for Syncrowave 250 DX TIGRunner 3X
See page 7. Recommended for Syncrowave 350 LX TIGRunner 3X
See page 7
Distributor: See Miller Parts Catalog
#043 688
#194 744
#129 340
#129 337
#187 208
#122 973
#122 974
#122 975
North/south fingertip control
Heavy-duty foot control
Hand control
Momentary/maintained rocker switch
Momentary rubber dome switch
25 ft (7.6 m)
50 ft (15.2 m)
75 ft (22.9 m)
TIG Torch Kits
Weldcraft® 250 A Water-Cooled Torch Kit
Weldcraft® 300 A Water-Cooled Torch Kit
Weldcraft® 400 A Water-Cooled Torch Kit
Consumables and Tungsten
Gas Cylinder, Hose and Fittings
Remote Controls
RCCS-14
RFCS-14 HD
RHC-14
RMLS-14
RMS-14
Extension Cords
Accessories
No. 37 Running Gear
Protective Cover
Gas Tungsten Arc (TIG) Welding Book
TIG Training CD
Video – GTAW Setup Procedures
Torch Adapters
Supplied with power source and torch kits
Cable Connectors
Dinse Connector 50 mm (1 male)
Dinse Connector 50 mm (1 male, 1 female)
Tweco Terminal Adapter
Cam-Lok Terminal Adapter
TIG Coolant
Water Coolant Systems
#195 282
#195 320
#170 555
#196 567
#108 241
#195 377
#195 379
#042 418
#042 419
#042 465
#042 466
#043 810
Contact your distributor
Contact your distributor
Adapts 250 or 350 A water-cooled torch to international-style connector
Adapts 1-pc.200 A air-cooled torch to international-style connector
Supplied with power source and torch kits
Used to connect weld lead to Dinse terminal machine
Used to extend weld cables
Male Dinse to female Tweco
Male Dinse to female Cam-Lok
Case of four 1-gallon bottles
See page 7
Miscellaneous
Stick Electrodes
Welding and Work Cables
Helmets
TIG Welding Gloves
See page 7
Date:
Total Quoted Price:
Distributed by:
Litho in USA
Qty.
Price
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