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Discussion Starter · #1 ·
So I bought a used Miller Syncrowave 250 about a year and a half ago.....I have put about 100 hrs on the machine. I have not used it much in the last six months accept to do some plug welds in AK47 receivers wich was 4140. Had mostly been doing aluminum perviously. So I went to weld some aluminum....set the machine to AC turned on the HF, dress the tungston brushed the aluminum....and the arc was all over the place. I cleaned and dressed the tungston again, cleaned tghe aluminum again, arc was still everywhere. I changed tungstons to a new one, got a different piece of AL, checked all my connections which were tight, still not able to focus the arc. I have played with the gas flow, balance, HF setting @ the bottom of the machine, I cleaned the HF points and set the gap to .008", still all over.......I don't know what else to do.....
Does anyone have any suggestions??? What should I have my HF set at????
PLEASE HELP......
 

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Re: NEED HELP!!!! with Miller Syncrowave 250......machine problems.... (Eganx)

is this an old machine?
crank up your apms to like 150, and give it full pedal. this should focus the beam.

also...
try NOT using the HF start.
do you know how to scratch start?
just rub the tungsten on the work piece then back off so your like a mm away and floor the pedal.
 

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Re: NEED HELP!!!! with Miller Syncrowave 250......machine problems.... (speed51133!)

I have the HF on constant....I have no problem welding in DC, only AC. No matter how much amperage I give it it will not focus.
I don't know the age of the machine....its older but not ancient
I am trying to avoid taking it in to our local miller dealer to have it worked on. I'm pretty much broke at the moment....and this is my personal machine not used for any production....
 

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Re: NEED HELP!!!! with Miller Syncrowave 250......machine problems.... (Eganx)

ok, disable the HF start.
google "tig welding scratch start".
try doing this in the meantime until you can afford to fix the HF.
scratch starting without HF should fix your issue.
i believe your HF start is shot.
 

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Discussion Starter · #5 ·
Re: NEED HELP!!!! with Miller Syncrowave 250......machine problems.... (speed51133!)

the HF start works fine.
I was under the understanding that HF was needed(set on constant)to weld aluminum in AC
My problem is welding aluminum in AC with the HF on constant
I have set the HF to start only while on aluminum, it will arc and then the arc cuts out when the HF turns off.
I have no problems welding in DC with the HF set on start
 

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Discussion Starter · #7 ·
Re: NEED HELP!!!! with Miller Syncrowave 250......machine problems.... (speed51133!)

Quote, originally posted by speed51133! »
ill say it again....your HF converter is ****ed

so it can go bad, but still work enough to start an arc in HF start, and maintain an arc in AC with HF on constant?
I was not sure I was clear in stating the issue....I figured if the HF was bad it wouldn't work at all
 

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Re: NEED HELP!!!! with Miller Syncrowave 250......machine problems.... (Eganx)

miller is very good about customer service.
call them during work hours and ask to speak to a technical person.
explain the situation.
i once got a new HF board for free for a tig that was years old.
 

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Re: NEED HELP!!!! with Miller Syncrowave 250......machine problems.... (speed51133!)

what kind of tungsten do you have? And your right. Without high frequency there will be no arc at all so the HF is working just fine. Whats your balance set at? how about gas flow?
 

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Discussion Starter · #10 ·
Re: NEED HELP!!!! with Miller Syncrowave 250......machine problems.... (TIGninja)

I usually use ceriated, but have also tried pure tungsten. I have always had my balance set at 3 and I have tried adjusting the gas from 15 to 30 cfm. The gas seem to have a small effect but nothing huge.
Tomorrow I'm going to play with it after work, I going to try turning up up the HF and balance.
A welder at work said to try moving my ground around. I had it on the work piece and then on the table.....I'll move it around and see.....
 

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I'll have to check mine but, I don't think I have ever used my 250 with HF on for Aluminum or steel.
 
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