Processes TIG (GTAW) Stick (SMAW) Pulsed TIG (GTAW-P) (Optional on 250 DX models)

Transcription

1 Syncrowave 0 DX/0 LX Issued Nov. 010 Index No. AD/4. TIG/Stick Welding Power Source Quick Specs Industrial Applications Precision Metal Fabrication Maintenance and Repair Light and Heavy Manufacturing Aerospace Shipbuilding Tube and Pipe Automotive Vocational Processes TIG (GTAW) Stick (SMAW) Pulsed TIG (GTAW-P) (Optional on 0 DX models) Input Power Requires 1-Phase Power Amperage Range 0: 10 0: 400 Max. Open-Circuit Voltage 80 VDC Rated Output 0: 0 A at 0 VAC, 40% Duty Cycle 00 A at 8 VAC, 60% Duty Cycle Weight 0: 0 A at 4 VAC, 40% Duty Cycle 00 A at VAC, 60% Duty Cycle Standard: 0: 8 lb (1 kg) 0: 496 lb ( kg) TIGRunner : 0: 48 lb (1 kg) 0: 96 lb (0 kg) The Power of Blue. See Page for Additional Features Syncrowave Complete Package includes: Syncrowave Coolmate X cooler No. running gear TIG torch kit with accessories Foot pedal Four gallons of coolant Standard Machine 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 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. Power source is warranted for years, parts and labor. Original main power rectifier parts are warranted for years. Miller Electric Mfg. Co. An Illinois Tool Works Company 16 West Spencer Street Appleton, WI 4914 USA Equipment Sales US and Canada Phone: FAX: International Phone: International FAX: Web Site

2 Additional Features Pulsed TIG control lowers the heat input into the part and reduces warping and distortion (optional on 0 DX models). TIGRunner system packages with Coolmate X cooler. A -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. -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 E018 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 by Miller Electric in 196. 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 00 F. The aluminum material that is located under this layer of oxide melts at 100 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%. Easy Load Dual Cylinder Rack minimizes cylinder lifting. (Cylinder not included.) AC Output: Balance Control AC Balance Balanced Wave Function Balanced 8 9 Medium bead Cleaning Bead Balanced Wave 0% Positive 0% Negative Max. Penetration Narrower bead for fillet welds Narrow bead, with no visible cleaning Bead No Visible Cleaning More Heat into Work % Positive 68% Negative Max. Cleaning 8 9 Wide bead Wider bead and cleaning action Cleaning Bead Greatest Cleaning Action % Positive 4% Negative

3 Specifications (Subject to change without notice.) Model Input Power Welding Amp Range Max OCV Rated Output Amps Input at AC Balance, Rated Load 00V 0V 0V 400V 440V 460V 0V V KVA KW Dimensions Weight Syncrowave 0 60 Hz, 1-Phase 0 Hz, 1-Phase 10 A 80 V 0 A at 0 V, 40% Duty Cycle A at 9 V, 40% Duty Cycle H: -1/4 in (84 mm)* W:-1/ in ( mm) D: in (6 mm)** with TIGRunner H: 46 in (1168 mm)* W:8-1/ in (4 mm) D: 40-1/ in (109 mm)** 8 lb (1 kg) 48 lb (1 kg) Syncrowave 0 IEC 0/400/ 440/0 0 or 60 Hz, 1-Phase 0 A at 0 V, 40% Duty Cycle H: -1/4 in (84 mm)* W:-1/ in ( mm) D: in (6 mm)** 8 lb (1 kg) Syncrowave 0 All Models 0 or 60 Hz, 1-Phase 400 A 80 V 0 A at 4 V, 40% Duty Cycle H: -1/4 in (84 mm)* W:-1/ in ( mm) D: in (6 mm)** 496 lb ( kg) with TIGRunner H: 46 in (1168 mm)* W:8-1/ in (4 mm) D: 40-1/ in (109 mm)** 96 lb (0 kg) Notes: See pg 6 for power factor correction kit. *Add in (6 mm) for lift eye. **Add 1-1/ in (8 mm) for handle. IEC models conform to the following standards: IEC : 00, IEC : 004, and EN 044 Certified by Canadian Standards Association to both the Canadian and U.S. Standards. Performance Data DUTY CYCLE CHART WELDING AMPERES Syncrowave 0 LX Syncrowave 0 DX RATED OUTPUT % DUTY CYCLE

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

5 Packages Syncrowave Power Sources Standard Model Syncrowave 0 DX # (00/0/460 VAC) #90 19 (0/460/ VAC) #90 16 (0/400/440/0 VAC) IEC Syncrowave 0 LX # (00/0/460 VAC) # (0/460/ VAC) #90 1 (0/400/440/0 VAC) IEC Primary cord and TIG torch adapter sold separately. TIGRunner Packages Syncrowave TIGRunner Syncrowave 0 DX TIGRunner X # (00/0/460 VAC) # (0/460/ VAC) Syncrowave 0 LX TIGRunner X # (00/0/460 VAC) # (0/460/ VAC) Completely assembled. TIGRunner includes Syncrowave, Coolmate X cooler, No. running gear, RFCS-14 HD remote foot control, and Dinse-style connectors. Primary cord, TIG torch adapter and TIG coolant sold separately. Syncrowave Complete (Syncrowave TIGRunner, TIG Coolant and Torch Kit) TIG Coolant 0 A Water-Cooled Torch Kit for Syncrowave 0 DX TIGRunner TIG Coolant 00 A Water-Cooled Torch Kit for Syncrowave 0 LX TIGRunner Syncrowave Complete Packages Syncrowave 0 DX Complete #91 11 (00/0/460 VAC) # (0/460/ VAC) Syncrowave 0 LX Complete # (00/0/460 VAC) #91 10 (0/460/ VAC) Completely assembled. Includes TIGRunner above (Syncrowave, Coolmate X cooler, No. running gear, RFCS-14 HD remote foot control, and Dinse-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.

6 Genuine Miller Options Field Options Sequencer Module 0/0 #00 4 Field Kit Effective with serial number LE898. 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 #00 48 Field Kit for Syncrowave 0 DX Effective with serial number LE898. 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. to 10 pulses per second. Power Factor Correction Kit # Field Kit for Syncrowave 0 DX #04 Field Kit for Syncrowave 0 LX Reduces primary amperage draw by approximately % allowing the use of smaller breakers/fuses and smaller primary cord. Power Factor does not reduce the power consumption/electrical bill. Genuine Miller Accessories No. Running Gear #19 8 Includes two 10 in (4 mm) wheels, two in (1 mm) casters, two-compartment rack (for gas cylinder(s) or Coolmate V coolant system), and handles. Provides excellent mobility and easy to install. Protective Cover #19 0 Heavy-duty, water- and mildew-resistant. Protects and maintains the finish of the welder. Remote Controls and Switches Wireless Remote Foot Control #00 49 For remote current and contactor control. Receiver plugs directly into the 14-pin receptacle of Miller machine. 90 ft (.4 m) operating range. Wireless Remote Hand Control #00 40 For remote current and contactor control. Receiver plugs directly into the 14-pin receptacle of Miller machine. 00 ft (91.4 m) operating range. RCCS-14 Remote Contactor and Current Control # 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 6. ft (8 m) control cord. RFCS-14 HD Foot Control # 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 0 ft (6 m) cord and 14-pin plug. RHC-14 Hand Control # Miniature hand control for remote current and contactor control. Dimensions: 4 x 4 x -1/4 in (10 x 10 x 8 mm). Includes 0 ft (6 m) cord and 14-pin plug. RMLS-14 Switch #19 Momentary- and maintained-contact rocker switch for contactor control. Push forward for maintained contact and backward for momentary contact. Includes 6. ft (8 m) cord and 14-pin plug. RMS-14 On/Off Control #18 08 Momentary-contact switch for contactor control. Rubber-covered pushbutton dome switch ideal for repetitive on-off applications. Includes 6. ft (8 m) cord and 14-pin plug. Extension Cables for 14-Pin Remote Controls # ft (.6 m) # ft (1. m) # ft (4.4 m) Gas Tungsten Arc (TIG) Welding Book #10 To order this item, distributors can call the Miller Literature Distribution Center at , or FAX pages 8-1/ 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 6 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 # To order this item, distributors can call the Miller Literature Distribution Center at , or FAX :00 minutes. A detailed demonstration on preparing your equipment for TIG welding. Uses a Syncrowave 0 power source, but topics fit any TIG setup including air-or water-cooled systems. In-depth discussion of tungstens and gases. 6

7 Genuine Miller Accessories (continued) TIG Welding Gloves # 81 Small # 814 Medium # 81 Large # 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 #19 Used to adapt a 0 or 0 A water-cooled torch (WP0, WP18, CS10) to a Dinsestyle connector. Air-Cooled Dinse #19 9 Used to adapt a 1-piece 00 amp air-cooled torch (WP6) to a Dinse-style connector. Torch Kits Tungsten Items below are available in packages of 10 and are -in lengths. % Ceriated (orange) for AC/DC applications #WC040X.040 in, A #WC116X 1/16 in, 0 10 A #WCX / in, A #WC018X 1/8 in, 400 A #WCX / in, A 1.% Lanthanum (gold) for AC/DC applications #WL040X.040 in, A #WL116X 1/16 in, 0 10 A #WLX / in, A #WL018X 1/8 in, 400 A #WLX / in, A Pure (green) for AC applications only #WP040X.040 in, A #WP116X 1/16 in, 0 10 A #WPX / in, A #WP018X 1/8 in, 400 A #WPX / in, A % Thoriated (red) for DC applications only #WT040X.040 in, A #WT116X 1/16 in, 0 10 A #WTX / in, A #WT018X 1/8 in, 400 A #WTX / in, A Coolant Systems For more information, see the Miller Coolant Systems literature sheet, Index No. AY/.. Coolmate V # VAC # VAC, CE For use with water-cooled torches rated up to 00 amps. Vertical design conveniently mounts to Miller cylinder rack in place of one cylinder. -gallon capacity. Coolmate X with Cart and Dual Cylinder Rack # Includes: Easy Load Dual Cylinder Rack, Includes Wheels running gear, and X industrial water cooler a perfect solution for water-cooled TIG torches. TIG Coolant # Sold in multiples of 4. Pre-mixed lowconductivity Miller coolant contains ethylene glycol and deionized water to protect from freezing and boiling - to F (-8 to 108 C). Coolant contains.4% algae growth inhibitor. 1-gallon plastic recyclable bottles. 0 A Water-Cooled Torch Kit #00 18 Recommended for Syncrowave 0 DX ft (.6 m) Weldcraft WP0 torch Torch cable cover AK4C torch accessory kit includes shielding cups, collets, collet bodies and % cerium tungsten electrodes (1/16, / and 1/8 in) Smith regulator/flowmeter HM01A-80 1 ft (. m) rubber gas hose (regulator to machine) Water-cooled Dinse torch adapter 1 ft (4.6 m) 1/0 weld lead with clamp (work or ground lead) and Dinse connector 00 A Water-Cooled Torch Kit #00 18 Recommended for Syncrowave 0 LX ft (.6 m) Weldcraft CS10 torch Torch cable cover CS10AKC torch accessory kit includes shielding cups, collets, collet bodies and % cerium tungsten electrodes (1/16, / and 1/8 in) Smith regulator/flowmeter HM01A-80 1 ft (. m) rubber gas hose (regulator to machine) Water-cooled Dinse torch adapter 1 ft (4.6 m) 1/0 weld lead with clamp (work or ground lead) and Dinse connector 400 A Water-Cooled Torch Kit # ft (.6 m) Weldcraft WP18SC torch Torch cable cover AK18C torch accessory kit includes shielding cups, collets, collet bodies and % cerium tungsten electrodes (/, 1/8 and / in) Smith regulator/flowmeter H194D-80 1 ft (. m) rubber gas hose (regulator to machine) Water-cooled thread lock torch adapters 1 ft (. m) 4/0 weld lead with clamp (work or ground lead)

8 Ordering Information Equipment and Options Stock No. Description Qty. Price Syncrowave 0 DX # /0/460 V, 0/60 Hz, Standard Model # /460/ V, 0/60 Hz, Standard Model # /400/440/0 V, 0/60 Hz, IEC # /0/460 V, 0/60 Hz, Syncrowave 0 DX TIGRunner X # /0/460 V, 0/60 Hz, Syncrowave 0 DX Complete # /460/ V, 0/60 Hz, Syncrowave 0 DX TIGRunner X # /460/ V, 0/60 Hz, Syncrowave 0 DX Complete Syncrowave 0 LX # /0/460 V, 0/60 Hz, Standard Model # /460/ V, 0/60 Hz, Standard Model #90 1 0/400/440/0 V, 0/60 Hz, IEC # /0/460 V, 0/60 Hz, Syncrowave 0 LX TIGRunner X # /0/460 V, 0/60 Hz, Syncrowave 0 LX Complete # /460/ V, 0/60 Hz, Syncrowave 0 LX TIGRunner X # /460/ V, 0/60 Hz, Syncrowave 0 LX Complete Sequencer Module #00 4 Field Pulser Module #00 48 Field. For Syncrowave 0 DX Power Factor Correction Kit # Field. For Syncrowave 0 DX #04 Field. For Syncrowave 0 LX TIG Torch Kits Weldcraft 0 A Water-Cooled Torch Kit #00 18 See page. Recommended for Syncrowave 0 DX TIGRunner X Weldcraft 00 A Water-Cooled Torch Kit #00 18 See page. Recommended for Syncrowave 0 LX TIGRunner X Weldcraft 400 A Water-Cooled Torch Kit # See page Consumables and Tungsten See page Gas Cylinder, Hose and Fittings Remote Controls Wireless Remote Foot Control #00 49 Foot control with wireless 90 ft (.4 m) operating range Wireless Remote Hand Control #00 40 Hand control with wireless 00 ft (91.4 m) operating range RCCS-14 # North/south fingertip control RFCS-14 HD # Heavy-duty foot control RHC-14 # Hand control RMLS-14 #19 Momentary/maintained rocker switch RMS-14 #18 08 Momentary rubber dome switch Extension Cables # ft (.6 m) # ft (1. m) # ft (.9 m) Accessories No. Running Gear #19 8 Protective Cover #19 0 Gas Tungsten Arc (TIG) Welding Book #10 Contact your distributor TIG Training CD #196 6 Video GTAW Setup Procedures # Contact your distributor Torch Adapters #19 Adapts 0 or 0 A water-cooled torch to Dinse-style connector Supplied with power source and torch kits #19 9 Adapts 1-pc 00 A air-cooled torch to Dinse-style connector Cable Connectors Supplied with power source and torch kits Dinse Connector 0 mm (1 male) # Used to connect weld lead to Dinse terminal machine Dinse Connector 0 mm (1 male, 1 female) # Used to extend weld cables Tweco Terminal Adapter #04 46 Male Dinse to female Tweco Cam-Lok Terminal Adapter # Male Dinse to female Cam-Lok TIG Coolant # Sold in multiples of 4. 1-gallon plastic bottles. Coolant Systems See page Date: Total Quoted Price: Distributed by: Litho in USA