Miller Electric Welding Generator 250 DX User manual

Processes
TIG (GTAW)
Stick (SMAW)
Pulsed TIG (GTAW-P)
(Optional)
Input Power Requires 1-Phase Power
Amperage Range 250: 3 – 310 350: 3 – 400
Max. Open-Circuit Voltage 80 VDC
Rated Output 250: 250 A at 30 VAC, 40% Duty Cycle
200 A at 28 VAC, 60% Duty Cycle
350: 350 A at 34 VAC, 40% Duty Cycle
300 A at 32 VAC, 60% Duty Cycle
Weight Standard: 250: 378 lb (172 kg) 350: 496 lb (225 kg)
TIGRunner®: 250: 478 lb (217 kg) 350: 596 lb (270 kg)
Industrial Applications
Precision Metal Fabrication
Maintenance and Repair
Light and Heavy Manufacturing
Aerospace
Shipbuilding
Tube and Pipe
Automotive
Vocational
Quick
Specs
See page 2 for
additional features
Syncrowave®250 DX/350 LX TIG/Stick Welding
Power Source
Issued April 2008 • Index No. AD/4.2
The Power of Blue® .
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Web Site
www.MillerWelds.com
International Headquarters
Phone: [phone]
USA FAX: [phone]
Canadian FAX: [phone]
International FAX: [phone]
The balance control is adjustable to provide
additional oxide removal (more cleaning) or less
cleaning based on the condition of the material
being welded. See pg 2 for more information on
this feature.
Syncro Start™allows the choice of Soft, Standard
or Hot TIG starts based on the application, lead
lengths and tungsten size.
Dual inline high-frequency points provide
intense high frequency for arc starting and
stabilization. Internal machine components are
protected from HF interference with additional
grounding and filtering for extended product life.
Digital welding meters display both amperage
and voltage for viewing of the actual and preset
values for greater accuracy and repeatability in
your welding procedure.
Last procedure recall simplifies changing your
Syncrowave back and forth from aluminum TIG
to stainless TIG to stick welding. One switch
makes all the control panel changes.
Standard Machine
Syncrowave Complete
Package includes:
Syncrowave®
Coolmate™3X cooler
No. 37 running gear
TIG torch kit with
accessories
Foot pedal
Four gallons of coolant
Power source is warranted for 3 years, parts and labor.
Original main power rectifier parts are warranted for 5 years.

2
AC Output: Balance Control
Additional Features
Balanced Wave
Greatest Cleaning Action
More Heat into Work
68%
Electrode
Negative
45%
Electrode
Negative
50%
Electrode
Negative
50%
Electrode
Positive
55%
Electrode
Positive
32%
Electrode
Positive
Balanced
Max.
Cleaning
Max.
Penetration
1
2
3
456
7
8
0
9
10
1
2
3
456
7
8
0
9
10
1
2
3
456
7
8
0
9
10
Cleaning
Wider bead and
cleaning action
Bead
Narrower bead
for fillet welds
Medium bead
Wide bead
Cleaning
Bead
AC Balance Balanced Wave Function
Narrow bead, with no
visible cleaning
No Visible Cleaning
Bead
Pulsed TIG control lowers the heat input into
the part and reduces warping and distortion
(optional on 250 DX models).
TIGRunner™system packages with
Coolmate™3X cooler. A 3-gallon cooling
system equipped with a visual flow indicator
ensures that the coolant is flowing. An external
coolant filter stops foreign objects from entering
the water cooled torch cable for better flow and
longer life. Extended cooling capacity ensures
maximum productivity. 3-year cooler warranty.
Stick welding features such as Adaptive
Hot Start™provide good arc strikes without
sticking. Once welding, the DIG control makes
dynamic adjustments to the welder to ensure
smooth E7018 and deep penetration E6010.
Tilted operator interface and built-in consumable
drawer provide added convenience to your
welding experience.
Arc timer/cycle counter records actual welding
time and number of arc starts. Great for estimating
job costs.
Squarewave technology developed and
patented by Miller Electric in 1976. Squarewave
technology was developed to improve your weld
quality and make TIG welding easier. Miller
Squarewave technology provides arc stability
when welding aluminum, prevents arc
rectification and eliminates tungsten erosion.
Welding aluminum? Oxides that form on
aluminum melt at temperatures over 3700° F.
The aluminum material that is located under
this layer of oxide melts at 1200° F. The
Syncrowave’s AC Squarewave welding current
automatically removes the layer of oxide which
is necessary for producing high quality welds.
Do you have power fluctuations?
The Syncrowave compensates for power
fluctuation without changing your welding
parameters. Line voltage compensation
works on fluctuating power ±10%.
NEW! Easy Load Dual Cylinder Rack ➡
minimizes cylinder lifting. (Cylinder not included.)

3
Specifications (Subject to change without notice.)
Model
Syncrowave
250
Syncrowave
250 CE
220/400/
440/520
Syncrowave
350
All Models
Rated Output
250 A at 30 V,
40% Duty Cycle
225 A at 29 V,
40% Duty Cycle
250 A at 30 V,
40% Duty Cycle
350 A at 34 V,
40% Duty Cycle
Welding
Amp Range
3–310 A
3–400 A
Max
OCV
80 V
80 V
Input
Power
60 Hz,
1-Phase
50 Hz,
1-Phase
50 or
60 Hz,
1-Phase
50 or
60 Hz,
1-Phase
Amps Input at AC Balance, Rated Load
200V 220V 230V 400V 440V 460V 520V 575V KVA KW
110 — 96 — — 48 — 38 22 12
101 — 88 — — 44 — 35 20 10
— 100 — 55 50 — 42 — 22 12
146 120 128 66 60 65 51 50 30 14
Dimensions
H: 33-1/4 in (845 mm)*
W:22-1/2 in (572 mm)
D: 25 in (635 mm)**
with TIGRunner®
H: 46 in (1168 mm)*
W:28-1/2 in (724 mm)
D: 40-1/2 in (1029 mm)**
H: 33-1/4 in (845 mm)*
W:22-1/2 in (572 mm)
D: 25 in (635 mm)**
H: 33-1/4 in (845 mm)*
W:22-1/2 in (572 mm)
D: 25 in (635 mm)**
with TIGRunner®
H: 46 in (1168 mm)*
W:28-1/2 in (724 mm)
D: 40-1/2 in (1029 mm)**
Weight
378 lb
(172 kg)
478 lb
(217 kg)
378 lb
(172 kg)
496 lb
(225 kg)
596 lb
(270 kg)
Certified to both the Canadian and U.S. Standards for welding equipment.
Note: See pg 6 for power factor correction kit. *Add 3 in (76 mm) for lift eye. **Add 1-1/2 in (38 mm) for handle.
Performance Data
RATED OUTPUT
% DUTY CYCLE
WELDING AMPERES
500
450
400
350
300
250
200
150
100
50 10 20 30 40 50 60 70 80 90 100
DUTY CYCLE CHART
Syncrowave 350 LX
Syncrowave 250 DX

4
Sequencer**
Module
Pulser*
Module
1
8
7
9
10
11
12
13
14
15
16
17
18
2
3
4
5
6
19
20
Common Bottom Panel
Control Panels
1. Voltmeter Display
2. Start Mode Control
(Lift-Arc, HF Start, HF Continuous)
3. Output Control
4. Amperage Control (Panel/Remote)
5. Process Control (Stick/TIG)
6. Balance/Dig Control (0 – 10)
7. Postflow Time Control (0 – 50 sec)
8. Ammeter Display
9. Pulser Control*
10. Background Amps Control (0 – 100%)*
11. Pulse-Per-Second Control (0.25 – 10 Hz)*
12. Peak Time Control (5 – 95%)*
13. Spot Time Control (0 – 5 sec)*
14. Final Slope Control (0 – 25 sec)*
15. Initial Time Control (0 – 15 sec)*
16. Final Amperage Control (0 – 100%)*
17. Initial Amperage Control (3 – 310/400 A)*
18. Amperage Adjustment Control (3 – 310/400 A)
19. Power Switch (On/Off)
20. Output Selector Switch (AC/DC-/DC+)
*Optional Pulser for 250 DX
**Optional Sequencer

5
Packages
Syncrowave®Power Sources
Syncrowave®250 DX
#907 194 (200/230/460 VAC)
#907 195 (230/460/575 VAC)
#907 197 (220/400/440/520 VAC) CE
Syncrowave®350 LX
#907 198 (200/230/460 VAC)
#907 199 (230/460/575 VAC)
#907 200 (220/400/440/520 VAC) CE
Primary cord and TIG torch adapter
sold separately.
TIGRunner®Packages
Syncrowave®250 DX TIGRunner®3X
#907 194-03-2 (200/230/460 VAC)
#907 195-03-2 (230/460/575 VAC)
Syncrowave®350 LX TIGRunner®3X
#907 198-03-2 (200/230/460 VAC)
#907 199-03-2 (230/460/575 VAC)
Completely assembled. TIGRunner includes
Syncrowave, Coolmate™3X cooler, No. 37
running gear, RFCS-14 HD remote foot
control, and international-style connectors.
Primary cord, TIG torch adapter and TIG
coolant sold separately.
Syncrowave®Complete Packages
Syncrowave®250 DX Complete
#951 117 (200/230/460 VAC)
#951 118 (230/460/575 VAC)
Syncrowave®350 LX Complete
#951 119 (200/230/460 VAC)
#951 120 (230/460/575 VAC)
Completely assembled. Includes TIGRunner
above (Syncrowave, Coolmate™3X cooler,
No. 37 running gear, RFCS-14 HD remote
foot control, and international-style
connectors), plus four gallons of TIG
coolant and a water-cooled torch kit (see
kits to left) consisting of torch, cable cover,
accessory kit, regulator/flowmeter, gas
hose, torch adapter, and weld lead with
clamp and Dinse connector.
Primary cord sold separately.
Syncrowave Complete
(Syncrowave TIGRunner,
TIG Coolant and Torch Kit)
250 A Water-Cooled Torch Kit
for Syncrowave 250 DX TIGRunner
TIG Coolant TIG Coolant
Syncrowave TIGRunner
300 A Water-Cooled Torch Kit
for Syncrowave 350 LX TIGRunner
Standard Model

No. 37 Running Gear #195 282
Includes two 10 in (254 mm) wheels, two
5 in (127 mm) casters, two-compartment
rack (for gas cylinder(s) or Coolmate V3
coolant system), and handles. Provides
excellent mobility and easy to install.
Protective Cover #195 320
Heavy-duty, water- and mildew-resistant.
Protects and maintains the finish of
the welder.
Remote Controls and Switches
RCCS-14 Remote Contactor and
Current Control #043 688 14-pin plug
North/south rotary-motion fingertip control
fastens to TIG torch using two Velcro®
straps. Great for applications that require a
finer amperage control. Includes 26.5 ft (8
m) control cord.
RFCS-14 HD Foot Control #194 744
Maximum flexibility is accomplished with a
reconfigurable cord that can exit the front,
back or either side of the pedal. Foot pedal
provides remote current and contactor
control. Includes 20 ft (6 m) cord and 14-
pin plug.
RHC-14 Hand Control
#129 340
Miniature hand control
for remote current and
contactor control.
Dimensions:
4 x 4 x 3-1/4 in
(102 x 102 x 83 mm). Includes 20 ft (6 m)
cord and 14-pin plug.
RMLS-14 Switch #129 337
Momentary- and maintained-contact rocker
switch for contactor control. Push forward
for maintained contact and backward for
momentary contact. Includes 26.5 ft (8 m)
cord and 14-pin plug.
RMS-14 On/Off Control #187 208
Momentary-contact switch for contactor
control. Rubber-covered pushbutton dome
switch ideal for repetitive on-off
applications. Includes 26.5 ft (8 m) cord
and 14-pin plug.
Extension Cords for 14-Pin Remote Controls
#122 973 25 ft (7.6 m)
#122 974 50 ft (15.2 m)
#122 975 75 ft (23 m)
Gas Tungsten Arc (TIG) Welding Book
#170 555
To order this item, distributors can call
the Miller Literature Distribution Center at
1-920-735-4356, or FAX [phone].
86 pages — 8-1/2 x 11 in. A comprehensive
text on all aspects of the GTAW process.
Filled with figures and tables to illustrate
process technique and equipment setup.
Glossary of TIG terms also provided.
TIG Training CD #196 567
Designed for anyone who’s looking to
better understand the TIG process. Easy
to understand instruction, proven teaching
steps, and expert advice help to create a
more effective academic approach to training.
Subject areas covered include system
components, process fundamentals, electrical
theory, safety, power source operation.
Video – GTAW Setup Procedures #108 241
To order this item, distributors can call
the Miller Literature Distribution Center at
1-920-735-4356, or FAX [phone].
13:00 minutes. A detailed demonstration
on preparing your equipment for TIG
welding. Uses a Syncrowave 250 power
source, but topics fit any TIG setup
including air-or water-cooled systems.
In-depth discussion of tungstens and gases.
6
Genuine Miller Accessories
Genuine Miller Options
Field Options
Sequencer Module #195 345 Field Kit
Provides a starting current higher or lower
than the welding current. Provides final slope
and final current for trailing the weld. Provides
a spot timer for TIG spot application.
Pulser Module
#195 344 Field Kit for Syncrowave 250 DX
For welding of thin materials. Provides a
heating and cooling effect of the weld
puddle to reduce heat input and control
distortion of the material. Provides 0.25 to
10 pulses per second.
Power Factor Correction Kit
#194 692 Field Kit for Syncrowave 250 DX
#043 757 Field Kit for Syncrowave 350 LX
Reduces primary amperage draw by
approximately 25% allowing the use of
smaller breakers/fuses and smaller primary
cord. Power Factor
does not reduce the
power consumption/electrical bill.

7
TIG Welding Gloves
#227 813 Small
#227 814 Medium
#227 815 Large
#227 816 X-Large
Designed to meet the
specific requirements high-
quality TIG welding demands.
Made from soft grain goatskin. Sewn with
Kevlar®thread.
TIG (GTAW) Torch Adapters
Water-Cooled Dinse #195 377
Used to adapt a 250 or 350 A water-cooled
torch (WP20, WP18, CS310) to an
International-style connector.
Air-Cooled Dinse #195 379
Used to adapt a 1-piece 200 amp air-cooled
torch (WP26) to an International-style
connector.
Tungsten
Items below are available in packages of 10 and
are 7-in lengths.
2% Ceriated (orange) for AC/DC applications
#WC040X7 .040 in, 10– 80 A
#WC116X7 1/16 in, 70– 150 A
#WC332X7 3/32 in, 140– 250 A
#WC018X7 1/8 in, 225– 400 A
#WC532X7 5/32 in, 300– 500 A
1.5% Lanthanum (gold) for AC/DC applications
#WL040X7 .040 in, 10– 80 A
#WL116X7 1/16 in, 70– 150 A
#WL332X7 3/32 in, 140– 250 A
#WL018X7 1/8 in, 225– 400 A
#WL532X7 5/32 in, 300– 500 A
Pure (green) for AC applications only
#WP040X7 .040 in, 10– 80 A
#WP116X7 1/16 in, 70– 150 A
#WP332X7 3/32 in, 140– 250 A
#WP018X7 1/8 in, 225– 400 A
#WP532X7 5/32 in, 300– 500 A
2% Thoriated (red) for DC applications only
#WT040X7 .040 in, 10– 80 A
#WT116X7 1/16 in, 70– 150 A
#WT332X7 3/32 in, 140– 250 A
#WT018X7 1/8 in, 225– 400 A
#WT532X7 5/32 in, 300– 500 A
Water Coolant Systems
For more information, see the Miller Coolant
Systems literature sheet, Index No. AY/7.2.
Coolmate™V3
#043 009 115 VAC
#043 009-01-2 115 VAC, CE
For use with water-cooled
torches rated up to 500 amps.
Vertical design conveniently
mounts to Miller cylinder
rack in place of one cylinder.
3-gallon capacity.
Coolmate™3X with
Cart and Dual Cylinder
Rack #300 419
Includes: Easy Load
Dual Cylinder Rack,
running gear, and 3X
industrial water cooler — a perfect
solution for water-cooled TIG torches.
TIG Coolant
#043 810
Sold in multiples of 4.
Pre-mixed low-
conductivity Miller
coolant contains
ethylene glycol and deionized water to
protect from freezing and boiling -37˚ to
227˚F (-38˚ to 108˚C). Coolant contains
2.4% algae growth inhibitor. 1-gallon plastic
recyclable bottles.
250 A Water-Cooled Torch Kit #300 185
Recommended for Syncrowave 250 DX
25 ft (7.6 m) Weldcraft®WP20 torch
Torch cable cover
AK4C torch accessory kit includes
shielding cups, collets, collet bodies and
2% cerium tungsten electrodes (1/16,
3/32 and 1/8 in)
Smith®regulator/flowmeter HM2051A-580
12 ft (3.7 m) rubber gas hose (regulator
to machine)
Water-cooled Dinse torch adapter
15 ft (4.6 m) 1/0 weld lead with clamp
(work or ground lead) and Dinse connector
300 A Water-Cooled Torch Kit #300 183
Recommended for Syncrowave 350 LX
25 ft (7.6 m) Weldcraft®CS310 torch
Torch cable cover
CS310AKC torch accessory kit includes
shielding cups, collets, collet bodies and
2% cerium tungsten electrodes (1/16,
3/32 and 1/8 in)
Smith®regulator/flowmeter HM2051A-580
12 ft (3.7 m) rubber gas hose (regulator
to machine)
Water-cooled Dinse torch adapter
15 ft (4.6 m) 1/0 weld lead with clamp
(work or ground lead) and Dinse connector
400 A Water-Cooled Torch Kit #300 186
25 ft (7.6 m) Weldcraft®WP18SC torch
Torch cable cover
AK18C torch accessory kit includes
shielding cups, collets, collet bodies and
2% cerium tungsten electrodes (3/32,
1/8 and 5/32 in)
Smith®regulator/flowmeter H1954D-580
12 ft (3.7 m) rubber gas hose (regulator
to machine)
Water-cooled thread lock torch adapters
12 ft (3.7 m) 4/0 weld lead with clamp
(work or ground lead)
Genuine Miller Accessories (continued)
Torch Kits
Includes Wheels

Litho in USA
Distributed by:
Equipment and Options Stock No. Description Qty. Price
Syncrowave®250 DX #907 194 200/230/460 V, 50/60 Hz, Standard Model
#907 195 230/460/575 V, 50/60 Hz, Standard Model
#907 197 220/400/440/520 V, 50/60 Hz, CE, Standard Model
#907 194-03-2 200/230/460 V, 50/60 Hz, Syncrowave 250 DX TIGRunner® 3X
#951 117 200/230/460 V, 50/60 Hz, Syncrowave 250 DX Complete
#907 195-03-2 230/460/575 V, 50/60 Hz, Syncrowave 250 DX TIGRunner® 3X
#951 118 230/460/575 V, 50/60 Hz, Syncrowave 250 DX Complete
Syncrowave®350 LX #907 198 200/230/460 V, 50/60 Hz, Standard Model
#907 199 230/460/575 V, 50/60 Hz, Standard Model
#907 200 220/400/440/520 V, 50/60 Hz, CE
#907 198-03-2 200/230/460 V, 50/60 Hz, Syncrowave 350 LX TIGRunner® 3X
#951 119 200/230/460 V, 50/60 Hz, Syncrowave 350 LX Complete
#907 199-03-2 230/460/575 V, 50/60 Hz, Syncrowave 350 LX TIGRunner® 3X
#951 120 230/460/575 V, 50/60 Hz, Syncrowave 350 LX Complete
Sequencer Module #195 345 Field
Pulser Module #195 344 Field. For Syncrowave 250 DX
Power Factor Correction Kit #194 692 Field. For Syncrowave 250 DX
#043 757 Field. For Syncrowave 350 LX
TIG Torch Kits
Weldcraft®250 A Water-Cooled Torch Kit #300 185 See page 7. Recommended for Syncrowave 250 DX TIGRunner 3X
Weldcraft®300 A Water-Cooled Torch Kit #300 183 See page 7. Recommended for Syncrowave 350 LX TIGRunner 3X
Weldcraft®400 A Water-Cooled Torch Kit #300 186 See page 7
Consumables and Tungsten See page 7
Gas Cylinder, Hose and Fittings
Remote Controls
RCCS-14 #043 688 North/south fingertip control
RFCS-14 HD #194 744 Heavy-duty foot control
RHC-14 #129 340 Hand control
RMLS-14 #129 337 Momentary/maintained rocker switch
RMS-14 #187 208 Momentary rubber dome switch
Extension Cords #122 973 25 ft (7.6 m)
#122 974 50 ft (15.2 m)
#122 975 75 ft (22.9 m)
Accessories
No. 37 Running Gear #195 282
Protective Cover #195 320
Gas Tungsten Arc (TIG) Welding Book #170 555 Contact your distributor
TIG Training CD #196 567
Video – GTAW Setup Procedures #108 241 Contact your distributor
Torch Adapters #195 377 Adapts 250 or 350 A water-cooled torch to international-style connector
Supplied with power source and torch kits #195 379 Adapts 1-pc 200 A air-cooled torch to international-style connector
Cable Connectors Supplied with power source and torch kits
Dinse Connector 50 mm (1 male) #042 418 Used to connect weld lead to Dinse terminal machine
Dinse Connector 50 mm (1 male, 1 female) #042 419 Used to extend weld cables
Tweco Terminal Adapter #042 465 Male Dinse to female Tweco
Cam-Lok Terminal Adapter #042 466 Male Dinse to female Cam-Lok
TIG Coolant #043 810 Sold in multiples of 4. 1-gallon plastic bottles.
Water Coolant Systems See page 7
Miscellaneous
Stick Electrodes
Welding and Work Cables
Helmets
TIG Welding Gloves See page 7
Date: Total Quoted Price:
Ordering Information