Miller Syncrowave 250 no output/hf problem

admin

Hi guys, I have a older sync 250, 1998 model, Serial kj245050. The issue i'm having is this.When i step on the foot pedal, the gas valve relay opens and I receive gas, but the HF and output don't activate. The 3 relays that control all the functions are receiving proper voltages. When i flip the output switch from remote to panel I still don't receive any output. However, the gas relay activates again. My main question is, the HF relay and output relay are they controlled by the main PC board that sits behind the bank of relays? As in, when i depress the foot pedal the gas relay activates because it is directly wired to the pedal from what I understand, but is the PC board what tells the HF and output to turn on? I've gone through all the wiring in the machine and its top notch, no lose or corroded connections. The HF points are in good shape, everything is hooked up properly. This just suddenly happened, i was chugging along welding, finished up my bead, and when i stepped on the pedal again i got nothing!. After fiddling around with connections inside the machine on the main PC board it started working again for a short while and then it just stopped again. Anybody have any suggestions as to what the issue may be? Is it possible that the PC board has gone bad over time?ESAB MigMaster 275Miller Econotwin HFMiller Syncrowave 250
Reply:Kinda sounds like the board. How about the remote/panel switches, have you tested them?Ian TannerKawasaki KX450 and many other fine tools
Reply:Have you tried stick welding, or scratch start? That would prove the contactor is good, and issue is hf.A 250dx at work went thru a similar episode, but it would not stick weld either then it just started working reliably again.Briggs weldnpower 225/210/cvLn-25 suitcaseMillermatic 130
Reply:I've tried everything, no matter what setting, polarity, anything there is zero output, but the gas works. According to a few people on the miller board its the PC1 board. The remote pedal and output switch are wired to the pc board, when the pedal is pressed/switch flipped it sends a signal to the board that says lets weld, thats where my problem is. I have a new board on the way, hopefully that solves the issue.ESAB MigMaster 275Miller Econotwin HFMiller Syncrowave 250
Reply:I suppose i should of done the simplest first but didn't. I noticed that I had a leak on the torch from the water return. Not sure if it was causing grounding out problems or not but I fixed that issue, and then decided to blow/vac out the machine it self. I pulled all the connectors on PC1 and hit them with compressed air and contact cleaner and everything seems to be running like a champ now. the PC1 board is still on its way so i'll need to return it, but moral of the story is, don't jump to conclusions. I always seem to look at the most complex part first when i should look at the easiest.ESAB MigMaster 275Miller Econotwin HFMiller Syncrowave 250
Reply:Good to hear. Was the leak at the torch head or at the lug?Ian TannerKawasaki KX450 and many other fine tools
Reply:Originally Posted by fortyonethirtyGood to hear. Was the leak at the torch head or at the lug?