Why won't my Syncro 210 MIG steel worth a darn?

[wasted income]

Long time listener, first time caller.

I picked up a Syncrowave 210 complete setup at SEMA back in November to replace my trusty Millermatic 135 and Syncrowave 200. I figured garage space is at a premium, so it would be great to combine both machines into one, especially since the vast majority of the welding I do is typically TIG.

The TIG portion of the machine works well. No complaints there. Inverter TIG FTW.

My complaint comes from the MIG portion, via the Spoolmate 100. I have it loaded up with Hobart .030 hard wire, 75/25 gas, and I've been working on sheetmetal replacement on a car restoration.

The problem is, that while doing tacks with the sheetmetal, the first second or two that the trigger is pulled, the wire just kind of melts and balls up at the end....It's quiet when it does this....and after that initial second or two, it will then will finally transition to the MIG "sizzle" sound. Once it's "sizzling" it seems to be fine for longer beads (on thicker material....not doing long beads on this sheetmetal). Basically once it's finally initiated, it will weld well for as long as the trigger is pulled.

I never had this problem with my Millermatic, and it's VERY frustrating to me.

I've tried it on the AutoSet, and quadruple checked the gas/wire diameter/metal thickness settings.......I've tried adjusting the WFS and voltage both ways.....I've tried adjusting the drag on the spool....nothing seems to work.

Does anybody have any pointers? I know there aren't a lot of people out there who MIG steel with a spool gun....pretty much just Syncro 210 owners I'd imagine.

[cruizer]

Going to guess and say that your polarity is backwards...

[MinnesotaDave]

I don't own one, but it sounds like you're describing a soft start feature gone haywire.

Or, the machine thinks you're in tig mode and you have an initial upslope that is on during wire feed - which it shouldn't be of course.

Im just guessing though - weird issue to have with your 210 - I'd call Miller right away and ask.

[wasted income]

Going to guess and say that your polarity is backwards...

Thanks for the reply. I don't know of any way to change the polarity with the Sync 210?

I don't own one, but it sounds like you're describing a soft start feature gone haywire.

Or, the machine thinks you're in tig mode and you have an initial upslope that is on during wire feed - which it shouldn't be of course.

Im just guessing though - weird issue to have with your 210 - I'd call Miller right away and ask.

Interesting theory. I guess that might make sense. Thanks for the response.

The good news is, that I got a PM from a Miller rep who wants to get this sorted out for me. Will reply back if/when we get it figured out.

Thanks!

[H80N]

Long time listener, first time caller.

I picked up a Syncrowave 210 complete setup at SEMA back in November to replace my trusty Millermatic 135 and Syncrowave 200. I figured garage space is at a premium, so it would be great to combine both machines into one, especially since the vast majority of the welding I do is typically TIG.

The TIG portion of the machine works well. No complaints there. Inverter TIG FTW.

My complaint comes from the MIG portion, via the Spoolmate 100. I have it loaded up with Hobart .030 hard wire, 75/25 gas, and I've been working on sheetmetal replacement on a car restoration.

The problem is, that while doing tacks with the sheetmetal, the first second or two that the trigger is pulled, the wire just kind of melts and balls up at the end....It's quiet when it does this....and after that initial second or two, it will then will finally transition to the MIG "sizzle" sound. Once it's "sizzling" it seems to be fine for longer beads (on thicker material....not doing long beads on this sheetmetal). Basically once it's finally initiated, it will weld well for as long as the trigger is pulled.

I never had this problem with my Millermatic, and it's VERY frustrating to me.

I've tried it on the AutoSet, and quadruple checked the gas/wire diameter/metal thickness settings.......I've tried adjusting the WFS and voltage both ways.....I've tried adjusting the drag on the spool....nothing seems to work.

Does anybody have any pointers? I know there aren't a lot of people out there who MIG steel with a spool gun....pretty much just Syncro 210 owners I'd imagine.

Did you follow the step by step setup as per the video..?? it is a little unusual compared to my experience..

https://www.youtube.com/watch?v=8yCDXyZJu3s

was unable to find any MIG info in the latest version of the manual in the resources section

http://www.millerwelds.com/om/o261726b_mil.pdf

[wasted income]

Did you follow the step by step setup as per the video..?? it is a little unusual compared to my experience..

https://www.youtube.com/watch?v=8yCDXyZJu3s

was unable to find any MIG info in the latest version of the manual in the resources section

http://www.millerwelds.com/om/o261726b_mil.pdf

H80N,

Thanks for the link. I've actually seen that video before. It was filmed at SEMA, and that is the gentleman who convinced me to buy the Sync 210. Coincidentally, also the same guy who PMd me to help me out.

We have almost come full circle. Ha.

[H80N]

H80N,

Thanks for the link. I've actually seen that video before. It was filmed at SEMA, and that is the gentleman who convinced me to buy the Sync 210. Coincidentally, also the same guy who PMd me to help me out.

We have almost come full circle. Ha.

Was really surprised to find NOTHING in the manual related to spoolgun operation on the Sync 210.... the videos were the only resource I could find on it..