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[jjohn76]

G-Man, the teflon liner is not recommended for hard wires, as it will wear quickly. MK sells a separate steel coil cable (like your normal mig liner) for about $300 to work with hard wire. The XRs have a removable liner, though I don't know if it is teflon only. That said, your Spoolmatic 30A should...

Ben, here is a link to my Dropbox that has a copy of the Syncrowave 350 Tech Manual. It lists some troubleshooting recommendations and board/connector voltages to run down your issues. Hope this helps,
Jon
https://www.dropbox.com/s/hdsx00jxqg...ical%20Service...

[jjohn76]

Definitely check connections. If I remember right, the op manual was pretty good at showing the interboard connections. Let me know if you need more info and are comfortable checking board voltages with a multimeter.

[jjohn76]

Could your gas be bad? It looks like the welds and tungsten are contaminated, which I why I figure your solenoid wasn't working. This isn't the amperage control issue you're running down. It's worth checking and cleaning all of the connectors to the boards, as well as checking the internal wiring and...

[jjohn76]

Nice area, had a couple Soldiers move out that way not too long ago. I lived in Wilmington for a couple years.

Jon

[jjohn76]

Benny, it seems to have a few issues
No gas at the torch does the gas valve engage/click if not, put a voltmeter on the gas solenoid terminals to see if it gets any voltage
Panel amperage doesn't match preset amperage - is that what you're seeing?
Panel contactor seems to be working,...

[jjohn76]

Dave, where are you located? It may be worth adding your location in your profile in case someone has something you're looking for.
Jon

[jjohn76]

I think that is high for what it is, but it depends on your location. How long has it been for sale? I have not worked on a TR-300HF, but looking at the panel, it is much closer to the Miller Aircrafter 330ST in design than the 330 AP-B. That means it uses a magnetic amplifier, but instead of a hug...

[jjohn76]

Yeah great find! That seller also has a pair of XMT 304 IGBT modules for something like $60 and the gate drive PCBs for around$20./

[jjohn76]

That looks like PM2 (left side IGBT kit?), with the input rectifier right behind it. What diode drop do you get C2/E1 to C1 and E2. Any shorts, and you likely burned other components. It's worth checking the diodes on the rectifier - diode drop tests from each line input to the + and - terminals on...

[jjohn76]

Are you checking flow at the torch? Seems like bad shielding gas.

[jjohn76]

Hi Jordan, I would recommend the 30A and WC-24, which is a solid spoolgun setup and direct plug in to your XMT-350. You could get the 3035 with an SGA-100 (no need for the separate contactor with a XMT-350), but you would need to modify the plugs (possibly wiring if your XMT-350 doesn't have an auxiliary...

[jjohn76]

That's not an uncommon problem, but you likely have more to fix than just the IGBT. Any signs of overheating/blister/fluid on the capacitors? Did this all just happen (you would have heard it, pretty loud pop)?

[jjohn76]

383, I think your SCRs and diodes are ok, since you're getting full power without HF. It could be the HF spikes getting into your auxiliary transformer. The spark gap works like a fast switch that sends spikes back through the primary of your HV transformer to the 115V auxiliary circuit that comes off...

[jjohn76]

We'll, I will have to think about that one some more. You basically had the HF coupling coil disconnected from the spark gap, so the noise is getting into the timing circuit from somewhere else. How do the other connections with the capacitors and large resistor look like on that HF board?...

[jjohn76]

Hi, when you say you removed the intensity knob altogether, did you just connect the two terminals together, or leave them disconnected? It seems like your intensity knob was still conducting because you still had HF/HV at the torch. If there was ever a break in that intensity rheostat winding, it probably...

[jjohn76]

I am amazed in the power of those things. I fixed an Aircrafter just a few weeks ago that had a bad start/panel amps relay. It's newer than the 330 A/BP, but the only difference is it uses some solid state switches instead of the big rheostat in the panel/pedal to control the amperage. After taking...

[jjohn76]

If you search load bank in the Miller manual section, you can find the load bank owner's manual (OM-849). The parts breakout give you an idea of the heating coil array they use and the operation portion gives you an idea on the total resistance ranges you should have.
Hope this helps,
J...

[jjohn76]

Edit: I think your XMT350 100% duty cycle is higher than 5kW output with a 6/3 power cord, possibly even with the 8/4 power cord that came with it. That's a lot of heat and probably warrants two big tubs...

[jjohn76]

The majority of the cost in those banks are in the precision of the meters. I use an oscilloscope with differential probes on the voltage and a hall probe.om the leads. You can use the nichrome coils (dryer/toaster element or coil your own from the wire and hold it with the ceramic standoffs) or do...