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2014-12-11
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TM-353E January 2001 Eff. w/Serial Number JJ339876 Processes TIG (GTAW) Welding Stick (SMAW) Welding Description Arc Welding Power Source R Syncrowave 250 60 Hz, 50 Hz Visit our website at www.MillerWelds.com TABLE OF CONTENTS 1. Safety Precautions – Read Before Using . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 Servicing Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 1 2 SECTION 2 – DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1. Warning Label Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2. Rating Label For CE Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 3 4 5 SECTION 3 – INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5. Dimensions And Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6. Tipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7. Weld Output Terminals And Selecting Cable Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8. Remote 14 Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9. 115 Volts AC Duplex Receptacle And Shielding Gas Connections . . . . . . . . . . . . . . . . . . . . . . 3-10.Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11.Placing Jumper Links And Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 6 6 7 8 8 9 9 10 10 11 12 SECTION 4 – OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2. Output Selector Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3. Meters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4. Crater Time Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5. Spot Time Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6. AC Balance Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7. Amperage Adjustment Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8. Output (Contactor) Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9. Arc Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10.Postflow Time Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11.High Frequency Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12.Preflow Time Control (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 13 14 14 15 15 16 17 17 18 18 19 19 SECTION 5 – THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 SECTION 6 – TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1. Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2. Troubleshooting Circuit Diagram For Welding Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3. Waveforms For Section 6-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4. Control Board PC1 Testing Information (Use With Section 6-5) . . . . . . . . . . . . . . . . . . . . . . . . 6-5. Control Board PC1 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6. Remote Board PC2 Testing Information (Use With Section 6-7) . . . . . . . . . . . . . . . . . . . . . . . . 6-7. Remote 14 Filter Board PC2 Test Point Values (Use With Section 6-2 And Section 6-6) . . . . 6-8. Meter Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9. Input Voltage Labels And Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 22 26 28 30 31 33 34 35 36 SECTION 7 – MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2. Circuit Breaker CB1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3. Fuses F1 And F2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4. Adjusting Spark Gaps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 37 37 38 38 SECTION 8 – HIGH FREQUENCY (HF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1. Welding Processes Using HF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2. Sources Of HF Radiation From Incorrect Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3. Correct Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 39 39 40 SECTION 9 – ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 SECTION 10 – PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 TM-353D Declaration of Conformity For European Community (CE) Products NOTE This information is provided for units with CE certification (see rating label on unit.) Miller Electric Mfg. Co. Manufacturer’s Name: 1635 W. Spencer Street Appleton, WI 54914 USA Manufacturer’s Address: Declares that the product: Syncrowave 250 conforms to the following Directives and Standards: Directives Low Voltage Directive: 73/23/EEC Machinery Directives: 89/392/EEC, 91/368/EEC, 93/C 133/04, 93/68/EEC Electromagnetic Capability Directives: 89/336, 92/31/EEC Standards Safety Requirements for Arc Welding Equipment part 1: EN 60974-1: 1990 Arc Welding Equipment Part 1: Welding Power Sources: IEC 974-1 (April 1995 – Draft revision) Degrees of Protection provided by Enclosures (IP code): IEC 529: 1989 Insulation coordination for equipment within low-voltage systems: Part 1: Principles, requirements and tests: IEC 664-1: 1992 Electromagnetic compatibility (EMC) Product standard for arc welding equipment: EN50199: August 1995 European Contact: Telephone: Fax: dec_con1 10/95 Mr. Luigi Vacchini, Managing Director MILLER Europe S.P.A. Via Privata Iseo 20098 San Giuliano Milanese, Italy 39(02)98290-1 39(02)98281-552 SECTION 1 – SAFETY PRECAUTIONS FOR SERVICING safety_stm1 4/95 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Y Marks a special safety message. . Means NOTE; not safety related. This group of symbols means Warning! Watch Out! possible ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the hazards. 1-2. Servicing Hazards WARNING The symbols shown below are used throughout this manual to call attention to and identify possible hazards. When you see the symbol, watch out, and follow the related instructions to avoid the hazard. Only qualified persons should service, test, maintain, and repair this unit. During servicing, keep everybody, especially children, away. ELECTRIC SHOCK can kill. HOT PARTS can cause severe burns. 1. Do not touch live electrical parts. 2. Stop engine or turn OFF welding power source and wire feeder, and disconnect and lockout input power using line disconnect switch, circuit breakers, or by removing plug from receptacle before servicing unless the procedure specifically requires an energized unit. 3. Insulate yourself from ground by standing or working on dry insulating mats big enough to prevent contact with the ground. 4. Do not leave live unit unattended. 5. When testing a live unit, use the one-hand method. Do not put both hands inside unit. Keep one hand free. 6. Disconnect input power conductors from deenergized supply line BEFORE moving a welding power source. SIGNIFICANT DC VOLTAGE exists after removal of input power on inverters. 2. Allow cooling period before servicing welding gun or torch. EXPLODING PARTS can cause injury. 1. Failed parts can explode or cause other parts to explode when power is applied to inverters. 2. Always wear a face shield and long sleeves when servicing inverters. ELECTRIC SHOCK HAZARD incorrect use of test equipment. from 1. Turn Off welding power source and wire feeder or stop engine before making or changing meter lead connections. 7. Turn Off inverter, disconnect input power, and discharge input capacitors according to instructions in Maintenance Section before touching any parts. 2. At least one meter lead should be a self-retaining spring clip such as an alligator clamp. STATIC ELECTRICITY can parts on circuit boards. HIGH-FREQUENCY RADIATION can interfere with radio navigation, safety services, computers, and communications equipment. damage 1. Put on grounded wrist strap BEFORE handling boards or parts. 2. Use proper static-proof bags to store, move, or ship PC boards. FIRE OR EXPLOSION can result from placing unit on, over, or near combustible surfaces. 1. Do not place unit on, over, or near combustible surfaces. 2. Do not service unit near flammables. Syncrowave 250 1. Do not touch hot parts bare handed. 3. Read instructions for test equipment. 1. Have only qualified persons familiar with electronic equipment perform this installation. 2. The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation. 3. If notified by the FCC about interference, stop using the equipment at once. FLYING PIECES OF METAL or DIRT can injure eyes. 4. Have the installation regularly checked and maintained. 1. Wear safety glasses with side shields or face shield during servicing. 2. Be careful not to short metal tools, parts, or wires together during testing and servicing. 5. Keep high-frequency source doors and panels tightly shut, keep spark gaps at correct setting, and use grounding and shielding to minimize the possibility of interference. TM-353 Page 1 FALLING EQUIPMENT can cause serious personal injury and equipment damage. MOVING PARTS can cause injury. 1. Use lifting eye to lift unit only, NOT running gear, gas cylinders, or any other accessories. OVERUSE can cause OVERHEATED EQUIPMENT. 2. Use equipment of adequate capacity to lift unit. MAGNETIC CURRENTS operation. FIELDS FROM HIGH can affect pacemaker 1. Pacemaker wearers keep away from servicing areas until consulting your doctor. MOVING PARTS can cause injury. 1. Keep away from moving parts such as fans. 2. Keep all doors, panels, covers, and guards closed and securely in place. 1. Keep away from moving parts. 2. Keep away from pinch points such as drive rolls. 1. Allow cooling period. 2. Reduce current or reduce duty cycle before starting to weld again. 3. Follow rated duty cycle. READ INSTRUCTIONS. 1. Use MILLER Testing Booklet (Part No. 150 853) when servicing this unit. 2. Consult the Owner’s Manual for welding safety precautions. 3. Use only genuine MILLER replacement parts. 1-3. EMF Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields The following is a quotation from the General Conclusions Section of the U.S. Congress, Office of Technology Assessment, Biological Effects of Power Frequency Electric & Magnetic Fields – Background Paper, OTA-BP-E-53 (Washington, DC: U.S. Government Printing Office, May 1989): “. . . there is now a very large volume of scientific findings based on experiments at the cellular level and from studies with animals and people which clearly establish that low frequency magnetic fields can interact with, and produce changes in, biological systems. While most of this work is of very high quality, the results are complex. Current scientific understanding does not yet allow us to interpret the evidence in a single coherent framework. Even more frustrating, it does not yet allow us to draw definite conclusions about questions of possible risk or to offer clear science-based advice on strategies to minimize or avoid potential risks.” TM-353 Page 2 To reduce magnetic fields in the workplace, use the following procedures: 1. Keep cables close together by twisting or taping them. 2. Arrange cables to one side and away from the operator. 3. Do not coil or drape cables around the body. 4. Keep welding power source and cables as far away as practical. 5. Connect work clamp to workpiece as close to the weld as possible. About Pacemakers: The above procedures are also recommended for pacemaker wearers. Consult your doctor for complete information. Syncrowave 250 SECTION 2 – DEFINITIONS 2-1. Warning Label Definitions Warning! Watch Out! There are possible hazards as shown by the symbols. 1 1.1 1.2 1.3 2 1 1.1 2.1 1.3 1.2 2.2 2.3 3 2 2.1 2.2 3.1 2.3 3.2 3 3.1 3.2 3.3 3.3 4 4.1 4 4.1 + + 5 + 6 5 Electric shock from welding electrode or wiring can kill. Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves. Protect yourself from electric shock by insulating yourself from work and ground. Disconnect input plug or power before working on machine. Breathing welding fumes can be hazardous to your health. Keep your head out of the fumes. Use forced ventilation or local exhaust to remove the fumes. Use ventilating fan to remove fumes. Welding sparks can cause explosion or fire. Keep flammables away from welding. Don’t weld near flammables. Welding sparks can cause fires. Have a fire extinguisher nearby and have a watch person ready to use it. Do not weld on drums or any closed containers. Arc rays can burn eyes and injure skin. Wear hat and safety glasses. Use ear protection and button shirt collar. Use welding helmet with correct shade of filter. Wear complete body protection. Become trained and read the instructions before working on the machine or welding. Do not remove or paint over (cover) the label. 6 + S-176 254-A Syncrowave 250 TM-353 Page 3 2-2. Rating Label For CE Products 1 1 U0 = 80V U0 = 80V ISO/IEC 974-1 7A/10.2V 310A/22.4V X 25% 60% I2 310A 200A 155A U2 22.4V 18V 100% 16.2V 5A/20.2V 310A/32.4V X 25% 60% I2 310A 200A 155A U2 32.4V 28V 100% 26.2V 1 U1 = 220 50 Hz U1 = 380 I1max = 117.2A I1Eff = 59A U1 = 415 I1max = 63.8A I1Eff = 32A I1max = 72.2A I1Eff = 36A IP 21S S-178 813-A TM-353 Page 4 Syncrowave 250 2-3. Symbols And Definitions NOTE A V Some symbols are found only on CE products. Amperes Panel–Local Gas Tungsten Arc Welding (GTAW) Shielded Metal Arc Welding (SMAW) Volts Do Not Switch While Welding Arc Force (DIG) Spot Timer Output Circuit Breaker Remote Temperature Protective Earth (Ground) Alternating Current High Frequency Start Input Postflow Timer Preflow Timer High Frequency Continuous High Frequency Gas (Supply) Gas Input Gas Output Increase/Decrease Of Quantity On Off Percent Direct Current Balance Control Maximum Cleaning Maximum Penetration Electrode Positive Electrode Negative Crater Time Meter Single-Phase Line Connection U0 Rated No Load Voltage (Average) U1 Primary Voltage U2 Conventional Load Voltage I1 Primary Current I2 Rated Welding Current X Duty Cycle IP Degree Of Protection I1eff Maximum Effective Supply Current I1max Rated Maximum Supply Current Electrode S Syncrowave 250 Work Thickness Gauge 1 1 Hz Single-Phase Combined AC/DC Power Source Hertz Spark Gap Seconds TM-353 Page 5 SECTION 3 – INSTALLATION 3-1. Specifications Rated Welding Output NEMA Class II (40) – 250 Amperes, 30 Volts AC, 40% Duty Cycle Amperes Input at AC Balanced Rated Load Output, 50/60 Hz, Single-Phase PFC** 200 V 230 V 460 V 575 V KVA KW No PFC 106 (4.6*) 92 (4*) 46 (2*) 37 (1.6*) 21 (0.89*) 11.4 (0.68*) With PFC 76 66 33 26 15.2 11.4 Amp Range Max OCV IP Rating 5–310 A 80 V 21 *While idling **Power Factor Correction Rated Welding Output NEMA Class I (60) – 200 Amperes, 28 Volts AC, 60% Duty Cycle Amperes Input at AC Balanced Rated Load Output, 50/60 Hz, Single-Phase PFC ** 200 V 220 V 230 V 260 V 380 V 415 V 460 V 520 V 575 V KVA KW No PFC 85 (4.6*) 77 (4.2*) 74 (4*) 65 (3.5*) 45 (2.4*) 41 (2.2*) 37 (2*) 33 (1.8*) 30 (1.6*) 17 (0.9*) 8.3 (0.7*) With PFC 55 (57*) 64 (51*) 48 (49*) 48 (49*) 37 (30*) 34 (27*) 24 (25*) 48 (49*) 19 (20*) 11 (11*) 8.3 (0.6*) Amp Range Max OCV IP Rating 5–310 A 80 V 21 *While idling **Power Factor Correction 3-2. Volt-Ampere Curves 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 curves shown. A. DC Mode B. AC Mode ssb1.1 10/91 – SB-116 199 / SB-116 200 TM-353 Page 6 Syncrowave 250 3-3. Duty Cycle And Overheating Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. If unit overheats, thermostat opens, output stops, light goes on (CE models only), and cooling fan runs. Wait fifteen minutes for unit to cool. Reduce amperage or duty cycle before welding. Y Exceeding duty cycle can damage unit and void warranty. 40% Duty Cycle At 250 Amperes (60 Hz Models Only) 4 Minutes Welding 6 Minutes Resting 60% Duty Cycle At 200 Amperes 6 Minutes Welding 4 Minutes Resting Overheating A 0 15 Minutes OR Reduce Duty Cycle duty1 4/95 / SB-116 198 Syncrowave 250 TM-353 Page 7 3-4. Selecting A Location 1 2 Lifting Eye Lifting Forks Use lifting eye or lifting forks to move unit. Movement If using lifting forks, extend forks beyond opposite side of unit. 1 3 4 OR 2 Location And Airflow Rating Label (Non CE Models Only) Rating Label (CE Models Only, See Section 2-2) Use rating label to determine input power needs. CE label located on rear panel. 5 6 6 Plate Label (CE Models Only) Line Disconnect Device Locate unit near correct input power supply. Y Special installation may be required where gasoline or volatile liquids are present – see NEC Article 511 or CEC Section 20. 3 4 18 in (460 mm) 5 18 in (460 mm) ST-800 402 / ST-117 264-F 3-5. Dimensions And Weights Dimensions A B C D Height 30-3/4 in (781 mm) Width 19-3/4 in (502 mm) Length 27-1/2 in (698 mm) A 27 in (686 mm) B 26 in (661 mm) C 25-1/4 in (642 mm) D 1-1/2 in (38 mm) E 1-1/8 (29 mm) F 17-7/8 (454 mm) G 19-1/4 (489 mm) H 1/2 in (13 mm) Dia E F Front G Weight H 6 Holes ST-154 792-B 355 lbs (161 kg) TM-353 Page 8 Syncrowave 250 3-6. Tipping Y Be careful when placing or moving unit over uneven surfaces. 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 100 ft (30 m) Or Less Weld Output Terminals Work 150 ft (45 m) 200 ft (60 m) 250 ft (70 m) 300 ft (90 m) 350 ft (105 m) 400 ft (120 m) Welding Amperes 10 – 60% Duty Cycle 60 – 100% Duty Cycle 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 2-4/0 400 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 2-4/0 500 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 3-3/0 3-3/0 10 – 100% Duty Cycle Electrode ST-154 795-C 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. Contact your distributor for the mm2 equivalent weld cable sizes. S-0007-E Syncrowave 250 TM-353 Page 9 3-8. Remote 14 Receptacle Socket* A B K Socket Information A 24 volts ac. B Contact closure to A completes 24 volts ac contactor control circuit. C Command reference; 0 to +10 volts dc output to remote control. D Remote control circuit common. E 0 to +10 volts dc input command signal from remote control. K Chassis common. J I H C L N D M G E F A ST-154 795-C *The remaining sockets are not used. 3-9. 115 Volts AC Duplex Receptacle And Shielding Gas Connections Y Turn Off power before connecting to receptacle. 1 115 V AC Receptacle Receptacle is protected from overload by circuit breaker CB1 (see Section 7-2). 5 4 6 2 3 Gas Valve In Fitting Gas Valve Out Fitting Fittings have 5/8-18 right-hand threads 4 Cylinder Valve Open valve slightly so gas flow blows dirt from valve. Close valve. 5 6 Regulator/Flow Gauge Flow Adjust Typical flow rate is 20 cfh (cubic feet per hour) (9.4 L/min) 7 1 High Frequency Control (see Section 4-1) 7 3 2 Ref. ST-154 795-C / Ref. ST-157 858 TM-353 Page 10 Syncrowave 250 3-10. Electrical Service Guide NOTE All values calculated at 60% duty cycle. Without Power Factor Correction 60 Hertz Models With Power Factor Correction Input Voltage 200 230 460 575 200 230 460 575 Input Amperes At Rated Output 85 74 37 30 55 48 24 19 Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes 125 110 60 45 80 70 35 30 4 6 10 10 8 8 12 14 Max Recommended Input Conductor Length In Feet (Meters) 173 (53) 158 (48) 291 (89) 455 (139) 86 (26) 114 (35) 186 (58) 189 (48) Min Grounding Conductor Size In AWG/Kcmil 6 6 10 10 8 8 12 14 Min Input Conductor Size In AWG/Kcmil Reference: 1996 National Electrical Code (NEC) 50 Hertz Models S-0092-J Without Power Factor Correction With Power Factor Correction Input Voltage 220 260 380 415 520 220 380 415 Input Amperes At Rated Output 77 65 45 41 33 64 37 34 Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes 125 100 70 60 50 90 60 50 6 6 8 8 10 6 10 10 Max Recommended Input Conductor Length In Feet (Meters) 145 (44) 202 (62) 291 (89) 347 (106) 372 (113) 145 (44) 291 (89) 347 (106) Min Grounding Conductor Size In AWG/Kcmil 6 8 8 10 10 6 8 10 Min Input Conductor Size In AWG/Kcmil Reference: 1996 National Electrical Code (NEC) Syncrowave 250 S-0092-J TM-353 Page 11 3-11. Placing Jumper Links And Connecting Input Power Check input voltage available at site. 1 200 VOLTS L 230 VOLTS L 460 VOLTS L L L Y Only make connections for the voltages shown on the label inside your unit. Do not make connections for any other voltages. If jumper link label is missing from inside unit, check rating label (see Section 3-4) for allowable input voltages. L S-083 566-C 230 VOLTS L 460 VOLTS L L 2 575 VOLTS L L 2 L 3 L 380 VOLTS L L 415 VOLTS L L L L 380 VOLTS L L 4 Reinstall side panel. Y Special installation may be required where gasoline or volatile liquids are present – see NEC Article 511 or CEC Section 20. L S-047 672-A 1 Line Disconnect Device Select type and size of overcurrent protection using Section 3-10. 520 VOLTS L Input And Grounding Conductors Select size and length using Section 3-10. L S-131 783-A 260 VOLTS Jumper Links Move jumper links to match input voltage. S-010 587-B 220 VOLTS Jumper Link Label Check label inside your unit– only one label is on unit. Connect GND/PE Conductor First GND/PE Earth Ground 4 L1 (U) L2 (V) 3 Connect GND/PE Conductor First Tools Needed: 3/8 in 3/8, 1/2, 7/16 in ST-117 263-K TM-353 Page 12 Syncrowave 250 SECTION 4 – OPERATION 4-1. Controls 1 7 8 2 9 Voltmeter See Section 4-3. 3 6 Ammeter See Section 4-3. High Frequency Switch See Section 4-11. 10 4 11 12 Output (Contactor) Switch See Section 4-8. 5 5 13 Spot Time Switch And Control (Optional) See Section 4-5. 6 Preflow Time Control (Optional) See Section 4-12. 4 3 7 AC Balance Control See Section 4-6. 8 Crater Time Control And Switch See Section 4-4. 14 9 Amperage Adjustment Control And Switch See Section 4-7. 10 Arc Force (Dig) Switch And Control See Section 4-9. 11 Postflow Time Control See Section 4-10. 2 12 High Temperature Shutdown Light (CE Models Only) 1 Lights when unit overheats and shuts down (see Section 3-3). 13 Power Switch And Pilot Light Use switch to turn unit and light On and Off. 14 Output Selector Switch See Section 4-2. 15 High Frequency Control See Section 4-11. 15 Ref. ST-117 264-F / Ref. ST-154 795-C Syncrowave 250 TM-353 Page 13 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 danger 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 without changing weld output cable connections. Ref. ST-181 675-A 4-3. Meters 1 1 2 Voltmeter Voltmeter displays voltage at the weld output terminals, but not necessarily the welding arc due to cable resistance, poor connections, etc. 2 Ammeter Ammeter displays weld amperage output of unit. TM-353 Page 14 Syncrowave 250 4-4. Crater Time Controls 1 1 Crater Time Control Use control to reduce current over a set period of time (0–15 seconds) at the end of the weld cycle when NOT using a remote current control. 2 Crater Time Switch ON – provides crater time. OFF – provides no crater time. Place switch in the OFF position for Shielded Metal Arc Welding (SMAW). Application: 2 Crater Time 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. 4-5. Spot Time Controls 1 Spot Time Switch Place switch in the ON position to turn on spot weld circuitry. 2 The (GTAW) TIG Spot process is generally used with a direct current electrode negative (DCEN) set-up. Place switch in the OFF position to turn off spot weld circuitry. Put switch in the OFF position while doing Shielded Metal Arc Welding (SMAW). 2 1 Spot Time Control Use control to set time (0–5.7 seconds) for Gas Tungsten Arc (GTAW) spot welds. Spot time begins at arc initiation. If the arc is broken during the spot time cycle, the timer stops but does not reset. When the spot time has ended, weld output stops. Postflow starts when the remote contactor is opened. The spot timer resets after the contactor opens. Application: TIG spot welding is used for joining thinner materials that are in close contact, with the fusion method. A good example would be joining coil ends. Syncrowave 250 TM-353 Page 15 4-6. AC Balance Control 1 AC Balance Control Balance Control (AC GTAW): Control changes the AC output square wave. Rotating the control towards 10 provides deeper penetration. Rotating the control towards 0 provides more cleaning action of the workpiece. 1 When the control is in the Balanced position, the wave shape provides equal penetration and cleaning action. Application: When welding on oxide forming materials such as aluminum or magnesium, excess cleaning is not necessary. To produce a good weld, only a minimal amount, approximately a 0.10 in (2.5mm) of etched zone along the weld toes is required. Setting Output Waveforms Balanced 3 50% Electrode Positive 50% Electrode Negative More Penetration 10 More Cleaning 0 32% Electrode Positive Arc Set control to 7 and adjust as necessary. Joint configuration, set-up, process variables, and oxide thickness may affect setting. Arc rectification can occur when welding above 200 amps and/or while welding with helium gas. If this condition occurs, increasing the Balance control towards maximum penetration, may help to restabilize the arc. 68% Electrode Negative 55% Electrode Positive 45% Electrode Negative Ref. S-0795-A TM-353 Page 16 Syncrowave 250 4-7. Amperage Adjustment Controls 1 1 Amperage Adjustment Control Use control to adjust amperage, and preset amperage on ammeter (see Section 4-3). This control may be adjusted while welding. For remote amperage control, front panel control setting is the maximum amperage available. For example: If front panel control is set to 200 A, the range of the remote amperage control is 5 to 200 A. For spot welding, use Amperage Adjust control to select from 5–310 amps of peak amperage (see Section 4-5). 2 Amperage Control Switch Use switch to select way of controlling amperage adjustment. For front panel control, place switch in the PANEL position. 2 For remote control, place switch in REMOTE 14 position, and connect remote control device (see Section 3-8). 4-8. Output (Contactor) Control Switch Y Weld output terminals are energized when Output (Contactor) switch is On and Power is On. 1 1 Output/Contactor Switch Use switch to select way of controlling unit output. For front panel control, place switch in ON position. When On is selected, HF and gas control are disabled. For remote control, place switch in REMOTE 14 position, and connect remote control device (see Section 3-8). Syncrowave 250 TM-353 Page 17 4-9. Arc Controls 1 Arc Control (Dig) For AC And DC SMAW Welding 1 When set at 0, short-circuit amperage at low arc voltage is the same as normal welding amperage. When setting is increased, shortcircuit amperage at low arc voltage increases. Set at 0 for GTAW welding. 2 2 Arc Control Switch Place switch in the ON position to turn on arc control circuitry. When switch is in the OFF position, no additional amperage is available at low arc voltages. Place switch in the OFF position while performing Gas Tungsten Arc Welding (GTAW). Application: Control helps arc starting or making vertical or overhead welds by increasing amperage at low arc voltage, and reduces electrode sticking while welding. 4-10. Postflow Time Control 1 1 Postflow Time Control Use control to set length of time (0–70 seconds) gas flows after welding stops. It is important to set enough time to allow gas to flow until after the tungsten and weld puddle has cooled down. Application: Postflow is required to cool tungsten and weld, and to prevent contamination of tungsten and weld. Increase postflow time if tungsten or weld are dark in appearance. TM-353 Page 18 Syncrowave 250 4-11. High Frequency Controls Y Place High Frequency switch in Off position before using the shielded metal arc welding (SMAW) process. 1 1 High Frequency Switch START – (Up position) provides HF for arc starting only. High frequency turns on to help start arc when output is enabled. High frequency turns off when arc is started, and turns on whenever arc is broken to help restart arc. Application: HF Start is used when the DCEN GTAW process is required. OFF – provides no HF. Use OFF for SMAW (stick electrode) welding. CONTINUOUS – (Down position) provides HF continuously throughout the weld. Application: HF Continuous is used when the AC GTAW process is required. 2 2 High Frequency Intensity Control Use control to change amount of HF energy used to start and maintain the arc. Set as low as practical to prevent interfering with electronic equipment. 4-12. Preflow Time Control (Optional) 1 Preflow Time Control Use control to set the length of time (0–15 seconds) that gas flows before an arc is started. Application: Preflow is used to purge the immediate weld area of atmosphere. Preflow also aids in consistent arc starting. 1 Syncrowave 250 TM-353 Page 19 SECTION 5 – THEORY OF OPERATION 1 Input Terminal Board TE1 2 1φ 2 1 Provides means for operation on different input voltages. Power Switch S1 1-Phase Line Input 3 Fan Motor FM Power Provides cooling of internal components. Input Terminal Board TE1 Power Switch S1 AC 1φ 4 24 Background Power Source Main Transformer T1 Provide on/off control of unit. 4 115 VAC 3 14 Fan Motor FM Main Transformer T1 Circuit Breaker CB1 Supplies power to weld output circuit, various control circuits, main control board PC1, and fan motor FM. 5 115 VAC Duplex Receptacle RC2 Control Board PC1 115 VAC 1φ , 10 VAC Synchronization Signal Also provides input connections for switches S3, S5, S6, and S7. Arc Control Switch S6 And Control R2 6 Crater Time Switch S7 And Control R11 8 7 Control Board PC1 7 Crater Time Control R11 Crater Time Switch S7 Thermostat TP1 If T1 overheats, TP1 opens stopping all weld output. 9 Arc Control Switch S6 Arc Control R2 R11 selects crater time when S7 is on, and Amperage Control switch S5 is in Panel position. SCR Gating Signals 5 6 R2 selects short-circuit amperage when S6 is On, and High Frequency control R13 is Off. 7 Main Rectifier SR1 15 Controls weld output by changing the SCR gate pulses (conduction times) after comparing current feedback to selected amperage signal. 6 DC 23 Output (Contactor) Switch S3 Selects On or remote contactor control. 9 16 8 Output (Contactor) Switch S3 17 10 AC Balance Control R3 AC Balance Control R3 11 Ammeter A1 And Voltmeter V1 11♦ Display weld amperage and voltage while welding. Ammeter A1 12 Amperage Control Switch S5 And Adjustment Control R1 13 Remote 14 Filter Board PC2/Remote 14 Receptacle RC1 PC2 protects unit from high frequency, and RC1 connects remote amperage and contactor controls to power source. 14 Circuit Breaker CB1 Protects 115 volts ac duplex receptacle RC2 from overload. TM-353 Page 20 Gas Valve GS1 10 Controls changes to ac output square wave. R1 selects weld output amperage when S5 is in Panel. Postflow Timer TD1 Thermostat TP1 12 Amperage Adjustment Control R1 12 13 Amperage Control Switch S5 Remote 14 Filter Board PC2 13 Remote Amperage Control Syncrowave 250 15 115 Volts AC Duplex Receptacle RC2 28 26 25 30 Work Weld Output Terminal Hall Device HD1 Stabilizer Z1 11♦ Voltmeter V1 Output Selector Switch S4 21 29 Line Filter FL1 Controls shielding gas and coolant postflow time. 30 Electrode Weld Output Terminal Provides shielding gas during the weld cycle. 18 Preflow Timer TD3, Control R12, And Switch S9 R12 selects time shielding gas flows before arc starts. S9 is an integral part of R12 so that when R12 is turned past zero (0), TD3 is off. 19 Spot Timer TD2, Switch S8, And Control R10 22 High Frequency Intensity Control R13 Integrated Rectifier SR2 16 Postflow Timer TD1 17 Gas Valve GS1 High Frequency Coupling Coil T3 27 Provides connection point for auxiliary equipment. R10 selects time output is available when spot welding. S8 selects Off or spot welding with remote contactor control. 20 High Frequency Transformer T2 21 Spark Gaps G Capacitor C4 Current Feedback Voltage Feedback Voltage Feedback Steps up input voltage and charges capacitor C4. 21 Spark Gaps G And High Frequency Coupling Coil T3 G provides path for C4 to discharge into T3. T3 supplies high-frequency to welding circuit. 20 High Frequency Transformer T2 22 High Frequency Intensity Control R13 Changes amount of HF energy used to start and maintain the arc. 23 Main Rectifier SR1 18 ♦ 19 ♦ Preflow Timer TD3 18♦ Preflow Time Control R12 Switch S9 115 VAC Spot Timer TD2 19 ♦ Spot Time Control R10 19 ♦ Spot Time Switch S8 AC Or DC Control 1φ Power Weld Current Circuit External Circuits ♦ Syncrowave 250 Changes the ac output from T1 to full-wave rectified dc. 24 Background Power Source Provides reduced weld output ripple at low weld output levels. 25 Stabilizer Z1 Smooths dc welding current. 26 Hall Device HD1 Provides current feedback signal to PC1 through line filter FL1. 27 Line Filter FL1 Filters current feedback signal. 28 Output Selector Switch S4 Provides either AC or DC and output polarity. 29 Integrated Rectifier SR2 Provides dc voltage feedback to PC1. 30 Electrode And Work Weld Output Terminals Provide weld output. Optional TM-353 Page 21 SECTION 6 – TROUBLESHOOTING 6-1. Troubleshooting Table . See Section 6-2 for test points and values and Section 10 for parts location. . Use MILLER Testing Booklet (Part No. 150 853) when servicing this unit. Trouble Prior to Serial No. KG164875, no weld output; unit completely inoperative – Effective with Serial No. KG164875, no weld output; unit completely inoperative; PL2 off. Remedy Be sure line disconnect switch is in the On position. Replace building line fuse(s) or reset circuit breaker(s) if open. Check for proper electrical input connections (see Section 3-11). Check for proper jumper link position (see Section 3-11). Check Power switch S1 and replace if necessary. Prior to Serial No. KG164875, no weld output; fan runs – Effective with Serial No. KG164875, no weld output; fan runs; PL2 on. If using remote control, place Output (Contactor) switch S3 in Remote 14 position, and connect remote control to Remote 14 receptacle RC1 (see Sections 3-8 and Section 4-8). If remote is not being used, place Output switch S3 in On position. Check, repair or replace remote control device. Allow a cooling period of approximately 15 minutes. If thermostats TP1 remain open, check continuity and replace if necessary (see Section 3-3). Check circuit breaker CB1, and reset if open (see Section 7-2). Place Output Selector switch S4 in desired position (see Section 4-2). Check optional preflow timer board TD3, and replace if necessary. Check optional spot timer relay TD2 for proper connections and resistance. Replace TD2 if necessary. Check continuity of Spot Time switch S8. Check condition of contacts. Repair or replace S8 if necessary. Check SR1, and replace necessary components. If components are replaced, check capacitors C7 thru C10. Replace capacitor(s) if necessary. Check control board PC1 and connections, and replace if necessary. Effective with Serial No. KB110695, check resistance and connections of HD1; HD1 is 1600 ohms ±10% between pins 1 and 3 of plug PLG3. Check input and output voltages. Replace HD1 if necessary. Unit provides only minimum weld output. Check position of Amperage Control switch S5 (see Section 4-7). Increase Amperage Adjustment control R1 setting if a remote control is used (see Section 4-7). Check, repair or replace remote control device. Check resistance and connections of Amperage Adjustment control R1; R1 is 1000 ohms ±10%. Replace R1 if necessary. Check SCRs in main rectifier SR1, and replace if necessary. If any SCRs are replaced, Check capacitors C7 through C10 for a short or open, and check for proper connections. Replace C7 through C10 if necessary. Check control board PC1 and connections, and replace if necessary. Effective with Serial No. KB110695, check resistance and connections of HD1; HD1 is 1600 ohms ±10% between pins 1 and 3 of plug PLG3. Check input and output voltages. Replace HD1 if necessary. Unit provides only maximum weld output. Check Amperage Adjustment control R1 for proper connections and resistance; R1 is 1000 ohms ±10%. Replace R1 if necessary. Effective with Serial No. KB110695, check resistance and connections of HD1; HD1 is 1600 ohms ±10% between pins 1 and 3 of plug PLG3. Check input and output voltages. Replace HD1 if necessary. Check connections for continuity to shunt device on units with Serial No. prior to KB110695. Check bypass capacitors C13, C14, C16, C17, C18, and C19 for broken leads, shorts, and leakage. Replace if necessary. TM-353 Page 22 Syncrowave 250 Trouble Remedy Check SCRs in main rectifier SR1, and replace if necessary. If any SCRs are replaced, Check capacitors C7 through C10 for a short or open, and check for proper connections. Replace C7 through C10 if necessary. Check control board PC1 and connections, and replace if necessary. Check connections to line filter FL1. Check input to PC1. Replace FL1 if necessary. Erratic weld output. Check for poor or improper input or output connections. See Sections 3-11 and 3-8. Replace electrode. Check torch assembly, and replace if necessary. Check fuse F2 in rectifier SR3 circuit, and replace if necessary. If Amperage Control switch S5 is in the Remote position check, repair, or replace remote amperage control device if necessary. Check connections for continuity to shunt device on units with Serial No. prior to KB110695. Check Amperage Adjustment control R1 for proper connections and resistance; R1 is 1000 ohms ±10%. Replace R1 if necessary. Check bypass capacitors C13, C14, C16, C17, C18, and C19 for broken leads, shorts, and leakage. Replace if necessary. Check SCRs in main rectifier SR1, and replace if necessary. If any SCRs are replaced, Check capacitors C7 through C10 for a short or open, and check for proper connections. Replace C7 through C10 if necessary. Check control board PC1 and connections, and replace if necessary. No or limited ac balance control. Check AC Balance control R3 for proper connections and resistance; R3 is 5000 ohms ±10%. Replace R3 if necessary. Check control board PC1 and connections, and replace if necessary. Check SCRs in main rectifier SR1, and replace if necessary. If any SCRs are replaced, Check capacitors C7 through C10 for a short or open, and check for proper connections. Replace C7 through C10 if necessary. No crater fill time. Check position of Crater switch S7 (see Section 4-4). Check position of Crater control R11 (see Section 4-4). Be sure arc voltage is below 24 volts (see Section 3-2. Volt-Ampere Curves). Check position of Amperage Control switch S5, S5 must be in Panel position (see Section 4-7). Check control board PC1 and connections, and replace if necessary. Crater fill time too long or does not time out. Check position of Crater control R11 (see Section 4-4). Check resistance and connections of Crater control R11; R11 is 5 meg ohms ±10%. Replace R11 if necessary. Check control board PC1 and connections, and replace if necessary. No arc control. Place Arc Control switch S6 in the On position. Place High Frequency switch S2 in the Off position. Be sure arc voltage is below 24 volts (see Section 3-2. Volt-Ampere Curves). Check position of Arc Control R2 (see Section 4-9). Check fuse F1 in rectifier SR3 circuit, and replace if necessary. Check resistance and connections of Arc control R2; R2 is 1000 ohms ±10%. Replace R1 if necessary. Check control board PC1 and connections, and replace if necessary. Lack of high frequency at tungsten electrode; difficulty in starting an arc. Use proper size tungsten for welding application. Use shortest possible cables (see Section 3-7). Check cables and torch for cracked or deteriorated insulation or bad connections. Repair or replace necessary parts. Be sure to disconnect SMAW electrode cable from weld output terminal when GTAW welding. Decrease gas flow setting. Use properly prepared tungsten. Increase setting of High Frequency Intensity control R13 (see Section 4-11). Check spark gaps G, and readjust if necessary (see 7-4). Syncrowave 250 TM-353 Page 23 Trouble No high frequency at spark gaps G. Remedy Check position of High Frequency switch S2 (see Section 4-11). Place Output (Contactor) switch S3 in Remote position and be sure remote control is connected to Remote receptacle RC1 (see Section 3-8). Check circuit breaker CB1, and reset if open (see Section 7-2). Check fuse F1 in rectifier SR2 circuit, and replace if necessary. Check coil voltage and connections of contactor control relay CR1. Check continuity of coil and condition of contacts. Replace CR1 if necessary. Check coil voltage and connections of contactor control relay CR5. Check continuity of coil and condition of contacts. Replace CR5 if necessary. Check spark gaps G, and readjust if necessary (see Section 7-4). Check resistance and connections of High Frequency Intensity control R13; R13 is 1.5 ohms ±10%. Replace R1 if necessary. Check capacitor C4 for a short or open, and check for proper connections. Replace C4 if necessary. Check transformer T2 for signs of winding failure. Check continuity across windings, and check for proper connections. Check secondary voltages. Replace T2 if necessary. Check coupling coil T3 for signs of winding failure. Check continuity across windings, and check for proper connections. Replace T3 if necessary. Check control board PC1 and connections, and replace if necessary. No preflow time (optional). Place Output (Contactor) switch S3 in Remote position and be sure remote control is connected to Remote receptacle RC1 (see Section 3-8). Check position of Preflow Time control R12. Check continuity of Preflow Time switch S9. Check condition of contacts. Repair or replace S9 if necessary. Remove jumper link 1 on terminal strip 1T. Check optional preflow timer board TD3, and replace if necessary. Optional spot timer relay TD2 does not time out. Place Spot Time switch S8 in the On position. Remove jumper link 2 from terminal strip 1T. Place Spot Time control R10 in desired position. Check coil voltage and connections of spot timer relay TD2. Check continuity of coil and condition of contacts. Replace TD2 if necessary. Check coil voltage and connections of control relay CR3. Check continuity of coil and condition of contacts. Replace CR3 if necessary. Check coil voltage and connections of control relay CR1. Check continuity of coil and condition of contacts. Replace CR1 if necessary. Postflow timer does not time out. Check position of Postflow Time control setting (see Section 4-10). Check Control relay CR5 contacts 2 and 5 for proper operation. Replace CR5 if necessary. Check coil voltage and connections of gas valve GS1. Check continuity of coils. Replace GS1 if necessary. Check input voltage and connections to Postflow timer board TD1. Check continuity of contacts. Replace TD1 if necessary. Check control board PC1 and connections, and replace if necessary. No postflow time. Check position of Postflow Time control setting (see Section 4-10). Place Output(Contactor) switch S3 in the Remote position, and connect a remote control to receptacle RC1 according to Section 3-8. Check coil voltage and connections of control relay CR5. Check continuity of coil and condition of contacts. Replace CR5 if necessary. Check coil voltage and connections of gas valve GS1. Check continuity of coils. Replace GS1 if necessary. Check input voltage and connections to Postflow timer board TD1. Check continuity of contacts. Replace TD1 if necessary. Check control board PC1 and connections, and replace if necessary. No gas flow. Place Output(Contactor) switch S3 in the Remote position, and connect a remote control to receptacle RC1 according to Section 3-8. Check circuit breaker CB1, and reset if open (see Section 7-2). TM-353 Page 24 Syncrowave 250 Trouble Remedy Check Control relay CR2 contacts 4 and 7 for proper operation. Replace CR2 if necessary. Check coil voltage and connections of gas valve GS1. Check continuity of coils. Replace GS1 if necessary. No power output at 115 volts ac receptacle RC1; weld output available. Check circuit breaker CB1, and reset if open (see Section 7-2). Fan motor FM does not run; weld output available. Effective with Serial No. KG164875, unit is equipped with FanOn-Demand, which only runs when cooling is required. Check and clear fan blade obstruction. Check coil voltage and connections of fan motor FM, and replace if necessary. Line fuse opens immediately when solid-state contactor SR1 turns on in DC mode only. Check diode D1, and replace if necessary. Check SCRs in main rectifier SR1, and replace if necessary. If any SCRs are replaced, Check capacitors C7 through C10 for a short or open, and check for proper connections. Replace C7 through C10 if necessary. No control of weld output. Check position of Amperage Control switch S5 (see Section 4-7). Check resistance and connections of Amperage Adjustment control R1; R1 is 1000 ohms ±10%. Replace R1 if necessary. Check, repair or replace remote control device. Effective with Serial No. KB110695, check resistance and connections of HD1; HD1 is 1600 ohms ±10% between pins 1 and 3 of plug PLG3. Check input and output voltages. Replace HD1 if necessary. Check control board PC1 and connections, and replace if necessary. Tungsten electrode oxidizing and not remaining bright after conclusion of weld. Check position of Postflow Time control R12 (see Section 4-10). Check and tighten all gas fittings if necessary. Increase gas flow setting. Shield weld zone from drafts. Properly prepare tungsten. Place High Frequency switch S2 in Start or Continuous position. Wandering arc - poor control of direction of arc. Use proper size tungsten for welding application. Properly prepare tungsten. Controls connected to Remote 14 receptacle RC1 do not work properly. Check, repair or replace remote control device. Check Amperage Control switch S5 position (see Section 4-7). Check and replace S5 if necessary. Check Output (Contactor) switch S3 position (see Section 4-8). Check and replace S3 if necessary. Check position of jumper links 1 and 2 on terminal strip 1T according to Section 6-2. Check coil voltage and connections of control relay CR2. Check continuity of coil and condition of contacts. Replace CR2 if necessary. Prior to Serial No. KF959379, check choke RFC1 connections. Check continuity of RFC1. Replace if necessary. Effective with Serial No. KF959379 check remote 14 filter board PC2 (see Section 6-6). Replace PC2 if necessary. Check control board PC1 and connections, and replace if necessary. Ammeter A1 not displaying correct weld output amperage. Calibrate ammeter as instructed in Section 6-8. Check ammeter A1 voltage; +1 millivolts dc per 3 ampere of weld output. Replace A1 if necessary. Check control board PC1 and connections, and replace if necessary. Effective with Serial No. KB110695, check resistance and connections of hall device HD1; HD1 is 1600 ohms ±10% between pins 1 and 3 of plug PLG3. Check input and output voltages. Replace HD1 if necessary. Voltmeter V1 not displaying correct arc voltage. Check connections for continuity to voltmeter V1. Replace V1 if necessary. Electronic equipment in welding area not working properly. HF interference problem. Check for proper installation, and correct problem (see Section 8). Syncrowave 250 TM-353 Page 25 6-2. Troubleshooting Circuit Diagram For Welding Power Source Y Disable high frequency by placing High Frequency switch S2 in Off position before testing unit. R1 R1 R1 V3 V2 V25 V1 V11 V4 V5 R1 V10 V9 V6 V8 V7 Link 1 Link 2 V13 V12 V14 V17 TD1 begins to time out when CR5 deenergizes TD3 begins to time out when CR4 energizes V15 V16 CR2 energizes when remote contactor switch closes See Figure 9-19 for PC3 circuit CR3 energizes during spot time when an arc is detected CR4 energizes when remote contactor switch closes See Section 6-6 for PC2 data TM-353 Page 26 See Section 3-8 for RC1 information Syncrowave 250 Test Equipment Needed: Voltage Readings See Figure 10-1 for HD1 location No calibration available for voltmeter V1 R1 V24 R1 V25 V23, B, C, D, E See Section 6-3 for waveforms B, C, D, E a) Tolerance – ±10% unless specified b) Reference – to circuit common (lead 42) unless noted c) Wiring Diagram Section 10 V1 230 volts ac V2 77 volts ac V3 82.5 volts ac V4 57 volts ac V5, V6 115 volts ac V7 24 volts ac V8, V9 18 volts ac V10 10 volts ac V11 80 volts dc V12. V13, V14 115 volts ac R2 A A see V15, V16, V17 24 volts ac V18 115 volts ac with S2 in Start or Continuous V19 0 to +10 volts dc with contactor on R3 V22 V21 – V20, V21 24 volts dc V22 0-80 volts dc (rectified arc voltage) V23 maximum 80 volts ac/dc V24 24 volts dc V25 16.5 millivolts dc per 1 ampere of weld output A CR1 energizes when open-circuit voltage is present; denergizes when an arc is struck A V20 See Section 6-3 for waveform A V18 See Section 6-8 for ammeter A1 calibration V19 See also Sections 6-4 and 6-5 for PC1 data CR5 energizes when contactor is on Resistance Values a) Tolerance – ±10% unless specified b) Turn Off unit and disconnect input power before checking resistance R1 All values for T1, Z1, and T3 are less than 1 ohm R2 5.3 ohms R3 6.1 K ohms SC-188 161 Syncrowave 250 TM-353 Page 27 6-3. Waveforms For Section 6-2 Waveforms shown are for 60 Hertz models; waveforms for 50 Hertz models are similar. 5 ms 1 V 5 ms 50 V gnd gnd A. SR1 Gate Pulse With Respect To Cathode At No Load B. DC Open-Circuit Voltage With Amperage Adjustment Control At Maximum 5 ms 20 V 5 ms 50 V gnd C. DC Output, 100 Amperes, 24 Volts DC (Resistive Load) TM-353 Page 28 gnd D. AC Open-Circuit Voltage With Amperage Adjustment Control At Maximum Syncrowave 250 5 ms 50 V gnd E. AC Output, 100 Amperes, 24 Volts AC (Resistive Load) Test Equipment Needed: Syncrowave 250 TM-353 Page 29 6-4. Control Board PC1 Testing Information (Use With Section 6-5) Y Disable high frequency by placing High Frequency switch S2 in Off position before testing unit. Be sure plugs are secure before testing. See Section 6-5 for specific values during testing. 1 2 1 Control Board PC1 2 Receptacle RC51 3 Receptacle RC52 4 Receptacle RC53 5 Receptacle RC54 6 Receptacle RC55 3 4 6 5 Test Equipment Needed: SB-178 976-A / ST-800 344-A TM-353 Page 30 Syncrowave 250 6-5. Control Board PC1 Test Point Values a) Tolerance specified PC1 Voltage Readings – ±10% unless b) Reference – to circuit common (lead 42) unless noted Receptacle Pin RC51 1 18 volts ac input 2 18 volts ac input 3 +10 volts dc output 4 Circuit common 5 Not used 6 Not used 1 Circuit common 2 +1 millivolt dc per 3 ampere of weld output 1 Gate pulse for SCR1 with respect to pin 2 (see Section 6-3) 2 Reference for gate pulse to SCR1 3 Gate pulse for SCR3 with respect to pin 4 (see Section 6-3) 4 Reference for gate pulse to SCR3 5 Gate pulse for SCR2 with respect to pin 6 (see Section 6-3) 6 Reference for gate pulse to SCR2 7 Gate pulse for SCR4 with respect to pin 8 (see Section 6-3) 8 Reference for gate pulse to SCR4 1 Not used 2 0 to +10 volts dc input from min. to max. of Amperage Adjustment control R1 with Amperage Control switch S5 in Panel position, and contactor on 3 0 volts with Output (Contactor) switch S3 in On position or +7.8 volts dc with S3 in Remote position 4 0 to +10 volts dc input from min. to max. of Crater Control R11 with Crater Fill switch S7 in On position, or +10 volts dc with S7 in Off position 5 +10 volts dc output with Output (Contactor) switch S3 in On position 6 –24 volts dc 7 –24 volts dc with contactor on or off 8 0 to +10 volts dc input from min. to max. of Amperage Adjustment control R1 with contactor on 9 0 to +10 volts dc input from min. to max. of Amperage Adjustment control R1 with contactor on 10 Circuit common 11 +24 volts dc 12 0 volts during open-circuit voltage condition; +24 volts with arc on or contactor off RC52 RC53 RC54 Syncrowave 250 Value TM-353 Page 31 Receptacle Pin RC55 1 Circuit common 2 +1.65 volts dc per 100 amperes of weld output with respect to pin 1 3 –15 volts dc output 4 0 to +4 volts dc input from min. to max. of Arc Control R2 with Arc Control switch S6 On 5 10 volts ac input for synchronization 6 +5.8 volts dc output 7 –15 volts dc input from Max. Penetration setting of AC Balance control R3 to +5.8 volts dc input at Max. Cleaning setting of R3 8 0 to 80 volts dc voltage feedback signal (rectified arc voltage) with respect to pin 9 9 0 to 80 volts dc voltage feedback signal (rectified arc voltage) with respect to pin 8 10 0 to +4 volts dc input from min. to max. of Arc Control R2 with Arc Control switch S6 Off TM-353 Page 32 Value Syncrowave 250 6-6. Remote Board PC2 Testing Information (Use With Section 6-7) Y Disable high frequency by placing High Frequency switch S2 in Off position before testing unit. Be sure plugs are secure before testing. See Section 6-7 for specific values during testing. 1 Remote 14 Filter Board PC2 2 Remote 14 receptacle RC1 See Section 3-8 for information. 1 3 Receptacle RC2 4 Receptacle RC3 4 3 2 Test Equipment Needed: ST-157 960-B / ST-800 344-A Syncrowave 250 TM-353 Page 33 6-7. Remote 14 Filter Board PC2 Test Point Values (Use With Section 6-2 And Section 6-6) a) Tolerance specified PC2 Voltage Readings Pin RC1 A 24 volts ac B Contact closure to A completes 24 volts ac contactor control circuit C Command reference; 0 to +10 volts dc output to remote control D Remote control circuit common E 0 to +10 volts dc input command signal from remote control K Chassis common 1 Command reference; 0 to +10 volts dc output to remote control 3 Contact closure to A completes 24 volts ac contactor control circuit 4 Remote control circuit common 5 0 to +10 volts dc input command signal from remote control 6 24 volts ac 1 Chassis common RC3 TM-353 Page 34 ±10% unless b) Reference – to circuit common (lead 42) unless noted Receptacle RC2 – Value Syncrowave 250 6-8. Meter Calibration Be sure plugs are secure before calibrating meter. No calibration available for ammeter offset, or for voltmeter V1. 1 Control Board PC1 2 Voltmeter V1 3 Ammeter A1 1 Top View R19 2 3 Amperes Adjust R19 for amperage gain to match external calibrated meter using load bank set at desired load. SB-130 690-D / ST-800 344-A Syncrowave 250 TM-353 Page 35 6-9. Input Voltage Labels And Connections 1 Input Voltage Label And Connection Diagram – Only One Label Is On Unit 2 Terminal Strip TE1 Test Equipment Needed: 2 1 ST-154 793-A / ST-114 947-A / ST-121 000-A / ST-131 735 TM-353 Page 36 Syncrowave 250 SECTION 7 – MAINTENANCE 7-1. Routine Maintenance Y Disconnect power before maintaining. 3 Months Clean And Tighten Weld Terminals Repair Or Replace Cracked Weld Cables Replace Unreadable Labels Adjust Spark Gaps Replace Cracked Parts 14-Pin Cord Torch Cable Gas Hose 6 Months OR Blow Out Or Vacuum Inside, During Heavy Service, Clean Monthly 7-2. Circuit Breaker CB1 1 Circuit Breaker CB1 If CB1 opens, output to the 115 volts ac duplex receptacle, high frequency, and gas flow stop. Press button to reset breaker. 1 CB1 Ref. ST-154 795-C Syncrowave 250 TM-353 Page 37 7-3. Fuses F1 And F2 1 Fuse F1 (See Parts List For Rating) Fuse F1 (between leads 50 and 150) protects wiring harness from shorted SR2. If F1 opens, you may experience problems with arc starting and arc performance in the DC TIG mode. 1 2 2 Fuse F2 (See Parts List For Rating) Fuse F2 (between leads 22 and 149) protects wiring harness from shorted SR3. If F2 opens, you may experience problems with arc control, and no high frequency in start high frequency. Tools Needed: 3/8 in 7-4. Adjusting Spark Gaps Y Turn Off power before adjusting spark gaps. 4 4 Open access door. 1 Replace point if tungsten end disappears; do not clean or dress tungsten. 3 3 2 Tungsten End Of Point 1 2 Spark Gap Normal spark gap is 0.008 in (0.203 mm). If adjustment is needed, proceed as follows: 3 Adjustment Screws Loosen screws. Place gauge of proper thickness in spark gap. 4 Pressure Point Apply slight pressure at point until gauge is held firmly in gap. Tighten screws to 12 in/lbs torque (overtightening will deform plastic base). Adjust other gap. Close access door. Tools Needed: Ref. ST-154 795-C / Ref. S-0043 TM-353 Page 38 Syncrowave 250 SECTION 8 – HIGH FREQUENCY (HF) 8-1. Welding Processes Using HF 1 HF Voltage GTAW – helps arc jump air gap between torch and workpiece and/ or stabilize the arc. SAW – helps arc reach workpiece through flux granules. 2 1 2 1 Work Work Gas Tungsten Arc Welding (GTAW) Submerged Arc Welding (SAW) Flux high_freq1 7/95 – S-0693 8-2. Sources Of HF Radiation From Incorrect Installation Weld Zone 11, 12 50 ft (15 m) 10 14 9 8 7 3 2 13 1 4 5 6 S-0694 Sources Of Direct HF Radiation 1 HF source (welding power source with built-in HF or separate HF unit) 2 Weld Cables 3 Torch 4 Work Clamp Syncrowave 250 5 6 Workpiece Work Table Sources Of Conduction Of HF 7 8 9 Input Power Cable Line Disconnect Device Input Supply Wiring Sources Of Reradiation Of HF 10 11 12 13 14 Ungrounded Metal Objects Lighting Wiring Water Pipes And Fixtures External Phone And Power Lines TM-353 Page 39 8-3. Correct Installation Weld Zone 6 50 ft (15 m) 50 ft (15 m) 4 1 5 2 7 3 7 Ground All Metal Objects And All Wiring In Welding Zone Using #12 AWG Wire Nonmetal Building Ground Workpiece If Required By Codes 8 7 7 10 Metal Building 9 Ref. S-0695 / Ref. S-0695 1 HF Source (Welder With Built-In HF Or Separate HF Unit) Ground metal machine case, work output terminal, line disconnect device, input supply, and worktable. Electrically join (bond) all conduit sections using copper straps or braided wire. Ground conduit every 50 ft (15 m). 5 Water Pipes And Fixtures 8 Metal Building Panel Bonding Methods Bolt or weld building panels together, install copper straps or braided wire across seams, and ground frame. Ground water pipes every 50 ft (15 m). 9 A circle 50 ft (15 m) from centerpoint between HF source and welding torch in all directions. 6 Cover all windows and doorways with grounded copper screen of not more than 1/4 in (6.4 mm) mesh. 3 7 2 Welding Zone And Centerpoint Weld Output Cables Keep cables short and close together. 4 Conduit Joint Bonding And Grounding TM-353 Page 40 External Power Or Telephone Lines Locate HF source at least 50 ft (15 m) away from power and phone lines. Grounding Rod Consult the National Electrical Code for specifications. Windows And Doorways 10 Overhead Door Track Ground the track. Syncrowave 250 SECTION 9 – ELECTRICAL DIAGRAMS . 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 Syncrowave 250 Serial Or Style Number Circuit Diagram Wiring Diagram JJ339876 thru JJ351864 SC-114 914 D-116 884-B♦♦ JJ351865 thru JJ365633 SC-120 877 D-120 878-B♦♦ JJ365634 thru JJ503983 SC-121 280 D-121 281-D♦♦ JJ503984 thru JK572897 SC-124 314 D-124 307-C♦♦ JK572898 thru JK617846 SC-124 785-B D-124 786-B♦♦ JK617847 thru JK682713 SC-124 785-B D-129 200-B♦♦ JK682714 thru JK690986 SC-124 785-B D-130 576-B♦♦ JK690987 thru KA806712 SC-132 697-A D-132 431-D♦♦ KA806713 thru KA877024 SC-137 431 D-137 430-A♦♦ KA877025 thru KB010829 SC-135 581 D-135 734-A♦♦ KB010830 thru KB110694 SC-142 524 D-142 525-A♦♦ KB110695 thru KC252675 SC-148 144 D-148 145-A♦♦ KC252676 thru KG029204 SC-154 649-C D-154 648-E♦♦ KG029205 thru KG062109 SC-178 835 D-174 039-A♦♦ KG062110 thru KG170300 SC-179 303-A D-179 305-A♦♦ KG170301 thru KH526230 SC-181 109-E SD-181 110-F♦♦ KH526231 and following SC-188 161-A SD-188162-A JJ339876 thru JJ399987 D-118 765♦♦ JJ399988 thru JK682713 D-122 270♦♦ JK682714 thru KA797306 D-130 691-A♦♦ KA797307 thru KG062109 D-135 253♦♦ KG062110 thru KH508254 SD-178 975♦♦ KH508255 and following SD-187644 RFC Circuit Board PC2 JJ365634 thru KB010829 SA-121 282 Remote 14 Filter Board PC2 KF959379 and following SA-158 763 Circuit Board PC3♦ JJ351865 and following SA-120 872 Timer TD1 JJ339876 and following SA-044 725-C Timer TD3♦ JJ339876 and following SA-045 288-D Circuit Board PC1 ♦ Optional ♦♦ Not included in this manual Syncrowave 250 TM-353 Page 41 SC-114 914 Figure 9-1. Circuit Diagram For Syncrowave 250 Effective With Serial No. JJ339876 Thru JJ351864 TM-353 Page 42 Syncrowave 250 SC-120 877 Figure 9-2. Circuit Diagram For Syncrowave 250 Effective With Serial No. JJ351865 Thru JJ365633 Syncrowave 250 TM-353 Page 43 SC-121 280 Figure 9-3. Circuit Diagram For Syncrowave 250 Effective With Serial No. JJ365634 Thru JJ503983 TM-353 Page 44 Syncrowave 250 SC-124 314 Figure 9-4. Circuit Diagram For Syncrowave 250 Effective With Serial No. JJ503984 Thru JK572897 Syncrowave 250 TM-353 Page 45 SC-124 785-B Figure 9-5. Circuit Diagram For Syncrowave 250 Effective With Serial No. JK572898 Thru JK690986 TM-353 Page 46 Syncrowave 250 SC-132 697-A Figure 9-6. Circuit Diagram For Syncrowave 250 Effective With Serial No. JK690987 Thru KA806712 Syncrowave 250 TM-353 Page 47 SC-137 431 Figure 9-7. Circuit Diagram For Syncrowave 250 Effective With Serial No. KA806713 Thru KA877024 TM-353 Page 48 Syncrowave 250 SC-135 581 Figure 9-8. Circuit Diagram For Syncrowave 250 Effective With Serial No. KA877025 Thru KB010829 Syncrowave 250 TM-353 Page 49 SC-142 524 Figure 9-9. Circuit Diagram For Syncrowave 250 Effective With Serial No. KB010830 Thru KB110694 TM-353 Page 50 Syncrowave 250 SC-148 144 Figure 9-10. Circuit Diagram For Syncrowave 250 Effective With Serial No. KB110695 Thru KC252675 Syncrowave 250 TM-353 Page 51 SC-154 649-C Figure 9-11. Circuit Diagram For Syncrowave 250 Effective With Serial No. KC252676 Thru KG029204 TM-353 Page 52 Syncrowave 250 SC-178 835 Figure 9-12. Circuit Diagram For Syncrowave 250 Effective With Serial No. KG029205 Thru KG062109 Syncrowave 250 TM-353 Page 53 SC-179 303-A Figure 9-13. Circuit Diagram For Syncrowave 250 Effective With Serial No. KG062110 Thru KG170300 TM-353 Page 54 Syncrowave 250 SC-181 109-E Figure 9-14. Circuit Diagram For Syncrowave 250 Effective With Serial No. KG170301 Thru KH526230 Syncrowave 250 TM-353 Page 55 SC-188 161-A Figure 9-15. Circuit Diagram For Syncrowave 250 Effective With Serial No. KH526231 And Following TM-353 Page 56 Syncrowave 250 Notes Syncrowave 250 TM-353 Page 57 Figure 9-16. Wiring Diagram For Syncrowave 250 Effective With Serial No. KH526231 And Following TM-353 Page 58 Syncrowave 250 SD-188 162-A Syncrowave 250 TM-353 Page 59 Figure 9-17. Circuit Diagram For Control Board PC1 Effective With Serial No. KH508255 And Following (Part 1 Of 2) TM-353 Page 60 Syncrowave 250 SD-187 644 (1 of 2) Syncrowave 250 TM-353 Page 61 Figure 9-18. Circuit Diagram For Control Board PC1 Effective With Serial No. KH508255 And Following (Part 2 Of 2) TM-353 Page 62 Syncrowave 250 SD-187 644 (2 of 2) Syncrowave 250 TM-353 Page 63 SA-121 282 Figure 9-19. Circuit Diagram For RFC Board PC2 Effective With Serial No. JJ365634 Thru KB010829 SA-158 763 Figure 9-20. Circuit Diagram For Remote 14 Filter Board PC2 Effective With Serial No. KF959379 And Following SA-120 872 Figure 9-21. Circuit Diagram For Optional Snubber Board PC3 Effective With Serial No. JJ351865 And Following TM-353 Page 64 Syncrowave 250 SA-044 725-C Figure 9-23. Circuit Diagram For Postflow Timer Board TD1 Effective With Serial No. JJ339876 And Following SA-045 288-D Figure 9-22. Circuit Diagram For Optional Preflow Timer Board TD3 Effective With Serial No. JJ339876 And Following Syncrowave 250 TM-353 Page 65 Notes TM-353 Page 66 Syncrowave 250 TM-353E January 2001 Eff. w/Serial Number JJ339876 Processes TIG (GTAW) Welding Stick (SMAW) Welding Description Arc Welding Power Source R Syncrowave 250 60 Hz, 50 Hz Visit our website at www.MillerWelds.com 16 23 29–Fig.10-2 1 28 2–Fig.10-3 5 6 27 3 4 7–Fig.10-5 8 26 25 9 24 10 22 11 12 15 14 31 30 13 21 20 19 18 17–Fig.10-4 SECTION 10 – PARTS LIST . Hardware is common and not available unless listed. TM-353 Page 68 ST-120 135-R Figure 10-1. Main Assembly Syncrowave 250 Item No. Dia. Mkgs. Part No. Description Quantity Figure 10-1. Main Assembly . 1 . . . . . . . . . . . . . 114 741 . 1 . . . . . . . . . . . . . 182 605 . 2 . . . . SR1 . . . . 181 106 . 3 . . . . . S4 . . . . 112 630 . 3 . . . . . S4 . . . . 133 061 . . . . . . PLG10 . . 164 899 . . . . . . PLG11 . . . 168 809 . . . . . . . C13 . . . . 155 082 . . . . . . . C13 . . . . 132 433 . 4 . . . . . . . . . . . . . 057 357 . 5 . . . . . . . . . . . . . 010 494 . 6 . . . . . . . . . . . . . 110 375 . 6 . . . . . . . . . . . . . 134 201 . 7 . . . . . . . . . . . . . Fig 10-4 . 8 . . . . . . . . . . . . . 083 147 . 9 . . . . . . . . . . . . . 114 754 . 9 . . . . . . . . . . . . . 181 101 10 . . . . . . . . . . . . 026 627 11 . . . . . . . . . . . . 070 026 12 . . . PC1 . . . . 117 981 12 . . . PC1 . . . . 138 058 12 . . . PC1 . . . . 180 014 12 . . . PC1 . . . . 187 642 . . . . . . PLG51 . . 115 093 . . . . . . PLG54 . . 130 203 . . . . . . PLG55 . . 115 091 13 . . . R14 . . . . 138 105 13 . . . FL1 . . . . 084 171 14 . . . HD1 . . . . 156 313 . . . . . . PLG3 . . . 130 204 15 . . . . . . . . . . . . 073 756 16 . . . . Z1 . . . . 114 826 17 . . . . . . . . . . . . Fig 10-4 . . . . . . . . . . . . . . . . 109 035 18 . . C11,12 . . 111 634 . . . . . . . . . . . . . . . . 172 078 19 . . . TE1 . . . . 034 587 . . . . . . . . . . . . . . . . 601 835 . . . . . . . . . . . . . . . . 601 836 . . . . . . . . . . . . . . . . 010 915 . . . . . . . . . . . . . . . . 083 426 . . . . . . . . . . . . . . . . 038 888 . . . . . . . . . . . . . . . . 010 913 . . . . . . . . . . . . . . . . 038 887 . . . . . . . . . . . . . . . . 038 618 20 . . . . . . . . . . . +114 751 20 . . . . . . . . . . . +181 097 20 . . . . . . . . . . . +182 606 21 . . . . T1 . . . . 115 097 21 . . . . T1 . . . . 138 171 21 . . . . T1 . . . . 180 674 21 . . . . T1 . . . . 138 175 21 . . . . T1 . . . . 180 673 21 . . . . T1 . . . . 121 161 21 . . . . T1 . . . . 138 172 21 . . . . T1 . . . . 180 672 21 . . . . T1 . . . . 191 887 . . . . . . . TP1 . . . . 020 520 . . . . . . . TP2 . . . . 168 891 Syncrowave 250 . . COVER, top (Prior to KG170301) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . COVER, top (Eff w/KG170301) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . RECTIFIER, si diode (Fig 10-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . SWITCH, plrty/changeover (Prior to KA759476) . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . SWITCH, plrty/changeover (Eff w/KA759476) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . CAPACITOR, cer disc. .003 200VAC (Prior to JK690987) . . . . . . . . . . . . . . . . . 1 . . CAPACITOR, cer disc. .05uf 500VDC (Eff w/JK690987) . . . . . . . . . . . . . . . . . . . 1 . . BUSHING, snap-in nyl .937 ID x 1.125mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . BUSHING, snap-in nyl 1.375 ID x1.750mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . STAND-OFF SUPPORT, PC card No. 6 screw (Prior to KG170301) . . . . . . . . 3 . . STAND-OFF SUPPORT, PC card No. 6 screw (Eff w/KG170301) . . . . . . . . . . 3 . . PANEL, mtg components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . GROMMET, screw No. 8/10 panel hole .312sq .500 high . . . . . . . . . . . . . . . . . . 4 . . FRAME, lifting (Prior to KG170301) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . FRAME, lifting (Eff w/KG170301) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . GASKET, lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . STAND-OFF, 6-32 x .437 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . CIRCUIT CARD, control (Prior to JJ389988) (Fig 10-5) . . . . . . . . . . . . . . . . . . . . 1 . . CIRCUIT CARD, control (Eff w/JJ389988 thru KB110694) (Fig 10-5) . . . . . . . . 1 . . CIRCUIT CARD, control (Eff w/ KB110695 thru KG060803) . . . . . . . . . . . . . . . . 1 . . CIRCUIT CARD, control (Eff w/KG060804) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . CONNECTOR PLUG & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . CONNECTOR PLUG & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . CONNECTOR PLUG & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . RESISTOR, (Eff w/KB110695 thru KG062110) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . FILTER, line power 115/250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . TRANSDUCER, current 300A (Eff w/KB110695) . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . CONNECTOR & SOCKETS, (Eff w/KB110695) . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . STAND-OFF, 6-32 x .625 lg (Eff w/KB110695) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . REACTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . PANEL, rear w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . LABEL, warning electric shock can kill etc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . BRACKET, mtg primary board (Eff w/KE727074) . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . TERMINAL ASSEMBLY, pri (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . NUT, brs hex 10-32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 . . . . NUT, brs hex .250-20 jam hvy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . . WASHER, flat brs .250 ID x .625 OD x .031thk . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . . TERMINAL BOARD, primary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . STUD, primary board brs .250-20 x 1.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . WASHER, flat brs .218 ID x 460 OD x .031thk . . . . . . . . . . . . . . . . . . . . . . . . . 6 . . . . STUD, primary board brs 10-32 x 1.375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 . . . . LINK, jumper term bd pri . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . PANEL, side (Prior to KG170301) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . PANEL, side (Eff w/KG170301 thru KG181270) . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . PANEL, side (Eff w/KG181271 and on) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . TRANSFORMER, pwr main 200/230/460 (Prior to KA877025) . . . . . . . . . . . . . 1 . . TRANSFORMER, pwr main 200/230/460 (Eff w/KA877025 thru KG082621) . 1 . . TRANSFORMER, pwr main 200/230/460 (Eff w/KG082622) . . . . . . . . . . . . . . . 1 . . TRANSFORMER, pwr main (220/380/415 (Prior to KG082622) . . . . . . . . . . . . 1 . . TRANSFORMER, pwr main 220/380/415 (Eff w/KG082622) . . . . . . . . . . . . . . . 1 . . TRANSFORMER, pwr main 230/460/575 (Prior to KA877025) . . . . . . . . . . . . . 1 . . TRANSFORMER, pwr main 230/460/575 (Eff w/KA877025 thru KG082621) . 1 . . TRANSFORMER, pwr main 230/460/575 (Eff w/KG082622) . . . . . . . . . . . . . . . 1 . . TRANSFORMER, pwr main 260/380/520 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . THERMOSTAT, NC (included w/transformer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . THERMOSTAT, NC (Eff w/KG170301) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 TM-353 Page 69 Item No. Dia. Mkgs. Part No. Description Quantity Figure 10-1. Main Assembly (Continued) 22 . . . . . . . . . . . . 22 . . . . . . . . . . . . 22 . . . . . . . . . . . . 23 . . . . . . . . . . . . 24 . . . . . . . . . . . . 25 . . . . . . . . . . . . 26 . . . . C2 . . . . 27 . . . . R5 . . . . 28 . . . . . . . . . . . . 29 . . . . . . . . . . . . 30 . . . . . . . . . . . . 31 . . . F1,2 . . . . ................ ................ 114 755 170 748 171 677 157 196 010 199 108 105 031 668 117 803 114 722 Fig 10-2 098 376 085 874 092 368 130 764 .. .. .. .. .. .. .. .. .. .. .. .. .. .. BASE, (Prior to KE727074) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BASE, (Eff w/KE727074 thru KF959176) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BASE, (Eff w/KF959177) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSULATOR, upright (Eff w/KC307050) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TUBING, stl .500 OD x 17ga x 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLAMP, capacitor 2.500dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAPACITOR, elctlt 4000uf 100VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RESISTOR, WW fxd 10W 1K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRACKET, mtg rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PANEL, front w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUSE, holder (Eff w/KH526231) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUSE, mintr gl slo-blo 10A (Eff w/KH526231) . . . . . . . . . . . . . . . . . . . . . . . . . . . . TUBING, stl .250 ID x 16ga x 3 (Prior to JK682714) . . . . . . . . . . . . . . . . . . . . . . TUBING, stl .250 ID x 16ga wall x 1.500 (Eff w/JK682714) . . . . . . . . . . . . . . . . 1 1 1 1 2 1 1 1 2 1 1 1 1 1 +When ordering a component originally displaying a precautionary label, the label should also be ordered. BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS. TM-353 Page 70 Syncrowave 250 8 9 10 2 4 1 5 6 7 3 4 12 13 Includes Item 26 11 14 29 28 27 15 1 16 26 25 24 23 17 22 18 Figure 10-6 19 21 20 ST-120 088-G Figure 10-2. Panel, Front w/Components Item No. Dia. Mkgs. Part No. Description Quantity Figure 10-2. Panel, Front w/Components (Fig 10-1 Item 29) . . . 1 . . . . . . . . . . . . . 097 922 . . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . . . . . . . . . . . . . . . . . . . . NAMEPLATE, (order by model & serial number) . . . . . . . . . . . . . . . . . . . . . . . . 3 . . . . . . . . . . . . . 109 013 . . BUSHING, snap-in nyl .375 ID x .562mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . . S6,7 . . . 089 085 . . SWITCH, tgl SPST 20A 125VAC (Prior to KF988252) . . . . . . . . . . . . . . . . . . . 4 . . . . S6,7 . . . 176 882 . . SWITCH, tgl SPST 20A 125VAC (Eff w/KF988252) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 983 . . BLANK, snap-in nyl .500mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 057 359 . . BLANK, snap-in nyl .375mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 . . . . . R3 . . . . 030 109 . . POTENTIOMETER, C sltd sft 1/T 2W 5000 ohm . . . . . . . . . . . . . . . . . . . . . . . 6 . . . . . R11 . . . 030 684 . . POTENTIOMETER, C sltd sft 1/T 2W 5 meg ohm . . . . . . . . . . . . . . . . . . . . . . 7 . . . . R1,2 . . . 035 897 . . POTENTIOMETER, C sltd sft 1/T 2W 1000 ohm . . . . . . . . . . . . . . . . . . . . . . . 8 . . . . . S5 . . . . . 011 609 . . SWITCH, tgl SPDT 15A 125VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 . . . . . S3 . . . . 052 769 . . SWITCH, tgl 4PDT 15A 125VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 . . . . . S2 . . . . . 011 610 . . SWITCH, tgl SPDT 15A 125VAC (Prior to JJ503984) . . . . . . . . . . . . . . . . . . . . 10 . . . . . S2 . . . . 088 409 . . SWITCH, tgl 2PDT 15A 125VAC (Eff w/JJ503984) . . . . . . . . . . . . . . . . . . . . . . 11 . . . . TD1 . . . 052 192 . . TIMER, delay on make - postflow (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . 12 . . . . . . . . . . . . . 039 449 . . . . BRACKET, mtg - circuit card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Syncrowave 250 3 1 1 2 2 1 2 1 1 2 1 1 1 1 1 1 TM-353 Page 71 Item No. Dia. Mkgs. Part No. Description Quantity Figure 10-2. Panel, Front w/ Components (Continued) . . . 13 . . . . . . . . . . . . . 044 723 . . . . CIRCUIT CARD, postflow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 . . . . . S1 . . . . 045 834 . . SWITCH, tgl DPST 60A 600VAC (Prior to KA759476) . . . . . . . . . . . . . . . . . . . 14 . . . . . S1 . . . . 128 757 . . SWITCH, tgl DPST 60A 600VAC (Eff w/KA759476) . . . . . . . . . . . . . . . . . . . . . 15 . . . . . . . . . . . . . 106 398 . . PIN, spring CS .156 x .625 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 . . . . . . . . . . . . . . 114 721 . . SHAFT, extension switch (Prior to KA759476) . . . . . . . . . . . . . . . . . . . . . . . . . . 16 . . . . . . . . . . . . . 133 276 . . EXTENSION, handle switch (Eff w/KA759476 thru KF959378) . . . . . . . . . . . 16 . . . . . . . . . . . . . 171 420 . . EXTENSION, handle switch (Eff w/KF959379) . . . . . . . . . . . . . . . . . . . . . . . . . 17 . . . . . . . . . . . . . 164 481 . . PANEL, front (Prior to KF959379) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 . . . . . . . . . . . . . 169 476 . . PANEL, front (Eff w/KF959379 thru KG170300) . . . . . . . . . . . . . . . . . . . . . . . . 17 . . . . . . . . . . . . . 181 096 . . PANEL, front (Eff w/KG170301) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 . . . . . . . . . . . . . . . . . . . . . . . . CONTROL PANEL, lower front (Fig 10-6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 . . . . . . . . . . . . . 128 230 . . LABEL, warning electric shock etc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 . . . . . . . . . . . . . 134 327 . . LABEL, warning electric shock etc CE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 . . . . . . . . . . . . +114 759 . . DOOR, access front (Prior to KG170301) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 . . . . . . . . . . . . +181 589 . . DOOR, access front (Eff w/KG170301) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605 583 . . CATCH, spring loaded door (Prior to KG170301) . . . . . . . . . . . . . . . . . . . . . . . 21 . . . . . . . . . . . . . 134 327 . . LABEL, warning general precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 . . . . . . . . . . . . . 176 254 . . LABEL, warning general precautionary CE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 . . . . . PL2 . . . 157 958 . . LIGHT, ind wht lens 28V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 . . . . . PL1 . . . 155 500 . . LED, yellow (50 Hz model) (Eff w/ KG060803) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLG5 . . . 135 635 . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLG6 . . . 131 054 . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 . . . . . . . . . . . . . 010 647 . . PIN, spring CS .156 x 1.250 (Prior to KF959379) . . . . . . . . . . . . . . . . . . . . . . . 24 . . . . . . . . . . . . . 169 136 . . PIN, handle (Eff w/KF959379) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 . . . . . . . . . . . . . 098 279 . . HANDLE, plrty/changeover switch (Prior to KF959379) . . . . . . . . . . . . . . . . . . 25 . . . . . . . . . . . . . 169 135 . . HANDLE, switch (Eff w/KF959379) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 . . . . . . . . . . . . . 052 370 . . . . KNOB, indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 . . . . . . . . . . . . . 097 924 . . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 . . . . . . . . . . . . ♦115 920 . . METER, amp AC/DC 100MV 0-300 scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 . . . . . . . . . . . . ♦004 189 . . METER, volt AC/DC 0–100 scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 +When ordering a component originally displaying a precautionary label, the label should also be ordered. ♦OPTIONAL BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS. TM-353 Page 72 Syncrowave 250 Item No. Dia. Mkgs. Part No. Description Quantity Figure 10-3. Rectifier, Si Diode (Fig 10-1 Item 2) . . . 1 . . . . C7-10 . . 031 689 . . . 2 . . . . . . . . . . . . . 083 884 . . . 2 . . . . . . . . . . . . . 166 667 . . . 3 . . . . . D1 . . . . 037 956 . . . 4 . . . . TP3 . . . 168 898 . . . 5 . . . SCR1-4 . . . 115 114 . . . 6 . . . . . . . . . . . . . 176 645 . . . 6 . . . . . . . . . . . . . 173 714 . . . . . . . . . . . . . . . . . . . 028 516 . . . . . . . . . PLG53 . . . 115 092 .. .. .. .. .. .. .. .. .. .. CAPACITOR, rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLAMP, thyristor rectifier (Prior to KG023560) . . . . . . . . . . . . . . . . . . . . . . . CLAMP, spring rectifier (Eff w/KG023560) . . . . . . . . . . . . . . . . . . . . . . . . . . DIODE, rect 275A 300V SP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . THERMOSTAT, NC open 125°C (Eff w/KG170301) . . . . . . . . . . . . . . . . . . THYRISTOR, SCR 300A 300V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLAMP, thyristor w/o thermostat (Eff w/KG023560) . . . . . . . . . . . . . . . . . . CLAMP, thyristor with thermostat (Eff w/KG170030) . . . . . . . . . . . . . . . . . . PIN, spring CS .125 x .250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 2 2 1 1 4 2 2 2 1 3 2 4 1 2 5 ST-120 205-A 6 5 Figure 10-3. Rectifier, Si Diode Item No. Dia. Mkgs. Part No. Description Quantity Figure 10-4. Panel, Rear w/Components (Fig 10-1 Item 17) . . . 1 . . . . . R4 . . . . 186 949 . . . 2 . . . . . . . . . . . . . 032 604 . . . 2 . . . . . . . . . . . . . 180 165 . . . 3 . . . . . . . . . . . . . . 114 752 . . . 3 . . . . . . . . . . . . . 181 099 . . . 4 . . . . . . . . . . . . . 131 361 . . . 4 . . . . . . . . . . . . . 173 283 . . . 5 . . . . . . . . . . . . . 124 274 . . . 6 . . . . . FM . . . . . 116 190 . . . . . . . . . . . . . . . . . . . 026 947 . . . . . . . . . . Shunt . . . . 114 723 . . . . . . . . . . . . . . . . . . . 176 272 .. .. .. .. .. .. .. .. .. .. .. .. RESISTOR, WW fxd 175W 20 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BLADE, fan 14 in 3 wing 19deg .375 bore CCW (Prior to KG198783) . . . BLADE, fan 14 in 3 wing 19deg .375 bore CCW (Eff w/KG198783) . . . . . PANEL, rear (Prior to KG170301) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PANEL, rear (Eff w/KG170301) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHAMBER, plenum 14 in (Prior to KG128812) . . . . . . . . . . . . . . . . . . . . . . CHAMBER, plenum 14 in (Eff w/KG128812) (50 Hz only) . . . . . . . . . . . . . BRACKET, mtg fan motor (Eff w/KG128812) . . . . . . . . . . . . . . . . . . . . . . . . MOTOR, 1/12 hp 230V 1550 RPM 50/60Hz 1.5A . . . . . . . . . . . . . . . . . . . . STAND-OFF, insul .250-20 x 1.000 lg (Prior to KB110695) . . . . . . . . . . . . SHUNT, (Prior to KB110695) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONNECTOR, clamp cable (50 Hz model) (Eff w/KG060803) . . . . . . . . . 2 1 1 1 1 1 1 1 1 1 2 1 1 3 1 4 6 5 ST-120 089-F Figure 10-4. Panel, Rear w/Components BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS. Syncrowave 250 TM-353 Page 73 Item No. Dia. Mkgs. Part No. Description Quantity Figure 10-5. Panel, Mtg Components (Fig 10-1 Item 7) . . 1 . . . . . R7 . . . . . 186 468 . . 2 . . . . . . . . . . . . . . . 117 721 . . 3 . . . CR2,6 . . . . . 110 386 . . 4 . . . . . 2T . . . . . 072 253 . . 5 . . . SR2,3 . . . . 035 704 . . 6 . . . SN1,2 . . . . . 118 625 . . 7 . . . . . R6 . . . . . . 117 803 . . 8 . . . . C20 . . . . . . 119 834 . . 9 . . . . . 1T . . . . . . 117 372 . . . . . . . . . . . . . . . . . . . 108 023 . . 10 . . . CR5 . . . . . 000 770 . . 11 . . . CR1 . . . . . 052 964 .. .. .. .. .. .. .. .. .. .. .. .. RESISTOR, WW fxd 100W 50 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PANEL, mtg relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RELAY, encl 24VAC DPDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STUD, single connection 10-32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RECTIFIER, integ 40A 800V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SNUBBER, poly metal film .5uf 200VDC 100 ohm . . . . . . . . . . . . . . . . . . . RESISTOR, WW fxd 10W 1K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAPACITOR, cer disc .05uf 500V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BLOCK, term 10A 15P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LINK, jumper term blk 10A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RELAY, encl 24VDC 3PDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RELAY, encl 24VDC DPDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 2 1 2 2 1 1 1 3 1 1 1 2 11 3 6 10 3 4 5 6 9 8 7 ST-120 090-F Figure 10-5. Panel, Mtg Components BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS. TM-353 Page 74 Syncrowave 250 15 14 17 5 16 13 3 6 2 4 7 11 8 1 9 10 18 23 22 19 21 20 ST-120 003-P Figure 10-6. Control Panel, Lower Front Item No. Dia. Mkgs. Part No. Description Quantity Figure 10-6. Control Panel, Lower Front (Fig 10-2 Item 18) . . . . . . . . . . . . . . . . . . . . 116 477 . . . . . . . . . . . . . . . . . . . 124 647 . . . . . . . . . . . . . . . . . . . 131 217 . . . . . . . . . . . . . . . . . . . 132 430 . . . . . . . . . . . . . . . . . . . 137 516 . . . . . . . . . . . . . . . . . . . 147 793 . . . . . . . . . . . . . . . . . . . 174 067 . . . . . . . . . . . . . . . . . . . 181 108 . . . 1 . . . . . . . . . . . . . . 114 742 . . . 1 . . . . . . . . . . . . . 124 784 . . . 1 . . . . . . . . . . . . . 130 582 . . . 1 . . . . . . . . . . . . . 147 795 . . . 1 . . . . . . . . . . . . . 171 652 . . . 2 . . . . R25 . . . 137 429 Syncrowave 250 .. .. .. .. .. .. .. .. .. .. .. .. .. .. CONTROL PANEL, lower (Prior to JK572898) . . . . . . . . . . . . . . . . . . . . . . . CONTROL PANEL, lower (Eff w/JK572898 thru JK682712) . . . . . . . . . . . CONTROL PANEL, lower (Eff w/JK682714 thru JK690986) . . . . . . . . . . . CONTROL PANEL, lower (Eff w/JK690987 thru KA806713) . . . . . . . . . . . CONTROL PANEL, lower (Eff w/KA806713 thru KA877024) . . . . . . . . . . CONTROL PANEL, lower (Eff w/KA877025 thru KF959378) . . . . . . . . . . . CONTROL PANEL, lower (Eff w/KF959379 thru KG170300) . . . . . . . . . . CONTROL PANEL, lower (Eff w/KG170301) . . . . . . . . . . . . . . . . . . . . . . . . PANEL, lower front (Prior to JK572898) . . . . . . . . . . . . . . . . . . . . . . . . . . . . PANEL, lower front (Eff w/JK572898 thru JK690986) . . . . . . . . . . . . . . . . . PANEL, lower front (Eff w/JK690987 thru KB093120) . . . . . . . . . . . . . . . . . PANEL, lower front (Eff w/KB093121 thru KF959176) . . . . . . . . . . . . . . . . PANEL, lower front (Eff w/KF959177) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RESISTOR, C 2W 3.3K ohm (Eff w/KA806713) . . . . . . . . . . . . . . . . . . . . . 1 1 1 1 1 1 1 1 1 1 1 1 1 1 TM-353 Page 75 Item No. Dia. Mkgs. Part No. Description Quantity Figure 10-6. Control Panel, Lower Front (Continued) ... 3 ............. . . . 3 . . . . C14 . . . . . . 3 . . . . C14 . . . ................... CAPACITOR ASSEMBLY, (Eff w/JK537589 thru JK690986) . . . . . . . . . . . CAPACITOR, (Prior to JK537589) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAPACITOR, (Eff w/JK690987) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RECEPTACLE/CAPACITOR,w/leads (Prior to JK682714) (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RC2 . . . 035 523 . . . . CONNECTOR, circ 5skt rcpt Amphenol MS-3102A-16S-8S . . . . . . . . . . . . . . . . . . C16-19 . . . 119 856 . . . . CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PC2/RFC1 121 273 . . . . CIRCUIT CARD, snubber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 039 273 . . CONNECTOR, circ 5 pin size 16S plug Amphenol MS-3106A-16S-8P . . . . . . . . . . . . . . . . . . . 039 685 . . CONNECTOR, circ clamp str rlf size 16 Amphenol 97-3057-8 . . . . . . . . . . . . . . . . . . . 142 523 . . CONNECTOR/CAPACITOR, w/leads (Eff w/JK674521 thru KF959378) (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RC2 . . . 143 976 . . . . CONNECTOR w/SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C16 . . . 143 899 . . . . LEAD ASSY, elect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C17 . . . 143 897 . . . . LEAD ASSY, elect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C18 . . . 143 898 . . . . LEAD ASSY, elect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C19 . . . 143 900 . . . . LEAD ASSY, elect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RFC1/PC2 142 522 . . . . CHOKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . PC2/RC1 . 157 959 . . CIRCUIT CARD ASSEMBLY, (Eff w/KF959379) (consisting of) . . . . . . . . . . . . . . . . . PLG21 . . 153 501 . . . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 734 . . CONNECTOR, circ 14 pin size 20 plug Amp 213571-2 . . . . . . . . . . . . . . . . . . . 079 534 . . CONNECTOR, circ skt push-in 14-18ga Amp 66358-6 . . . . . . . . . . . . . . . . . . . 079 739 . . CONNECTOR, circ clamp str rlf size 17-20 Amp 206322-2 . . . 5 . . . . . C6 . . . . 164 290 . . CAPACITOR, polyp film 3.5uf 600VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 . . . . PLG3 . . . 131 204 . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 . . . . RC2 . . . 604 176 . . RECEPTACLE, straight duplex grd 2P3W 15A 125V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 073 690 . . CAP, straight P & S 2P3W 5266 DF . . . 8 . . . . C15 . . . 170 920 . . CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 . . . . CB1 . . . 093 995 . . CIRCUIT BREAKER, man reset 1P 15A 250V . . . . . . . . . . . . . . . . . . . . . . . . . . 10 . . . . R13 . . . 605 828 . . RHEOSTAT, WW 50W 1.5 ohm (Prior to KG170301) . . . . . . . . . . . . . . . . . . . . 10 . . . . R13 . . . 174 037 . . RHEOSTAT, WW 50W 1.5 ohm (Eff w/KG170301 thru LA292998) . . . . . . . . 10 . . . . R13 . . . 198 547 . . RHEOSTAT, WW 25W 1.5 ohm (Eff w/LA292999) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 010 493 . . BUSHING, snap-in nyl .625 ID x .875 mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . 11 . . . . . . G . ♦♦020 623 . . SPARK GAP ASSEMBLY (Prior to LA337284) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ♦♦095 621 . . . . BASE, spark gap (Prior to LA337284) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ♦♦020 622 . . . . HOLDER, points (Prior to LA337284) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ♦♦*020 603 . . . . POINT, spark gap (Prior to LA337284) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 . . . . . . G . ♦♦203 419 . . SPARK GAP ASSEMBLY SERVICE KIT (for units prior to LA337284)) . . . . 11 . . . . . . G . ♦♦199 854 . . SPARK GAP ASSEMBLY (Eff w/LA337284) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ♦♦199 855 . . . . BASE, spark gap (Eff w/LA337284) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ♦♦199 856 . . . . HOLDER, points (Eff w/LA337284) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ♦♦*196 455 . . . . POINT, spark gap (Eff w/LA337284) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 088 731 . . BUSHING, snap-in nyl .375 ID x .500mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . . 12 . . . . . . . . . . . . . 097 712 . . STRIP, insulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 . . . . . . . . . . . . . 174 070 . . BRACKET, mtg components (Eff w/KG959379) . . . . . . . . . . . . . . . . . . . . . . . . . 14 . . . . . C3 . . . . 106 935 . . CAPACITOR, polyp film 10uf 250VAC (Prior to KK001554) . . . . . . . . . . . . . . . 14 . . . . . C3 . . . . 191 944 . . CAPACITOR, polyp film 10uf 250VAC (Eff w/KK001554) . . . . . . . . . . . . . . . . . 15 . . . . . R8 . . . . 083 784 . . RESISTOR, WW fxd 100W 10 ohm (Prior to KG170301) . . . . . . . . . . . . . . . . 15 . . . . . R8 . . . . 181 107 . . RESISTOR ASSEMBLY w/LEADS, (Eff w/KG170301) . . . . . . . . . . . . . . . . . . . 16 . . . . . C4 . . . . 096 761 . . CAPACITOR, mica .002uf 10000V (CE Models Only) . . . . . . . . . . . . . . . . . . . 16 . . . . . C4 . . . . 096 761 . . CAPACITOR, mica .002uf 10000V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Prior to KK001554 for nonCE Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 . . . . . C4 . . . . 201 197 . . CAPACITOR, polyp met film .002uf 10000VDC/4400VAC pnl mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Eff w/KK001554 for nonCE Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 000 681 . . STRIP, mtg HF coil (Prior to JK572898) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 649 . . STRIP, mtg HF coil (Eff w/JK572898) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 000 682 . . TUBING, fiber vulc .250 ID x .312 OD x .812 (Prior to JK572898) . . . . . . . . . . . . . . . . . . . . . . . . . 125 949 . . TUBING, fiber vulc .250 ID x .312 OD x 1.125 (Eff w/JK572898) . . . . . . . . . . 17 . . . . . T2 . . . . 074 398 . . TRANSFORMER, high voltage 115V pri 3600V sec 30mA . . . . . . . . . . . . TM-353 Page 76 126 750 098 566 132 433 121 270 .. .. .. .. 1 1 3 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 4 1 1 1 4 4 2 1 1 1 1 1 1 1 1 1 1 1 2 2 1 Syncrowave 250 Item No. Dia. Mkgs. Part No. Description Quantity Figure 10-6. Control Panel, Lower Front (Fig 10-2 Item 18) (Continued) . . . 18 . . . . . T3 . . . . . 115 967 . . . 18 . . . . . T3 . . . . 124 650 . . . 18 . . . . . T3 . . . . 174 692 . . . . . . . . . . . R9 . . . . 030 603 . . . 19 . . . . Work Electrode . 039 047 . . . . . . . . . . . . . . . . . . . 601 976 . . . . . . . . . . . . . . . . . . . 039 049 . . . . . . . . . . . . . . . . . . . 601 880 . . . . . . . . . . . . . . . . . . . 039 044 . . . . . . . . . . . . . . . . . . . 601 879 . . . 20 . . . . GS1 . . . 174 036 . . . . . . . . . . . . . . . . . . . 010 296 . . . . . . . . . . . . . . . . . . . 035 601 . . . . . . . . . . PLG4 . . . 131 203 . . . 21 . . . . . . . . . . . . . 174 038 . . . 22 . . . . . . . . . . . . . 097 922 . . . 23 . . . . . . . . . . . . . 010 357 . . . 24 . . . . . . . . . . . . . 605 742 .. .. .. .. COIL, HF coupling (Prior to JK572898) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COIL, HF coupling (Eff w/JK572898 thru KF959378) . . . . . . . . . . . . . . . . . COIL, HF coupling (Eff w/KF959379) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RESISTOR, WW fxd 10W 10K ohm (Prior to KA877025) . . . . . . . . . . . . . 1 1 1 1 . . TERMINAL, power output (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SCREW, stl hexhd .500-13 x 1.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TERMINAL BOARD, red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NUT, stl hex jam .500 -13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BUS BAR, term bd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NUT, stl hex full fnsh .500-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VALVE, w/fittings & leads (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FITTING, hose brs elbow M 1/4NPT x .625-18 . . . . . . . . . . . . . . . . . . . . . . . . . VALVE, 115VAC 2 way 1/4 IPS port 1/8 orf . . . . . . . . . . . . . . . . . . . . . . . . . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PANEL, door access HF (Eff w/KF959379) . . . . . . . . . . . . . . . . . . . . . . . . . . . KNOB, pointer (Eff w/JK572898) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEED NUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLIP, mtg resistor .500 ID core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 1 1 1 1 1 1 2 1 1 1 1 1 2 *Recommended Spare Parts ♦♦Effective with Serial No.LA337284, Spark Gap Assembly 020 623 consisting of: Base 095 621, Holder 020 622, and Points 020 603, is no longer available. If replacement parts are needed for any units with a Serial No. prior to LA337284, you must first order and install Spark Gap Assembly Service Kit 203 419. To replace spark gap parts in units with Serial No. LA337284 and following, or for units with Spark Gap Assembly Service Kit 203 419 installed, order appropriate spark gap parts listed above as, eff/w Serial No. LA337284. BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS. Syncrowave 250 TM-353 Page 77 Eff w/KE558763 the Water Valve Option (042 138) is no longer available and all other options are available as Field Options only. Dia. Mkgs. Part No. Description Quantity Optional Equipment . . . . . . . . . . . . . . . . . . . . . . 042 138 . . . . . . . . WSI . . . . . . . . . 035 601 . . . . . . . . . . . . . . . . . . . . . . 010 295 . . . . . . . . . . . . . . . . . . . . . . 116 201 . . . . . . . . . . . . . . . . . . . . . . 042 140 . . . . . . . . . A . . . . . . . . . . 115 920 . . . . . . . . . V . . . . . . . . . . 004 189 . . . . . . . . . . . . . . . . . . . . . . 131 054 . . . . . . . . . . . . . . . . . . . . . . 113 746 . . . . . . . . . . . . . . . . . . . . . . 042 142 . . . . . . . CR3 . . . . . . . . . 006 393 . . . RFC,VR1/PC3 . . . . . 120 875 . . . . . . . . R10 . . . . . . . . . 030 108 . . . . . . . . S8 . . . . . . . . . . . 011 611 . . . . . . . . TD2 . . . . . . . . . 047 133 . . . . . . . . . . . . . . . . . . . . . . 097 922 . . . . . . . . . . . . . . . . . . . . . . 042 144 . . . . . . . CR4 . . . . . . . . . 006 393 . . . . . . R12,S9 . . . . . . . . 115 862 . . . . . . . . TD3 . . . . . . . . . 116 476 . . . . . . . . . . . . . . . . . . . . . . 115 856 . . . . . . . . A50 . . . . . . . . . 008 971 . . . . . . . . C50 . . . . . . . . . 039 482 . . . . . . . . C51 . . . . . . . . . 091 378 . . . . . . . . C52 . . . . . . . . . 039 481 . . . . . . . . C53 . . . . . . . . . 031 677 . . . . . . . . C54 . . . . . . . . . 166 199 . . . . . . . CR50 . . . . . . . . 039 486 . . . . . . D50,51 . . . . . . . . 026 202 . . . . . . . . Q50 . . . . . . . . . 000 088 . . . . . . . . R50 . . . . . . . . . 074 121 . . . . . . . . R52 . . . . . . . . . 108 432 . . . . . . . . R53 . . . . . . . . . 000 342 . . . . . . . . R54 . . . . . . . . . 093 030 . . . . . . . . R55 . . . . . . . . . 028 273 . . . . . . . . R56 . . . . . . . . . 093 037 . . . . . . . . R57 . . . . . . . . . 605 919 . . . . . . . . . . . . . . . . . . . . . . 039 449 . . . . . . . . . . . . . . . . . . . . . . 097 922 . . . . . . . . . . . . . . . . . . . . . . 042 353 . . . . . . . . C1 . . . . . . . . . . 125 781 . . . . . . . . . . . . . . . . . . . . . . 129 201 TM-353 Page 78 . . WATER VALVE, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VALVE, 115VAC 2 way 1/4 IPS port 1/8 orf . . . . . . . . . . . . . . . . . . . . . . . . . FITTING, pipe brs elbow M 1/4NPT x .625-18 . . . . . . . . . . . . . . . . . . . . . . BRACKET, mtg valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . METER KIT, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . METER, amp AC/DC 100MV 0-300 scale . . . . . . . . . . . . . . . . . . . . . . . . . . METER, volt AC/DC 0-100 scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . CONNECTOR, rect skt 24-18ga Molex 39-00-0038 . . . . . . . . . . . . . . SPOT TIMER, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RELAY, encl 24VAC DPDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT CARD, snubber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . POTENTIOMETER, C sltd sft 1/T 2W 100K ohm . . . . . . . . . . . . . . . . . . . SWITCH, tgl DPDT 15A 125V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RELAY, delay adj 120VAC DPDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PRE-FLOW TIMER, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RELAY, encl 24VAC DPDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . POTENTIOMETER, C sltd sft 1/T .50W 500K ohm . . . . . . . . . . . . . . . . . . TIMER, delay on make - preflow (consisting of) . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT CARD, preflow (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IC, linear 741 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAPACITOR, elctlt 100uf 35VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAPACITOR, tantlm 33uf 35VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAPACITOR, elctlt 3.3uf 50VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAPACITOR, elctlt 5.6uf 35VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAPACITOR, cer disc .05uf 500VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RELAY, encl 24VDC SPDT 2.5A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DIODE, rect 1A 400V SP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSISTOR, NPN 800mA 400V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RESISTOR, C 2W 3.3K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RESISTOR, MF .25W 2.21K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . POTENTIOMETER, cermet trmr 1/T .5W 5K ohm . . . . . . . . . . . . . . . . . . . RESISTOR, MF .25W 15K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RESISTOR, C .5W 2.7K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RESISTOR, MF .25W 47.5K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RESISTOR, C .25W 47 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRACKET, mtg circuit card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . POWER FACTOR CORRECTION, (consisting of) . . . . . . . . . . . . . . . . . . . . CAPACITOR, polyp film 150uf 250VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRACKET, mtg capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 2 1 1 1 1 1 8 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 4 2 Syncrowave 250 Call 1-800-4-AMILLER for your local Miller distributor. Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA International Headquarters–USA Phone: 920-735-4505 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 1998 Miller Electric Mfg. Co.
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