User manual | Syncrowave - ITW Welding

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 on 250 DX models)
Air Carbon Arc (CAC-A)
250: 3/16-in. maximum
350: 1/4-in. maximum
Issued April 2012 • 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
Standard: 250: 378 lb. (172 kg) 350: 496 lb. (225 kg)
TIGRunner®: 250: 478 lb. (217 kg) 350: 596 lb. (270 kg)
The Power of Blue .
®
See Page 2 for
Additional Features
Syncrowave Complete
Package includes:
Syncrowave®
Coolmate™ 3X cooler
No. 37 running gear
TIG torch kit with
accessories
Foot pedal
Four gallons of coolant
Standard Machine
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 page 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.
Equipment Sales US and Canada
Website
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Phone: 866-931-9730
FAX: 800-637-2315
International Phone: 920-735-4554
International FAX: 920-735-4125
MillerWelds.com
Additional Features
Pulsed TIG control lowers the heat input into
the part and reduces warping and distortion
(optional on 250 DX models).
TIGRunner ™ system packages with
Coolmate™ 3X cooler. A three-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. Three-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 provides added
convenience to your welding experience.
Arc timer/cycle counter records actual welding
time and number of arc starts. Great for estimating
job costs.
Squarewave technology developed by Miller®
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°
Fahrenheit. The aluminum material that is
located under this layer of oxide melts at 1200°
Fahrenheit. 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 percent.
Easy Load Dual Cylinder Rack (see photo at
right) minimizes cylinder lifting. Cylinder is
not included.
AC Output: Balance Control
AC Balance
4
5
Balanced Wave Function
Balanced Wave
6
3
7
2
Medium bead
8
Bead
9
1
0
4
5
Cleaning
6
3
7
2
8
Narrower bead
for fillet welds
0
More Heat into Work
Narrow bead, with no
visible cleaning
9
1
Bead
32%
Electrode
Positive
68%
Electrode
Negative
10
Min.
Cleaning
4
5
No Visible Cleaning
Wider bead and
cleaning action
6
3
7
2
Greatest Cleaning Action
Wide bead
8
9
1
Bead
10
Max.
Cleaning
2
50%
Electrode
Negative
10
Balanced
0
50%
Electrode
Positive
Cleaning
55%
Electrode
Positive
45%
Electrode
Negative
Specifications
(Subject to change without notice.)
Model
Input
Power
Max
Welding
Amp Range OCV
Syncrowave
250
60 Hz,
1-Phase
3 – 310 A
Rated Output
80 V 250 A at 30 V,
40% Duty Cycle
Amps Input at AC Balance, Rated Load
200V 220V 230V 400V 440V 460V 520V 575V KVA KW
110
50 Hz,
1-Phase
225 A at 29 V,
40% Duty Cycle
101
Syncrowave
250 IEC
220/400/
440/520
50 or
60 Hz,
1-Phase
250 A at 30 V,
40% Duty Cycle
—
Syncrowave
350
All Models
50 or
60 Hz,
1-Phase
80 V 350 A at 34 V,
40% Duty Cycle
146
3 – 400 A
—
96
—
—
48
—
38
22 12
—
88
—
—
44
—
35
20 10
Dimensions
Weight
H: 33.25 in. (845 mm)*
W:22.5 in. (572 mm)
D: 25 in. (635 mm)**
378 lb.
(172 kg)
with TIGRunner®
H: 46 in. (1168 mm)*
478 lb.
W:28.5 in. (724 mm)
(217 kg)
D: 40.5 in. (1029 mm)**
—
55
50
—
42
—
22 12
H: 33.25 in. (845 mm)*
W:22.5 in. (572 mm)
D: 25 in. (635 mm)**
378 lb.
(172 kg)
120 128
66
60
65
51
50
30 14
H: 33.25 in. (845 mm)*
W:22.5 in. (572 mm)
D: 25 in. (635 mm)**
496 lb.
(225 kg)
100
with TIGRunner®
H: 46 in. (1168 mm)*
596 lb.
W:28.5 in. (724 mm)
(270 kg)
D: 40.5 in. (1029 mm)**
Notes: See page 6 for power factor correction kit. *Add 3 inches (76 mm) for lift eye. **Add 1.5 inches (38 mm) for handle.
IEC models conform to the following standards: IEC 60974-1: 2005, IEC 60974-10: 2004, and EN 50445
Certified by Canadian Standards Association to both the Canadian and U.S. Standards.
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 seconds)
8. Ammeter Display
9. Pulser Control*
10. Background Amps Control (0 – 100%)*
11. Pulse-Per-Second Control (0.25 – 10 Hz)*
12. Peak Time Control (5 – 95%)*
4
Pulser*
Module
13.
14.
15.
16.
17.
18.
19.
20.
Spot Time Control (0 – 5 seconds)**
Final Slope Control (0 – 25 seconds)**
Initial Time Control (0 – 15 seconds)**
Final Amperage Control (0 – 100%)**
Initial Amperage Control (0 – 100%)**
Amperage Adjustment Control (3 – 310/400 A)
Output Selector Switch (AC/DC-/DC+)
Power Switch (On/Off)
*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)
#907 516 (220/400/440/520 VAC) IEC
Standard Model
Syncrowave® 350 LX
#907 198 (200/230/460 VAC)
#907 199 (230/460/575 VAC)
#907 517 (220/400/440/520 VAC) IEC
Primary cord and TIG torch adapter
sold separately.
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)
Syncrowave TIGRunner
Completely assembled. TIGRunner includes
Syncrowave, Coolmate™ 3X cooler, No. 37
running gear, and RFCS-14 HD remote
foot control.
Primary cord, TIG torch adapter, Dinse
connector and TIG coolant sold separately.
Syncrowave Complete Packages
®
Syncrowave® 250 DX Complete
#951 117 (200/230/460 VAC)
#951 118 (230/460/575 VAC)
Syncrowave Complete
(Syncrowave TIGRunner,
TIG Coolant and Torch Kit)
Syncrowave® 350 LX Complete
#951 119 (200/230/460 VAC)
#951 120 (230/460/575 VAC)
TIG Coolant
TIG Coolant
Completely assembled. Includes TIGRunner
above (Syncrowave, Coolmate™ 3X cooler,
No. 37 running gear, and RFCS-14 HD
remote foot control), plus four gallons of
TIG coolant and a water-cooled torch kit
(see kits to left) consisting of torch, cable
cover, accessory kit, regulator/flowmeter,
gas hose, torch adapter, and weld lead with
clamp and Dinse connector.
Primary cord sold separately.
250 A Water-Cooled Torch Kit
for Syncrowave 250 DX TIGRunner
300 A Water-Cooled Torch Kit
for Syncrowave 350 LX TIGRunner
5
Genuine Miller Options
®
Field Options
Sequencer Module
#300 547 Field Kit for Syncrowave 250/350
Effective with serial number LE282983.
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
#300 548 Field Kit for Syncrowave 250 DX
Effective with serial number LE282983.
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 percent allowing the
use of smaller breakers/fuses and smaller
primary cord. Power Factor does not reduce
the power consumption/electrical bill.
Genuine Miller Accessories
®
RCCS-14 Remote Contactor and
Current Control #043 688
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-foot
(8 m) cord and 14-pin plug.
No. 37 Running Gear #195 282
Includes two 10-inch (254 mm) wheels,
two 5-inch (127 mm) casters, twocompartment 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
Wireless Remote
Foot Control
#300 429
For remote
current and
contactor control.
Receiver plugs
directly into the 14-pin receptacle of Miller
machine. 90-foot (27.4 m) operating range.
Wireless Remote Hand
Control #300 430
For remote current
and contactor control.
Receiver plugs directly
into the 14-pin receptacle
of Miller machine. 300-foot (91.4 m)
operating range.
6
RMS-14 On/Off Control #187 208
Momentary-contact switch for contactor
control. Rubber-covered pushbutton
dome switch ideal for repetitive on-off
applications. Includes 26.5-foot (8 m) cord
and 14-pin plug.
Extension Cables for 14-Pin Remote Controls
#242 208 025 25 ft. (7.6 m)
#242 208 050 50 ft. (15.2 m)
#242 208 080 80 ft. (24.4 m)
Educational Materials
Please visit MillerWelds.com/resources/tools to order
the following.
RFCS-14 HD Foot Control #194 744
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-foot (6 m) cord and
14-pin plug.
RHC-14 Hand Control
#242 211 020
Miniature hand control
for remote current
and contactor control.
Dimensions: 4 x 4 x
3.25 inches (102 x 102 x 83 mm). Includes
20-foot (6 m) cord and 14-pin plug.
RMLS-14 Switch #129 337
Momentary- and maintained-contact rocker
switch for contactor control. Push forward
for maintained contact and backward for
momentary contact. Includes 26.5-foot
(8 m) cord and 14-pin plug.
Gas Tungsten Arc (TIG) Welding Book
#170 555
A comprehensive text on all aspects of the
TIG process. Filled with figures and tables
to illustrate process technique and
equipment setup. Glossary of TIG terms
also provided. 86 pages—8.5 x 11 inches.
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
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 watercooled systems. In-depth discussion of
tungstens and gases. 13:00 minutes.
Genuine Miller Accessories
®
(continued)
TIG (GTAW) Torch Adapters
Coolant Systems
For more information, see the Miller Coolant
Systems literature sheet, Index No. AY/7.2.
TIG Gloves
#249 178 Medium
#249 179 Large
#249 180 X-Large
Durable goatskin back and palm for
extended wear and ultimate dexterity.
Flame-resistant cotton fleece back and
padded palm provide excellent protection.
Water-Cooled Dinse #195 377
Used to adapt a 250- or 350-amp watercooled torch (WP20, WP18, CS310) to a
Dinse-style connector.
Coolmate™ 3X with
Cart and Dual Cylinder
Rack #300 419
Includes: easy-load
dual cylinder rack,
Includes Wheels
running gear, and
3X industrial water cooler — a perfect
solution for water-cooled TIG torches.
Air-Cooled Dinse #195 379
Used to adapt a one-piece 200-amp
air-cooled torch (WP26) to a Dinse-style
connector.
Low-Conductivity TIG
Coolant #043 810
Sold in multiples of
four one-gallon
recyclable plastic
bottles. Miller coolants
contain a base of ethylene glycol and
deionized water to protect against freezing
to -37° Fahrenheit (-38° C) or boiling to
227° Fahrenheit (108° C).
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-foot (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-inch)
Smith® regulator/flowmeter HM2051A-580
Gas hose (regulator to machine)
Water-cooled Dinse torch adapter
15-foot (4.6 m) 1/0 weld lead with clamp
(work or ground lead) and Dinse connector
25-foot (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-inch)
Smith® regulator/flowmeter HM2051A-580
Gas hose (regulator to machine)
Water-cooled Dinse torch adapter
15-foot (4.6 m) 1/0 weld lead with clamp
(work or ground lead) and Dinse connector
400 A Water-Cooled Torch Kit #300 186
25-foot (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-inch)
Smith® regulator/flowmeter H1954D-580
Gas hose (regulator to machine)
Water-cooled thread lock torch adapters
12-foot (3.7 m) 4/0 weld lead with clamp
(work or ground lead)
Tungsten
Tungsten
Amp Range
2% Ceriated (AC/DC)
2% Lanthanated (AC/DC)
2% Thoriated (DC)
Zirconiated (AC)
1/16 in. (1.6 mm)
70 –150 A
WC116X7
WL2116X7
WT116X7
WZ116X7
3/32 in. (2.4 mm)
140 – 250 A
WC332X7
WL2332X7
WT332X7
WZ332X7
1/8 in. (3.2 mm)
225 – 400 A
WC018X7
WL2018X7
WT018X7
WZ018X7
5/32 in. (4.0 mm)
300 – 500 A
WC532X7
WL2532X7
WT532X7
WZ532X7
7
Ordering Information
Equipment and Options
Stock No.
Description
Syncrowave® 250 DX
#907 194
#907 195
#907 516
#907 194-03-2
#951 117
#907 195-03-2
#951 118
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, IEC
200/230/460 V, 50/60 Hz, Syncrowave 250 DX TIGRunner ® 3X
200/230/460 V, 50/60 Hz, Syncrowave 250 DX Complete
230/460/575 V, 50/60 Hz, Syncrowave 250 DX TIGRunner ® 3X
230/460/575 V, 50/60 Hz, Syncrowave 250 DX Complete
Qty.
Syncrowave® 350 LX
#907 198
#907 199
#907 517
#907 198-03-2
#951 119
#907 199-03-2
#951 120
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, IEC
200/230/460 V, 50/60 Hz, Syncrowave 350 LX TIGRunner ® 3X
200/230/460 V, 50/60 Hz, Syncrowave 350 LX Complete
230/460/575 V, 50/60 Hz, Syncrowave 350 LX TIGRunner ® 3X
230/460/575 V, 50/60 Hz, Syncrowave 350 LX Complete
Sequencer Module
#300 547
Field. For Syncrowave 250 DX and 350 LX
Pulser Module
#300 548
Field. For Syncrowave 250 DX
Power Factor Correction Kit
#194 692
#043 757
Field. For Syncrowave 250 DX
Field. For Syncrowave 350 LX
Weldcraft® 250 A Water-Cooled Torch Kit
#300 185
See page 7. Recommended for Syncrowave 250 DX TIGRunner 3X
Weldcraft® 300 A Water-Cooled Torch Kit
#300 183
See page 7. Recommended for Syncrowave 350 LX TIGRunner 3X
Weldcraft® 400 A Water-Cooled Torch Kit
#300 186
TIG Torch Kits
Consumables and Tungsten
See page 7
See page 7
Gas Cylinder, Hose and Fittings
Remote Controls
Wireless Remote Foot Control
#300 429
Foot control with wireless 90-ft. (27.4 m) operating range
Wireless Remote Hand Control
#300 430
Hand control with wireless 300-ft. (91.4 m) operating range
RCCS-14
#043 688
North/south fingertip control
RFCS-14 HD
#194 744
Heavy-duty foot control
RHC-14
#242 211 020
Hand control
RMLS-14
#129 337
Momentary/maintained rocker switch
RMS-14
#187 208
Momentary rubber dome switch
Extension Cables
#242 208 025
#242 208 050
#242 208 080
25 ft. (7.6 m)
50 ft. (15.2 m)
80 ft. (22.9 m)
Accessories
No. 37 Running Gear
#195 282
Protective Cover
#195 320
Gas Tungsten Arc (TIG) Welding Book
#170 555
TIG Training CD
#196 567
Video – GTAW Setup Procedures
#108 241
Torch Adapters
Supplied with power source and torch kits
#195 377
#195 379
Cable Connectors
Dinse Connector 50 mm (1 male)
#042 418
Dinse Connector 50 mm (1 male, 1 female)
#042 419
Tweco Terminal Adapter
#042 465
Cam-Lok Terminal Adapter
#042 466
Coolmate™ 3X w/Cart and Dual Cylinder Rack
#300 419
TIG Coolant
#043 810
Date:
Sold in multiples of four one-gallon plastic bottles.
Total Quoted Price:
Distributed by:
Litho in USA
Order at MillerWelds.com/resources/tools
Order at MillerWelds.com/resources/tools
Order at MillerWelds.com/resources/tools
Adapts 250 or 350 A water-cooled torch to Dinse-style connector
Adapts 1-piece 200 A air-cooled torch to Dinse-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
Price

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