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Syncrowave 250 Started acting up tonight while doing some Aluminum Welding.

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  • Syncrowave 250 Started acting up tonight while doing some Aluminum Welding.

    Hi All,
    First time poster here on the Forum.

    I have an Older Syncrowave 250 (Circa 1990 if I recall)
    I was doing some welding on an aluminum radiator for my buggy.
    Things were going good/ normal for a while, then after a bit I noticed the Arc was having a hard time starting. Got to the point where I was laying into the pedal pretty hard and **** near touching the tungsten to the work piece to get it to start. Once started It does weld. Flipped over to DC- and tried to burn some steel rod.... Same story there, hard to get it started.
    High frequency Start is already maxed @ the 100 setting.
    Cleaned the points/ gapped to 8 thou, checked ground, torch & collet connections.
    Everything looks OK.
    I suspect a component malfunction being as this occurred while the machine was in use.

    Anyone care to share Any Ideas as to where I should be looking?
    As a side note, board was replaced 4 yrs ago and machine doesnt see much use.

    Thanks

  • #2
    Originally posted by Turbodon View Post
    Hi All,
    First time poster here on the Forum.

    I have an Older Syncrowave 250 (Circa 1990 if I recall)
    I was doing some welding on an aluminum radiator for my buggy.
    Things were going good/ normal for a while, then after a bit I noticed the Arc was having a hard time starting. Got to the point where I was laying into the pedal pretty hard and **** near touching the tungsten to the work piece to get it to start. Once started It does weld. Flipped over to DC- and tried to burn some steel rod.... Same story there, hard to get it started.
    High frequency Start is already maxed @ the 100 setting.
    Cleaned the points/ gapped to 8 thou, checked ground, torch & collet connections.
    Everything looks OK.
    I suspect a component malfunction being as this occurred while the machine was in use.

    Anyone care to share Any Ideas as to where I should be looking?
    As a side note, board was replaced 4 yrs ago and machine doesnt see much use.

    Thanks
    PLS post Serial Number...

    Pull the covers and blow it out with compressed air... then run it in a dark room and see if there are any blue sparks anyplace other than the spark gaps... collected dust will bleed off the HV... and kill the HF...

    Another avenue... is there healthy spark at the gaps..?? if so you may have a damaged conduit in the torch.... try another torch...
    .

    *******************************************
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    Comment


    • #3
      Wouldn't be the torch in this case, as the hf is less, I'd suggest that the hf transformer is toast

      Comment


      • #4
        Serial Number is JK577858.

        Pulled the manual for the model that corresponds with that serial no. range
        http://www.millerwelds.com/om/o353a_mil.pdf

        looks like the HF transformer is pn 074 398

        Can you guys verify?

        Also, what would be a good source to order the replacement part?

        Thanks!
        Last edited by Turbodon; 04-23-2015, 03:57 PM.

        Comment


        • #5
          Www.Miller4less.com

          Comment


          • #6
            Syncrowave 250 Started acting up tonight while doing some Aluminum Welding.

            I had a similar problem on my syncrowave. The micro switch in the foot pedal was flakey. It's easily checked with a meter. Bought a new one at grainger .

            Comment


            • #7
              Micro switch turns the gas, arc & HF on. if they are all wonky then its the pedal, if only one then its some other problem.

              If the arc is erratic but the HF is ok, then its likely the gun, HF jumps through a bad conduit.

              Comment

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