2007 Synchrowave 200 no gas

admin

I have a 2007 Synchrowave 200 which i purchased new.  It probably has no more than 100 hours on in.  Recently after 10-20 minutes of usage the gas flow solenoid has a delay in opening, then it stops opening altogether.  Do the solenoids heat up and stop working or should i look for an electrical problem (?)  thanksSean
Reply:When the machine is OFF  make sure the fittings are tight.On your torch cable and ground.Some times those power cables come loose from vibration.Make sure you still have argon, and the pressure is high enough.No trouble code in left LED window?Go to page 3-8 in your owners manual and read about POST FLOW ADJUSTMENT when using less than 50 amps.I have a new one of those machines also.Last edited by Donald Branscom; 02-14-2011 at 07:04 PM.AWS certified welding inspectorAWS certified welder
Reply:fittings are tight, plenty of gas, set at 150 amps, post flow setting is good.  it works perfectly for a little while, then the problem starts.  To be more specific.  I was welding a custom exhaust header (many short welds)  Once the gas is flowing it is fine.  On restarts, initially its fine, after 10-20 minutes it hesitates, then after a few more minutes it stops allowing gas to flow.  I took the solenoid apart and it appeared OK.  My plan is to weld until it stops working, then check the voltage to the solenoid while pressing the pedal.  I was just wondering if these symptoms are typical of a solenoid problem or an electrical problem? If its a solenoid, i can order one so i will have it for the weekend. FWIW, the welder is kept in a heated shop
Reply:After it stop allowing gas altogether, then how long does it have to sit before it will start working again?If the primary windings in the solenoid are bad, it could keep getting hotter and hotter as you are welding, till it opens the circuit in the solenoid, thus stopping it from working.I would test like this.I would attach a volt meter to the solenoid input, then begin welding, while having someone watch the volt meter, and then when your gas stops, you will know if it is the solenoid or power supply.If voltage remains, then bad solenoid, if voltage fails, power supply.By the symptoms that you describe, I suspect the solenoid.
Reply:Did you call Miller welding Company and ask if that is a known issue??Maybe they can send you a solenoid.Did you take the welding machine cover off to get at the solenoid?My Syncrowave 200 is a newer one, and The torch just plugs into the DINS connecter and the gas solenoid is inside the machine. not external.Is your solenoid external?BTW if you were welding exhaust tubing it would probably be at less than 50 amps on thin tubing.AWS certified welding inspectorAWS certified welder
Reply:I am sort of shocked that a solenoid would fail after only 100 hours on a light industrial machine.That would only be about one month worth of welding in a shop.AWS certified welding inspectorAWS certified welder
Reply:the solenoid is inside, i pulled the side cover.  I waited a few minutes for things to cool off, but that wasnt enough and I had other stuff to do.  I have a few hours of shop time planned for tomorrow.  I tried more amps on thicker scrap, but it made no difference.  The solenoid said 24V on it, however i am not sure if its AC or DC...i suspect the solenoid will have that info if i look again.Tomorrow, i will weld 'til it fails, then do a voltage test.  Ill call the LWS where I purchased it, too.I am a little disappointed that this problem has appeared.  I purchased this machine just for personal hobby use, thinking it would be trouble free for a long time. However, If its just a $30 solenoid, i wont be too upset. ill post when i find the answer...
Reply:I had the same problem with the same symptoms with my sync 180, but it turned out it wasn't the solenoid it was just the regulator going bad (the original one that miller supplied). This might be your problem as well. Swap out the regulator and see if that helps at all.
Reply:If the solenoid says 24V, it will be dc, as ac voltage on a solenoid would cause it to chatter.The triggering in the solenoid is only an electro-magnet, and the 60 hertz switching would cause the magnet to turn off and on 60 times a second, causing chatter.
Reply:Steve, i upgraded to a flowmeter a while back.  It flows fine when the hose is disconnected from the welder.  Boilermaker, i hadnt though about it that in depth.  I a$$umed that the low voltage was DC, but i wasnt completely certain.I have a LASIK follow up appointment this AM  (it MAGIC, no glasses after 37 years) then i am headed to the shop
Reply:Be sure and wear your safety glasses and protect that investment!
Reply:yup, ALWAYS safety glasses.I welded yesterday for about an hour. just as i was getting ready to quit, it acted up again.  I removed the watercooler adapter from the welder to see if i had gas there.  It would build up pressure then go POOOOF and work.  After researching flowmeters, i am suspicious that regulator part of the flowmeter (the diaphragm) is sticking.  I ran out of time, but next time i go to the shop, ill run it til it quits then swap to the original regulator...