Another Sycrowave 200 Question

[12six]

Well, actually several more questions. I want to say that I have welded tig with great results, but that was 15 years ago. I had recently purchased a new Syncrowave 200. Upon using the welder, I am having much difficulty holding an arc. With the "pulse feature" off, the unit seems like its always pulsing. With the "pulse feature" on, it will start to pulse erratic for the first coulple seconds, and then will go to the pulse that has been set. Things I did to correct the problem is, 1- a new dedicated grinder finishing the tungsten with 120 grit 2- Cleaning the .060 mild steel with acetone 3- turning up the argon from 15cf to 20cf. Results are still the same. When I am able to get an arc stable, the weld looks contaminated with rust like coloring around the weld. For the first several days, I've been thinking that it was operator error. Now, on day 5, and half a 150 cf bottle used, I am thinking it might be the unit, and argon bottle.

Starting with the unit(which I stated is new), the "quick connect" for the tig torch does not spin in tight. It will spin around in a full circle, as on the ground cable side, will spin on tight, and will not spin in a full circle. So what I did is, spin it on, and when it starts to tighten up a little, I stop. I thought that it shouldnt be a problem, cause the argon is still flowing through.

Second problem I see is, the argon bottle I received does not have a label stating it is 100% argon, but instead is labeled as 75% argon 25% co2. Could the people at the welding store given me the wrong gas?? Or is it normal to have a bottle with 100% argon, but label being differ?

With so many factors for why a tig weld is not going right, it makes it a lot more difficult if a faulty unit or the wrong gas, is mixed in with the equation.
Also, I am not the original buyer of the unit. I purchased the unit in brand new condition from someone that had it for only 5 months, but I do have all original receipts. Am I still able to get the 3 year warranty if I am not the original purchaser?

Sorry for the long read, any answers will be greatly appreciated.

Thanks,
Charles

[SundownIII]

Charles,

I'd bet dollars to donuts you've got a bottle of C25 and not straight Argon.

Not that familar with the Sync 200, but have owned a couple of Sync 250's. Have you tried resetting the machine to the factory default settings?

The international dinse 50 plug should not rotate a full 360 degrees. Sounds as if someone has stripped it out. Is the ear missing from the plug itself?

Miller warranty is good for three (3) years, based on time of delivery of the machine. You do not have to be the original purchaser to get warranty repairs.

What tungsten (type) are you using and in what mode (AC or DCEN)?

[cruizer]

Yep wrong gas for sure.

Can't remember if you can do a system reset on that unit or not, have to look over the service manuals, though you can tell how many weld cycles it's had ect....

As for warranty it's done by the serial#, could have had 50 owners, but if it's still within that 3 yr time frame warranty centers won't care. If its getting close to the end of it's warranty period, it'll be kinda nice for you to have the original bill of sale.

[12six]

Charles,

I'd bet dollars to donuts you've got a bottle of C25 and not straight Argon.

Not that familar with the Sync 200, but have owned a couple of Sync 250's. Have you tried resetting the machine to the factory default settings?

The international dinse 50 plug should not rotate a full 360 degrees. Sounds as if someone has stripped it out. Is the ear missing from the plug itself?

Miller warranty is good for three (3) years, based on time of delivery of the machine. You do not have to be the original purchaser to get warranty repairs.

What tungsten (type) are you using and in what mode (AC or DCEN)?

Yep wrong gas for sure.

Can't remember if you can do a system reset on that unit or not, have to look over the service manuals, though you can tell how many weld cycles it's had ect....

As for warranty it's done by the serial#, could have had 50 owners, but if it's still within that 3 yr time frame warranty centers won't care. If its getting close to the end of it's warranty period, it'll be kinda nice for you to have the original bill of sale.

Thanks for chiming in you guys. Yes, I have read somewhere in this forum that the Syncrowave 200 could be reset to default settings. I believe it is pushing all buttons(Amps-Process-Balance-Pulse) while turning on the power switch, then wait for 7 sec. I will try to reset the default settings. On the international dinse 50, the ear is still there, but on one of the corners, it looks like a little has been shaved off. Also, the ground dinse looks a little larger than the torch dinse. Possible factory defect?? Unit is set on DCEN, and using 2% thoriated 3/32" (red end)tungsten, as recommended by the salesman. Should I be using 1/16" since the project is with .060 mild steel?? I really hope it is the gas, or a bad connect for the torch cable. Was feeling pretty depressed, thought I was getting too old, and was about to hang the towel up, until I started to inspect the unit and saw the gas label and the not so tight plug.

[benny365]

I guarantee you what it says is in the bottle is what is in the bottle. Take it back and set it on the counter, and politely ask for a FULL 100% ARGON TANK.

[SundownIII]

Charles,

The dinse connector for your torch is probably bad. Not sure that they will cover that under warranty though. You can get a new one (Miller #194 722)(air cooled torch) from IOC for about $30.

As far as the tungsten, yes I'd recommend going to the 1/16" for the work you're doing.

You do know you can download a copy of the full owners manual from the resources area. That will walk you thru the reset procedure.

Don't give up the ship. Just a minor leak. It'll all come back when you get hooked up to the right gas and get that plug straight. The Sync 200 (if it's anything like the 250) is a tough machine.

I just upgraded my old sync 250 (1996 model) to a 3yr old 250 Tigrunner. All I can say is that miller has come a long ways in the last 12 years.

[monte55]

I just pulled my torch connector off and reinstalled. Once inserted it turns CW
around 180 degrees and stops. Make sure your socket is not spinning. I have the 200 also.

[projectwelder]

C25 will cause all kinds of problems just like you are experiencing. I would get a replacement Dinse connector and swap out the one you have, it will make life easier, especially when running HF, you don't want a loose connector allowing HF to radiate.

[12six]

Thanks again for all the help. Come Monday morning, I will be getting a bottle swap. I am spinning the dinse plug clock wise, but does not stop. I did try the ground clamp dinse on the torch socket, and it does stop, so I believe it is the dinse on the torch side, and not the socket. I am pretty excited to get the correct bottle exchanged, to see what a difference it will be. Will let all of you know how it goes.

Regards,
Charles

[12six]

Id like to thank all for the inputs. Got the mixed bottle exchanged for the correct one(100% argon), also got the dinse plug swapped out for a new one. WOW!!!!The machine is like a new one now. Working better than I thought it would.

Thanks again,
Charles