Miller Electric Syncrowave 500 Owner's Manual

Syncrowave 500ProcessesDescriptionRTIG (GTAW) WeldingStick (SMAW) WeldingArc Welding Power SourceOM-350 000 739ABDecember 2001Visit our website atwww.

OM-350 Page 6Le rayonnement de l’arc du procédé de soudagegénère des rayons visibles et invisibles intenses(ultraviolets et infrarouges) susceptibles

OM-350 Page 71-3. Dangers supplémentaires en relation avec l’installation, le fonctionnementet la maintenanceRisque D’INCENDIE OUD’EXPLOSION.D Ne pas

OM-350 Page 81-4. Principales normes de sécuritéSafety in Welding and Cutting, norme ANSI Z49.1, de l’American Wel-ding Society, 550 N.W. Lejeune Rd,

OM-350 Page 9SECTION 2 – INSTALLATION2-1. SpecificationsRated Welding AmperageMaximum Open-Circuit VoltageAmperes Input at Rated Load Output,60 Hz, Si

OM-350 Page 102-4. Typical Process ConnectionsWARNINGHIGH-FREQUENCY RADIATION can interfere with radio navigation, safety services,computers, and comm

OM-350 Page 112-6. Overall Dimensions And Base Mounting Hole LayoutOverall dimensions (A, B, and C) include lifting eye, handles, hardware, etc.NOTEST

OM-350 Page 122-9. Lower Front PanelRef. ST-144 405-B1 Work Output Terminal2 Electrode Output Terminal3 High Frequency IntensityControl (See Section 3

OM-350 Page 132-11. 115 Volts AC Duplex Receptacle And Circuit Breaker1 115 Volts AC DuplexReceptacleThis welding power source sup-plies up to 15 ampe

OM-350 Page 142-13. Remote 14 Receptacle Information And Connectionssb7.1 5/94 – Ref. ST-144 405-B / Ref. S-0004-A / S-07501 Remote 14 Receptacle RC2(

OM-350 Page 152-15. Positioning Jumper Linksssb5.1 2/92 – ST-800 337-BY Disconnect and lockout/tag-out input power before plac-ing or moving jumper li

Miller Electric manufactures a full lineof welders and welding related equipment.For information on other quality Millerproducts, contact your local M

OM-350 Page 162-17. Connecting Input PowerWARNINGHIGH-FREQUENCY RADIATION caninterfere with radio navigation, safetyservices, computers, and communica

OM-350 Page 17SECTION 3 – OPERATIONWARNINGELECTRIC SHOCK can kill.• Always wear dry insulating gloves.• Insulate yourself from work and ground.• Do no

OM-350 Page 183-2. Work Clamp1 Work ClampConnect work clamp to a clean,paint-free location on workpiece, asclose to weld area as possible.Use wire bru

OM-350 Page 193-4. Amperage Controls1 Amperage Adjustment ControlUse control to select weld outputamperage.2 Amperage Control SwitchUse switch to sele

OM-350 Page 203-6. Output (Contactor) Switch1 Output (Contactor) SwitchUse switch to select way of control-ling unit output.For weld output, place swi

OM-350 Page 213-8. Postflow Time Control1 Postflow Time ControlUse control to set the length of timein seconds gas (and coolant if appli-cable) flows

OM-350 Page 223-11. Ammeter And Voltmeter1 AmmeterAmmeter displays weld amperageoutput of unit.2 VoltmeterVoltmeter displays voltage at theweld output

OM-350 Page 233-13. Shielding Gas1 Shielding Gas Cylinder2 Valve3 Fingertip Control4 Foot ControlOpen valve on cylinder just beforewelding.Fingertip c

OM-350 Page 24SECTION 4 – MAINTENANCE & TROUBLESHOOTING4-1. Routine Maintenance3 MonthsCleanAndTightenWeldTerminalsReplaceUnreadableLabels14-Pin C

OM-350 Page 254-3. TroubleshootingTrouble RemedyNo weld output; unit completely inoperative. Place Power switch in On position (see Section 3-12).Plac

TABLE OF CONTENTSSECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1. . .

OM-350 Page 26SECTION 5 – ELECTRICAL DIAGRAMFigure 5-1. Circuit Diagram For Welding Power Source

OM-350 Page 27SD-202 703-A

OM-350 Page 28SECTION 6 – HIGH FREQUENCY6-1. Welding Processes Requiring High Frequencyhigh_freq 12/96 – S-06931 High-Frequency VoltageTIG – helps ar

OM-350 Page 296-3. Correct Installation1 High-Frequency Source (weldingpower source with built-in HF orseparate HF unit)Ground metal machine case, wor

OM-350 Page 30SECTION 7 – SELECTING AND PREPARING TUNGSTENELECTRODE FOR DC OR AC WELDINGac/dc_gtaw 2/2000Y Whenever possible and practical, use DC wel

OM-350 Page 317-2. Preparing Tungsten Electrode For WeldingY Grinding the tungsten electrode produces dust and flying sparks which can cause injury a

OM-350 Page 32SECTION 8 – GUIDELINES FOR TIG WELDING (GTAW)8-1. Positioning The TorchY Weld current can damageelectronic parts in vehicles.Disconnect

OM-350 Page 338-2. Torch Movement During WeldingST-162 002-BTungsten Without Filler RodTungsten With Filler RodForm pool Tilt torch Move torch to fron

OM-350 Page 348-3. Positioning Torch Tungsten For Various Weld JointsST-162 003 / S-079275°70°90°20°20°10°15°75°20-40°30°15°75°90°15°Butt Weld And Str

OM-350 Page 35Notes

OM-350 Page 36SECTION 9 – PARTS LISTST-127 627-C123456Fig 9-47Fig 9-5891012131516111417181920Fig 9-6Fig 9-2 & 9-32122. Hardware is common andnot a

OM-350 Page 37Replace Coils At Factory Or Factory Authorized Service Station/Service DistributorDescription QuantityPartNo.Dia.Mkgs.ItemNo.Figure 9-1.

OM-350 Page 3815678 9111213141510161017 181920 212223242522297303132ST-127 629-B262728. Hardware is common andnot available unless listed.Figure 9-2.

OM-350 Page 39Description QuantityPartNo.Dia.Mkgs.ItemNo.Figure 9-2. Panel, Front (Lower Section) w/Components(Fig 9-1 Item 20)1 003 045 PANEL, front

OM-350 Page 40Figure 9-3. Panel, Front (Upper Section) w/ComponentsST-127 628-A1Fig 9-7234546478910111213141516171819202124 222523262728Fig 9-11293031

OM-350 Page 41Description QuantityPartNo.Dia.Mkgs.ItemNo.Figure 9-3. Panel, Front (Upper Section) w/Components(Fig 9-1 Item 20)1 S5,7 059 081 SWITCH,

OM-350 Page 42Description QuantityPartNo.Dia.Mkgs.ItemNo.Figure 9-4. Panel, Rear w/Components (Fig 9-1 Item 6)1 020 729 CHAMBER, plenum 18in 1. . . .

OM-350 Page 43Description QuantityPartNo.Dia.Mkgs.108 323ItemNo.Figure 9-6. HF Panel (Fig 9-1 Item 19)1 601 838 NUT, brs hex .375-16 jam hvy 4. . . .

OM-350 Page 44Description QuantityPartNo.Dia.Mkgs.059 081ItemNo.Figure 9-7. Switch, Range/Polarity/Selector (Fig 9-3 Item 1)1 048 314 STUD, stl .250-2

OM-350 Page 45Description QuantityPartNo.ItemNo.059 084Figure 9-8. Contact Board Assembly, Switch Selector AC/DC(Fig 9-7 Item 2)1 070 318 CONTACT BOAR

OM-350 Page 1SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USINGsom _nd_4/981-1. Symbol UsageMeans Warning! Watch Out! There are possible hazardswith t

OM-350 Page 46Description QuantityPartNo.ItemNo.059 083Figure 9-9. Contact Board Assembly, Switch Selector AC/DC(Fig 9-7 Item 6)1 070 318 CONTACT BOAR

OM-350 Page 47Description QuantityPartNo.ItemNo.059 082Figure 9-10. Contact Board Assembly, Switch Polarity (Fig 9-7 Item 10)1 070 317 CONTACT BOARD A

OM-350 Page 48Description QuantityPartNo.Dia.Mkgs.119 939ItemNo.Figure 9-11. Rectifier, SCR Main (Fig 9-3 Item 28)SR11 166 667 CLAMP, spring 4. . . .

Warranty Questions?Call1-800-4-A-MILLERfor your localMiller distributor.miller_warr 10/01Your distributor also givesyou ...ServiceYou always get the f

PRINTED IN USA  2000 Miller Electric Mfg. Co. 6/00Miller Electric Mfg. Co.An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914 US

OM-350 Page 2Arc rays from the welding process produce intensevisible and invisible (ultraviolet and infrared) raysthat can burn eyes and skin. Sparks

OM-350 Page 31-3. Additional Symbols For Installation, Operation, And MaintenanceFIRE OR EXPLOSION hazard.D Do not install or place unit on, over, or

OM-350 Page 41-5. EMF InformationConsiderations About Welding And The Effects Of Low FrequencyElectric And Magnetic FieldsWelding current, as it flows

OM-350 Page 5SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANTUTILISATIONsom _nd_fre 4/981-1. Signification des symbolesSignifie Mise en garde ! Soyez vi