Gebruiksaanwijzing /service van het product TM-353E van de fabrikant Miller Electric
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Processes TM-353E January 2001 Eff. w/Serial Number JJ339876 Description TIG (GT A W ) W elding Stick (SMA W) W elding Arc Welding Power Source Syncrowave 250 60 Hz, 50 Hz R Visit our website at www.
T ABLE OF CONTENTS 1. Safety Precautions – Read Before Using 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
dec_con1 10/95 Declaration of Conformity For European Community (CE) Products This information is provided for units with CE certification (see rating label on unit.) NOTE Manufacturer ’ s Name: Miller Electric Mfg. Co. Manufacturer ’ s Address: 1635 W .
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TM-353 Page 1 Syncrowave 250 SECTION 1 – SAFETY PRECAUTIONS FOR SER VICING safety_stm1 4/95 1-1. Symbol Usage Means W arning! W atch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols.
TM-353 Page 2 Syncrowave 250 F ALLING EQUIPMENT can cause serious personal injury and equipment damage. 1. Use lifting eye to lift unit only , NOT running gear , gas cylinders, or any other accessories. 2. Use equipment of adequate capacity to lift unit.
TM-353 Page 3 Syncrowave 250 SECTION 2 – DEFINITIONS 2-1. W arning Label Definitions S-176 254-A 1 1.1 1.2 1.3 3 3.1 3.2 3.3 4 4.1 + 2 2.1 2.2 + + 5 6 + 2.3 W arning! W atch Out! There are possible hazards as shown by the symbols. 1 Electric shock from welding electrode or wiring can kill.
TM-353 Page 4 Syncrowave 250 2-2. Rating Label For CE Products S-178 813-A ISO/IEC 974-1 X 25% 60% 100% 7A/10.2V 310A/22.4V U 0 = 80V I 2 310A 200A 155A U 2 22.4V 18V 16.2V X 25% 60% 100% 5A/20.2V 310A/32.4V U 0 = 80V I 2 310A 200A 155A U 2 32.4V 28V 26.
TM-353 Page 5 Syncrowave 250 2-3. Symbols And Definitions Some symbols are found only on CE products. NOTE A Amperes Panel – Local Gas Tungsten Arc W elding (GT AW) Shielded Metal Arc W elding (SMA .
TM-353 Page 6 Syncrowave 250 SECTION 3 – INST ALLA TION 3-1. Specifications Amperes Input at AC Balanced Rated Load Output, 50/60 Hz, Single-Phase Rated W elding Output PFC** 200 V 230 V 460 V 575 V KV A KW Amp Range Max OCV IP Rating NEMA Class II (40) – 250 No PFC 106 (4.
TM-353 Page 7 Syncrowave 250 3-3. Duty Cycle And Overheating 4 Minutes W elding 6 Minutes Resting 6 Minutes W elding 4 Minutes Resting Duty Cycle is percentage of 10 mi n- utes 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.
TM-353 Page 8 Syncrowave 250 3-4. Selecting A Location 1 Lifting Eye 2 Lifting Forks Use lifting eye or lifting forks to move unit. If using lifting forks, extend forks beyond opposite side of unit. 3 Rating Label (Non CE Models Only) 4 Rating Label (CE Models Only , See Section 2-2) Use rating label to determine input power needs.
TM-353 Page 9 Syncrowave 250 3-6. Tipping Y Be careful when placing or moving unit over uneven surfaces. 3-7. W eld Output T erminals And Selecting Cable Sizes Y ARC WELDING can cause Electromagnetic Interference. T o reduce possible interference, keep weld cables as short as possible, close together , and down low , such as on the floor .
TM-353 Page 10 Syncrowave 250 3-8. Remote 14 Receptacle Socket* 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. AJ B K I D Remote control circuit common.
TM-353 Page 1 1 Syncrowave 250 3-10. Electrical Service Guide All values calculated at 60% duty cycle. NOTE 60 Hertz Models Without Power Factor Correction With Power Factor Correction Input V oltage .
TM-353 Page 12 Syncrowave 250 1 3-1 1. Placing Jumper Links And Connecting Input Power ST-1 17 263-K Check input voltage available at site. 1 Jumper Link Label Check label inside your unit – only one label is on unit. Y Only make connections for th e voltages shown on the l a - bel inside your unit.
TM-353 Page 13 Syncrowave 250 SECTION 4 – OPERA TION 4-1. Controls Ref. ST-1 17 264-F / Ref. ST-154 795-C 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 1 Ammeter See Section 4-3. 2 V oltmeter See Section 4-3. 3 High Frequency Switch See Section 4-1 1. 4 Output (Contactor) Switch See Section 4-8.
TM-353 Page 14 Syncrowave 250 4-2. Output Selector Switch Ref. ST-181 675-A 1 Output Selector Switch Y Do not use AC output in damp areas, if movement is confined, or if there is dan- ger of falling. Use AC output ONL Y if required for the welding process, and then use a remote control.
TM-353 Page 15 Syncrowave 250 4-4. Crater Time Controls 1 Crater T ime Control Us e 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.
TM-353 Page 16 Syncrowave 250 4-6. AC Balance Control Ref. S-0795-A 1 AC Balance Control Balance Control (AC GT A W): Control changes the AC output square wave. Rotating the control towards 10 provides deeper pene- tration. Rotating the control towards 0 provides more cleaning action of the workpiece.
TM-353 Page 17 Syncrowave 250 4-7. Amperage Adjustment Controls 1 Amperage Adjustment Control Use control to adjust amperage, and preset amperage on ammeter (see S e c t i o n 4 - 3 ) . T h i s c o n t r o l m a y be adjusted while welding. For remote amperage control , front panel control setting is the maximum amperage available.
TM-353 Page 18 Syncrowave 250 4-9. Arc Controls 1 Arc Control (Dig) For AC And DC SMA W W elding When set at 0, short-circuit amper- age at low arc voltage is the same as normal welding amperage. When setting is increased, short- circuit amperage at low arc voltage increases.
TM-353 Page 19 Syncrowave 250 4-1 1. High Frequency Controls Y Place High Frequency switch in Off position before using the shielded metal arc welding (SMA W) process. 1 High Frequency Switch ST ART – (Up position) provides HF for arc starting only .
TM-353 Page 20 Syncrowave 250 1 Input T erminal Board TE1 Provides means for operation on dif ferent input voltages. 2 Power Switch S1 Provide on/off control of unit.
TM-353 Page 21 Syncrowave 250 15 1 15 V olts AC Duplex Recep- tacle RC2 Provides connection point for auxil- iary equipment. 16 Postflow Timer TD1 Controls shielding gas and coolant postflow time. 17 Gas V alve GS1 Provides shielding gas during the weld cycle.
TM-353 Page 22 Syncrowave 250 SECTION 6 – TROUBLESHOOTING 6-1. T roubleshooting T able . See Section 6-2 for test points and values and Section 10 for parts location. . Use MILLER T esting Booklet (Part No. 150 853) when servicing this unit. T rouble Remedy Prior to Serial No.
TM-353 Page 23 Syncrowave 250 T rouble Remedy Check SCRs in main rectifier SR1, and replace if necessary . If any SCRs are replaced, Check capac- itors C7 through C10 for a short or open, and check for proper connections. Replace C7 through C10 if necessary .
TM-353 Page 24 Syncrowave 250 T rouble Remedy No high frequency at spark gaps G. Check position of High Frequency switch S2 (see Section 4-1 1). Place Output (Contactor) switch S3 in Remote position and be sure remote control is connected to Remote receptacle RC1 (see Section 3-8).
TM-353 Page 25 Syncrowave 250 T rouble 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 nec- essary . No power output at 1 15 volts ac recep- tacle RC1; weld output available.
TM-353 Page 26 Syncrowave 250 6-2. T roubleshooting Circuit Diagram For Welding Power Source Y Disable high frequency by placing High Frequency switch S2 in Off position before testing unit.
TM-353 Page 27 Syncrowave 250 SC-188 161 T e st Equipment Needed: V24 V22 V21 R3 R2 V20 A A A A R1 V25 Resistance V alues a) T olerance – ± 10% unless specified b) T u rn Off unit and disconnect input power before checking resistance R1 All values for T1, Z1, and T3 are less than 1 ohm R2 5.
TM-353 Page 28 Syncrowave 250 6-3. W aveforms For Section 6-2 W aveforms shown are for 60 Hertz models; waveforms for 50 Hertz models are similar. 5 ms 1 V A. SR1 Gate Pulse With Respect T o Cathode At No Load 5 ms 50 V B. DC Open-Circuit V oltage With Amperage Adjustment Control At Maximum 5 ms 20 V C.
TM-353 Page 29 Syncrowave 250 T e st Equipment Needed: 5 ms 50 V E. AC Output, 100 Amperes, 24 V olts AC (Re- sistive Load) gnd.
TM-353 Page 30 Syncrowave 250 6-4. Control Board PC1 T esting Information (Use With Section 6-5) SB-178 976-A / ST-800 344-A Y Disable high frequency by placing High Frequency switch S2 in Off position before testing unit. Be sure plugs are secure before testing.
TM-353 Page 31 Syncrowave 250 6-5. Control Board PC1 T est Point V alues PC1 V oltage Readings a) T olerance – ± 10% unless specified b) Reference – to circuit common (lead 42) unless noted Recep.
TM-353 Page 32 Syncrowave 250 Receptacle V alue 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.
TM-353 Page 33 Syncrowave 250 6-6. Remote Board PC2 T esting Information (Use With Section 6-7) ST-157 960-B / ST -800 344-A Y Disable high frequency by placing High Frequency switch S2 in Off position before testing unit. Be sure plugs are secure before testing.
TM-353 Page 34 Syncrowave 250 6-7. R emote 14 Filter Board PC2 T est Point V alues (Use With Section 6-2 And Section 6-6) PC2 V oltage Readings a) T olerance – ± 10% unless specified b) Reference .
TM-353 Page 35 Syncrowave 250 6-8. Meter Calibration SB-130 690-D / ST-800 344-A Be sure plugs are secure before calibrating meter . 1 Control Board PC1 2 V oltmeter V1 3 Ammeter A1 T op V iew R19 Amperes No calibration available for ammeter offset, or for voltmeter V1.
TM-353 Page 36 Syncrowave 250 6-9. Input V oltage Labels And Connections ST-154 793-A / ST -1 14 947-A / ST-121 000-A / ST -131 735 1 Input V ol t a g e L a b e l A n d C o n - nection Diagram – Onl.
TM-353 Page 37 Syncrowave 250 SECTION 7 – MAINTENANCE 7-1. Routine Maintenance Y Disconnect power before maintaining. 3 Months Replace Unreadable Labels Clean And T ighten W eld T erminals Repair Or.
TM-353 Page 38 Syncrowave 250 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 start- ing and arc performance in the DC TIG mode.
TM-353 Page 39 Syncrowave 250 SECTION 8 – HIGH FREQUENCY (HF) 8-1. W elding Processes Using HF high_freq1 7/95 – S-0693 1 HF V oltage GT A W – helps arc jump air gap between torch and workpiece and/ or stabilize the arc. SA W – helps arc reach workpiece through flux granules.
TM-353 Page 40 Syncrowave 250 8-3. Correct Installation 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. 2 Welding Zone And Centerpoint A circle 50 ft (15 m) from centerpoint between HF source and welding torch in all directions.
TM-353 Page 41 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.
TM-353 Page 42 Syncrowave 250 SC-1 14 914 Figure 9-1. Circuit Diagram For Syncrowave 250 Effective With Serial No. JJ339876 Thru JJ351864.
TM-353 Page 43 Syncrowave 250 Figure 9-2. Circuit Diagram For Syncrowave 250 Effective With Serial No. JJ351865 Thru JJ365633 SC-120 877.
TM-353 Page 44 Syncrowave 250 SC-121 280 Figure 9-3. Circuit Diagram For Syncrowave 250 Effective With Serial No. JJ365634 Thru JJ503983.
TM-353 Page 45 Syncrowave 250 Figure 9-4. Circuit Diagram For Syncrowave 250 Effective With Serial No. JJ503984 Thru JK572897 SC-124 314.
TM-353 Page 46 Syncrowave 250 SC-124 785-B Figure 9-5. Circuit Diagram For Syncrowave 250 Effective With Serial No. JK572898 Thru JK690986.
TM-353 Page 47 Syncrowave 250 Figure 9-6. Circuit Diagram For Syncrowave 250 Effective With Serial No. JK690987 Thru KA806712 SC-132 697-A.
TM-353 Page 48 Syncrowave 250 Figure 9-7. Circuit Diagram For Syncrowave 250 Effective With Serial No. KA806713 Thru KA877024 SC-137 431.
TM-353 Page 49 Syncrowave 250 Figure 9-8. Circuit Diagram For Syncrowave 250 Effective With Serial No. KA877025 Thru KB010829 SC-135 581.
TM-353 Page 50 Syncrowave 250 Figure 9-9. Circuit Diagram For Syncrowave 250 Effective With Serial No. KB010830 Thru KB1 10694 SC-142 524.
TM-353 Page 51 Syncrowave 250 Figure 9-10. Circuit Diagram For Syncrowave 250 Effective With Serial No. KB1 10695 Thru KC252675 SC-148 144.
TM-353 Page 52 Syncrowave 250 Figure 9-11. Circuit Diagram For Syncrowave 250 Effective With Serial No. KC252676 Thru KG029204 SC-154 649-C.
TM-353 Page 53 Syncrowave 250 Figure 9-12. Circuit Diagram For Syncrowave 250 Effective With Serial No. KG029205 Thru KG062109 SC-178 835.
TM-353 Page 54 Syncrowave 250 Figure 9-13. Circuit Diagram For Syncrowave 250 Effective With Serial No. KG0621 10 Thru KG170300 SC-179 303-A.
TM-353 Page 55 Syncrowave 250 Figure 9-14. Circuit Diagram For Syncrowave 250 Effective With Serial No. KG170301 Thru KH526230 SC-181 109-E.
TM-353 Page 56 Syncrowave 250 SC-188 161-A Figure 9-15. Circuit Diagram For Syncrowave 250 Effective With Serial No. KH526231 And Following.
TM-353 Page 57 Syncrowave 250 Notes.
TM-353 Page 58 Syncrowave 250 Figure 9-16. Wiring Diagram For Syncrowave 250 Effective With Serial No. KH526231 And Following.
TM-353 Page 59 Syncrowave 250 SD-188 162-A.
TM-353 Page 60 Syncrowave 250 Figure 9-17. Circuit Diagram For Control Board PC1 Effective With Serial No. KH508255 And Following (Part 1 Of 2).
TM-353 Page 61 Syncrowave 250 SD-187 644 (1 of 2).
TM-353 Page 62 Syncrowave 250 Figure 9-18. Circuit Diagram For Control Board PC1 Effective With Serial No. KH508255 And Following (Part 2 Of 2).
TM-353 Page 63 Syncrowave 250 SD-187 644 (2 of 2).
TM-353 Page 64 Syncrowave 250 Figure 9-19. Circuit Diagram For RFC Board PC2 Effective With Serial No. JJ365634 Thru KB010829 Figure 9-20. Circuit Diagram For Remote 14 Filter Board PC2 Effective With Serial No. KF959379 And Following SA-120 872 SA-121 282 Figure 9-21.
TM-353 Page 65 Syncrowave 250 SA-045 288-D Figure 9-22. Circuit Diagram For Optional Preflow Timer Board TD3 Effective With Serial No. JJ339876 And Following SA-044 725-C Figure 9-23. Circuit Diagram For Postflow Timer Board TD1 Effective With Serial No.
TM-353 Page 66 Syncrowave 250 Notes.
Syncrowave 250 Processes 60 Hz, 50 Hz R TM -353E January 2001 Eff. w/Serial Number JJ339876 Descr iption TIG (GT A W ) W elding Stick (SMA W) W elding Arc Welding Power Source Visit our website at www.
TM-353 Page 68 Syncrowave 250 SECTION 10 – P ARTS LIST Figure 10-1. Main Assembly ST-120 135-R . Hardware is common and not available unless listed. 1 2 – Fig.10-3 3 4 5 6 7 – Fig.10-5 8 9 10 11 12 13 30 31 14 15 16 17 – Fig.10-4 18 19 20 21 22 23 24 25 26 27 28 29 – Fig.
TM-353 Page 69 Syncrowave 250 Figure 10-1. Main Assembly Description Quantity Part No. Dia. Mkgs. Item No. 1 1 14 741 COVER, top (Prior to KG170301) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TM-353 Page 70 Syncrowave 250 Figure 10-1. Main Assembly (Continued) Description Quantity Part No. Dia. Mkgs. Item No. 22 1 14 755 BASE, (Prior to KE727074) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TM-353 Page 71 Syncrowave 250 1 2 ST-120 088-G 3 4 5 6 7 4 8 9 10 12 13 Includes Item 26 11 14 15 16 17 18 19 23 25 26 27 1 21 20 28 29 22 24 Figure 10-6 Figure 10-2. Panel, Front w/Components Figure 10-2. Panel, Front w/Components (Fig 10-1 Item 29) Description Quantity Part No.
TM-353 Page 72 Syncrowave 250 Figure 10-2. Panel, Front w/ Components (Continued) Description Quantity Part No. Dia. Mkgs. Item No. 13 044 723 CIRCUIT CARD, postflow 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TM-353 Page 73 Syncrowave 250 Figure 10-3. Rectifier , Si Diode (Fig 10-1 Item 2) Description Quantity Part No. Dia. Mkgs. Item No. 1 C7-10 031 689 CAP ACITOR, rectifier 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TM-353 Page 74 Syncrowave 250 Figure 10-5. Panel, Mtg Components (Fig 10-1 Item 7) Description Quantity Part No. Dia. Mkgs. Item No. 1 R7 186 468 RESIST OR, WW fxd 100W 50 ohm 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TM-353 Page 75 Syncrowave 250 ST-120 003-P 1 2 3 4 5 6 7 8 9 10 11 13 14 15 16 17 18 19 20 21 22 23 Figure 10-6. Control Panel, Lower Front Figure 10-6. Control Panel, Lower Front (Fig 10-2 Item 18) Description Quantity Part No. Dia. Mkgs. Item No. 1 16 477 CONTROL P ANEL, lower (Prior to JK572898) 1 .
TM-353 Page 76 Syncrowave 250 Figure 10-6. Control Panel, Lower Front (Continued) Description Quantity Part No. Dia. Mkgs. Item No. 3 126 750 CAP ACITOR ASSEMBL Y , (Eff w/JK537589 thru JK690986) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . .
TM-353 Page 77 Syncrowave 250 Figure 10-6. Control Panel, Lower Front (Fig 10-2 Item 18) (Continued) Description Quantity Part No. Dia. Mkgs. Item No. 18 T3 1 15 967 COIL, HF coupling (Prior to JK572898) 1 . . . . . . . . . . . . . . . . . . . . . . .
TM-353 Page 78 Syncrowave 250 Eff w/KE558763 the W ater V alve Option (042 138) is no longer available and all other options are available as Field Options only . Description Quantity Part No. Dia. Mkgs. Optional Equipment 042 138 WA TER V AL VE, (consisting of) 1 .
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PRINTED IN USA 1998 Miller Electric Mfg. Co. Miller Elect ric Mfg. Co. An I l li noi s T ool Works Company 1635 W es t Spenc er St reet Applet on, WI 54914 USA International He adquarters – USA .
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In een situatie waarin je al een beziter van Miller Electric TM-353E bent, maar toch heb je de instructies niet gelezen, moet je het doen voor de hierboven beschreven redenen. Je zult dan weten of je goed de alle beschikbare functies heb gebruikt, en of je fouten heb gemaakt die het leven van de Miller Electric TM-353E kunnen verkorten.
Maar de belangrijkste taak van de handleiding is om de gebruiker bij het oplossen van problemen te helpen met Miller Electric TM-353E . Bijna altijd, zal je daar het vinden Troubleshooting met de meest voorkomende storingen en defecten #MANUAl# samen met de instructies over hun opplosinge. Zelfs als je zelf niet kan om het probleem op te lossen, zal de instructie je de weg wijzen naar verdere andere procedure, bijv. door contact met de klantenservice of het dichtstbijzijnde servicecentrum.
