Syncrowave 250 was hooked up to wrong voltage

[notslow]

Hi everyone, I just got a slightly used Syncrowave 250. I hooked it up to the 230v service and turned it on to try it out. The fan was running very slow and there was nothing from the torch. I checked and found that the jumper links were set for 460. I moved them to the 230 setting, but now I get nothing but some relays buzzing when I switch it on. Did I damage something by powering it with 230 volts when it was set for 460?

[Raul]

Originally Posted by notslow

but now I get nothing but some relays buzzing when I switch it on.

I'd pull the relays and replace them. They will have their specifications right on them.
If not go to the maker and get their branded parts. Relays are funny things there are a half a dozen different kinds and they each work differently.
Relays are Cheap and easy to swap out and curiously, the relays may be why the thing was switched to 460. Maybe the previous owner toasted 'em.

[trackbird]

The schematic is on page 33 here:

http://www.millerwelds.com/om/o353u_mil.pdf

Beyond the relays, there is an "F1" fuse on that schematic on the 57 volt supply line that feeds a bridge rectifier that should supply power to a portion of the welder, there is also an "F2" fuse shown near a second rectifier. I'd make sure it didn't blow either of those fuses. Beyond that, I'd start looking for the 57 volt, 110 volt, 24 volt, 18 volt, and 10 volt supply voltages from the transformer and see if they are all "there".

I'll also suggest that you might want a professional electronics tech or a qualified service tech to do this work if you're not trained or comfortable. Accidentally getting yourself inserted into the internal circuitry of this unit can have very unfortunate consequences (and be fatal). I only state this since I don't know your background or the background of anyone else who might read this post.

[notslow]

Thanks for the help guys.
Well, I checked the relays and they have correct continuity. I checked voltage in and voltage past the power switch and its around 215v. So I have power in right and jumpers are correct. I looked on the circuit board and there is nothing obviously damaged. The fuses are fusible links on the jumper terminal block and they are all good. The welder was in an industrial shop that likely ran it on 460. I didn't realize it when I hooked it up to 230.

The only thing I noticed wrong is the power light is missing. I can't find it on the diagram or inside. Any ideas what the power light is labeled on the diagram?

Also, isn't the fan supposed to come on when you first switch the welder on? Mine doesn't and the relay for the fan is wired for normally closed. When power is switched on, the relay activates and disconnects the fan immediately. Is this normal?

[DSW]

The fan on my Syncrowave 200 will only come on if the machine gets "hot". Doing low amp tig it will almost never go on. Doing high amp tig, say 1/4" alum, it will come on after a bit of welding to keep the internals cool. I can't remember it the fans kick on full time with the Syncrowave 250's at the tech school. Theres so much noise from the exhaust fans there, it could play jazz and I'd probably not notice it.

[Rbeckett]

Ummmm, just being the devils advocate here. Is your machine single or three phase? Makes a difference if you need three phase and only have it hooked to single. Didnt see any thought given to that...
Bob

[trackbird]

Does it do anything at all at this point? Also, there is a circuit breaker on the front that protects the 110v outlet. If it trips, you lose gas, high frequency and arc output. Might want to make sure it's reset (and not bad/damaged?).

[notslow]

It's single phase, I will check voltage at the front 110v outlet and check the 110v breaker.

[Plasman]

You likley did not damage anything by applying a lower voltage than it was linked for.
The jumpers on the terminal block are not fuse links.
The problem may be you only have 215VAC input and the machine is linked for 230VAC.
The secondarys of the transformer are going to be low if the primary of the transformer is low. This could be why your relays are chattering and not fully changing state. The coil voltage to the relays is probably a little low.
This is a fan on demand unit the fan should come on after the welder gets warm.

[trackbird]

One other thing. The schematic indicates that the 230v setting has two sections of the input side of the transformer running in parallel. If the jumpers are dirty, you could have only one side of the transformer actually connected (one of the two coils). If that were to happen, you'd see the correct voltages everywhere, but you'll only have 50% of the current capacity. I'd make sure your jumper links are clean and not corroded.

Did you ever try this machine? Is it functioning at all now?

[notslow]

I cleaned all of the relay contacts and the jumper contacts this last weekend. Everything seems good now. Still not sure what exactly was wrong, but as long as it's working I'm happy. One thing I'm trying to figure out is the power on indicator light is missing. I'm not sure where it's supposed to hook up and can't find it on the schematic. Anyone have an idea? I want to get a replacement for it.
Thanks, Will

[Oldiron2]

Early machines had the fan on all the time; later ones had the FOD option. I installed the option in my earlier unit and have a thread about it

Here.

Near the bottom is a link to a site where another member posted the kit directions and schematic, which wouldn't fit here. That should show where your light hooks up, I'd think.
If you're still not sure, you could EMail the Miller technicians with your machine's serial number and your questions.

[notslow]

Thanks for the link. It looks like it is just a bulb connected to the 18v. Theoretically, I could use any panel indicator in the same place or connect to the 10v supply depending on the rating of the indicator.