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  • Syncrowave 500 start up issues

    Hi,

    New to the forum and first post. I have a sync 500 hooked up to a 50A breaker in a 100A sub panel that is fed to my workshop from a 100A breaker in my house panel. when I turn the welder on it trips the 50 that has #6 awg from the welder to the sub panel then bypasses the 100 main in the sub then trips the 100 in my house that feeds the sub. every once in a while I can get it to turn on without tripping. When I am lucky enough to get it running it will be pulling 9.9 amps at idle. I did some test welding just to see how much current it would draw and when tig, it would draw around 60 amps at 175. Does that sound about right? I have already tested the diodes and scr's in the rectifier while I had the covers off just looking around for any obvious issues.

    Any help greatly appreciated

  • #2
    Originally posted by cj62565 View Post
    Hi,

    New to the forum and first post. I have a sync 500 hooked up to a 50A breaker in a 100A sub panel that is fed to my workshop from a 100A breaker in my house panel. when I turn the welder on it trips the 50 that has #6 awg from the welder to the sub panel then bypasses the 100 main in the sub then trips the 100 in my house that feeds the sub. every once in a while I can get it to turn on without tripping. When I am lucky enough to get it running it will be pulling 9.9 amps at idle. I did some test welding just to see how much current it would draw and when tig, it would draw around 60 amps at 175. Does that sound about right? I have already tested the diodes and scr's in the rectifier while I had the covers off just looking around for any obvious issues.

    Any help greatly appreciated
    The Sync 500 wants to see an input of 180 Amps at 230 Volts for a full output of 625 Amps

    here is a link to the manual... just match it to your serial number..

    http://www.millerwelds.com/service/l...&submit=Search

    .

    *******************************************
    The more you know, The better you know, How little you know

    “The bitterness of poor quality remains long after the sweetness of low price is forgotten”

    Buy the best tools you can afford.. Learn to use them to the best of your ability.. and take care of them...

    My Blue Stuff:
    Dynasty 350DX Tigrunner
    Dynasty 200DX
    Millermatic 350P w/25ft Alumapro & 30A
    Millermatic 200

    TONS of Non-Blue Equip, plus CNC Mill, Lathes & a Plasmacam w/ PowerMax-1000

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    • #3
      The serial # isJD693537. I have disconnected the secondary leads #26 & #28 and was able to get it to fire up after a couple tries. Still getting a 10 amp draw at idle and FYI, according to the prints it does not have power factor correction. I verified by checking for caps on the primary and found none. Does everything sound ok? Can I just get a type of breaker that handles inrush current better? I have Square D homeline panels.

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      • #4
        Originally posted by cj62565 View Post
        The serial # isJD693537. I have disconnected the secondary leads #26 & #28 and was able to get it to fire up after a couple tries. Still getting a 10 amp draw at idle and FYI, according to the prints it does not have power factor correction. I verified by checking for caps on the primary and found none. Does everything sound ok? Can I just get a type of breaker that handles inrush current better? I have Square D homeline panels.
        Maybe some slo-blo variety.... one of our electrician wizards like WillieB could answer that..

        BTW.. this is the manual version that matches the serial you provided..

        http://www.millerwelds.com/om/o350l_mil.pdf
        Last edited by H80N; 10-27-2014, 05:13 PM.
        .

        *******************************************
        The more you know, The better you know, How little you know

        “The bitterness of poor quality remains long after the sweetness of low price is forgotten”

        Buy the best tools you can afford.. Learn to use them to the best of your ability.. and take care of them...

        My Blue Stuff:
        Dynasty 350DX Tigrunner
        Dynasty 200DX
        Millermatic 350P w/25ft Alumapro & 30A
        Millermatic 200

        TONS of Non-Blue Equip, plus CNC Mill, Lathes & a Plasmacam w/ PowerMax-1000

        Comment


        • #5
          Your breaker in the sub panel carries less load. One carries garage load, the other carries garage and house. I suggest you upgrade your service including the transformer. NEC allows a 200% breaker over welder peak load. It offers no such luxury for service disconnect or sub panel. That 200% is contingent on code compliance where it concerns circuit conductor sizing. Were it a Syncrowave 250 I'd say you can limp if you can't upgrade. A 500 is severe overload. Thank God for the breakers tripping, if they don't you are going to have a meltdown on the scale of Chernobyl.
          Dynasty 280DX
          Bobcat 250
          MM252
          Spool gun
          Twentieth Century 295
          Twentieth Century 295 AC
          Marquette spot welder
          Smith torches

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          • #6
            I have a stop on the current dial so it can't be turned above 175. So a melt down should hopefully not be in my future. So I'm hoping my only dilemma is the breakers. If anyone knows of a Square D Homeline 100A that has a delay to it, I would greatly appreciate the info.

            Thanks

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            • #7
              Massive machine, running on a toy power supply. Time to rethink your plans for this thing. Get a smaller machine thats easy on your $$$ input power

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              • #8
                A 350 is a little overkill for a home shop let alone a 500... Just saying.
                Dynasty 400 wireless
                Coolmate 3.5
                Sw320 speedway
                Ck flex lock 230
                4 victor flow meters
                2 Flametech Duel flowmeters
                2 genuine miller torch buttons
                A$$ loads of tungsten
                XMT 350 CC/CV
                S74DX feeder
                Stick leads from here to China
                A30 Spool gun
                WC24
                Langmuir crossfire hobby table
                Everlast powerplasma 100 w hypertherm torch
                Harris O/A
                Pet raccoon
                I'm just a peckerwood in the boonies with fancy welding equipment

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