Miller Syncrowave 180 Manual

Syncrowave 200	Issued November 2005 • Index No. AD/4.4
®	TIG/Stick Welding
Power Source

Light Industrial Applications	Processes	Input Power Requires 1-Phase Power
Light Metal Fabrication	TIG (GTAW) Welding	Amperage Range	5 – 200	A
Maintenance/Repair Operations	Stick (SMAW) Welding	Rated Output 150 A at 26		V, 40% Duty Cycle
Light Manufacturing	Pulsed TIG (GTAW-P) Welding
Automotive Repair	Weight Base Model: 238 lb (108 kg)
Vocational Training
	Runner:	271 lb (123 kg)
Hobbyist

My Miller 180 SD is approx 5 years old rarely do I weld aluminum, when I do its 1/8 thick max, 6061, cleaned with acetone,. It just welds poor, when I use my friends 351 on same material almost perfect. High Frequency is on when switched to AC. Using 100% Argon. Question is anyone else out there use a 180 SD for aluminum work with nice results? Miller Electric Mfg. International Headquarters. Web Site An Illinois Tool Works Company. Phone: 920-735-4505. Www.MillerWelds.com 1635 West Spencer Street. USA FAX: 920-735-4134 Appleton, WI 54914 USA. Canadian FAX: 920-735-4169.

The Power of Blue®.

Squarewave output with AC balance control features adjustable penetration and cleaning action while increasing arc stability on various aluminum alloys, and helps eliminate tungsten spitting and arc rectification.

NEW! Cable management system uses dual cable hangers and foot control storage conveniently attach to the power source side panels to allow all weld cables and the remote foot control to be neatly stored, preventing torch, cable or remote damage.

NEW! Syncro Start™ allows the operator to choose from three different starting conditions to optimize the application (Soft/Standard/Hot).

NEW! Runner has low cylinder rack to eliminate the need for lifting when changing gas cylinders.

Fan-On-Demand™improves power
efficiency and reduces noise and		Syncrowave
maintenance by lessening the amount
of airborne contaminants pulled		200 Runner
through the machine.
Adaptive Hot Start™ for
Stick arc starts automatically
increases the output amperage at
the start of a weld should the start
require it. Prevents the electrode from
sticking and creating an inclusion.
NEW! Weldcraft® WP1712SFDI50
	TIG torch. 150 A, air-cooled torch
features super flex (SF) braided nylon
power cable for maximum flexibility.

Power source is warranted for 3 years, parts and labor.

Original main power rectified parts are warranted for 5 years.

NEW! Auto-Postflowprotects the weld end zone and electrode by optimizing postflow time based on welding amperage — for adequate shielding every time without waste and no need for adjustment.

NEW! Dual digital meters with alpha-numeric displays allow for quick and easy viewing and preset values for voltage, amperage and other key variables. Allows for greater accuracy and repeatability in the welding procedure.

NEW! Built-in pulse control enhances weld bead and puddle control for improved appearance and quality — reduce burn through, coordinate the addition of filler material, and reduce the warping effects of distortion by reducing the average heat input.

NEW! 115 V auxiliary power receptacle is conveniently located on the front panel, allowing for operation of a Coolmate™ torch coolant system or other small tools.

Arc hour/cycle counter records actual welding time and number of arc starts.

DIG control allows the arc characteristics to be changed for specific applications and electrodes. Lower the DIG setting for smooth running electrodes like E7018 and increase the DIG setting for stiffer, more penetrating electrodes like E6010.

Miller Electric Mfg. Co.	International Headquarters	Web Site
				An Illinois Tool Works Company	Phone: 920-735-4505	www.MillerWelds.com
1635 West Spencer Street	USA FAX: 920-735-4134
		Appleton, WI 54914 USA	Canadian FAX: 920-735-4169
International FAX: 920-735-4125

Specifications (Subject to change without notice.)

575 V

12.35

6.0

Certified to both the Canadian and U.S. Standards for welding equipment.

Miller Syncrowave 180 Sd New

1. Balance/DIG Pushbutton Control

2. Process Pushbutton Control

3. Power Switch

4. Polarity Switch

5. Voltmeter and Parameter Adjust

6. Ammeter and Parameter Adjust

7. Encoder Adjustment Control

8. Main Amps Pushbutton

(Amperage Control)

9. Pulse Pushbutton Control

Miller Syncrowave 180 Service Repair Manual

by rcl

Miller Syncrowave 180 Technical Manual

Hey Jody, thanks again for your emails with TIG tips, they are great.
Hope you don’t mind a question, since from your website it seems you are familiar with the syncrowave machines.
For the life of me, I can’t figure out how to set my Syncrowave 180 high frequency parameters.
The Miller manual has a section (see below) where they show you how to set the “TIG Starting Characteristics” – which I think is frequency? - but these don’t seem to correlate?
From the Miller manual...
'
Application:
Select 1 (light/soft start) − when welding at
low amperages on thin gauge material.
Select 2 (medium/normal start) − factory default
setting used for most welding applications.
Select 3 (high/hot start) − when welding at
high amperages on thick materials with a
large diameter tungsten.'
From Weldingtipsandtricks.com tips...
1. For Steels, stainless steels, Nickel alloys, titanium etc (everything except aluminum and magnesium)
DCEN, high frequency on start only, Argon gas flowmeter set on 20 cfh with a #7 gas lens type nozzle/cup, amperage switch on remote, contactor switch on remote
2. For Aluminum and Magnesium
A/C, high frequency set to continuous, argon, or argon/helium mix flowmeter set to 15 cfh with a #7 cup if machine is equipped with A/C balance, set it to 7, amperage switch on remote, contactor
switch on.
--------------------------------------------------------------------
Good Question...,
the settings from miller are the start amperage settings and not high freq adjustments.
what i wrote is geared toward the older syncrowaves and tons of other older machines.
the newer version syncrowaves kind of dumb down the high freq setting functions and default the correct high freq modes by process...so if you are set for tig welding on DC, you are automatically set to dcen with high frequency start only that starts the arc but then shuts off.,you dont notice it but thats what happens.
with the machine set to tig with the current set on ac, the high freq defaults to continuous so that it starts the arc and continues to run in the background to stabilize the arc as it alternates polarity at 60hz. (thats what happens on ac)
the only other high freq setting is intensity and its usually located under the front panel. usually a setting of 50% is good. high settings wont hurt, but high frequency is kind of like medicine.... all you need is enough to do the job and more is not always better.
hope this clears things up a little,
jody