Question about Miller Electric Manufacturing Electric Syncrowave 250 DX TIG 907194032 Welder

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I have a syncrowave 250, it is about 12 years old. I bought it new and use it rarely. Recently I went to weld some light aluminum and when I tried to start an arc,it acted as though I had no ground connection. I checked everything and it was O.K. I tried again and got a little better arc but not normal. I kept the unit on and rolled up to 225 amps and back down several times. The arc got better the longer I stayed on it, until it seemed normal and I finished my job. I went to use it again about 2 weeks later and got the same issue. I have tried one time since and the same. I've checked the obvious ie; connections,gas,tungsten etc. Any suggestions??? Thanks, Jon.

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I would like to suggest to you that you post this question on the millerwelds forum. There are some very experienced tech guys there that can help you much better. Go to and select the forums under the resources tab. You will be surprised. Hope you can get it running again.


Posted on Apr 21, 2017


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Posted on Jan 02, 2017

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SOURCE: how to prepare tungsten for aluminum

To make successful aluminum welds you must set your TIG machine to A/C, so make sure you get a tungsten rod meant for running alternating current. If it is pure tungsten (green band on the end), you're good. For the tip, just grind a tip like you normally would. When you start welding a bit of aluminum will collect on your electrode. After that you may need to break off the tip every now and then if you get a lot of junk in the ball. Make sure you practice on some scrap first, aluminum is very different to run than other metals. Getting the right operating temperature down is a bit trickier too.

Just in case you're working on something serious like a motorcycle frame, make sure the aluminum you're using is a grade that's able to be welded. I've heard about a guy that built costom bikes and used the wrong grade, when the customer took the bike down the highway it fell apart on him.

Posted on Aug 08, 2009

  • 1036 Answers

SOURCE: my tungsten appers to be melting when i am welding

What gas are you running ?
Aluminium needs Argon mix - try increasing gas rate to provide sufficient shielding - and work indoors.
If this doesn't solve it -
Try using a lower amperage as I think you may be overheating. Alternatively - use a different make of tungsten.
Don't dip electrode, as this will eat it up.

Posted on Aug 28, 2009

  • 24 Answers

SOURCE: cannot get syncrowave to weld aluminum

must use remote output for tig

Posted on Sep 18, 2009

  • 3433 Answers

SOURCE: Miller Syncrowave 200 wont strike arc for TIG

proper polarity?

Posted on Nov 12, 2009

  • 194 Answers

SOURCE: I have a miller microwave 200. what settings

I think you mean you have a Miller Synchrowave 200.

Typically, you would want to use AC below about 250 amps. In this case (to keep it simple), use AC, adjust your balance to about 4, use an 1/8" pure tungsten, pure argon at about 20CFh, and set the panel at 170amps to get things started. For general purpose, use 4043 filler.

Now - these are just generic settings, but they will get you going.

Posted on Jan 12, 2010

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