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Miller Syncrowave 200 welding cart

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  • Miller Syncrowave 200 welding cart

    I am building a welding cart for my new welding machine.
    It is a copy of a design I saw that was built around a Syncrowave 250.
    The design made sense to me.
    The blue paint is Rustoleum industrial (tall spray can) #7524. Matches very close to the Miller blue.
    The top tubular cage on my design will unbolt to be removed if necessary.
    I plan to put a tray on top of mine to hold a water cooling unit.
    I can hardly wait to try out the new machine but first I need to get a water cooler with WP-20 torch. I will be comparing it to a Miller Syncrowave 250 which I have used on a daily basis for at least thirteen years 6 hours per day.

    I will report back.

    Last edited by Donald Branscom; 01-19-2011, 05:44 PM. Reason: Add detail

  • #2
    Nice job. So you didn't build the cart with your new toy? I thought that's what you did with a new unit. LOL.

    Comment


    • #3
      Looks Nice!

      Hope you enjoy your new toy!

      Comment


      • #4
        Originally posted by willy View Post
        Hope you enjoy your new toy!
        Toy??? NO...no This is an absolutely necessary part of life.

        Comment


        • #5
          Originally posted by Donald Branscom View Post
          Toy??? NO...no This is an absolutely necessary part of life.
          OK got me there, sounds like the same thing I told my Wife when I bought mine

          Comment


          • #6
            Nice job, clean build, good lines, like the tubing design you used. Good attention to details, I appreciate the rounded corners on the flat steel. Well done!

            Gord

            Comment


            • #7
              Dang,

              That thing can't be any good. It's got digital meters.

              I could have sworn that you made the comment that digital meters were crap. That analog meters (and your mind) were the way to go.

              Comment


              • #8
                Originally posted by SundownIII View Post
                Dang,

                That thing can't be any good. It's got digital meters.

                I could have sworn that you made the comment that digital meters were crap. That analog meters (and your mind) were the way to go.
                You are right Sundown III but for this size machine I did not get a choice.
                This machine (Syncrowave 200) is more appropriate for my home shop and home electrical system.
                I already found out that to adjust the arc starting mode Soft,med,hard, you have to turn off the power, then turn on the power WHILE holding down (seven seconds) on the "A"(amp) button to select one of the three modes.. The workshop manual does not say HOW you select one of the three modes though.
                The default for arc start is MEDIUM. (thats good)
                Who carries a stop watch?

                I would rather have had a knob with 3 detents. soft, med, hard.
                But the newer generation just loves to peck at little buttons with multiple modes.

                I have noticed they are trying to make the welding machines almost all automatic (Diversion 165), because the young men now don't understand all those buttons and the manufacturers want to baby them along so they won't have to actually learn what those buttons do. They would not want to actually take a class.

                I understand that creative people want to create and not really learn to weld, but sooner or later they will have to learn more about the welding processes.
                Last edited by Donald Branscom; 01-24-2011, 07:42 AM.

                Comment


                • #9
                  Today I fabricated ,designed, and welded the gas bottle bottom support to the welding dolly.
                  I used 10 Ga. plate.
                  Last edited by Donald Branscom; 01-21-2011, 03:54 PM.

                  Comment


                  • #10
                    TIG welding tip for today.

                    When you look at a welding machine designed for TIG welding you will often see a knob that says POST FLOW.

                    This knob adjusts the amount of seconds argon gas comes out of the welding torch after you release the foot pedal or hand torch control.
                    Your torch should stay over the end of the weld during this time. The gas coming out also helps get rid of heat.
                    Select 10-12 seconds for steel or stainless and increase the time for aluminum.

                    If you are welding aluminum make sure crater fill is ON also if the machine has that feature so that the last part of the weld does not get a crater (and hole) in the end of the weld. That would be a stress riser in the end of the weldment.
                    Crater fill makes the arc extinguish slowly.

                    Comment


                    • #11
                      I received the Miller Coolmate1 cooler today and fabricated a shelf for the cooler to sit on.
                      I painted it and will be able to post photos tomorrow.

                      It will not look like you expect.

                      Comment


                      • #12
                        Today I installed the water cooler and some of the lines.
                        I had the torch and the adapter / solenoid but apparently I was told by a Miller tech that I still need two more 5/8 fittings, (one union) but when I look at it all, it seems that a "T" fitting and hose will also be needed.

                        The water cooler shelf is made from 14 ga. and is 2 inches high. It is 8 inches wide and 20 inches in length.

                        The handbook that came with the water cooler only shows schematic hook ups for water cooling on a wire feed welder, and GTAW with inverter welding machine.
                        Nothing else.

                        I have never had trouble before and never needed help with hooking up a water cooler but this seems more complicated.

                        I put the water fill on the side of the machine because if it was facing forward
                        water could get spilled or leaked onto the control panel of the welding power source. The vent facing forward is exhaust warm air from the cooler.
                        Air intake is in the rear of the machine.

                        The red wire on photo 3 laying near the floor is a ground wire to the welding machine cabinet a grounding rod for HF protection as shown in the manual.
                        I will shrink wrap it with green and mark it ground.


                        There will enough room on top of the machine for two trays. One for my welding helmet and one tray for welding accessories. I am making those as we speak. Photos coming.
                        Then I will move onto a system for holding my filler wires.
                        Last edited by Donald Branscom; 02-02-2011, 01:43 PM. Reason: additional info.

                        Comment


                        • #13
                          OK...Figured it out.
                          In addition to the solenoid adapter, and water cooled torch, and water cooler
                          You will need these 3 parts for connecting a Miller Coolmate 1 water cooler to the Miller Syncrowave 200.


                          ONE R/H female to female 5/8-18 coupler to hook the gas hose from the regulator on the argon tank to the short hose on the adapter/solenoid gas out connection.

                          ONE L/H coupler female to female 5/8-18 to connect the short hose from the adapter/solenoid to a 3 foot hose to the water return on the cooler upper fitting/

                          ONE 3 foot water cooler hose 3 feet with 5/8-18 L/H male fittings on each end. 1/4 inch hose barbs and 1/4 inch hose.
                          LIST:
                          Part # coupling female /female AW430
                          Part # coupling female/female AW 431
                          And water return hose with two male L/H threads 5/8-18

                          You are done!
                          This is the CORRECT DIAGRAM
                          Last edited by Donald Branscom; 02-07-2011, 08:08 AM.

                          Comment


                          • #14
                            [QUOTE=Donald Branscom;257283]OK...Figured it out.
                            In addition to the solenoid adapter, and water cooled torch, and water cooler
                            You will need these 3 parts for connecting a Miller Coolmate 1 water cooler to the Miller Syncrowave 200.


                            ONE R/H female to female 5/8-18 coupler to hook the gas hose from the regulator on the argon tank to the short hose on the adapter/solenoid gas out connection.

                            ONE L/H coupler female to female 5/8-18 to connect the short hose from the adapter/solenoid to a 3 foot hose to the water return on the cooler upper fitting/

                            ONE 3 foot water cooler hose 3 feet with 5/8-18 L/H male fittings on each end. 1/4 inch hose barbs and 1/4 inch hose.
                            LIST:
                            Part # coupling female /female AW430
                            Part # coupling female/female AW 431
                            And water return hose with two male L/H threads 5/8-18

                            You are done!

                            This is the Correct Diagram
                            Last edited by Donald Branscom; 02-07-2011, 08:09 AM.

                            Comment

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