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Weak high freq. Syncrowave 250 DX

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  • Weak high freq. Syncrowave 250 DX

    The last six months its gone from a mad "proffessor " 12 inch arc to 3/8" .
    While it still welds aluminum I worry the transformer is going T3 T4 (208045).
    I only found one post on this in searching ,, wonder if there is an ohm
    reading to check each side of the coil . Any other ideas besides CB 1 and R5 rheostat .

    Thanks

  • #2
    Originally posted by helitech View Post
    The last six months its gone from a mad "proffessor " 12 inch arc to 3/8" .
    While it still welds aluminum I worry the transformer is going T3 T4 (208045).
    I only found one post on this in searching ,, wonder if there is an ohm
    reading to check each side of the coil . Any other ideas besides CB 1 and R5 rheostat .

    Thanks
    I would pull the covers and thoroughly blow the dust out of it....

    and download the manual that matches your serial number..

    http://www.millerwelds.com/service/ownersmanuals.php

    then adjust the HF spark gaps...

    if spark is still weak... i would run the machine in a dark room with the covers off to see if you have any blue corona spark leakage tracks.... dirt and dust can be conductive and bleed off your HV...

    barring that I would ask Cruizer what the next step might be...
    .

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    • #3
      Originally posted by H80N View Post
      I would pull the covers and thoroughly blow the dust out of it....

      and download the manual that matches your serial number..

      http://www.millerwelds.com/service/ownersmanuals.php

      then adjust the HF spark gaps...

      if spark is still weak... i would run the machine in a dark room with the covers off to see if you have any blue corona spark leakage tracks.... dirt and dust can be conductive and bleed off your HV...

      barring that I would ask Cruizer what the next step might be...
      I have cleaned it with a vac. brush , air hose ( been unpluged for days ).
      I will try the spark gap check . Thanks

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      • #4
        I had a similar problem with my Syncrowave 200 recently. The HF was erratic and you could see fluctuations in the arc.

        I checked the manual and looked at the area for trouble shooting. It mentions cleaning and checking the HF gaps. I first unplugged the main cable to the machine and then I removed the right hand cover and started by blowing out the dust and wiping the whole area clean. I then checked the gaps. They were still correct at .008 checking with my feeler gauge set. I dipped the feeler gauge in acetone and worked it in and out on each gap and then blew the unit dry.

        When I reassembled the cover and started the machine again, the difference was really quite dramatic. The arc is now stable and the machine is back to its old self.

        I plan on doing this at least once a year from now on. Although my machine is a transformer unit, I guess the DX series also has spark gaps. If so, it's best to check them as mentioned above.
        Miller Syncrowave 200
        Milermatic 252
        Lincoln AC/DC "Tombstone"

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