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Syncrowave 210 help- won’t boot up

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  • Syncrowave 210 help- won’t boot up

    I Have a Syncrowave 210 that I purchased in 2014 or 2015. Until recently I have only tig welded with it and have not had any problems.

    I was attempting to weld with some 1/8 inch 7018 at 120 amps. I was running the machine on a 240 V outlet. After about an inch and a half of weld the machine stopped working.

    When I turn the machine on, the display reads “SYNC 210” and the fan runs constantly. I cannot access any of the menus or machine functions after that.It seems like the machine is booting up but stops at that point.

    I tested the outlet with a multi meter and it’s approximately 250V. I have plugged the machine into a 120 V outlet with the same result.

    I pulled the cover off the machine and I did not observe anything on the circuit boards that was physically damaged or burned.

    I would greatly appreciate any guidance or help with repairing this myself, if possible.

  • #2
    Does anyone know if there is a technical manualavailable for the syncrowave 210?

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    • #3
      Not available to anyone except Miller techs.

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      • #4
        How much voltage do you measure from heatsink HS6 in reference to heatsink HS2 when the unit is turned on?

        It should measure about 440 VDC when the boost circuit is operating properly in the PC1 board.
        Attached Files

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        • #5
          Originally posted by blue_tech View Post
          How much voltage do you measure from heatsink HS6 in reference to heatsink HS2 when the unit is turned on?

          It should measure about 440 VDC when the boost circuit is operating properly in the PC1 board.
          Thanks you for the reply!

          I got a reading of .488 VDC. I turned the power off and it dropped back to 0 VDC. I turned the power on again and got a reading of .512 VDC.


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          • #6
            Am I reading that response correctly? It looks like you typed .488 VDC? or was there no decimal and it was 488 VDC? That is a big difference if it was almost 0 volts at .488, or if it was close to 500 volts at 488 VDC. Two very different troubleshooting paths.

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            • #7
              Sorry, I should have been more clear. You read it correctly and it was almost 0 volts.

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              • #8
                Finally took the machine to my nearest miller survive which was Airgas. They diagnosed the problem as a bad PC board and quoted a repair price of $2,435.60!

                “WORK SCOPE
                REMOVE COVERS AND TROUBLESHOOT. POWERED UP - DISPLAY WOULD SHOW SYNCROWAVE 210 BUT IT WOULDNT LET YOU ACCESS
                THE MENU AND THERE WAS NO OUTPUT IN ANY OF THE WELD PROCESSES. TRACED TO BAD PC BOARD, CHECKED THE SECONDARY
                SIDE DIODE ASSY - TESTED OK. WILL REPLACE PC BOARD, REASSEMBLE, LOAD TEST AND WELD TEST”

                Does anyone know if this board is available at a lower price anywhere else. There’s no way I’d pay that price to have machine repaired, especially since this part failed during regular use with relatively low hours on the machine.

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                • #9
                  They aren’t cheap
                  Bob Wright

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                  • #10
                    Inverters rule.

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                    • #11
                      That's surprising you're not even showing around 160V across those two heatsinks without popping your circuit breaker.

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                      • #12
                        Originally posted by Helios View Post
                        Inverters rule.
                        Until they don't.

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                        • #13
                          List price on that PC1 board is $1367 US, and thats List, We don't pay list..... another Grand to t-shoot and replace seems a little much

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