Miller Electric Welding System 250 DX User Manual

Issued April 2008 • Index No. AD/4.2  
TIG/Stick Welding  
Power Source  
®
Syncrowave 250 DX/350 LX  
Industrial Applications  
Processes  
TIG (GTAW)  
Input Power Requires 1-Phase Power  
Amperage Range 250: 3310 350: 3400  
Max. Open-Circuit Voltage 80 VDC  
Precision Metal Fabrication  
Maintenance and Repair  
Light and Heavy Manufacturing  
Aerospace  
Stick (SMAW)  
Pulsed TIG (GTAW-P)  
(Optional)  
Quick  
Specs  
Rated Output 250: 250 A at 30 VAC, 40% Duty Cycle  
Shipbuilding  
Tube and Pipe  
Automotive  
Vocational  
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®  
Coolmate3X 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 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.  
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.  
Syncro Startallows the choice of Soft, Standard  
or Hot TIG starts based on the application, lead  
lengths and tungsten size.  
Power source is warranted for 3 years, parts and labor.  
Original main power rectifier parts are warranted for 5 years.  
Miller Electric Mfg. Co.  
An Illinois Tool Works Company  
1635 West Spencer Street  
Appleton, WI 54914 USA  
International Headquarters Web Site  
Phone: 920-735-4505  
USA FAX: 920-735-4134  
Canadian FAX: 920-735-4169  
International FAX: 920-735-4125  
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Specifications  
(Subject to change without notice.)  
Input  
Power  
Welding  
Amp Range OCV Rated Output  
Max  
Amps Input at AC Balance, Rated Load  
200V 220V 230V 400V 440V 460V 520V 575V KVA KW Dimensions  
Model  
Weight  
Syncrowave 60 Hz,  
3–310 A  
80 V 250 A at 30 V,  
40% Duty Cycle  
110  
96  
48  
38  
22 12 H: 33-1/4 in (845 mm)*  
W:22-1/2 in (572 mm)  
378 lb  
(172 kg)  
250  
1-Phase  
D: 25 in (635 mm)**  
50 Hz,  
1-Phase  
225 A at 29 V, 101  
40% Duty Cycle  
88  
44  
35  
20 10  
with TIGRunner®  
H: 46 in (1168 mm)*  
W:28-1/2 in (724 mm)  
D: 40-1/2 in (1029 mm)**  
478 lb  
(217 kg)  
Syncrowave 50 or  
250 A at 30 V,  
40% Duty Cycle  
100  
55  
50  
60  
65  
42  
51  
50  
22 12 H: 33-1/4 in (845 mm)*  
W:22-1/2 in (572 mm)  
378 lb  
(172 kg)  
250 CE  
220/400/  
440/520  
60 Hz,  
1-Phase  
D: 25 in (635 mm)**  
Syncrowave  
350  
All Models  
50 or  
60 Hz,  
1-Phase  
3–400 A  
80 V 350 A at 34 V, 146 120 128 66  
40% Duty Cycle  
30 14 H: 33-1/4 in (845 mm)*  
W:22-1/2 in (572 mm)  
496 lb  
(225 kg)  
D: 25 in (635 mm)**  
with TIGRunner®  
H: 46 in (1168 mm)*  
W:28-1/2 in (724 mm)  
D: 40-1/2 in (1029 mm)**  
596 lb  
(270 kg)  
Note: See pg 6 for power factor correction kit. *Add 3 in (76 mm) for lift eye. **Add 1-1/2 in (38 mm) for handle.  
Certified to both the Canadian and U.S. Standards for welding equipment.  
Performance Data  
DUTY CYCLE CHART  
RATED OUTPUT  
500  
450  
400  
350  
300  
Syncrowave 350 LX  
Syncrowave 250 DX  
250  
200  
150  
100  
50  
10  
20  
30  
40  
50  
60  
70  
80  
90 100  
% DUTY CYCLE  
3
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Control Panels  
9
10  
11  
12  
Pulser*  
Module  
1
2
3
4
13  
14  
5
Sequencer**  
Module  
15  
16  
6
17  
18  
7
8
Common Bottom Panel  
19  
20  
1. Voltmeter Display  
2. Start Mode Control  
12. Peak Time Control (595%)*  
13. Spot Time Control (0 5 sec)*  
(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 (050 sec)  
8. Ammeter Display  
14. Final Slope Control (025 sec)*  
15. Initial Time Control (0 15 sec)*  
16. Final Amperage Control (0100%)*  
17. Initial Amperage Control (3 310/400 A)*  
18. Amperage Adjustment Control (3 310/400 A)  
19. Power Switch (On/Off)  
20. Output Selector Switch (AC/DC-/DC+)  
9. Pulser Control*  
10. Background Amps Control (0 – 100%)*  
11. Pulse-Per-Second Control (0.2510 Hz)*  
*Optional Pulser for 250 DX  
**Optional Sequencer  
4
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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  
Standard Model  
#907 198 (200/230/460 VAC)  
#907 199 (230/460/575 VAC)  
#907 200 (220/400/440/520 VAC) CE  
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, Coolmate3X cooler, No. 37  
running gear, RFCS-14 HD remote foot  
control, and international-style connectors.  
Primary cord, TIG torch adapter 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® 350 LX Complete  
#951 119 (200/230/460 VAC)  
#951 120 (230/460/575 VAC)  
Syncrowave Complete  
(Syncrowave TIGRunner,  
TIG Coolant and Torch Kit)  
TIG Coolant  
TIG Coolant  
Completely assembled. Includes TIGRunner  
above (Syncrowave, Coolmate3X cooler,  
No. 37 running gear, RFCS-14 HD remote  
foot control, and international-style  
connectors), 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  
300 A Water-Cooled Torch Kit  
for Syncrowave 250 DX TIGRunner  
for Syncrowave 350 LX TIGRunner  
5
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Genuine Miller Options  
Pulser Module  
Power Factor Correction Kit  
Field Options  
#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.  
#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.  
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.  
Genuine Miller Accessories  
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 ft (8 m) cord  
and 14-pin plug.  
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 ft (6 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)  
No. 37 Running Gear #195 282  
Gas Tungsten Arc (TIG) Welding Book  
#170 555  
RHC-14 Hand Control  
#129 340  
Miniature hand control  
for remote current and  
contactor control.  
Dimensions:  
4 x 4 x 3-1/4 in  
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.  
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.  
Protective Cover #195 320  
Heavy-duty, water- and mildew-resistant.  
Protects and maintains the finish of  
the welder.  
(102 x 102 x 83 mm). Includes 20 ft (6 m)  
cord and 14-pin plug.  
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.  
Remote Controls and Switches  
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 ft (8 m)  
cord and 14-pin plug.  
RCCS-14 Remote Contactor and  
Current Control #043 688 14-pin plug  
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.  
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.  
6
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Genuine Miller Accessories  
(continued)  
TIG Welding Gloves  
#227 813 Small  
Tungsten  
Water Coolant Systems  
For more information, see the Miller Coolant  
Systems literature sheet, Index No. AY/7.2.  
Items below are available in packages of 10 and  
are 7-in lengths.  
#227 814 Medium  
#227 815 Large  
#227 816 X-Large  
Designed to meet the  
2% Ceriated (orange) for AC/DC applications  
#WC040X7 .040 in, 10– 80 A  
Coolmate V3  
#043 009 115 VAC  
#WC116X7 1/16 in, 70– 150 A  
#WC332X7 3/32 in, 140– 250 A  
#WC018X7 1/8 in, 225400 A  
#WC532X7 5/32 in, 300500 A  
#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.  
specific requirements high-  
quality TIG welding demands.  
Made from soft grain goatskin. Sewn with  
Kevlar® thread.  
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, 225400 A  
#WL532X7 5/32 in, 300500 A  
TIG (GTAW) Torch Adapters  
Coolmate 3X with  
Cart and Dual Cylinder  
Rack #300 419  
Includes: Easy Load  
Dual Cylinder Rack,  
running gear, and 3X  
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, 225400 A  
#WP532X7 5/32 in, 300500 A  
Includes Wheels  
Water-Cooled Dinse #195 377  
Used to adapt a 250 or 350 A water-cooled  
torch (WP20, WP18, CS310) to an  
International-style connector.  
industrial water cooler — a perfect  
solution for water-cooled TIG torches.  
TIG Coolant  
#043 810  
Sold in multiples of 4.  
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, 225400 A  
#WT532X7 5/32 in, 300500 A  
Pre-mixed low-  
conductivity Miller  
coolant contains  
Air-Cooled Dinse #195 379  
Used to adapt a 1-piece 200 amp air-cooled  
torch (WP26) to an International-style  
connector.  
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. 1-gallon plastic  
recyclable bottles.  
Torch Kits  
300 A Water-Cooled Torch Kit #300 183  
Recommended for Syncrowave 350 LX  
25 ft (7.6 m) Weldcraft® CS310 torch  
Torch cable cover  
400 A Water-Cooled Torch Kit #300 186  
250 A Water-Cooled Torch Kit #300 185  
25 ft (7.6 m) Weldcraft® WP18SC torch  
Torch cable cover  
Recommended for Syncrowave 250 DX  
25 ft (7.6 m) Weldcraft® WP20 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)  
CS310AKC torch accessory kit includes  
shielding cups, collets, collet bodies and  
2% cerium tungsten electrodes (1/16,  
3/32 and 1/8 in)  
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 H1954D-580  
12 ft (3.7 m) rubber gas hose (regulator  
to machine)  
Smith® regulator/flowmeter HM2051A-580  
12 ft (3.7 m) rubber gas hose (regulator  
to machine)  
Smith® regulator/flowmeter HM2051A-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)  
Water-cooled Dinse torch adapter  
15 ft (4.6 m) 1/0 weld lead with clamp  
(work or ground lead) and Dinse connector  
Water-cooled Dinse torch adapter  
15 ft (4.6 m) 1/0 weld lead with clamp  
(work or ground lead) and Dinse connector  
7
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Ordering Information  
Equipment and Options  
Syncrowave® 250 DX  
Stock No.  
Description  
Qty.  
Price  
#907 194  
#907 195  
#907 197  
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  
#907 194-03-2 200/230/460 V, 50/60 Hz, Syncrowave 250 DX TIGRunner® 3X  
#951 117  
200/230/460 V, 50/60 Hz, Syncrowave 250 DX Complete  
#907 195-03-2 230/460/575 V, 50/60 Hz, Syncrowave 250 DX TIGRunner® 3X  
#951 118  
230/460/575 V, 50/60 Hz, Syncrowave 250 DX Complete  
Syncrowave® 350 LX  
#907 198  
#907 199  
#907 200  
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  
#907 198-03-2 200/230/460 V, 50/60 Hz, Syncrowave 350 LX TIGRunner® 3X  
#951 119  
200/230/460 V, 50/60 Hz, Syncrowave 350 LX Complete  
#907 199-03-2 230/460/575 V, 50/60 Hz, Syncrowave 350 LX TIGRunner® 3X  
#951 120  
#195 345  
#195 344  
230/460/575 V, 50/60 Hz, Syncrowave 350 LX Complete  
Sequencer Module  
Pulser Module  
Field  
Field. For Syncrowave 250 DX  
Power Factor Correction Kit  
#194 692  
#043 757  
Field. For Syncrowave 250 DX  
Field. For Syncrowave 350 LX  
TIG Torch Kits  
Weldcraft® 250 A Water-Cooled Torch Kit #300 185  
Weldcraft® 300 A Water-Cooled Torch Kit #300 183  
Weldcraft® 400 A Water-Cooled Torch Kit #300 186  
Consumables and Tungsten  
See page 7. Recommended for Syncrowave 250 DX TIGRunner 3X  
See page 7. Recommended for Syncrowave 350 LX TIGRunner 3X  
See page 7  
See page 7  
Gas Cylinder, Hose and Fittings  
Remote Controls  
RCCS-14  
RFCS-14 HD  
RHC-14  
RMLS-14  
RMS-14  
#043 688  
#194 744  
#129 340  
#129 337  
#187 208  
North/south fingertip control  
Heavy-duty foot control  
Hand control  
Momentary/maintained rocker switch  
Momentary rubber dome switch  
Extension Cords  
#122 973  
#122 974  
#122 975  
25 ft (7.6 m)  
50 ft (15.2 m)  
75 ft (22.9 m)  
Accessories  
No. 37 Running Gear  
Protective Cover  
Gas Tungsten Arc (TIG) Welding Book  
TIG Training CD  
Video – GTAW Setup Procedures  
Torch Adapters  
#195 282  
#195 320  
#170 555  
#196 567  
#108 241  
#195 377  
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 #195 379  
Cable Connectors  
Dinse Connector 50 mm (1 male)  
Dinse Connector 50 mm (1 male, 1 female) #042 419  
Supplied with power source and torch kits  
Used to connect weld lead to Dinse terminal machine  
Used to extend weld cables  
#042 418  
Tweco Terminal Adapter  
Cam-Lok Terminal Adapter  
TIG Coolant  
#042 465  
#042 466  
#043 810  
Male Dinse to female Tweco  
Male Dinse to female Cam-Lok  
Sold in multiples of 4. 1-gallon plastic bottles.  
See page 7  
Water Coolant Systems  
Miscellaneous  
Stick Electrodes  
Welding and Work Cables  
Helmets  
TIG Welding Gloves  
See page 7  
Date:  
Total Quoted Price:  
Distributed by:  
Litho in USA  
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