Syncrowave 250DX 350LX Technical Manual

TM-363E 2007−01
Eff. w/Serial No. LE223624 For 350 LX Models

Eff. w/Serial No. LE282983 For 250 DX Models
Processes
TIG (GTAW) Welding
Stick (SMAW) Welding
Description
Arc Welding Power Source
Effective with Serial No. LE223624 Thru LH010000L
Syncrowave 250 DX / 350 LX

R
And
R
w/Integrated Cooler
CE And Non-CE Models
Visit our website at

File: TIG (GTAW)
www.MillerWelds.com
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-2. Servicing Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-3. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1-4. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SECTION 2 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2-1. Warning Label Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2-2. Torch/Cable Holder Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2-3. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SECTION 3 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3-1. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3-2. Dimensions And Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3-3. Cooler Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3-4. Welding Power Source Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3-5. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3-6. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3-7. Weld Output Terminals And Selecting Cable Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3-8. Remote 14 Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3-9. Shielding Gas Connections And 115 Volts AC Duplex Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3-10. Cooler Connections And Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3-11. TIG Connections With A Water-Cooled Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3-12. TIG Connections With A Two-Piece Air-Cooled Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3-13. TIG Connections With A One-Piece Air-Cooled Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3-14. Front Panel Display For TIG HF Impulse DCEN (Direct Current Electrode Negative) . . . . . . . . . . . . . 16
3-15. Front Panel Display For TIG AC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3-16. Stick Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3-17. Front Panel Display For Stick DCEP (Direct Current Electrode Positive) . . . . . . . . . . . . . . . . . . . . . . . 19
3-18. Front Panel Display For Stick AC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3-19. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3-20. Placing Jumper Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3-21. Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
SECTION 4 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4-1. Controls (350 LX Nameplates Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4-2. Output Selector Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4-3. Process Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4-4. Amperage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4-5. Output Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4-6. 4T, 4T Momentary, And Mini Logoic Trigger Operation (Requires Optional Sequence Controls) . . . . . 30
4-7. Reconfiguring Trigger Hold For 4T And Mini Logic Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4-8. Selecting TIG Starting Characteristics Using Syncro-Startt Technology . . . . . . . . . . . . . . . . . . . . . . . . 34
4-9. Start Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4-10. Balance/DIG Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4-11. Preflow Time Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4-12. Pulse Controls (Standard On 350 LX Models, Optional On 250 DX Models) . . . . . . . . . . . . . . . . . . . . . 40
4-13. Sequence Controls (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4-14. Initial Time Control And Initial Amperage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4-15. Final Slope Control And Final Amperage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4-16. Spot Time Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4-17. Timer/Cycle Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4-18. Resetting Unit To Factory Default Settings (All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
SECTION 5 − THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
TABLE OF CONTENTS
SECTION 6 − TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
6-1. Measuring Capacitor Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
6-2. Voltmeter/Ammeter Help Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6-3. Direction Of Coolant Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
6-4. Troubleshooting The Welding Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
6-5. Troubleshooting The Welding Coolant System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
6-6. Troubleshooting Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
6-7. Waveforms for Sections 6-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
6-8. Control Board PC1 Testing Information (Use with Section 6-9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
6-9. Control Board PC1 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
6-10. Pulser Board PC2 Testing Information (Use with Section 6-11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
6-11. Pulser Board PC2 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
6-12. Sequencer Board PC3 Testing Information (Use with Section 6-13) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
6-13. Sequencer Board PC3 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
SECTION 7 − MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
7-1. Routine Welding Power Source Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
7-2. Routine Cooler Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
7-3. Circuit Breaker CB1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
7-4. Adjusting Spark Gaps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
SECTION 8 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
SECTION 9 − HIGH FREQUENCY (HF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
9-1. Welding Processes Requiring High Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
9-2. Correct Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
SECTION 10 − SELECTING AND PREPARING TUNGSTEN ELECTRODE FOR DC OR AC WELDING . . 85
10-1. Selecting Tungsten Electrode (Wear Clean gloves To Prevent Contamination Of Tungsten) . . . . . . . . 85
10-2. Preparing Tungsten Electrode For Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
SECTION 11 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Declaration of Conformity for
European Community (CE) Products
NOTE This information is provided for units with CE certification (see rating label on unit).
Manufacturer: European Contact:

Miller Electric Mg. Co. Mr. Danilo Fedolfi,
1635 W. Spencer St. Managing Director
Appleton, WI 54914 USA ITW Welding Products Italy S.r.l.
Phone: (920) 734-9821 Via Privata Iseo 6/E
20098 San Giuliano
Milanese, Italy
Phone: 39(02)98290-1
Fax: 39(02)98290203
European Contact Signature:
Declares that the product: Syncrowave R 250 DX

conforms to the following Directives and Standards:
Directives
Low Voltage Directive: 73/23/EEC
Electromagnetic compatibility Directives: 89/336/EEC, 92/31/EEC
Machinery Directives: 98/37/EEC, 91/368/EEC, 92/31/EEC, 133/04, 93/68/EEC
Standards
Arc Welding Equipment − Part 2: Liquid Cooling Systems. IEC 60974-2 Ed. 1
Arc Welding Equipment − Part 10: Electromagnetic Compatibility (EMC) Requirements. IEC 60974-10, August 2002
Arc Welding Equipment − Part 1: Welding Power Sources: IEC 60974-1, Ed. 2.1
Degrees of Protection Provided By Enclosure (IP 23): IEC 60529 Ed. 2.1
Insulation Coordination For Equipment Within Low-Voltage Systems − Part 1: Principles, Requirements, And Tests.
IEC 60664-1 Ed. 1.1
dec_stat_6/05
Declaration of Conformity for
European Community (CE) Products
NOTE This information is provided for units with CE certification (see rating label on unit).
Manufacturer: European Contact:

Miller Electric Mg. Co. Mr. Danilo Fedolfi,
1635 W. Spencer St. Managing Director
Appleton, WI 54914 USA ITW Welding Products Italy S.r.l.
Phone: (920) 734-9821 Via Privata Iseo 6/E
20098 San Giuliano
Milanese, Italy
Phone: 39(02)98290-1
Fax: 39(02)98290203
European Contact Signature:
Declares that the product: Syncrowave R 350 LX

conforms to the following Directives and Standards:
Directives
Low Voltage Directive: 73/23/EEC
Electromagnetic compatibility Directives: 89/336/EEC, 92/31/EEC
Machinery Directives: 98/37/EEC, 91/368/EEC, 92/31/EEC, 133/04, 93/68/EEC
Standards
Arc Welding Equipment − Part 2: Liquid Cooling Systems. IEC 60974-2 Ed. 1
Arc Welding Equipment − Part 10: Electromagnetic Compatibility (EMC) Requirements. IEC 60974-10, August 2002
Arc Welding Equipment − Part 1: Welding Power Sources: IEC 60974-1, Ed. 2.1
Degrees of Protection Provided By Enclosure (IP 23): IEC 60529 Ed. 2.1
Insulation Coordination For Equipment Within Low-Voltage Systems − Part 1: Principles, Requirements, And Tests.
IEC 60664-1 Ed. 1.1
dec_stat_6/05
Notes
SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING
Y Warning: Protect yourself and others from injury — read and follow these precautions.
1-1. Symbol Usage

OM-363Q - 5/06, safety_stm 3/06
Means Warning! Watch Out! There are possible hazards

with this procedure! The possible hazards are shown in
the adjoining symbols.
This group of symbols means Warning! Watch Out! possible

Y Marks a special safety message. ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
. Means “Note”; not safety related. to avoid the hazards.
1-2. Servicing Hazards
Y The symbols shown below are used throughout this manual to

call attention to and identify possible hazards. When you see FLYING METAL or DIRT can injure eyes.
the symbol, watch out, and follow the related instructions to
avoid the hazard. D Wear safety glasses with side shields or face
shield during servicing.
Y Only qualified persons should service, test, maintain, and re- D Be careful not to short metal tools, parts, or
pair this unit.
wires together during testing and servicing.
Y During servicing, keep everybody, especially children, away.
ELECTRIC SHOCK can kill. HOT PARTS can cause severe burns.
D Do not touch live electrical parts. D Do not touch hot parts bare handed.
D Turn Off welding power source and wire feeder D Allow cooling period before working on
and disconnect and lockout input power using equipment.
line disconnect switch, circuit breakers, or by removing plug from re- D To handle hot parts, use proper tools and/or
ceptacle, or stop engine before servicing unless the procedure spe- wear heavy, insulated welding gloves and
cifically requires an energized unit. clothing to prevent burns.
D Insulate yourself from ground by standing or working on dry insulat-

ing mats big enough to prevent contact with the ground.
D Do not leave live unit unattended. EXPLODING PARTS can cause injury.
D If this procedure requires an energized unit, have only personnel
familiar with and following standard safety practices do the job. D Failed parts can explode or cause other parts to
explode when power is applied to inverters.
D When testing a live unit, use the one-hand method. Do not put both D Always wear a face shield and long sleeves
hands inside unit. Keep one hand free. when servicing inverters.
D Disconnect input power conductors from deenergized supply line
BEFORE moving a welding power source.
SIGNIFICANT DC VOLTAGE exists after removal of SHOCK HAZARD from testing.

input power on inverters.
D Turn Off welding power source and wire feeder
D Turn Off inverter, disconnect input power, and discharge input or stop engine before making or changing me-
capacitors according to instructions in Troubleshooting Section be- ter lead connections.
fore touching any parts.
D Use at least one meter lead that has a self-
retaining spring clip such as an alligator clip.
D Read instructions for test equipment.
STATIC (ESD) can damage PC boards.
D Put on grounded wrist strap BEFORE handling
boards or parts.
D Use proper static-proof bags and boxes to FALLING UNIT can cause injury.
store, move, or ship PC boards.
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
FIRE OR EXPLOSION hazard. D Use equipment of adequate capacity to lift and
support unit.
D Do not place unit on, over, or near combustible D If using lift forks to move unit, be sure forks are
surfaces. long enough to extend beyond opposite side of
D Do not service unit near flammables. unit.
Syncrowave 250 DX /350 LX TM-363 Page 1

MOVING PARTS can cause injury. H.F. RADIATION can cause interference.
D Keep away from moving parts such as fans. D High-frequency (H.F.) can interfere with radio
D Keep away from pinch points such as drive navigation, safety services, computers, and
rolls. communications equipment.
D Have only qualified persons remove doors, D Have only qualified persons familiar with
panels, covers, or guards for maintenance as electronic equipment install, test, and service
necessary. H.F. producing units.
D Keep hands, hair, loose clothing, and tools D The user is responsible for having a qualified electrician prompt-
away from moving parts. ly correct any interference problem resulting from the installa-
D Reinstall doors, panels, covers, or guards tion.
when maintenance is finished and before re- D If notified by the FCC about interference, stop using the
connecting input power. equipment at once.
D Have the installation regularly checked and maintained.
D Keep high-frequency source doors and panels tightly shut, keep
MAGNETIC FIELDS can affect pacemakers. spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
D Pacemaker wearers keep away from servicing
areas until consulting your doctor.
READ INSTRUCTIONS.
OVERUSE can cause OVERHEATING. D Use Testing Booklet (Part No. 150 853) when
servicing this unit.
D Allow cooling period; follow rated duty cycle. D Consult the Owner’s Manual for welding safety
D Reduce current or reduce duty cycle before precautions.
starting to weld again. D Use only genuine replacement parts from the
D Do not block or filter airflow to unit. manufacturer.
1-3. California Proposition 65 Warnings

Y Welding or cutting equipment produces fumes or gases which For Gasoline Engines:
contain chemicals known to the State of California to cause Y Engine exhaust contains chemicals known to the State of
birth defects and, in some cases, cancer. (California Health & California to cause cancer, birth defects, or other reproductive
Safety Code Section 25249.5 et seq.) harm.
Y Battery posts, terminals and related accessories contain lead For Diesel Engines:
and lead compounds, chemicals known to the State of Y Diesel engine exhaust and some of its constituents are known
California to cause cancer and birth defects or other to the State of California to cause cancer, birth defects, and
reproductive harm. Wash hands after handling. other reproductive harm.
1-4. EMF Information

Considerations About Welding And The Effects Of Low Frequency 1. Keep cables close together by twisting or taping them.
Electric And Magnetic Fields
Welding current, as it flows through welding cables, will cause electro- 2. Arrange cables to one side and away from the operator.
magnetic fields. There has been and still is some concern about such
3. Do not coil or drape cables around your body.
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National 4. Keep welding power source and cables as far away from opera-
Research Council concluded that: “The body of evidence, in the
tor as practical.
committee’s judgment, has not demonstrated that exposure to power-
frequency electric and magnetic fields is a human-health hazard.” 5. Connect work clamp to workpiece as close to the weld as possi-
However, studies are still going forth and evidence continues to be
ble.
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when About Pacemakers:
welding or cutting. Pacemaker wearers consult your doctor before welding or going near
To reduce magnetic fields in the workplace, use the following welding operations. If cleared by your doctor, then following the above
procedures: procedures is recommended.
TM-363 Page 2 Syncrowave 250 DX /350 LX

SECTION 2 − DEFINITIONS
2-1. Warning Label Definitions
Warning! Watch Out! There are possible 2 Breathing welding fumes can be 3.3 Do not weld on drums or any closed
hazards as shown by the symbols. hazardous to your health. containers.
2.1 Keep your head out of the fumes. 4 Arc rays can burn eyes and injure
1 Electric shock from welding electrode skin.
or wiring can kill. 2.2 Use forced ventilation or local
exhaust to remove the fumes. 4.1 Wear hat and safety glasses. Use ear
1.1 Wear dry insulating gloves. Do not 2.3 Use ventilating fan to remove fumes. protection and button shirt collar. Use
touch electrode with bare hand. Do welding helmet with correct shade of
not wear wet or damaged gloves. 3 Welding sparks can cause explosion
or fire. filter. Wear complete body protection.
1.2 Protect yourself from electric shock 3.1 Keep flammables away from welding. 5 Become trained and read the
by insulating yourself from work and Do not weld near flammables. instructions before working on the
ground. machine or welding.
3.2 Welding sparks can cause fires. Have
1.3 Disconnect input plug or power before a fire extinguisher nearby, and have a 6 Do not remove or paint over (cover)
working on machine. watchperson ready to use it. the label.
1 1.1 1.2 1.3 4 4.1
2 2.1 2.2 2.3 5
3 3.1 3.2 3.3 6
197 310-A
2-2. Torch/Cable Holder Label

1 3 1 Warning! Watch Out! There
are possible hazards as
shown by the symbols.
2 Electric shock from wiring can
kill.
3 Do not operate unit or reach
inside when torch/cable
holder is removed.
4 Do not exceed 25 lb (12.4 kg)
maximum load on gun/cable
holder or holder may break.
2
Syncrowave 250 DX / 350 LX TM-363 Page 3

2-3. Symbols And Definitions
NOTE Some symbols are found only on CE products.
A Amperes Panel−Local
Gas Tungsten Arc
Welding (GTAW)
Shielded Metal Arc
Welding (SMAW)
V Volts
Do Not Switch
While Welding
Arc Force (DIG) Background Amps
Output Circuit Breaker Remote Temperature
Protective Earth High Frequency -

Alternating Current Water Input
(Ground) Start
High Frequency -
Postflow Timer Preflow Timer Water Output
Continuous
Increase/Decrease
Gas (Supply) Gas Output Gas Input
Of Quantity
On Off Percent Direct Current
Maximum
Balance Control Maximum Cleaning Electrode Positive
Penetration
Electrode
Final Slope Meter Single-Phase
Negative
U0 Rated No Load
Voltage (Average) U1 Primary Voltage
U2 Conventional Load
Voltage
Line Connection
I1 I2 X
Single-Phase
Rated Welding 1 1
Primary Current Duty Cycle Combined AC/DC
Current
Power Source
IP Degree Of
Protection I1eff Maximum Effective
Supply Current I1max Rated Maximum
Supply Current Hz Hertz
Electrode Work Thickness Gauge Spark Gap
S Seconds Final Amperage Initial Time Initial Amperage
Pulse Percent On 4 Step Trigger Op-

Spot Time Lift-Arct
Time 4T eration Sequence
Trigger Hold Pulser On-Off Pulse Frequency Input
Cooling
TM-363 Page 4 Syncrowave 250 DX / 350 LX

SECTION 3 − INSTALLATION
3-1. Selecting A Location
Movement
OR
Location And Airflow 5 250 DX Models 350 LX Models

3 3
LR5071 LR5071
SERIAL NO. XXXXXXX3 SERIAL NO. XXXXXXX3
® ®
STOCK NO. XXXXXXXXXXXXXX4 C US STOCK NO. XXXXXXXXXXXXXX4 C US
1 PROTECTED B Y ONE OR MORE OF THE PROTECTED B Y ONE OR MORE OF THE
FOLLOWING US. PATENTS: FOLLOWING US. PATENTS:
XXXXX05 XXXXX06 XXXXX07 XXXXX09 XXXXX05 XXXXX06 XXXXX07 XXXXX09
XXXXX42 XXXXX47 XXXXX48 XXXXX42 XXXXX47 XXXXX48
EVIDENCE OF LABEL T AMPERING VOIDS WARRANTY EVIDENCE OF LABEL T AMPERING VOIDS WARRANTY
18 in
(460 mm)
18 in (460 mm)
4 4
Y Falling Unit Can Cause Injury. 1 Lifting Eye 5 Line Disconnect Device
S Use lifting eye to lift unit only, NOT 2 Lifting Forks
Locate unit near correct input power supply.
running gear, gas cylinders, or any Use lifting eye or lifting forks to move unit.
other accessories. If using lifting forks, extend forks beyond Y Special installation may be required
S Use equipment of adequate capacity opposite side of unit. where gasoline or volatile liquids
to lift and support unit. are present − see NEC Article 511 or
3 Serial Number/Patent Label
CEC Section 20.
S If using lift forks to move unit, be sure 4 Rating Label
forks are long enough to extend Use rating label to determine input power Y Be careful when placing or moving
beyond opposite side of unit. needs. unit over uneven surfaces.
Ref. 117 264-C / 803 584-A / 216 202-D / 216 203-C / 208 998

3-2. Dimensions And Weights
A Dimensions
D
B Height 36-1/4 in (921 mm)
C C G
Width 23 in (584 mm)
Length 28 in (711 mm)
A 25 in (635 mm)
B 1-25/64 in (35 mm)

Front E
F
C 1-5/8 in (41 mm)
D 22 in (559 mm)
E 20 in (508 mm)
F 22-1/4 (565 mm)
H 803 616-A
G 1-1/8 in (29 mm)
H 1/2 in (13 mm) Dia
Weight
400 lbs (181 kg) For 250 DX Models
496 lbs (225 kg) For 350 LX Models
3-3. Cooler Specifications

Cooler Specifications
Cooler Tank Capacity 3 gallons (11.4 L)
Coolant Flow Rate 1 liter per minute (1.1 quart)
Use With Torches Rated Up To 400 Amperes
Cooling Power 1.28 kW Maximum Pressure 60 PSI (.41 MPa)
3-4. Welding Power Source Specifications
A. For 350 LX Models

Amperes Input at AC Balanced Rated Load Output, Amperage Max
Rated 50/60 Hz, Single-Phase Range OCV
Welding PFC
Output ** 200V 220V 230V 400V 440V 460V 520V 575V KVA KW
NEMA Class I No 125 103 110 57 52 55 43 42 25.0 10.6
(60) − 300 PFC 3.3* 2.2* 2.0* 1.5* 1.2* 1.7* 1.0* 1.1* 0.9* 0.6*
Amperes 32
Amperes, 3 − 400A 80V
Volts AC, 60% With 92 77 78 40 39 38 33 31 18.0 10.5
Duty Cycle PFC 77* 67* 69* 36* 33* 34* 28* 27.2* 16.6* 0.6*
NEMA Class II No 146 120 128 66 60 65 51 50 29.5 13.7

(40) − 350 PFC 3.3* 2.2* 2.6* 2.5* 1.2* 1.7* 1.0* 1.1* 0.9* 0.4*
Amperes 34
Amperes, 3 − 400A 80V
Volts AC, 40% With 114 95 94 49 47 47 40 38 21.7 13.3
Duty Cycle PFC 77* 67* 69* 36* 33* 34* 28* 27.2* 16.6* 0.6*
*While idling
**Power Factor Correction

B. For 250 DX Models
Amperes Input at AC Balanced Rated

Load Output, 60 Hz, Single-Phase
Rated Amperage Max

Welding Output PFC** 200V 230V 460V 575V KVA KW Range OCV
No 88 77 38 31 17.6 8.6
NEMA Class I (40) − 3 − 310A 80V
PFC *3.3 *2.8 *1.5 *1.1 *.59 *.29
200 Amperes, 28
Volts AC, 60% Duty 60 52 26 21 12.06 8.11
Cycle With
3 − 310A 80V
PFC *55.3 *49.5 *24.5 *19.6 *11.2 *.39
No 110 96 48 38 21.98 11.76

NEMA Class II (40) − 3 − 310A 80V
PFC *3.3 *2.8 *1.5 *1.1 *.59 *.29
250 Amperes, 30
Volts AC, 40% Duty 82 71 35 28 16.32 11.81
Cycle With
3 − 310A 80V
PFC *55.3 *49.5 *24.5 *19.6 *11.2 *1.93
*While idling

Load Output, 50/60 Hz, Single-Phase
Rated Amperage Max

No 82 45 41 35 17.6 8.6
NEMA Class I (40) − 3 − 310A 80V
PFC *3.0 *1.6 *1.4 *1.2 *.59 *.29
200 Amperes, 28
Volts AC, 60% Duty 61 34 31 26 12.06 8.11
Cycle With
3 − 310A 80V
PFC *45.9 *25.1 *22.8 *23.2 *11.2 *.39
No 100 55 50 42 21.98 11.76

NEMA Class II (40) − 3 − 310A 80V
PFC *3.0 *1.6 *1.4 *1.2 *.59 *.29
250 Amperes, 30
Volts AC, 40% Duty 81 44 40 34 16.32 11.81
Cycle With
3 − 310A 80V
PFC *45.9 *25.1 *22.8 *23.2 *11.2 *1.93
*While idling

Load Output, 50 Hz, Single-Phase
Rated Amperage Max

No 80 69 35 28 15.9 7.4
NEMA Class I (40) − 3 − 310A 80V
PFC *3.3 *2.8 *1.5 *1.1 *.59 *.29
175 Amperes, 27
Volts AC, 60% Duty 52 45 22 18 10.3 7.3
Cycle With
3 − 310A 80V
PFC *55.3 *49.5 *24.5 *19.6 *11.2 *.39
No 101 88 44 35 20.2 10.2

NEMA Class II (40) − 3 − 310A 80V
PFC *3.3 *2.8 *1.5 *1.1 *.59 *.29
225 Amperes, 29
Volts AC, 40% Duty 74 64 32 26 14.7 10.1
Cycle With
3 − 310A 80V
PFC *55.3 *49.5 *24.5 *19.6 *11.2 *1.93
*While idling

3-5. Duty Cycle And Overheating
Duty Cycle is the percentage of 10
minutes that the unit can weld at
rated load without overheating.
If unit overheats, output stops, front
panel voltmeter/ammeter displays
a HLP3 or HLP5 message (see
Section 6-2), and cooling fans run.
250 DX Models Wait fifteen minutes for unit to cool.
Reduce amperage or duty cycle be-
fore welding.
Y Exceeding duty cycle can
damage unit and void war-
ranty.
40% Duty Cycle At 250 Amperes 60% Duty Cycle At 200 Amperes
6 Minutes Welding 4 Minutes Resting

Overheating
0 A
15
OR
Minutes Reduce Duty Cycle
duty1 4/95 / Ref. 116 198
350 LX Models
40% Duty Cycle At 350 Amperes 60% Duty Cycle At 300 Amperes

Overheating 0 A
15
OR
Minutes Reduce Duty Cycle
duty1 4/95 / 190 276

3-6. Volt-Ampere Curves
A. For 250 DX Models
The volt-ampere curves show the

minimum and maximum voltage
and amperage output capabilities of
the welding power source. Curves
of other settings fall between the
Non CE Models curves shown.
80 80
70 70
60 60
50 50
40 40
30 30
20 20
10 10
0 0
0 50 100 150 200 250 300 350 400 450 0 50 100 150 200 250 300 350 400 450
AMPS AMPS
194 385-A / 194 384-A
CE Models
80 80
70 70
60 60
50 50
40 40
30 30
20 20
10 10
0 0
0 50 100 150 200 250 300 350 400 450 0 50 100 150 200 250 300 350 400 450
AMPS AMPS
205 631 / 205 632

B. For 350 LX Models
The volt-ampere curves show the
350 Amperes Models minimum and maximum voltage
and amperage output capabilities of
the welding power source. Curves
of other settings fall between the
curves shown.
ssb1.1 10/91 − ST-190 277 / ST-190 278

3-7. Weld Output Terminals And Selecting Cable Sizes
Y ARC WELDING can cause Electromagnetic Interference.

To reduce possible interference, keep weld cables as short as possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment. Be sure this welding machine is installed
and grounded according to this manual. If interference still occurs, the user must take extra measures such as moving
the welding machine, using shielded cables, using line filters, or shielding the work area.
Total Cable (Copper) Length In Weld Circuit Not Exceeding
150 ft 200 ft 250 ft 300 ft 350 ft 400 ft

100 ft (30 m) Or Less
(45 m) (60 m) (70 m) (90 m) (105 m) (120 m)
Weld Output
Terminals
Y Turn off power before 10 − 60% 60 − 100%
connecting to weld out- Welding
Duty Duty 10 − 100% Duty Cycle
put terminals. Amperes
Cycle Cycle
Y Do not use worn, dam-
aged, undersized, or
poorly spliced cables.
100 4 4 4 3 2 1 1/0 1/0
150 3 3 2 1 1/0 2/0 3/0 3/0
200 3 2 1 1/0 2/0 3/0 4/0 4/0
250 2 1 1/0 2/0 3/0 4/0 2-2/0 2-2/0
300 1 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0
350 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0 2-4/0
Electrode Work 400 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 2-4/0
Ref. 803 588-A 500 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 3-3/0 3-3/0
Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere
*Select weld cable size for pulsing application at peak amperage value.. S-0007-D
3-8. Remote 14 Receptacle Information
Y Turn off power before Socket* Socket Information

connecting to receptacle
receptacle.
A Contactor control 24 volts dc.
24 VOLTS DC
A J OUTPUT B Contact closure to A completes 24 volts dc
K I
B CONTACTOR contactor control circuit and enables output.
C L N H
C Output to remote control; 0 to +10 volts dc output
D M G to remote control.
E F A
REMOTE D Remote control/feedback circuit common.
OUTPUT
CONTROL E 0 to +10 volts dc input command signal from
remote control.
A/V F Current feedback; +1 volt dc per 100 amperes.

AMPERAGE
VOLTAGE H Voltage feedback; +1 volt dc per 10 volts output.
Ref. 803 588-A GND K Chassis common.
*The remaining sockets are not used.

3-9. Shielding Gas Connections And 115 Volts AC Duplex Receptacle
Y Turn Off power before con-
necting to receptacle.
4 1 Gas Valve In Connection
Located on rear of unit.
2 Gas Valve Out Connection
5 3
Connections have 5/8-18 right-
hand threads.
3 Cylinder Valve
Tools Needed: Open valve slightly so gas flow
blows dirt from valve. Close valve.
5/8, 3/4, 1-1/8 in 4 Regulator/Flow Gauge
Connect regulator/flow gauge to
gas cylinder.
Connect customer supplied gas
hose between regulator/flow gauge
and gas in fitting.
5 Flow Adjust
Typical flow rate is 20 cfh (cubic feet
per hour).
6 115 V 15 Amp AC Receptacle
Receptacle is protected from over-
load by circuit breaker CB1 (see
2 Section 7-3).
Rear View
Front View 1
6
Ref. 803 588-A / Ref. 803 585-B / Ref. 157 858

3-10. Cooler Connections And Operation
Y Turn Off power before con-
Cooler Tank Capacity: 3 gallons (11.4 L) necting to coolant fittings.
1 Coolant Tank Cap
Cooler Flow Rate: 1 liter per minute (1.1 qt)
Use table below to select proper
Tools Needed:
Use With Torches Rated Up To 400 Amperes coolant. Remove cap and add cool-
5/8, 3/4, 1-1/8 in ant. Fill to capacity. Keep coolant
level full.
Connect torch as shown in Section
3-11.
Priming
Initial setup requires priming of the
coolant system before operation.
To prime the system, proceed as
follows:
2 Process Control Switch
For cooler operation, place Pro-
cess Control switch in the GTAW
(TIG) position according to Section
4-3.
1 Press and HOLD the Process Con-
trol switch. After 2 seconds the volt-
meter displays [CLR] to indicate sys-
tem priming has initiated.
2 Continue to hold the Process Con-
trol switch until the amp meter dis-
plays [FLO] to indicate priming is
complete and adequate flow has
been detected (approx. 40 sec-
onds).
Operation
Cooler will activate when a valid arc
is detected. A system pressure
switch will detect and monitor cool-
ant flow. If flow is not detected within
5 seconds of welding, weld output
stops, and Help Message 19 is dis-
played on the volt/amp meters (see
Section 6-2).
During normal operation cooler will
continue to operate for 40 seconds
after welding arc ends, or until the
coolant temperature is adequately
reduced.
Changing A Water-Cooled Torch
Y Turn Off power before mak-
ing torch and coolant con-
nections.
Connect new torch and follow prim-
ing procedure described above. To
avoid a Help Message Code, press
and hold Process Control switch for
approximately 40 seconds to en-
GTAW Or Where sure the torch is completely primed,
Application even if amp meter displays [FLO]
HF* Is Used
sooner.
MILLER Low Conductivity

Coolant No. 043 810**;
Distilled Or Deionized Water
OK Above 32° F (0° C)
Coolant
*HF: High Frequency Current

**MILLER coolants protect to -37° F (-38°C) and resist algae growth.
Y Use of any coolant other than those listed in the table voids the warranty on any parts
that come in contact with the coolant (pump, radiator, etc.).

3-11. TIG Connections With A Water-Cooled Torch
Y Turn Off power before making con-
nections.
1 Gas-In Connection
Connect gas hose from gas supply to gas-
in connector.
6 2 Output Selector Switch (See Section
4-2)
7 Switch is shown in DCEN (direct current
electrode negative) position for TIG HF Im-
8 2 pulse DCEN welding. For front panel con-
trol dispay, see Section 3-14. For TIG AC
welding, place switch in AC position. For
3 TIG AC front panel control dispay, see Sec-
tion 3-15.
3 Electrode Weld Output Terminal
Connect TIG torch to electrode weld outout
terminal.
4 Work Weld Output Terminal
Connect work lead to work weld output ter-
1 minal.
4
5 Remote 14 Receptacle
5 Connect desired remote control to Remote
14 receptacle (see Section 3-8).
6 Water-In (From Torch) Connection
Connect torch water-out (red) hose to
welding power source water-in connection.
Tools Needed: 7 Gas−Out Connection
11/16, (21 mm) Connect torch gas hose to gas-out fitting.
8 Water-Out (To Torch) Connection
Connect torch water-in (blue) hose to weld-
803 601-B ing power source water-out connection.
3-12. TIG Connections With A Two-Piece Air-Cooled Torch

Y Turn Off power before making
connections.
1 Gas-In Connection
Connect gas hose from gas supply to
gas-in connection.
2 Output Selector Switch (See
2 Section 4-2)
6 Switch is shown in DCEN (direct cur-
rent electrode negative) position for
TIG HF Impulse DCEN welding. For
5
front panel control dispay, see Section
3-14. For TIG AC welding, place switch
in AC position (see Section 4-2). For
TIG AC front panel control dispay, see
Section 3-15.
Connect work lead to work weld output
1 terminal.
3
4
Connect desired remote control to Re-
mote 14 receptacle (see Section 3-8).
Connect TIG torch to electrode weld
11/16, (21 mm) output terminal.
Tools Needed: 6 Gas-Out Connection
Connect torch gas hose to gas-out
fitting.
803 586-B

3-13. TIG Connections With A One-Piece Air-Cooled Torch
Y Turn Off power before making
connections.
1 Gas-In Connection
Connect gas hose from gas supply to
gas−in connection.
2 Output Selector Switch (See
2 Section 4-2)
6 Switch is shown in DCEN (direct cur-

rent electrode negative) position for
TIG HF Impulse DCEN welding. For
5 front panel control dispay, see Section
3-14. For TIG AC welding, place switch
in AC position (see Section 4-2). For
TIG AC front panel control dispay, see
Section 3-15.
Connect work lead to work weld output
1 terminal.
3
Connect desired remote control to Re-
4 mote 14 receptacle (see Section 3-8).
Connect TIG torch to electrode weld
output terminal.
Tools Needed:
6 Gas-Out Connection
11/16, (21 mm)
Connect torch gas hose to gas-out
fitting.
803 615-A

3-14. Front Panel Display For TIG HF Impulse DCEN (Direct Current Electrode Negative)
1 Front Panel . For all front panel switch pad NOTE: Green on nameplate indi-
cates a TIG function (see Section
Correct front panel display for ba- controls: press switch pad to
4-1 for description of controls).
sic TIG HF Impulse DCEN turn on light and enable
welding. function.
(CE Nameplate)

3-15. Front Panel Display For TIG AC
1 Front Panel . For all front panel switch pad NOTE: Green on nameplate indi-
cates a TIG function (see Sec-
controls: press switch pad to
Correct front panel display for tion 4-1 for description of con-
turn on light and enable
basic TIG AC welding. function. trols).
(CE Nameplate)

3-16. Stick Connections
Y Turn Off power before mak-
ing connections.
Connect work lead to work weld
output terminal.
2 Electrode Weld Output
Terminal
Connect electrode holder to elec-
trode weld outout terminal.
If desired, connect remote control
4 to Remote 14 receptacle (see Sec-
tion 3-8).
2 4 Output Selector Switch (See
Section 4-2)
Switch is shown in DCEP (direct
current electrode positive) position
for Stick DCEP welding. For front
panel control dispay, see Section
3 3-17. For Stick AC welding, place
switch in AC position. For Stick AC
1 front panel control dispay, see Sec-
tion 3-18.
Tools Needed:
11/16, (21 mm), 3/4 in
803 587-A

3-17. Front Panel Display For Stick DCEP (Direct Current Electrode Positive)
1 Front Panel . For all front panel switch pad NOTE: Gray on nameplate indi-
cates a Stick function (see Sec-
basic Stick DCEP welding. function. trols).
(CE Nameplate)

3-18. Front Panel Display For Stick AC
1 Front Panel . For all front panel switch pad NOTE: Gray on nameplate indi-
cates a Stick function (see Sec-
basic Stick AC welding. function. trols).
(CE Nameplate)

3-19. Electrical Service Guide
A. For 250 DX Models
NOTE All values in both tables were calculated at 60% duty cycle.
NOTE Actual input voltage cannot exceed ± 10% of indicated required input voltage
shown in both tables. If actual input voltage is outside of this range, damage to unit
may occur.
50/60 Hertz Models Without Power Factor Correction

Input Voltage 200 220 230 400 440 460 520 575
Input Amperes At Rated Output* 88 82 77 45 41 38 35 31
Max Recommended Standard Fuse Or Circuit Breaker

Rating In Amperes Circuit Breaker 1
Time-Delay Fuse 2 125 125 125 70 60 60 50 45
Normal Operating (Fast) Fuse 3 125 125 125 70 60 60 50 45
Min Input Conductor Size In AWG 4 4 6 6 8 8 10 10 10
Max Recommended Input Conductor Length In 167 137 153 305 369 281 352 439
Feet (Meters) (51) (42) (47) (93) (112) (86) (107) (134)
Min Grounding Conductor Size In AWG 4 6 6 6 8 10 10 10 10
* Input amperes at rated output is the amperage draw for that particular input voltage if the machine is run at its rated welding
output (see Section 3-4 for rated welding output).
Reference: 1999 National Electrical Code (NEC)
1If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.
2“Time-Delay” fuses are UL class “RK5” .
3“Normal Operating” (fast) fuses are UL class “K5” (up to and including 60 amp), and UL class “H” ( 65 amp and above).
4Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table
310.16. If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable requirements.
Y Failure to follow these fuse and circuit breaker recommendations could create an electric shock or fire hazard.
50/60 Hertz Models With Power Factor Correction

Input Voltage 200 220 230 400 440 460 520 575

Time-Delay Fuse 2 90 90 80 50 45 40 40 30
Max Recommended Input Conductor Length In 102 115 226 274 308 383 295
87 (26)
Feet (Meters) (31) (35) (69) (84) (94) (117) (90)
B. For 350 LX Models
NOTE All values in both tables were calculated at 60% duty cycle.
NOTE Actual input voltage cannot exceed ± 10% of indicated required input voltage
shown in both tables. If actual input voltage is outside of this range, damage to unit
may occur.
50/60 Hertz Models Without Power Factor Correction

Input Voltage 200 220 230 400 440 460 520 575

Time-Delay Fuse 2 150 125 125 70 70 60 60 50
Feet (Meters) (46) (56) (52) (75) (91) (99) (127) (155)
50/60 Hertz Models With Power Factor Correction

Input Voltage 200 220 230 400 440 460 520 575

Time-Delay Fuse 2 110 100 90 50 50 45 40 35
Feet (Meters) (44) (36) (40) (80) (97) (106) (91) (112)
3-20. Placing Jumper Links
Y Disconnect and lockout/tag-
Label found on 250 DX models with the following stock numbers: out input power before
907194, 907194-021 and, 907194-031 installing or moving jumper
links.
Label found on 350 LX models with the following stock numbers:
2 907198, 907198-011, 907198-021, and 907198-031 Check input voltage available at
site.
200 VOLTS 230 VOLTS 460 VOLTS 1 Jumper Link Label
1 Check label − only one label is on
unit.
L L L L L L
2 Jumper Links
083 566-E Move jumper links to match input
voltage.
Or Close and secure access door, or
Label found on 250 DX models with the following stock numbers: go on to Section 3-21.
907195, 907195-021 and, 907195-031
Label found on 350 LX models with the following stock numbers:
907199, 907199-021, and 907199-031
230 VOLTS 460 VOLTS 575 VOLTS

1
L L L L L L
010 587-D
Or
Label found on 250 DX models with stock number 907197
Label found on 350 LX models with stock number 907200
191 440-A
Tools Needed:
3/8 in
Ref. 803 585-B

3-21. Connecting Input Power
8 =GND/PE Earth Ground
10
L1 6
L2
4
1 2
6 5
Tools Needed:
3/8 in
4 803 585-B
3
Y Installation must meet all National and Welding Power Source Input Power Con- Disconnect Device Input Power Connec-
Local Codes − have only qualified per- nections tions
sons make this installation. 7 Disconnect Device (switch shown in
2 Strain Relief
Y Disconnect and lockout/tagout input OFF position)
power before connecting input con- Route conductors (cord) through strain relief
8 Disconnect Device (Supply) Grounding
ductors from unit. and tighten screws.
Terminal
Y Make input power connections to the 3 Machine Grounding Terminal Connect green or green/yellow grounding
welding power source first. 4 Green Or Green/Yellow Grounding conductor to disconnect device grounding ter-
Y Always connect green or green/yellow Conductor minal first.
conductor to supply grounding termi- 9 Disconnect Device Line Terminals
nal first, and never to a line terminal. Connect green or green/yellow grounding
conductor to welding power source grounding Connect input conductors L1 and L2 to
See rating label on unit and check input volt- terminal first. disconnect device line terminals.
age available at site.
5 Welding Power Source Line Terminals 10 Overcurrent Protection
1 Input Power Conductors (Customer
Supplied Cord) 6 Input Conductors L1 And L2 Select type and size of overcurrent protection
Select size and length of conductors using using Section 3-19 (fused disconnect switch
Connect input conductors L1 and L2 to weld- shown).
Section 3-19. Conductors must comply with ing power source line terminals.
national, state, and local electrical codes. If Close and secure door on line disconnect de-
applicable, use lugs of proper amperage Close and secure access door on welding vice. Remove lockout/tagout device, and
capacity and correct hole size. power source. place switch in the On position.

SECTION 4 − OPERATION
4-1. Controls (350 LX Nameplates Shown)
A. For 200/230/460 Volts And Non CE Units
11
1 2 3 4 5 6
12
10
7 8
. Top row of lights in upper left corner are ment available. 8 Power Switch
On for SMAW. Bottom row are On for 6 Amperage Adjustment Use switch to turn unit Off and On.
GTAW. Control
9 Postflow Time Control
Green on nameplate indicates a TIG function, Use control to adjust amperage, and preset
Use control to set length of time (0−50 sec-
Gray indicates a Stick function. amperage on ammeter. This control may be
onds) gas flows after welding stops. It is im-
adjusted while welding.
1 Process Control portant to set enough time to allow gas to flow
For remote amperage control, front panel until after the tungsten and weld puddle has
See Section 4-3. control setting is the maximum amperage cooled down.
2 Amperage Control available. For example: If front panel control
is set to 200 amps, the range of the remote Application:
See Section 4-4. amperage control is 3 to 200 amps for 250 DX Postflow is required to cool the tungsten and
3 Output Control models, and 3 to 200 amps for 350 LX weld, and to prevent contamination of tung-
models. sten and weld. Increase postflow time if tung-
See Section 4-5.
For pulse welding, use Amperage Adjust sten or weld are dark in appearance (approxi-
4 Start Mode Control control to select from 3-300 amps of peak am- mately 1 second per 10 ampere of welding
See Section 4-9. perage for 250 DX models, or 3−400 amps of current).
peak amperage for 350 LX models (see Sec- 10 Balance/DIG Control
5 Voltmeter And Ammeter
tion 4-12).
Voltmeter displays average voltage (to the See Section 4-10.
For spot welding, use Amperage Adjust
nearest 0.1 V) at the weld output terminals. control to select from 3-310 amps for 250 DX 11 Pulser Controls (Optional on 250 DX
model)
Use meter to preset amperage. Meter dis- models, or 3−400 amps for 350 LX models
plays average weld amperage output of unit (see Section 4-16). See Section 4-12.
to nearest ampere when welding. 7 Output Selector Switch 12 Sequence Controls (Optional)
NOTE: Meters are self-calibrating. No adjust- See Section 4-2. See Section 4-13.
217 264-A / 213 106-A

B. For CE Units
11
1 2 3 4 5 6
12
10
7 8
. Top row of lights in upper left corner are NOTE: Meters are self-calibrating. No adjust-
ment available.
8 Power Switch
On for SMAW. Bottom row are On for Use switch to turn unit Off and On.
GTAW. 6 Amperage Adjustment
9 Postflow Time Control
Control
Green on nameplate indicates a TIG function, Use control to set length of time (0−50 sec-
Use control to adjust amperage, and preset
Gray indicates a Stick function. onds) gas flows after welding stops. It is im-
amperage on ammeter. This control may be
adjusted while welding. portant to set enough time to allow gas to flow
1 Process Control
until after the tungsten and weld puddle has
See Section 4-3. For remote amperage control, front panel cooled down.
control setting is the maximum amperage
2 Amperage Control available. For example: If front panel control Application:
is set to 200 A, the range of the remote amper- Postflow is required to cool the tungsten and
See Section 4-4.
age control is 3 to 200 amps for 250 DX mod- weld, and to prevent contamination of tung-
3 Output Control els, and 3 to 200 amps for 350 LX models.. sten and weld. Increase postflow time if tung-
See Section 4-5. For pulse welding, use Amperage Adjust sten or weld are dark in appearance (approxi-
control to select from 3-300 amps of peak am- mately 1 second per 10 ampere of welding
4 Start Mode Control perage for 250 DX models, or 3−400 amps of current).
See Section 4-9. peak amperage for 350 LX models (see Sec- 10 Balance/DIG Control
tion 4-12).
5 Voltmeter And Ammeter See Section 4-10.
For spot welding, use Amperage Adjust
Voltmeter displays average voltage (to the control to select from 3-310 amps for 250 DX 11 Pulser Controls (Optional on 250 DX
nearest 0.1 V) at the weld output terminals. model)
models, or 3−400 amps for 350 LX models
(see Section 4-16). See Section 4-12.
Use meter to preset amperage. Meter dis-
plays average weld amperage output of unit 7 Output Selector Switch 12 Sequence Controls (Optional)
to nearest ampere when welding. See Section 4-2. See Section 4-13.
215 460-A / 218 584-A

4-2. Output Selector Switch
1 Output Selector Switch
Y Do not use AC output in
damp areas, if movement is
confined, or if there is dan-
ger of falling. Use AC output
ONLY if required for the
welding process, and then
use a remote control.
1 Y Do not change position of
switch while welding or
while under load.
Use switch to select (DCEN) Direct
Current Electrode Negative, AC, or
(DCEP) Direct Current Electrode
Positive output.
NOTE: Changing position of Out-
put Selector switch may change
Process control, Current control,
and Start Mode control, and may re-
quire changing Output control set-
tings to properly function with latest
Output Selector switch setting.
4-3. Process Control

1 Process Control
(CE Nameplate)
Use control to select Shielded Met-
al Arc Welding (SMAW) or Gas
Tungsten Arc Welding (GTAW) pro-
cess.
For SMAW, press button to toggle
LED to Stick position.
For GTAW, press button to toggle
LED to TIG position.
NOTE: Lit LED indicates selected
1 mode.
1 When Output Selector switch posi-
tion changes, LED may change
position, based upon last selection.
Ref. 217 264-A / Ref. 215 460-A
4-4. Amperage Control

(CE Nameplate) 1 Amperage Control
Use control to select front panel or
remote amperage control.
For front panel amperage control,
press button to toggle LED to Panel
position.
For remote amperage control,
press button to toggle LED to Re-
mote position (see Section 3-8).
NOTE: Lit LED indicates selected
1 mode.
1
When Output Selector switch posi-
tion changes, LED may change
position, based upon last selection.

4-5. Output Control
Remote (Standard)Torch Trigger Operation
(CE Nameplate)
2 2
1 1
Current (A)
Remote (Standard)Torch Trigger Operation
Weld Amps
Final Slope
Initial Amps
Final Amps
Preflow Postflow
Push & Hold Release For Release Foot Or

Foot Or Finger Maintained Switch Finger Remote
Remote Control Control
1 Output Control 2 Remote Trigger (Standard) Operation NOTE: If On/Off only type trigger is used,
Y Weld output terminals are ener- it must be a maintained switch. All func-
For remote output control, press button to tions become active.
gized when power is On, and Out- toggle LED to Remote position (see Sec-
put On LED is lit. tion 3-8). Application: Use Remote Trigger when
Use control to select front panel, trigger the operator desires to use a foot pedal or
hold, or remote output control. Torch trigger operation is as shown. finger amperage control.
NOTE: Lit LED indicates selected mode.
NOTE: Initial weld amperage and final am- When Output Selector switch (see Section
For weld output, press button to toggle LED perage is controlled by the remote device, 4-2) position changes, Output control LED
to On position. not by the welding power source. will always switch to Remote.

Trigger Hold (2T)
(CE Nameplate)
3 3
Current (A) 2T Torch Trigger Operation
Weld Amps
Final Slope
Initial Amps
Final Amps
Preflow Postflow
Push & Release Trigger Push & Release Trigger

In Less Than 3/4 Sec. In Less Than 3/4 Sec.
NOTE: If torch trigger is held more than 3 seconds, operation reverts to Remote Trigger (Standard) mode (see previous
page).
If arc is broken and trigger is depressed, HLP-10 will be displayed (see Section 6-2).
3 Trigger Hold NOTE: When a foot or finger remote con- power source.
For trigger hold operation, press button to trol is connected to the welding power Application: Trigger Hold (2T) can help
toggle LED to Trigger Hold position. source, only trigger input is functional, as to reduce operator fatigue when long ex-
Torch trigger operation is as shown. amperage is controlled by the welding tended welds are made.

4-6. 4T, 4T Momentary, And Mini Logoic Trigger Operation (Requires Optional Sequence
Controls)
4T Torch Trigger Operation
If unit is equipped with optional Sequence lows the operator to toggle between weld Application:
Controls (see Section 4-13), 4T trigger current and final current without breaking
method is available. the arc. Use 4T trigger method when the functions
of a remote current control are desired, but
4T torch trigger operation is as shown. NOTE: When a remote switch is connected only a remote on/off control is available.
to the welding power source, only trigger in-
While in 4T mode, there is a feature avail- put is functional. Amperage is controlled by Select 4T trigger method according to Sec-
able during the main weld sequence that al- the welding power source. tion 4-7.
Current (A)
Weld Amps
Final Slope
Initial Amps
Final Amps
Preflow Postflow
Push & Hold Release Push & Release Push & Release Push & Hold Release
Trigger Trigger Trigger In Less Trigger In Less Trigger Trigger
Than 3/4 Sec. Than 3/4 Sec.
4T Momentary Torch Trigger Operation
If unit is equipped with optional Sequence NOTE: When a remote switch is connected Application:
Controls (see Section 4-13), 4T Momen- to the welding power source, only trigger in- Use 4T Momentary trigger method when
tary trigger method is available. put is functional. Amperage is controlled by the functions of a remote current control are
4T Momentary torch trigger operation is as the welding power source. desired, but only a remote on/off control is
shown. available.
While in 4T Momentary mode, once the op- Select 4T Momentary trigger method ac-
erator toggles out of weld current and be- cording to Section 4-7.
gins final slope, toggling again will break
the arc and go to postflow.
Current (A)
Weld Amps
Final Slope
Initial Amps
Final Amps
Preflow Postflow
Push & Release Push & Release Push & Release Push & Release
Trigger Trigger Trigger Trigger

Mini Logic Operation
If unit is equipped with optional Sequence from the initial amps level to the main weld the welding power source.
Controls (see Section 4-13), Mini Logic op- amps level by pressing and releasing the
Application: This ability to change amper-
eration is available. torch trigger in less than 3/4 seconds.
age levels without either initial slope or final
Torch trigger operation is as shown. slope, gives the operator the opportunity to
NOTE: When a remote switch is connected
adjust filler metal without breaking the arc.
During Mini Logic welding operation, the to the welding power source, only trigger in-
weld amperage can be manually changed put is functional. Amperage is controlled by Select Mini Logic according to Section 4-7.
Weld Amps
Final Slope
Initial Amps
Initial Amps
Final Slope
Preflow Rate Postflow
Push & Hold Push & Hold Push & Release Push & Hold
Trigger Trigger For More Trigger In Less Trigger For More
Than 3/4 Sec. Than 3/4 Sec. Than 3/4 Sec.
Release Trigger Push & Release Push & Release

Trigger In Less Trigger In Less
Than 3/4 Sec. Than 3/4 Sec.

4-7. Reconfiguring Trigger Hold For 4T And Mini Logic Control
1 Output Control
2
2 Power Switch
To reconfigure Trigger Hold, turn Off
power, push and hold Output control
button and turn On power switch.
Hold button for approximately 7 sec-
onds (or until software version num-
ber _ _ _ _ _ _-_clears, and meters
display [SEL] [H−2]. Front Panel
Press Output control button to
change functions. Active function will
be displayed on amperage (bottom)
meter. 1
3 Meter Displays
Meter displays for the different func-
tions will be as shown.
Press torch trigger or turn power Off
to save setting.
Proceed to Section 4-6 for 4T Opera- SEL
tion.
Proceed to Section 4-6 for Mini Logic
H−2
operation.
Proceed to Section 4-6 for 4T Mo-
mentary operation.
NOTE: These features are only
available when optional Sequencer
is installed.
SEL SEL SEL

= 4T Momentary
(See Section 4-6) = 4T (See Section 4-6) = Mini Logic (See Section 4-6)
H-4E H−4 H4L

2
(CE Nameplate)
1 Front Panel
SEL
H−2
SEL SEL SEL

= 4T Momentary
(See Section 4-6) = 4T (See Section 4-6) = Mini Logic (See Section 4-6)
H-4E H−4 H4L

4-8. Selecting TIG Starting Characteristics Using Syncro-Startt Technology
1 4
E−
−2−
Use this function to select desired TIG start- turn On power. Hold button for approximately Press torch trigger or turn Off power to save
ing characteristics. 7 seconds (or until software version number_ setting.
1 Start Mode _ _ _ _ _-_ clears meters).
Application:
2 Power Switch The TIG LED and all four Start LEDs will light,
Select 1 (light/soft start) − when welding at
3 Output Selector Switch and the meters will display [E−] [−2−], [AC] [−2−],
low amperages on thin gauge material.
4 Meters or [EP] [−2−], depending on position of Polarity
switch. Select 2 (medium/normal start) − factory de-
To select or change TIG starting characteris- fault setting used for most welding applica-
tics, proceed as follows: turn Off power. Press Start Mode button again to step tions.
Place Output Selector switch in desired posi- through the three start characteristics
tion (each position, DCEN, AC, or DCEP has choices. Amperage (bottom) meter displays Select 3 (high/hot start) − when welding at
three applicable start characteristics op- active choice 1= light start, 2=medium/normal high amperages on thick materials with a
tions). Push and hold Start Mode button and start, 3=high/hot start. large diameter tungsten.

(CE Nameplate)
1 4
E−
−2−

4-9. Start Mode
(CE Nameplate)
1 1
2 3
Lift-Arct Start Method
1−2
“Touch” Seconds
Do NOT Strike Like A Match!
1 Start Mode onds, and slowly lift electrode. An arc will turns off when arc is started, and turns on
form when electrode is lifted. whenever arc is broken to help restart arc.
For SMAW welding, press button to toggle
LED to Off position. Shielding gas begins to flow when elec- Application:
trode touches work piece.
For GTAW welding, use control to select HF Start is used when the DCEN GTAW
Normal open-circuit voltage is not present process is required.
Off for no HF, Lift-Arct, HF for arc starting
before tungsten electrode touches work-
only, or continuous HF. When HF Continuous is selected, start
piece; only a low sensing voltage is pres-
ent between electrode and workpiece. arc as follows:
Application:
The solid state output contactor does not High frequency turns on when output is
When Off is selected, use the scratch energize until after electrode is touching energized and remains on for duration of
method to start an arc for both the SMAW workpiece. This allows electrode to touch weld.
and GTAW processes. workpiece without overheating, sticking,
or getting contaminated. Application:
When Lift-Arc is selected, start arc as
follows: Application: HF Continuous is used when the AC
GTAW process is required.
2 TIG Electrode Lift-Arc is used for the DCEN GTAW pro-
cess when HF Start method is not per- NOTE: Lit LED indicates selected mode.
3 Workpiece mitted, or to replace the scratch method. When Output Selector switch position
When HF Start is selected, start arc as changes, LED may change position,
Touch tungsten electrode to workpiece at
follows: based upon last selection.
weld start point, enable output with torch
trigger, foot control, or hand control. Hold High frequency turns on to help start arc NOTE: Some start methods may not be
electrode to workpiece for 1-2 sec- when output is enabled. High frequency available for all processes.

4-10. Balance/DIG Control
1 Balance/DIG Control
(CE Nameplate)
Balance Control (AC GTAW):
Control changes the AC output
1 square wave. Rotating the control
1 towards 10 provides deeper pene-
tration. Rotating the control towards
0 provides more cleaning action of
the workpiece.
When the control is in the Balanced
position, the wave shape provides
equal penetration and cleaning
action.
Application:
When welding on oxide forming ma-
terials such as aluminum or magne-
sium, excess cleaning is not neces-
sary. To produce a good weld, only
Balance Control Examples a minimal amount, approximately a
0.10 in (2.5mm) of etched zone
Setting Output Waveforms Arc
along the weld toes is required.
Balanced 50% Electrode Set control to 3 and adjust as nec-
3 Positive essary. Joint configuration, set-up,
process variables, and oxide thick-
50% Electrode
ness may affect setting.
Negative
NOTE: Arc rectification can occur
Max Penetration when welding above 200 amps
32% Electrode
Positive and/or while welding with helium
gas. If this condition occurs, in-
68% Electrode creasing the Balance control to-
10 Negative wards maximum penetration, may
Max Cleaning help to restabilize the arc.
55% Electrode
Positive
45% Electrode DIG Control (AC And DC SMAW):
0 Negative When set at 0, short-circuit amper-
age at low arc voltage is the same
as normal welding amperage.
When setting is increased, short-
circuit amperage at low arc voltage
increases. Set control at 2 and ad-
just as necessary. Joint configura-
tion, set-up, and process variables
may affect setting.
Application:
Control helps arc starting or making
vertical, or overhead welds by in-
creasing amperage at low arc volt-
age, and reduces electrode sticking
while welding.
Ref. S-0795-A

4-11. Preflow Time Control
1 4
00.4
SEL
Use control to set length of time (0.2, 0.4, 0.6, Turn power off. Push and hold Process Con- time, press and release Process Control but-
0.8, 1.0, 1.5, 2.0, 2.5, 3.0, 3.5, 4.0, 4.5, 5.0 trol button and turn On power. Hold button for ton until desired time is displayed on meters.
seconds) gas flows before welding starts. approximately 7 seconds (or until software
1 Process Control version number_ _ _ _ _ _-_ clears meters). Application:
2 Power Switch The TIG LED will light and the meters will dis- Preflow is used to purge the immediate weld
3 Meters play [o.4] [SEL]. The factory preflow default area of atmosphere. Preflow also aids in con-
To change preflow time, proceed as follows: setting is 0.4 seconds. To change preflow sistent arc starting.

(CE Nameplate)
1 4
00.4
SEL

4-12. Pulse Controls (Standard On 350 LX Models, Optional On 250 DX Models)
1 On/Off Control
3 4 Use control to turn pulse function

1 2 On and Off.
2 Background Amps
Use Background Amps control to
set the low pulse of the weld amper-
age, which cools the weld puddle
and affects overall heat input.
Background Amps is set as a per-
centage of peak amperage.
3 Pulse Frequency
Ranges from 0.25−10.0 pps
(pulses per second). Control is
(CE Nameplate) used to determine appearance of
weld bead.
3 4 Peak Time
1 2 4
A range of 5−95% of each pulse
cycle can be spent at the peak am-
perage level.
Peak amperage (3-310 amps for
250 DX models, and 3−400 amps
for 350 LX models), is set with the
Amperage Adjustment control (see
Section 4-1). Peak amperage is the
highest welding amperage allowed
to occur in the pulse cycle. Weld
penetration varies directly with
peak amperage.
5
5 Pulsed Output Waveforms
Example shows affect changing
the Peak Time control has on the
pulsed output waveform.
Percent (%) Peak Pulsed Output Waveforms Application:
Time Control Setting
Pulsing refers to the alternating
PPS raising and lowering of the weld
(50%) output at a specific rate. The raised
Balanced Bkg Amp portions of the weld output are con-
trolled in width, height, and frequen-
Peak Amp cy, forming pulses of weld output.
These pulses and the lower amper-
age level between them (called the
background amperage) alternately
heat and cool the molten weld
puddle. The combined effect gives
the operator better control of pene-
More Time tration, bead width, crowning, un-
At Peak dercutting, and heat input. Controls
Amperage (80%)
can be adjusted while welding.
Pulsing can also be used for filler
material addition technique
training.
More Time At NOTE: Function is enabled, when

Background LED is lit.
Amperage
(20%)

4-13. Sequence Controls (Optional)
1 Initial Time Control
See Section 4-14.
2 Initial Amperage Control
See Section 4-14.
5
3 Final Slope Control
3
1 See Section 4-15.
4 Final Amperage Control
See Section 4-15.
5 Spot Time Control
See Section 4-16.
2 4
(CE Nameplate)
5
3
1
2 4

4-14. Initial Time Control And Initial Amperage Control
1 Initial Time Control
Indicator light is on when Initial
Time control function is active.
(CE Nameplate) NOTE: Initial Sequence control
function is inactive when Spot Time
function is active.
1
1 Use control to select 0−15 seconds
of start time.
2 Initial Amperage Control
Indicator Light is on when Initial Se-
quence control function is active.
NOTE: Initial Amperage control
function is inactive when Spot Time
function is active.
Use control to select a starting am-
perage (3−400 amps) that is differ-
ent from the weld amperage. Note:
Initial Amperage can be used with
or without a remote control (Initial
2 Amperage and Initial Time control
2 settings will override a remote con-
trol device).
Application:
Initial Amperage can be used while
GTAW welding to assist in preheat-
ing cold material prior to depositing
filler material, or to ensure a soft
start. Initial Amperage can also be
used for SMAW to ensure a more
consistent arc strike.
NOTE: Function is enabled, when
LED is lit.

4-15. Final Slope Control And Final Amperage Control
1 Final Slope Control
Indicator light is on when Final Slope
control function is active.
(CE Nameplate)
Note: Final Slope control function is
inactive when Spot Time function is
active.
1 Use control to reduce amperage over

a set period of time (0−15 seconds) at
the end of the weld cycle when NOT
using a remote current control.
2 Final Amperage Control
Indicator light is on when Final Am-
perage control function is active.
Note: Final Amperage control func-
tion is inactive when Spot Time func-
tion is active (see Section 4-16).
Final amperage is the amperage to
which weld amperage has sloped
down to (0−100% of amperage set on
Amperage Adjust control).
Application:
2 Final Slope should be used while
GTAW welding materials that are
crack sensitive, and/or the operator
wants to eliminate the crater at the
end of the weld.
Note: This applies if the operator is
using an on/off only type control to
start and stop the welding process.
Note: Do not use this function with a
foot or finger amperage control.
NOTE: Function is enabled, when
LED is lit.
4-16. Spot Time Control

(CE Nameplate)
1 1
1 Spot Time Control Used with the (GTAW) TIG Spot pro- Application:
cess, generally with a direct current
TIG spot welding is used for joining thin-
Indicator light is on when Spot Time electrode negative (DCEN) set-up.
ner materials that are in close contact
function is active. When Spot Time func-
Use control to select 0−15 seconds of with the fusion method. A good example
tion is active, Initial Time, Initial Amper-
spot time. would be joining coil ends.
age, Final Slope, and Final Amperage
functions are inactive (see Section Use Amperage Adjust control (see Sec- NOTE: Function is enabled, when LED
4-13). tion 4-1) to set amperage. is lit.

4-17. Timer/Cycle Counter
1 2 3
3
1 2
4 5 6
1 2 3
(CE Nameplate) 4
4 5 6
1 2
1 Amperage Control software number and revision for the first seconds, and are read as 1, 234 hours
2 Output Control (Contactor) seven seconds. It will then show arc time and 56 minutes.
To read timer/cycle counter, hold Amper- and cycle count. 4 Cycle Display
age and Output (contactor) buttons while 3 Timer Display The cycles are displayed on the volt and
turning on power. When machine first The hours and minutes are displayed on amp meters for the next five seconds,
powers up, the displays will show the the volt and amp meters for the first five and are read as 123, 456 cycles.

4-18. Resetting Unit To Factory Default Settings (All Models)
1 2 3 4
(CE Nameplate)
1 2 3 4
1 Process Control 5 Power Switch Output, and Start controls and turn On pow-
2 Amperage Control er. Hold switch pads for approximately 7
To reset all welding power source functions
3 Output Control seconds (or until software version number
to original factory settings, turn power off.
_ _ _ _ _ _-_clears meters).
4 Start Control Push and hold the Process, Amperage,

SECTION 5 − THEORY OF OPERATION
1 Input Terminal Board TE1

Provides means for operation on
different input voltages.
2 Power Switch S1
Provides on/off control of welding
power source. 1 1φ 2 1φ 3
3 Main Transformer T1 Single-Phase Input Main
Terminal Power Transformer
Supplies power to weld output cir- Line Input Switch S1
Power Board TE1 T1
cuit, various control circuits, main
control board PC1, and fan motors
FM1 and FM2.
DC
4 Main Rectifier 4
Changes the ac output from T1 to Main
full-wave rectified dc and controls Rectifier
output current level.
5 Fan Motors FM1, FM2
Provides cooling of internal compo-
5
nents.
6 115 VAC Duplex Receptacle Fan Motors
RC2 FM1, FM2
Provides connection point for aux
iliary equipment.
7 Circuit Breaker CB1
Protects 115 volts AC winding.
8 Control Board PC1
Controls weld output by changing
the SCR gate pulses (conduction 6 7
times) after comparing current 115 VAC Duplex Circuit
feedback to selected amperage Receptacle Breaker
signal. Also provides user inter- RC2 CB1
face.
9 Thermistor TH1
Provides temperature feedback 8
about the rectifier back to control
board PC1. 9
10 Thermistor TH2 Thermistor
Provides temperature feedback to TH1
the control board PC1 about main
transformer T1. Control Board PC1
10
11 Remote 14 Receptacle RC1
Thermistor
Provides connect point for remote
TH2
amperage and contactor devices.
12 Gas Valve GS1
Provides control of shielding gas.
13 Integrated Cooler
Provides control of cooling for the 13♦
11 12
TIG torch.
Remote 14-Pin Gas Valve
GS1 Integrated Cooler
Receptacle RC1

14 Stabilizer Z1
Smooths DC welding current.
15 Hall Device HD1
Provides current feedback signal to
PC1.
16 Output Selector Switch S5
Provides either AC or DC and out-
16
put polarity.
14 15
18 17 High Frequency Coupling Coil
Stabilizer Hall Device T4
Z1 HD1 Output
Selector Provides high frequency to welding
Switch circuit.
S5 17 18 Electrode And Work Weld
Output Terminals
High Provide weld output.

Frequency 19 High Frequency Transformer
Coupling T3
Coil T4 18
Steps up voltage to charge high fre-
quency circuit.
20 Spark Gaps G1
Provides current path for high fre-
quency ringer circuit. Also, coarse
adjustment for high frequency in-
tensity.
21 Pulser Control Board PC2
(Field Option Only)
Provides user interface for pulser
functions.
19 22 Sloper Control Board PC3
20 (Optional In 250 DX Models)
High Spark Gaps G
Frequency Provides user interface for sloper
Transformer Capacitor C3 functions.
T3
21♦
Pulser Control Board PC2
22♦
Sloper Control Board PC3
AC Or DC Control Circuits
1φ Power
Weld Current Circuit

♦ Optional

SECTION 6 − TROUBLESHOOTING
Y Turn Off welding power source and disconnect and lockout/tagout input power before servicing.
Y Measure input capacitor voltage according to Section 6-1, and be sure volatge is near zero
before touching any parts.
6-1. Measuring Capacitor Voltage

Y Significant DC voltage can
remain on capacitors after
unit is Off. Always check ca-
pacitors as shown to be sure
they have discharged before
working on unit.
2 Y Disconnect and lockout/tag-
1
out input power before be-
ginning.
Remove cover and side panels.
1 Electrolytic Capacitor C2
2 Voltmeter
Check capacitor C2 as shown.
Measure the dc voltage across the
positive (+) and negative (−)
terminals until voltage drops to near
0 (zero) volts.
Proceed with job inside unit.
Reinstall cover and side panels
when finished.
Tools Needed:
3/8 in
803 787-A

6-2. Voltmeter/Ammeter Help Displays
0 1 2 3 4 5
V V V V V V
HLP HLP HLP HLP HLP HLP
A A A A A A
−−0 −−1 −−2 −−3 −−4 −−5
6 7 8 9 10 11
V V V V V V
HLP HLP HLP HLP HLP HLP
A A A A A A
−−9 −10 −11 −12 −17 −18

12 802 883 / 200 852-B
HLP
A
−19
. All directions are in reference to the front of the unit. All circuitry 6 Help 9 Display
referred to is located inside the unit. Indicates a short in the thermal protection circuitry located on the recti-
0 Help 0 Display fier assembly of the unit.
Indicates a short in the thermal protection circuitry located on the trans- 7 Help 10 Display
former/stablizer of the unit. Indicates Remote Output control is activated. Release Remote Output
1 Help1 Display control to clear help message.
An SCR overcurrent or undercurrent condition has occurred. Turn 8 Help 11 Display
power off and back on to correct condition.
Output Selector switch is not in correct position (see Section 4-2).
2 Help 2 Display
9 Help 12 Display
Indicates an open in the thermal protection circuitry located on the
transformer/stablizer of the unit. Indicates a non-allowable set-up of the front panel.
3 Help 3 Display 10 Help 17 Display
Indicates the transformer/stablizer of the unit has overheated. The unit Malfunction in the thermal protection circuitry of the cooler.
has shut down to allow the fan to cool it (see Section 3-5). Operation
will continue when the unit has cooled. 11 Help 18 Display
4 Help 4 Display Coolant system coolant has overheated. The unit has shut down to al-
Indicates an open in the thermal protection circuitry located on the rec- low the coolant to cool (see Section 3-5). Operation will continue when
tifier assembly of the unit. the coolant has cooled.
5 Help 5 Display 12 Help 19 Display
Rectifier assembly has overheated. The unit has shut down to allow Indicates low coolant flow in the coolant system. The unit output has
the fan to cool unit (see Section 3-5). Operation will continue when the shut down and will not start again until the coolant flow level is cor-
unit has cooled. rected, and the power is turned off and back on.

6-3. Direction Of Coolant Flow
1 Torch
2 Dinse Adapter
3 Check Valve
4 Radiator
5 Pressure Switch
6 Fan
7 Tank
8 Filter
9 Pump/Motor
10 Check Valve
COOLANT
FLOW
5 7
10
AIR 6
3 FLOW
1 2
804 106-A

6-4. Troubleshooting The Welding Power Source
Refer to Section 6-2 for any Help (HLP) message displayed on voltmeter/ammeter.
Trouble Remedy
No weld output; unit completely Place line disconnect switch in On position (see Section 3-21).
inoperative
inoperative.
Check and replace line fuse(s), if necessary (see Section 3-21).
Check for proper input power connections (see Section 3-21).

Check for proper jumper link position (see Section 3-20).
No weld output; unit on. If using remote control, place Output control in Remote 14 position, and make sure remote control is
connected to Remote 14 receptacle. If remote is not being used, place Output control in On position
(see Section 4-1).
Check, repair, or replace remote control.

Have Factory Authorized Service Agent check unit.
Unit provides only maximum or Make sure Amperage control is in proper position (see Section 4-1).
minimum weld output.
output
Have Factory Authorized Service Agent check unit.
Erratic or improper weld output. Use proper size and type of weld cable (see Section 3-7).
Clean and tighten all weld connections.
Check position of Output Selector control (see Section Figure 4-1).
If using remote control, check position of Amperage Adjustment control (see Section 4-1).
No control of weld output. If using remote control, place Output control in Remote 14 position, and make sure remote control is
connected to Remote 14 receptacle. If remote is not being used, place Output control in On position
(see Section 4-1).
Make sure Amperage control is in proper position (see Section 4-1).

No output from duplex receptacle RC2 Reset circuit breaker CB1 (see Section 7-3).
and no high frequency.
Lack of high frequency; difficulty in Reset circuit breaker CB1 (see Section 7-3).
starting GTAW arc.
arc
Select proper size tungsten (see Section 10).
Be sure torch cable is not close to any grounded metal.

Check cables and torch for cracked insulation or bad connections. Repair or replace.
Check spark gaps (see Section 7-4).
Wandering arc − poor control of Reduce gas flow rate.
direction of arc
arc.
Select proper size tungsten (see Section 10).
Properly prepare tungsten (see Section 10).

Tungsten electrode oxidizing and not Shield weld zone from drafts.
remaining bright after conclusion of
weld. Increase postflow time.
Check and tighten all gas fittings.
Properly prepare tungsten.

Check for water in torch, and repair torch if necessary.
Fan not operating. Unit equipped with Fan-On-Demandt. Fans run only when necessary. Unit equipped with circuitry to
protect against overheating.

6-5. Troubleshooting The Welding Coolant System
Refer to Section 6-2 for any Help (HLP) message displayed on voltmeter/ammeter.
Trouble Remedy
Coolant system does not work. Check line fuses or circuit breaker, and replace or reset if necessary.
Motor overheated. Unit starts running when motor has cooled.
Check and replace motor if necessary.
Decreased or no coolant flow. Add coolant (see Section 3-10).
Check for clogged hoses or coolant filter.
Disconnect return line and place it in a container of clean coolant. Prime unit according to Section
3-10. Flow rate should be a minimum of 1 liter (1.1 qt) per minute. If flow rate is still low, check pump
motor and/or circuit board PC1 and replace if necessary.
Decreased cooling ability; coolant too Clean heat exchanger fins and blower assembly (see Section 7-2).
hot.
Foaming Coolant Check for cracked or loose hoses or loose cover on filter, and tighten or replace.
Check for loose cap or bad seal on filter assembly, and tighten or replace as necessary.

Notes
Work like a Pro!

Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.

6-6. Troubleshooting Circuit Diagram
Y Disable high frequency by placing Mode switch in Off Y Discharge capacitor according to Section 6-1 and be
position before testing unit. sure voltage is near zero (0) before touching any parts.
Test Equipment Needed:

. No calibration available for voltmeter V or ammeter A.
R1
V1
V2
V3
V2
V4
V5
V6
V8/R3
See Section
6-8 for
PC1 data
V7/R2

. Circuit diagram for 350 LX models shown − Voltage and resistance
test point locations and values are the same for 250 DX Models
Voltage Readings
a) Tolerance − ±10% unless
specified
b) Reference − to circuit common
(lead 4) unless noted
R4 c) Wiring Diagram − see Section 8
d) Reference − single arrow:

reference to circuit common (lead
4); double arrow: reference to
points indicated
V9 V11 V1 83 volts ac
V10 V2 230 volts ac
See Section 6-7
for waveforms V3 115 volts ac
V4 58 volts ac for 350 LX models
53 volts ac for 250 DX models
V12 V5 19 volts ac
V6 19 volts ac
V7 115 volts ac with fans on
V8 115 volts ac with cooler on
V9 +15 volts dc
R7 V10 -15 volts dc
V11 +2.0 volts dc per 100 amperes of
V13/R8 weld output
R6
R5 V12 75 volts ac / 75 volts dc
R9 V13 115 volts ac w/ HF on
V14 +24 volts dc w/contactor on and in
GTAW mode
V14/R10
Resistance Values
a) Tolerance − ±10% unless specified
b) Turn Off unit and disconnect input
power before checking resistance
R1 All values for T1 are less than 1 ohm
R11 R2 1.8 k ohms

R3 1.8 k ohms
R4 Less than 1 ohm
R5 10 k ohms @ 25° C/77° F
R6 30 k ohms @ 25° C/77° F
See Section 6-10 R7 6.1 k ohms
See Section 3-8 for PC2 information
R8 5.1 ohms
for RC1 See Section 6-12
information for PC3 data R9 30 k ohms @ 25° C/77° F
R10 90 ohms
R11 3.4 ohms
222 683-C

6-7. Waveforms for Sections 6-6
The waveforms represent the output of the welding

power source. When operating properly, the power
source waveforms should match those shown.
5 ms 50 V 5 ms 20 V
gnd gnd
B. 30 Volts AC, 250 Amperes, Arc/Balance

A. AC Open-Circuit Voltage, Amperage Ad- Control At Balanced Position (Resistive
justment Control At Max, Arc/Balance Load)
Control At Balanced Position
5 ms 50 V 5 ms 50 V
gnd gnd
C. 30 Volts AC, 250 Amperes, Arc/Balance Con- D. 30 Volts AC, 250 Amperes, Arc/Balance
trol At Max Cleaning Position (Resistive Control At Max Penetration Position (Re-
Load) sistive Load)

5 ms 50 V 5 ms 5 V
gnd gnd
E. DC Open-Circuit Voltage, Amperage Adjust- F. 10 Volts DC, 150 Amperes, Arc/Balance Con-
ment Control At Max, Arc/Balance Control At trol At Balanced Position (Resistive Load)
Balanced Position, Waveform May Not Be
Stable
5 ms 1 V
gnd
G. SCR Gate Pulses With Respect To Cathode

At 10 Volts AC, 150 Amperes (Resistive
Load)

6-8. Control Board PC1 Testing Information (Use with Section 6-9)
Y Disable high frequency by
placing Mode switch in Off
position before testing unit.
Be sure plugs are secure before
testing. See Section 6-9 for specific
values during testing.
1 Control Board PC1
2 Receptacle RC1
3 Receptacle RC2
4 Receptacle RC3
5 Receptacle RC4
6 Receptacle RC5
7 Receptacle RC6
8 Receptacle RC7
9 Receptacle RC8
1 11 10 Receptacle RC9
11 PGM
10 5 8 7 6 2 4 3
803 787-A / 209 879-C

6-9. Control Board PC1 Test Point Values
PC1 Voltage Readings
Receptacle Pin Value
RC1 1 Gate pulse for module 1, SCR 2
2 Reference for pin 1
3 Gate pulse for module 2, SCR 1
5 +15 volts DC for hall device HD1
6 -15 volts DC for hall device HD1
11 Hall device HD1 current feedback signal, 2 volts per 100 amps
12 Ground reference signal for hall device HD1
RC2 1 Ground reference signal for pulser board PC2
2 Ground reference signal for potentiometers on pulser board PC2
3 Pulse Peak Time reference, 0 to +5 volts DC variable
4 Not used
5 Pulse Background Amperage reference, 0 to +5 volts DC variable
6 Pulser board present, 0 volts DC while connected, and +5 volts DC while not connected
7 Pulse Frequency reference, 0 to +5 volts DC variable
8 Pulser LED, +3.6 volts DC while on, 0 volts DC while off
9 Pulser On/Off, 0 volts DC, +5 volts DC while off
10 +5 volts DC
RC3 1 Final Amperage reference, 0 to +5 volts DC variable
2 Initial Time reference, 0 to +5 volts DC variable
3 Final Time reference, 0 to +5 volts DC variable
4 Ground reference for sequencer board PC3
5 Initial Amperage reference, 0 to +5 volts DC variable
6 Ground reference for potentiometers on sequencer board
7 Spot Time reference, 0 to +5 volts DC variable
8 +5 volts DC
9 Not used
10 Initial Time LED, +3.6 volts DC while on, 0 volts DC while off
11 Final Time LED, +3.6 volts DC while on, 0 volts DC while off
12 Spot Time LED, +3.6 volts DC while on, 0 volts DC while off
13 Sequencer board present, 0 volts DC while connected, +5 volts DC While not connected

14 Not used
RC4 1 Output selector switch S5 position sense signal, 0 volts DC while in AC or DCEN positions, +5 volts
DC while in DCEP position
2 Output selector switch S5 position sense signal, 0 volts DC while in AC or DCEP positions, +5 volts
DC while in DCEN position
3 Output selector switch S5 position sense ground reference
4 Voltage feedback sense lead − work
5 Voltage feedback sense lead − electrode
6 Background voltage negative; -98 volts DC
RC5 1 Thermistor input from rectifier, +5 to 0 volts DC variable
2 +5 volts DC for rectifier thermistor
RC6 1 +24 volts DC output
2 Contactor; +24 volts DC with external output control closed
3 Remote Amperage control reference, +10 volts DC
4 Ground reference for Remote Amperage control
5 Remote Amperage control input, 0 to +10 volts DC variable
6 Output current feedback, +1 volt DC per 100 amps of weld output
7 Ground reference for +24 volts DC
8 Output voltage feedback, +1 volt DC per 10 volts of weld output
RC7 1 Thermistor input from stabilizer, +5 to 0 volts DC variable
2 +5 volts DC for stabilizer thermistor
RC8 1 Cooler on demand control, 115 volts AC while on; 0 volts AC while off
2 Ground reference for water hookup
3 Pressure switch, 0 volts DC while closed, +5 volts Dc while open
4 Cooler present, 0 volts Dc while connected, +5 volts DC while not connected
5 Thermistor input from cooler, +5 to 0 volts DC variable
6 115 volts AC from cooler
7 Water hookup, 0 volts DC while door is closed, +5 volts DC while door is open
8 Water hookup, 0 volts DC while door is closed, +5 volts DC while door is open
9 Ground reference for water hookup
10 +5 volts DC for cooler thermistor
RC9 1 Background voltage positive, +98 volts DC
2 Ground reference for chassis
3 115 volts AC input from transformer T1
4 High Frequency control, 115 volts Ac while on, 0 volts AC while off
5 Ground reference for 19 volts AC winding
8 104 volts AC input from transformer T1, background voltage
9 104 volts AC input from transformer T1, background voltage

10 Ground reference for gas valve
11 +24 volts DC signal to gas valve
12 Ground reference for 19 volts AC winding
13 115 volts AC
14 Fan−On-Demand control, 115 volts AC while on, 0 volts AC while off
15 115 volts AC from HF
16 Ground reference, 115 volts AC input from transformer T1
17 Machine select, +5 volts DC (Syncrowave 250 DX), 0 volts DC (Syncrowave 350 LX)
18 Ground reference for machine select
PGM 1 0 volts DC while in reset, +5 volts DC otherwise
2 +5 volts DC
3 MOSI (nothing to measure)
4 Ground reference
5 SCK (nothing to measure)
6 MISO (nothing to measure)

6-10. Pulser Board PC2 Testing Information (Use with Section 6-11)
1
Be sure plugs are secure before
testing. See Section 6-11 for
specific values during testing.
1 Pulser Board PC2
2 Plug PLG2
803 787-A / 215 447-B
6-11. Pulser Board PC2 Test Point Values

PLG2 1 Ground reference for pulser board
2 Ground reference for potentiometers on pulser board
3 Pulse Peak Time reference, 0 to +5 volts DC variable
4 Not used
5 Pulse Background Amperage reference, 0 to +5 volts DC variable
6 Pulser board present, 0 volts DC while connected and +5 volts DC while not connected
7 Pulse Frequency reference, 0 to +5 volts DC variable
8 Pulser LED, +3.6 volts DC while on, 0 volts DC while off
9 Pulser On/Off, 0 volts DC while on; +5 volts DC while off
10 +5 volts DC

6-12. Sequencer Board PC3 Testing Information (Use with Section 6-13)
1 Timer Board PC3
2 Plug PLG3
1
2
803 787-A / 215 442-A
6-13. Sequencer Board PC3 Test Point Values

PLG3 1 Final Amperage reference, 0 to +5 volts DC variable
2 Initial Time reference, 0 to +5 volts DC variable
3 Final Time reference, 0 to +5 volts DC variable
4 Ground reference for sloper (sequencer) board
5 Start Amperage reference, 0 to +5 volts DC variable
6 Ground reference for potentiometers on sloper (sequencer) board
7 Spot Time, 0 to +5 volts DC
8 +5 volts DC
9 Not used
10 Initial LED, +3.6 volts DC while on, 0 volts DC while off
11 Final LED, +3.6 volts DC while on, 0 volts DC while off
12 Spot LED, +3.6 volts DC while on, 0 volts DC while off
13 Sloper (sequencer) board present, 0 volts DC while connected and +5 volts DC while not connected
14 Not used

SECTION 7 − MAINTENANCE
7-1. Routine Welding Power Source Maintenance
Y Turn Off welding power source and disconnect and lockout/tagout input power before
maintaining.
Y Measure voltage of input capacitors according to Section 6-1, and be sure volatge is near zero
before touching any parts.
3 Months
Replace Repair Or Clean And

Unreadable Replace Tighten
Labels Cracked Weld
Weld Terminals
Cables
Adjust Spark Gaps

Adjust Spark Replace
Gaps Cracked
Parts
14-Pin Cord Gas Hose Torch Cable
6 Months
Blow Out Or Vacuum Inside,

During Heavy Service, Clean Monthly
OR
Y Warranty is void if machine fails
due to contaminates inside.
7-2. Routine Cooler Maintenance
Y Disconnect power
before maintaining.
1 Month
Y Clean coolant strainer. Severe conditions Blow Out Heat

may require more frequent cleaning (continu- Exchanger Fins
ous use, high/low temperatures, dirty envi-
ronment, etc.). Failure to properly clean
coolant strainer voids pump warranty.
6 Months
Replace Replace
Cracked Change Coolant Damaged Or
Hoses (If Using Water) Unreadable
see Section 3-10 Labels
12 Months
Oil
Motor Change Coolant (If Using MILLER
Coolant) see Section 3-10

7-3. Circuit Breaker CB1
Y Turn off power before reset-

ting breaker.
1 Circuit Breaker CB1
If CB1 opens, high frequency and
output to the 115 volts ac duplex re-
1 ceptacle stop. Press button to reset
breaker.
Ref. 803 588-A
7-4. Adjusting Spark Gaps

Y Turn Off welding power
source and disconnect and
lockout/tagout input power
before adjusting spark gaps.
2
1 Remove right side panel..
1 Tungsten End Of Point
Replace point if tungsten end dis-
appears; do not clean or dress
4 tungsten.
2 Spark Gap
Normal spark gap is 0.008 in (0.203
mm).
If adjustment is needed, proceed as
follows:
3
3 Adjustment Screws
Loosen screws. Place gauge of
proper thickness in spark gap.
Tools Needed: 4 Pressure Point

Apply slight pressure at point until
0.008 in (0.203 mm) gauge is held firmly in gap. Tighten
screws. Adjust other gap.
803 592-B
Reinstall right side panel.
3/8 in 5/32 in

Notes

SECTION 8 − ELECTRICAL DIAGRAM
. The circuits in this manual can be used for troubleshooting, but there might be minor circuit differences from your machine. Use circuit
inside machine case or contact distributor for more information.
The following is a list of all diagrams for models covered by this manual.
Model Serial Or Style Number Circuit Diagram Wiring Diagram
Syncrowave 250 DX LE282983 thru LE420473 215 704-C 215 705-B♦♦
LE420474 and following 222 681-D 222 682-D
Syncrowave 350 LX LE223624 thru LE420473 219 003-C 219 004-B♦♦
LE420474 and following 222 683-D 222 684-D
Circuit Board PC1 LE223624 and following 209 880-B
Circuit Board PC2 LE223624 and following 215 448-A
Circuit Board PC3 LE223624 and following 215 443-A
♦♦ Not included in this manual

215 704-C
Figure 8-1. Circuit Diagram For Syncrowave 250 DX Models Eff w/LE223624 Thru LE420473

222 681-D
Figure 8-2. Circuit Diagram For Syncrowave 250 DX Models Eff w/LE420474 And Following

219 003-C
Figure 8-3. Circuit Diagram For Syncrowave 350 LX Models Eff w/LE223624 Thru LE420473

222 683-D
Figure 8-4. Circuit Diagram For Syncrowave 350 LX Models Eff w/LE420474 And Following

Figure 8-5. Wiring Diagram For Syncrowave 250 DX Models Eff w/LE420474 And Following

222 682-D

Figure 8-6. Wiring Diagram For Syncrowave 350 LX Models Eff w/LE420474 And Following

222 684-D

Figure 8-7. Circuit Diagram For Main Control Board PC1 Effective
With Serial No. LE223624 And Following (Part 1 Of 3)

209 880-B


209 880-B


209 880-B

L E D 1
P L G 2
8
1 0 P I N
2 1 5 4 4 5
G R E E N
1 9 2 9 2 8
S 1
P L G 2
9
1 0 P I N
P L G 2 2 1 5 4 4 5
P B N O
1 0
1 0 P I N 0 8 9 0 4 0
2 1 5 4 4 5
P L G 2
1
1 0 P I N
2 1 5 4 4 5
P L G 2
5
1 0 P I N
2 1 5 4 4 5
C W 2
1 3
P L G 2
6
1 0 P I N
R 1 2 1 5 4 4 5
1 0 K
1 8 2 7 7 1
P L G 2
7
1 0 P IN
2 1 5 4 4 5 C W 2
1 3
P L G 2
4 N C
1 0 P I N
R 2 2 1 5 4 4 5
1 0 K
P L G 2 1 8 2 7 7 1
3
1 0 P IN
2 1 5 4 4 5
C W 2
1 3
R 3
1 0 K
P L G 2 1 8 2 7 7 1
2
1 0 P IN
2 1 5 4 4 5
215 448-A
Figure 8-10. Circuit Diagram For Pulser Board PC2 (Optional In 250 DX Models,
Standard In 350 LX Models) Effective With Serial No. LE223624

8
P L G 3
2 1 5 4 5 0
1 3
P L G 3
2 1 5 4 5 0
5
P L G 3
2 1 5 4 5 0
4
C W 2 P L G 3
1 3
R 1 2 1 5 4 5 0
1 0 K
1 8 2 7 7 1
2
P L G 3
2 1 5 4 5 0
C W
2
L E D 1
1 3
R 2
1 1
P L G 3
1 0 K 2 1 5 4 5 0
1 8 2 7 7 1 G R E E N
3
P L G 3 1 9 2 9 2 8
2 1 5 4 5 0
C W 2
1 3 L E D 2
R 3 1 0
P L G 3
1 0 K 2 1 5 4 5 0
1 8 2 7 7 1
G R E E N
1
P L G 3 1 9 2 9 2 8
2 1 5 4 5 0
C W 2 L E D 3
1 3 9
R 4
1 2
P L G 3 P L G 3
N C
1 0 K 2 1 5 4 5 0 2 1 5 4 5 0
1 8 2 7 7 1 G R E E N
7
P L G 3 1 9 2 9 2 8
1 4
2 1 5 4 5 0 P L G 3
N C
2 1 5 4 5 0
C W 2
1 3
R 5
1 0 K
1 8 2 7 7 1
6
P L G 3
2 1 5 4 5 0
215 443-A
Figure 8-11. Circuit Diagram For Optional Sequencer Board PC3 Effective With Serial No. LE223624

SECTION 9 − HIGH FREQUENCY (HF)
9-1. Welding Processes Requiring High Frequency
1 High-Frequency Voltage
TIG − helps arc jump air gap
1 between torch and workpiece and/
or stabilize the arc.
Work
TIG
9-2. Correct Installation
6
Weld Zone
50 ft 50 ft
(15 m) (15 m)
1
5
2
7
3
7
Ground All
Metal Objects
And All Wiring
In Welding Zone 8
Using #12 AWG Ground
Wire Workpiece
If Required
Nonmetal By Codes
Building
7
7
10
Metal Building
9
1 HF Source (Welder With Built-In HF Or Electrically join (bond) all conduit sections 8 Metal Building Panel Bonding Methods
Separate HF Unit) using copper straps or braided wire. Ground
conduit every 50 ft (15 m). Bolt or weld building panels together, install
Ground metal machine case, work output copper straps or braided wire across seams,
terminal, line disconnect device, input 5 Water Pipes And Fixtures and ground frame.
supply, and worktable.
Ground water pipes every 50 ft (15 m). 9 Windows And Doorways
2 Welding Zone And Centerpoint
6 External Power Or Telephone Lines Cover all windows and doorways with
A circle 50 ft (15 m) from centerpoint
grounded copper screen of not more than
between HF source and welding torch in all Locate HF source at least 50 ft (15 m) away 1/4 in (6.4 mm) mesh.
directions. from power and phone lines.
3 Weld Output Cables 10 Overhead Door Track
7 Grounding Rod
Keep cables short and close together. Ground the track.
Consult the National Electrical Code for
4 Conduit Joint Bonding And Grounding specifications.

SECTION 10 − SELECTING AND PREPARING TUNGSTEN
ELECTRODE FOR DC OR AC WELDING
ac/dc_gtaw 2/2000
Y Whenever possible and practical, use DC weld output instead of AC weld output.
10-1. Selecting Tungsten Electrode (Wear Clean gloves To Prevent Contamination Of Tungsten )
Amperage Range - Gas Type♦ - Polarity

Electrode Diameter (DCEN) − Argon AC − Argon
Direct Current Electrode Negative 65% Electrode Negative
2% Ceria (Orange Band), 1.5% Lanthanum (Gray Band), Or 2% Thorium (Red Band) Alloy Tungstens
.040” (1 mm) 25-85 20-80
1/16” (1.6 mm) 50-160 50-150
3/32” (2.4 mm) 135-235 130-250
1/8” (3.2 mm) 250-400 225-360
Pure Tungsten (Green Band)
.040” (1 mm) Pure Tungsten Not Recommended 10-60
1/16” (1.6 mm) For DCEN − Argon 50-100
3/32” (2.4 mm) 100-160
1/8” (3.2 mm) 150-210
♦Typical argon shielding gas flow rates are 11 to 35 cfh (cubic feet per hour).
Figures listed are a guide and are a composite of recommendations from American Welding Society (AWS) and electrode manufacturers.
10-2. Preparing Tungsten Electrode For Welding

Y Grinding the tungsten electrode produces dust and flying sparks which can cause injury and start fires. Use
local exhaust (forced ventilation) at the grinder or wear an approved respirator. Read MSDS for safety infor-
mation. Consider using tungsten containing ceria, lanthana, or yttria instead of thoria. Grinding dust from
thoriated electrodes contains low-level radioactive material. Properly dispose of grinder dust in an environ-
mentally safe way. Wear proper face, hand, and body protection. Keep flammables away.
A. Preparing Tungsten For DC Electrode Negative (DCEN) Welding Or AC Welding With Inverter Machines
2-1/2 Times 1 Grinding Wheel
Radial Grinding Electrode Diameter
Causes Wandering Arc Grind end of tungsten on fine grit, hard
2 3 abrasive wheel before welding. Do not use
wheel for other jobs or tungsten can become
1 contaminated causing lower weld quality.
2 Tungsten Electrode
3 Flat
Diameter of this flat determines amperage
4 capacity.
Wrong Tungsten Preparation
Ideal Tungsten Preparation − Stable Arc 4 Straight Ground
Grind lengthwise, not radial.
B. Preparing Tungsten For Conventional AC Welding 1 Tungsten Electrode

2 Balled End
1 − 1-1/2 Times Ball end of tungsten by applying AC amper-
Electrode Diameter age recommended for a given electrode
diameter (see Section 10-1). Let ball on end
1 of the tungsten take its own shape.
2

Notes

TM-363E 2007−01
Processes
TIG (GTAW) Welding
Stick (SMAW) Welding
Description
Arc Welding Power Source

R
And
R
w/Integrated Cooler
Eff w/LE223624 And Following For 350 LX Models

Eff w/LE282983 And Following For 250 DX Models
For OM-363 (213 117) Revision A And Following
Visit our website at

www.MillerWelds.com
CE And Non-CE Models
SECTION 11 − PARTS LIST
. Hardware is common and

not available unless listed.
350 LX Model Illustrated
106
4
107
55
66
108
68
63
70 105
16
23
103
20 91
25
89
12
104
26
14
15
49
104
29
40
21
19 22
48
18
28
Figure 12-1. Main Assembly

350 LX Model Illustrated
41
87
104
43
109
108
65
44
59
54
39
11
34
42 37 33
38
96
35
95
97
83 104
3
5
7
46
6 13
10
52
90
9
78
53
80
75
1 73
58
2
82
76
72 97 78
104
803 804-F

Item Dia. Part Quantity
No. Mkgs. No. Description
Model
Figure 12-1. Main Assembly 250 350
DX LX
. . . 1 . . . . . . . . . . . 211038 . . BASE,ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . 2 . . . . . . . . . . 215656 . . END CAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . 4
. . . 3 . . T1/Z1 . 212555 . . XFMR/STABILIZER ASSY, 200/230/460 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . T1/Z1 . . 211041 . . XFMR/STABILIZER ASSY, 230/460/575 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . T1/Z1 . 219652 . . XFMR/STABILIZER ASSY, 220/400/440/520 . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . T1/Z1 . 215767 . . XFMR/STABILIZER ASSY, 200/230/460 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . T1/Z1 . 215389 . . XFMR/STABILIZER ASSY, 230/460/575 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . T1/Z1 . 217801 . . XFMR/STABILIZER ASSY, 220/400/440/520 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . TH1 . . 201443 . . THERMISTOR, NTC 10K OHM @ 25 DEG C 27.5 IN LEAD . . . . . . . . . . . 1 . . . 1
. . . 4 . . . . . . . . . . 212550 . . PANEL, LEFT WINDTUNNEL (for non-TIGRUNNER models) . . . . . . . . . . 1 . . . 1
. . . 5 . . . TE1 . . 214127 . . TERM ASSY, PRI 1PH 3V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . 6 . . . . . . . . . . 213248 . . LUG, UNIV W/SCREW 2/0−14 WIRE .266STD . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . 7 . . C5, 6 . . 111634 . . CAPACITOR ASSY, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . 8 . . . SR1 . . 212558 . . RECTIFIER, SCR MAIN (INCLUDES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . . . . . . . . . . . . . . 218581 . . . . THYRISTOR, SCR 300A 300V HOCKEY PUCK . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . . . . . . . TH2 . . 217069 . . THERMISTOR, NTC 30K OHM @ 25 DEG C 40 IN LEAD
. . . . . . . . . . . . . . . . . . . . . . . . . . . (PRIOR TO LG220001l) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . . . . . . . TH2 . . 218580 . . THERMISTOR, NTC 30K OHM @ 25 DEG C 40 IN LEAD
. . . . . . . . . . . . . . . . . . . . . . . . . . . (EFF W/LG220001l) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . 9 . . . . . . . . . . 218670 . . BRACKET, RECTIFIER RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . 10 . . . . . . . . . . 212559 . . BRACKET, RECTIFIER LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . 11 . . . . R3 . . 218173 . . RESISTOR, WW FXD 400 W 35 OHM W/MTG BKT . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . 12 . . . . S5 . . 215390 . . SWITCH ASSY, POLARITY W/LEADS & HARDWARE (DX) . . . . . . . . . . . 1 . . . 1
. . . 13 . . . . . . . . . +213105 . . PANEL, RIGHT WINDTUNNEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . 14 . . . . S1 . . 215937 . . SWITCH, TGL ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . 15 . . . . . . . . . . . 213114 . . FRONT PANEL ASSY, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . . . . . . . . . . . . . . . 117860 . . BLANK, SNAP−IN NYL .187 MTG HOLE BLACK . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . . . . . . . . . . . . . . 107983 . . BLANK, SNAP−IN NYL .500 MTG HOLE BLACK . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . . . . . . . . . . . . . . 143397 . . BLANK, SNAP−IN NYL .312 MTG HOLE BLACK . . . . . . . . . . . . . . . . . . . . 8 . . . 8
. . . 16 . . . PC1 . . 209877 . . CIRCUIT CARD ASSY, CONTROL & INTERFACE W/PROGRAM . . . . . . 1 . . . 1
. . . . . . PLG13,15 131054 . . HOUSING RCPT+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 2
. . . . . . . . PLG14 . 115092 . . HOUSING PLG+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . . . . . . PLG4 . . 115093 . . HOUSING PLG+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . . . . . . PLG17 203800 . . HOUSING PLG+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . . . . . . PLG16 . 115091 . . HOUSING PLG+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . . . . . . PLG10 . . . . 130 . . HOUSING PLG+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . 18 . . . . . . . . . . 183332 . . KNOB, POINTER .570 DIA X .125 ID W/SPRING CLIP . . . . . . . . . . . . . . . 2 . . . 5
. . . 19 . . . . . . . . . . 174991 . . KNOB, POINTER 1.250 DIA X .250 ID W/SPRING CLIP−.21 . . . . . . . . . . 1 . . . 1
. . . 20 . . . . . . . . . . 195778 . . ACTUATOR PUSH BUTTON ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . 21 . . . . . . Figure 12-2 . . PANEL,LOWER DINSE CONN ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . 22 . . . C14 . . 209587 . . CAPACITOR ASSY, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . 23 . . . PC2♦♦195344 . . CIRCUIT CARD ASSY, PULSER (INCLUDES) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . PC2 . . 195344 . . CIRCUIT CARD ASSY, PULSER (INCLUDES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 215446 . . . . CIRCUIT CARD, PULSER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . . . . . . . . . . . . . . 183332 . . . . KNOB, POINTER .570 DIA X .125 ID W/SPRING CLIP . . . . . . . . . . . . . 3 . . . 3
. . . . . . . . . . . . . . . . 195778 . . . . ACUATOR, PUSH BUTTON ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . . . . . . . . . . . . . . 190512 . . . . STAND-OFF, NO. 6-32 X .640LG X .250 HEX AL FEM . . . . . . . . . . . . . . 1 . . . 1
. . . 25 . . . . . . . . . . . . . . . . . . . . . NAMEPLATE, UPPER (ORDER BY MODEL AND SERIAL NUMBER) . . 1
. . . 26 . . . . . . . . . . . . . . . . . . . . . NAMEPLATE, LOWER (ORDER BY MODEL AND SERIAL NUMBER) . . 1
. . . 28 . . . . . . . . . . 175952 . . PLASTIC, HANDLE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . . . . . . . . . . . . . . 169136 . . PIN, HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . 29 . . . . . . . . . . 215685 . . PANEL, GAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . 29 . . . . . . . . . ♦215691 . . PANEL, GASWATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1

Model
250 350
Figure 12-1. Main Assembly (continued)
DX LX
. . . 33 . . . . . . . . . . 212548 . . PANEL, REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1

. . . 34 . . . . . . . . . . 184058 . . FAN, PLENUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . 35 . . . . . . . . . . 187807 . . BRACKET, MTG MOTOR FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 2
. . . 37 . . . . . . . . . . 150783 . . BLADE, FAN 9.000 5WG 39DEG .312 BORE CW PLSTC . . . . . . . . . . . . . 2 . . . 2
. . . 38 . . FM1, 2 220393 . . MOTOR, FAN 230V 50/60HZ 1550 RPM .312 DIA SHAFT . . . . . . . . . . . . 2 . . . 2
. . . 39 . . . . 1T . . 199312 . . BLOCK, TERMINAL FAST−ON,20 AMP,250 VOLT . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . 40 . . . GS1 . . 215776 . . VALVE, 24VDC 2WAY CUSTOM PORT 1/8 ORF W/FRICT . . . . . . . . . . . . 1 . . . 1
. . . 41 . . . . . . . . . . 208408 . . FTG, BRS BARBED FEM 1/4 TBG X .625−18 FLANGE MTG . . . . . . . . . 1 . . . 1
. . . . . . . . . . . . . . . . . 217111 . . PLUG, PROTECTIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 2
. . . 42 . . . . . . . . . . 204293 . . SUPPORT, LIFT EYE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 42 . . . . . . . . . . 212552 . . SUPPORT, LIFT EYE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 43 . . . . . . . . . . 218280 . . HINGE, CONT POLYOLEFIN COPOLYMER 2.000 L W/.125H . . . . . . . . 1 . . . 1
. . . 44 . . . . . . . . . +215657 . . DOOR, ACCESS (PRIOR TO LG220001L) . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . 44 . . . . . . . . . +229068 . . DOOR, ACCESS (EFF W/LG220001L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . 46 . . . . . . . . . . 217553 . . LABEL, GROUND/PROTECTIVE EARTH . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . 48 . . . . T4 . . 215771 . . COIL, HF COUPLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . 49 . . . . . . . . . . 207560 . . INSULATOR, STANDOFF WITH STUD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 2
. . . 52 . . . . . . . . . ♣211043 . . PANEL, SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 2
. . . 53 . . . . . . . . . . 199479 . . LABEL, MILLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 2
. . . 54 . . . . . . . . . . 026627 . . GASKET, LIFTING EYE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . 55 . . . . . . . . . +211040 . . COVER, TOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . 58 . . . . . . . . . . 208294 . . CONNECTOR, FASTON MALE 4−PRONG . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 2
. . . 59 . . . . . . . . . . 010467 . . CONN, CLAMP CABLE 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . 63 . . . . . . . . . . 203990 . . LABEL, WARNING GENERAL PRECAUTIONARY STATIC . . . . . . . . . . . 1 . . . 1
. . . 65 . . . . . . . . . . 218598 . . LABEL, WARNING ELECTRIC SHOCK AND INCORRECT INPUT P . . . 1 . . . 1
. . . 66 . . . . . . . . . . . . . . . . . . . . . FOR MODELS WITHOUT TIGRUNNER OR COOLER OPTIONS
. . . 66 . . . . . . . . . . 201019 . . LABEL, WARNING ELECTRIC SHOCK EXCESS WEIGHT
. . . . . . . . . . . . . . . . . . . . . . . . . . . (200/230/460 VOLT MODELS ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 2
. . . 66 . . . . . . . . . . 217137 . . LABEL, WARNING ELECTRIC SHOCK CAN KILL (ENG/FR)
. . . . . . . . . . . . . . . . . . . . . . . . . . . (230/460/575 VOLT MODELS ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 2
. . . 66 . . . . . . . . . . 206343 . . LABEL, WARNING ELECTRIC SHOCK EXCESS WEIGHT WORDLES
. . . . . . . . . . . . . . . . . . . . . . . . . . . (220/400/440/520 VOLT MODELS ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 2
. . . 66 . . . . . . . . . . . . . . . . . . . . . FOR MODELS WITH TIGRUNNER OR COOLER OPTIONS, THERE ARE TWO
. . . . . . . . . . . . . . . . . . . . . . . . . . . SEPERATE LABELS FOR EACH VOLTAGE. CHECK BELOW TO ORDER .
. . . . . . . . . . . . . . . . . . . . . . . . . . . CORRECT LABEL OR LABELS FOR CORRESPONDING VOLTAGES.
. . . 66 . . . . . . . . . . 201019 . . LABEL, WARNING ELECTRIC SHOCK EXCESS WEIGHT
. . . . . . . . . . . . . . . . . . . . . . . . . . . (200/230/460) VOLT MODELS ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . 66 . . . . . . . . . . 219178 . . LABEL, CAUTION INCORRECT COOLANT (200/230/460
. . . . . . . . . . . . . . . . . . . . . . . . . . . VOLT MODELS ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . 66 . . . . . . . . . . 217137 . . LABEL, WARNING ELECTRIC SHOCK CAN KILL (ENG/FR)
. . . . . . . . . . . . . . . . . . . . . . . . . . . (230/460/575 VOLT MODELS ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . 66 . . . . . . . . . . 219177 . . LABEL, CAUTION INCORRECT COOLANT (ENG/FR)
. . . . . . . . . . . . . . . . . . . . . . . . . . . 230/460/575 VOLT MODELS ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . 66 . . . . . . . . . . 206343 . . LABEL, WARNING ELECTRIC SHOCK EXCESS WEIGHT WORDLES
. . . . . . . . . . . . . . . . . . . . . . . . . . . (220/400/440/520 VOLT MODELS ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . 66 . . . . . . . . . . 219176 . . LABEL, CAUTION INCORRECT COOLANT (CE)
. . . . . . . . . . . . . . . . . . . . . . . . . . . 220/400/440/520 VOLT MODELS ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . 68 . . . . . . . . . ♣204389 . . HOLDER, TORCH/CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 2
. . . 70 . . . . . . . . . . 212557 . . DRAWER, ASSY (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . . . . . . . . . . . . . . . 213111 . . . . DRAWER, PLASTIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . . . . . . . . . . . . . . . 213112 . . . . DRAWER, FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . . . . . . . . . . . . . . 217255 . . . . SLIDE, DRAWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 2
. . . 72 . . . . T3 . . 219927 . . XFMR, HIGH VOLTAGE 115V PRI 3600V SEC 34 MA W/TERM . . . . . . . 1 . . . 1
. . . 73 . . . . G1 . . 199854 . . KIT, SPARK GAP ASSY QUAD, (Prior to LF251061) . . . . . . . . . . . . . . . . . 1 . . . 1
. . . 73 . . . . G1 . . 221738 . . SPARK GAP ASSY, (includes) (Eff w/LF251061) . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . . . . . . . . . . . . . . 221735 . . . . BASE, SPARK GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . . . . . . . . . . . . . . 221734 . . . . HOLDER, POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 . . . 3
. . . . . . . . . . . . . . . . 221736 . . . . POINTS, SPARK GAP (DUAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . . . . . . . . . . . . . . 221737 . . . . POINTS, SPARK GAP (SINGLE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 2
Model
250 350
Figure 12-1. Main Assembly (continued)
DX LX
. . . . . . . . . . . . . . . . 227581 . . . . SCREW, 250−20X .37 SOC HD−HEX NYLON 6/6 . . . . . . . . . . . . . . . . . . 3 . . . 3
. . . 75 . . . . R8 . . 188067 . . RESISTOR, WW FXD 100 W 200 OHM W/CLIPS . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . 76 . . . . C3 . . 215779 . . CAPACITOR, MICA .002 UF 10000 V PANEL MTG W/LEA . . . . . . . . . . . . 1 . . . 1
. . . 78 . C11, 19 195552 . . CAPACITOR, POLYP MET FILM 20. UF 250 VAC 10% . . . . . . . . . . . . . . . 2 . . . 2
. . . 80 . . . . R1 . . 220808 . . RESISTOR, WW FXD 100 W 50 OHM W/CLIPS . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . 82 . . . C13 . . 206878 . . CAPACITOR ASSY, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . 83 . . . . . . . . . . 216081 . . BRACKET, RESISTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . 87 . . . . . . . . . . 218170 . . HOSE, NPRN BRD NO 1 X .250 ID X 24.000 . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . 89 . . . . . . . . . . . 211039 . . BEZEL, FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . 90 . . . . . . . . . . 224459 . . LABEL, WARNING ELECTRICAL SHOCK ETC . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . 91 . . . HD1 . . 191941 . . TRANSDUCER, CURRENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . 95 . . . . C2 . . 031668 . . CAPACITOR, ELCTLT 4000 UF 100 VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . 96 . . . . . . . . . . 108105 . . CLAMP, CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . 97 . . R2, 4 . . 118459 . . RESISTOR, WW FXD 10 W 1K OHM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 2
. . 103 . . PC3♦♦195345 . . CIRCUIT CARD ASSY, SEQUENCER (INCLUDES) . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . . . . . . . . . . . . . . 215441 . . . . CIRCUIT CARD ASSY, SEQUENCER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . . . . . . . . . . . . . . 183332 . . . . KNOB, POINTER .570 DIA X .125 ID W/SPRING CLIP . . . . . . . . . . . . . 5 . . . 5
. . 104 . . . . ♦Figure 12-4 . . TIGRUNNER RUNNING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . 105 . . . . ♦Figure 12-3 . . ASSY, COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . 106 . . . . . . . . ♦212556 . . PANEL, SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . 107 . . . . . . . . ♦211037 . . HOLDER, COOLANT FILLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . 108 . . CR1 . ♦059266 . . RELAY, ENCL 120VAC DPDT 10A/120VAC 8PIN (PRIOR TO LE420474) 1 . . . 1
. . 108 CR1, CR2♦059266 . . RELAY, ENCL 120VAC DPDT 10A/120VAC 8PIN (EFF W/LE420474) . . . 2 . . . 2
. . 109 . . . . . . . . . 222451 . . BRACKET, RELAY (EFF W/LE420474) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . . . . . . . . . . . . . ♦194744 . . RFCS−14HD (FOOT CONTROL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
♦Part of TIGRUNNER option.
♦♦Field option only.
♣For TIGRUNNER models, the quantity is 1.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

12
not available unless listed. 11
10
3
12
10
11 5
14
9
1
13
8
14
9 2
13
8 803 775-A
Figure 12-2. Panel, Lower Dinse Connector Assembly
Item Dia. Part

No. Mkgs. No. Description Quantity
220 509 Figure 12-2. Panel, Lower Dinse Connector Assy (Figure 12-1 Item 21)
... 1 .......... 213109 .. PANEL, LOWER DINSE CONN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

... 2 .......... 218784 .. LABEL, COMPONENT IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 3 .......... 224529 .. CONN, CIRC MS/CPC 14SKT SIZE 20 RCPT W/FILTERING . . . . . . . . . . . . . 1
... 5 .......... 218174 .. RECEPTACLE, W/LEADS & CIRCUIT BREAKER . . . . . . . . . . . . . . . . . . . . . . . 1
... 8 .......... 202553 .. RECEPTACLE, TWIST LOCK BRASS POWER (FEMALE) . . . . . . . . . . . . . . . 2
... 9 .......... 185712 .. INSULATOR, BULKHEAD FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 10 .......... 185713 .. INSULATOR, BULKHEAD REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 11 .......... 185714 .. WASHER, TOOTH 22MMID X 31.5MMOD 1.310−1MMT INTERN . . . . . . . . . 2
... 12 .......... 185717 .. NUT, M20−1.5 1.00HEX .19H BRS LOCKING . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 13 .......... 186228 .. O−RING, 0.739 ID X 0.070 H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 14 .......... 185718 .. O−RING, 0.989 ID X 0.070 H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2 15
3
5
20
17
18
7
6 21
13 4
19 1
3
16
10
9
5 23
22 16 803 779-F
Figure 12-3. Optional Cooler Assembly
Item Dia. Part

229 675 Figure 12-3. Cooler Assy (Optional) Figure 12-1 Item 105)
. . . 1 . . . . . . . . . . . 211036 . . TANK, COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 2 . . . . . . . . . . 215667 . . FILTER, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . 215669 . . HOSE, RUBBER BRAIDED 3/8 ID X 1/2 OD X 2 IN (PRIOR TO LE352937) 1
. . . 3 . . . . . . . . . . 215669 . . HOSE, RUBBER BRAIDED 3/8 ID X 1/2 OD X 2 IN (EFF W/LE352937) . . . 2
. . . 4 . . . . . . . . . . 215688 . . FITTING, MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . 215675 . . HOSE, RUBBER BRAIDED 3/8 ID X 5/8 OD X 19 IN . . . . . . . . . . . . . . . . . . . . 2
. . . 6 . . . . . . . . . . 215679 . . SWITCH, PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . 221819 . . FTG, HOSE BRS BARBED 45 DEGREE ELBOW M3/8 X 3/8 NPT . . . . . . . 1
. . . 8 . . . . . . . . . . 217173 . . RADIATOR, HEAT EXCHANGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . 211042 . . FAN, AC 230V BRUSHLESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . . 211045 . . PUMP, COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . 215682 . . HOSE, RUBBER BRAIDED 3/8 ID X 1/2 OD X 8 1/2 IN
........................... (PRIOR TO LE352936) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . 215683 . . HOSE, RUBBER BRAIDED 3/8 ID X 1/2 OD X 16 IN (PRIOR TO LE352937) 1
. . . 13 . . . . . . . . . . 215683 . . HOSE, RUBBER BRAIDED 3/8 ID X 1/2 OD X 13.5 IN (EFF W/LE352937) . 1
. . . 15 . . . . . . . . . . 166608 . . CAP, TANK SCREW−ON W/VENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . 220921 . . VALVE, CHECK BIDIRECTIONAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 17 . . . . . . . . . . 215690 . . HOSE, RUBBER BRAIDED 3/8 ID X 1/2 OD X 4 1/2 IN
........................... (PRIOR TO LE352937) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . 215690 . . HOSE, RUBBER BRAIDED 3/8 ID X 1/2 OD X 3 1/2 IN (EFF W/LE352937) 1
. . . 18 . . . . . . . . . . . . . 5523 . . FTG, HOSE BRS BARBED ELBOW M 3/8 TBG X 3/8 NPT . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . 126978 . . FTG, BRS BARBED M 3/8 TBG X 3/8 NPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . 215673 . . FITTING, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . TH3 . . 217069 . . THERMISTOR,NTC 30K OHM @ 25 DEG C 40IN LEAD . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . 227110 . . PLENUM,COOLER FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. Hardware is common and 4
3
2
13
12
9
6
8
11 7
10 Ref. 803 725-B
Figure 12-4. Optional Running Gear
Item Dia. Part

Figure 12-4. Running Gear (Optional) (Figure 12-1 Item 104)
. . . 1 . . . . . . . . . . 218134 . . HANDLE, LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . +215928 . . BOTTLE SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . 168663 . . HOOK SPRING SNAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 4 . . . . . . . . . . 602387 . . CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 5 . . . . . . . . . . . 191158 . . BOTTLE TRAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . 121614 . . RETAINING RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 7 . . . . . . . . . . 602250 . . WASHER, 812 ID X 1.469 OD X .134 T STL PLD ANSI. 750 . . . . . . . . . . . . . 4
. . . 8 . . . . . . . . . . 163463 . . WHEEL (PRIOR TO LG260242L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 8 . . . . . . . . . . 209869 . . WHEEL (EFF W/LG260242L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 9 . . . . . . . . . . . 191167 . . AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . 168247 . . CASTER, SWIVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 11 . . . . . . . . . . . 191163 . . CASTER MOUNTING BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . 218135 . . HANDLE, RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . 217140 . . LABEL,WARNING CYL MAY EXPLODE IF DAMAGED (ENG/FR)
........................... (230/460/575 VOLT MODELS ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . 200285 . . LABEL,WARNING CYLINDER MAY EXPLODE IF DAMAGED
........................... (200/230/460 VOLT MODELS ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.

Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
European Headquarters −
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
PRINTED IN USA © 2006 Miller Electric Mfg. Co.

Syncrowave 250DX 350LX Technical Manual

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TM-363E 2007−01

Eff. w/Serial No. LE223624 For 350 LX Models

Stick (SMAW) Welding

Arc Welding Power Source

Effective with Serial No. LE223624 Thru LH010000L

Syncrowave 250 DX / 350 LX

CE And Non-CE Models

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SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Manufacturer: European Contact:

European Contact Signature:

Declares that the product: Syncrowave R 250 DX

Manufacturer: European Contact:

European Contact Signature:

Declares that the product: Syncrowave R 350 LX

1-1. Symbol Usage

Means Warning! Watch Out! There are possible hazards

This group of symbols means Warning! Watch Out! possible

1-2. Servicing Hazards

Y The symbols shown below are used throughout this manual to

D Insulate yourself from ground by standing or working on dry insulat-

SIGNIFICANT DC VOLTAGE exists after removal of SHOCK HAZARD from testing.

Syncrowave 250 DX /350 LX TM-363 Page 1

1-3. California Proposition 65 Warnings

1-4. EMF Information

TM-363 Page 2 Syncrowave 250 DX /350 LX

2-1. Warning Label Definitions

1 1.1 1.2 1.3 4 4.1

2 2.1 2.2 2.3 5

3 3.1 3.2 3.3 6

2-2. Torch/Cable Holder Label

Syncrowave 250 DX / 350 LX TM-363 Page 3

NOTE Some symbols are found only on CE products.

Output Circuit Breaker Remote Temperature

Protective Earth High Frequency -

On Off Percent Direct Current

Electrode Work Thickness Gauge Spark Gap

S Seconds Final Amperage Initial Time Initial Amperage

Pulse Percent On 4 Step Trigger Op-

Trigger Hold Pulser On-Off Pulse Frequency Input

TM-363 Page 4 Syncrowave 250 DX / 350 LX

3-1. Selecting A Location

Location And Airflow 5 250 DX Models 350 LX Models

Syncrowave 250 DX / 350 LX TM-363 Page 5

Length 28 in (711 mm)

B 1-25/64 in (35 mm)

F 22-1/4 (565 mm)

H 1/2 in (13 mm) Dia

400 lbs (181 kg) For 250 DX Models

496 lbs (225 kg) For 350 LX Models

3-3. Cooler Specifications

Cooler Tank Capacity 3 gallons (11.4 L)

Coolant Flow Rate 1 liter per minute (1.1 quart)

Use With Torches Rated Up To 400 Amperes

Cooling Power 1.28 kW Maximum Pressure 60 PSI (.41 MPa)

3-4. Welding Power Source Specifications

A. For 350 LX Models

NEMA Class II No 146 120 128 66 60 65 51 50 29.5 13.7

TM-363 Page 6 Syncrowave 250 DX / 350 LX

Amperes Input at AC Balanced Rated