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

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

    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.
    - Syncrowave 210 TIG/MIG
    - Hypertherm Powermax 30

    Just an engineer who likes to melt metal and build hot rods.

  • #2
    Going to guess and say that your polarity is backwards...

    Comment


    • #3
      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.
      "Beware of false knowledge; it is more dangerous than ignorance." ~George Bernard Shaw~

      Airco 300 Heliwelder
      Dialarc 250 AC/DC
      ESAB 161
      Invertec v250 and v300 Pro
      SA200
      Spectrum 700 plasma
      MM210
      Miller HF-15-1
      Dirty ugly tools - perfect

      Comment


      • #4
        Originally posted by cruizer View Post
        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?

        Originally posted by MinnesotaDave View Post
        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!
        - Syncrowave 210 TIG/MIG
        - Hypertherm Powermax 30

        Just an engineer who likes to melt metal and build hot rods.

        Comment


        • #5
          Originally posted by wasted income View Post
          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
          Last edited by H80N; 02-24-2015, 06:46 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


          • #6
            Originally posted by H80N View Post
            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.
            Last edited by wasted income; 02-24-2015, 07:05 PM.
            - Syncrowave 210 TIG/MIG
            - Hypertherm Powermax 30

            Just an engineer who likes to melt metal and build hot rods.

            Comment


            • #7
              Originally posted by wasted income View Post
              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..
              .

              *******************************************
              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

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