Miller Aerowave Question

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Can anyone please explain what all the damn buttons on this machine do? I've been welding with it for two years now at work, and have been able to adjust the "main four" dials to get decent aluminum welds, but I would really like to understand this machine. I've tried looking up the manual online but trying to understand that just made my eyes cross. Even all my coworkers look at all the dials like they are a damn mystery. I've read that once you understand it it is a great machine.
Reply:Hello LivingstonIPresume, short story might go something like this: Boeing was looking for a way to deal with particular challenges with welding a number of different materials, although, mainly, various aluminum grades. Engineers got their heads together and addressed just about every issue known to man at the time with regard to this task. They packaged it up in what was called the "Aerowave". Boeing purchased nearly a 100 of these units, as the story goes, and after a relatively short period of time they mothballed them due to the lack of use by their welders. Pretty much everyone of them got frustrated with trying to figure out all of the features/variables and reverted to their old machines. They really are/were a very advanced machine capable of some amazing things once their capabilities were figured out and applied. You may actually be able to parallel some of your machines features with those of the Dynasty 350 or 700 and better be able to apply these features on your machine based on having somewhat of an understanding based on the Dynasty series. What the Dynastys do digitally, the Aerowave likely handles in an analog fashion. For what it's worth that's my $.02. Good luck and best regards, Allanaevald
Reply:One thing you can do on a Aerowave is change the amps on either the electrode positive or negative side of the ac power wave. For example if you had some super clean thick new material you could dial in more amps on the electrode positive side for more penetration and less electrode negative amps for less cleaning action. Very adjustable machine. Look up John Marcella he had a Aerowave before he bought his Dynasty 350, simply the best aluminum welder out there Imo and he understood the machines functions and capitalized on them.
Reply:The aerowave is a hybrid transformer/inverter tig. It does much of what the dynasty does like mentioned, but on a limited basis.Study your manual and read/watch the articles and videos on the Miller resources page.There are push buttons to the ritght. Push them to display the values on the meter the adjust with the dial. There should be EN, EP, Balance, and such like the dynasty.I remember they came with a setup chart. You may want to call miller technical dept to see if one could be emailed to you.Weld like a "WELDOR", not a wel-"DERR" MillerDynasty700DX,Dynasty350DX4ea,Dynasty200DX,Li  ncolnSW200-2ea.,MillerMatic350P,MillerMatic200w/spoolgun,MKCobraMig260,Lincoln SP-170T,PlasmaCam/Hypertherm1250,HFProTig2ea,MigMax1ea.
Reply:I currently use the amperage, frequency, ac balance, and pre/post flow for my welds, but all these other buttons are on here that seem like they could be helping me control more of my aluminum welds. (I added pictures of the panel, a weld from when I started using the machine and after I've learned how to use SOME of the controls) Attached Images
Reply:I've never run one but I'd like to.  I'm on a passive hunt for one and have read the manual.  It's pretty clear IF you can read Millerspeak.  They have thier own language but it's pretty consitant between manuals.  For typical GTAW w/ a foot control you've got the parameters that control the AC wave; -relative duration of EN to EP (balance)-amperage for the EP-amperage for the EN-AC frequency.  Standard transformer machine only produces a 60hz AC wave.  Increase the hz, and increase arc focus.-Pulse, same controls as any Miller pulse module except the Aero has high and low range for the frequence of pulse.  To this day I can't remember how the "background" relates to the "peak" amperage and have to run a few test beads to get the pulse program right.-preflow and post flow are self explanatory.That's about it for the "standard" stuff.  The other stuff is for "writing" rudimentary welding programs that can be triggered w/ a momentary switch on the torch. That's what the "smaw/gtaw trigger hold/gtaw" selector is for.  You can set up start and stop programs. Press the switch once, preflow starts, press it again and the initial ramp starts, then the welding amperage or pulse program kicks in.  Press the switch a third time and the crater fill ramp down starts, then the postflow... The "gtaw trigger hold" switch shows you what the momentary switch triggers.  The arrows point to trigger points.Pretty neat if you're welding out of possition but it's got to be tough to get everything dialed in (I impress my self when I use "crater fill" on my Sync, couldn't imagine ever getting all the other stuff figured).Your best bet is to crate it up and send it over to MA. I'll poke around a bit and post a video on youtube.Last edited by wendell; 03-01-2013 at 08:36 AM.Syncrowave 300Maxtron 450, S-52E, 30A
Reply:Wendell, John Marcella had one in the swapmeet here.Seems like it was his one and only post here.
Reply:Originally Posted by 7A749I have never had one come in the shop, but have been told by a few reputable service ppl that if they fail, they're a nightmare to repair. They could be very temperamental, but being what they were for the time that's understandable. Ppl say the same thing about Maxtrons, but once you learn your way around them, they are fine machines.I've seen them come up at auction for under a few grand. Think they were well over the 10K mark when new. Didn't you own a couple at one time Terry?IMHO of course
Reply:I remember now. Never, ever mess with the bottom set of controls. Pulse is dumb on this machine. The upper controls are self explainitory. We could tune them pretty good.Weld like a "WELDOR", not a wel-"DERR" MillerDynasty700DX,Dynasty350DX4ea,Dynasty200DX,Li  ncolnSW200-2ea.,MillerMatic350P,MillerMatic200w/spoolgun,MKCobraMig260,Lincoln SP-170T,PlasmaCam/Hypertherm1250,HFProTig2ea,MigMax1ea.
Reply:Originally Posted by Showdog75Wendell, John Marcella had one in the swapmeet here.Seems like it was his one and only post here.
Reply:Originally Posted by 7A749That's cheaper than I thought. I have heard they have a tendency to puke. I sure wouldn't mind having one, but I don't need anything like that. My S'Wave 250 DX took a dump on me last week on that plow job. Looks like the potentiometer has problems. Problem is, it's connected to the DRO board & is prolly expensive. Maybe I need a Dynasty..... I'm gonna take a look at it after I get these machines out of here. Got an XMT 300 I'm working on right now. Oh, joy. I know you said you didn't have a good experience with S'Wave machines, but that S'Wave 500 is a beast tho. Still sought after too. They bring good money, regardless of the year.
Reply:Originally Posted by wendellI've never run one but I'd like to.  I'm on a passive hunt for one and have read the manual.  It's pretty clear IF you can read Millerspeak.  They have thier own language but it's pretty consitant between manuals.  For typical GTAW w/ a foot control you've got the parameters that control the AC wave; -relative duration of EN to EP (balance)-amperage for the EP-amperage for the EN-AC frequency.  Standard transformer machine only produces a 60hz AC wave.  Increase the hz, and increase arc focus.-Pulse, same controls as any Miller pulse module except the Aero has high and low range for the frequence of pulse.  To this day I can't remember how the "background" relates to the "peak" amperage and have to run a few test beads to get the pulse program right.-preflow and post flow are self explanatory.That's about it for the "standard" stuff.  The other stuff is for "writing" rudimentary welding programs that can be triggered w/ a momentary switch on the torch. That's what the "smaw/gtaw trigger hold/gtaw" selector is for.  You can set up start and stop programs. Press the switch once, preflow starts, press it again and the initial ramp starts, then the welding amperage or pulse program kicks in.  Press the switch a third time and the crater fill ramp down starts, then the postflow... The "gtaw trigger hold" switch shows you what the momentary switch triggers.  The arrows point to trigger points.Pretty neat if you're welding out of possition but it's got to be tough to get everything dialed in (I impress my self when I use "crater fill" on my Sync, couldn't imagine ever getting all the other stuff figured).Your best bet is to crate it up and send it over to MA. I'll poke around a bit and post a video on youtube.
Reply:Originally Posted by shovelonI remember now. Never, ever mess with the bottom set of controls. Pulse is dumb on this machine. The upper controls are self explainitory. We could tune them pretty good.