Miller Non-CE User manual

Miller Non-CE User manual
Dynasty 300 Series
Issued February 2001 • Index No. AD/5.0
™
Quick
Specs
TIG/Stick Welding
Power Source
Heavy Industrial Applications
Processes
Input Power
Precision Metal Fabrication
Aerospace
Bicycle Manufacturing
Mechanical Contractors
Shipboard Installation/Repair
Maintenance/Repair Operations
Automation
TIG (GTAW) Welding
Pulsed TIG (GTAW-P) Welding
with DX and LX Models
Stick (SMAW) Welding
Amperage Range
Requires 3- or 1-Phase Power
Rated Output
Weight
5 – 300 A
250 A at 30 V, 40% Duty Cycle (AC)
200 A at 28 V, 40% Duty Cycle (DC)
Without Auxiliary Power: 90 lb (41 kg)
With Auxiliary Power: 106 lb (48.1 kg)
The Power of Blue .
®
Advanced Squarewave arc for improved
weldability on aluminum and magnesium
using low power. Continuous high-frequency
is NOT needed because of the advanced
Squarewave arc, and extended balance
control allows you to fine-tune the duration
of the electrode negative portion of the cycle
from 50 to 90%. This provides precise
cleaning control and prolonged tungsten life.
Available in Three Models:
SD: Provides the basic features that are
required for most AC/DC TIG or Stick
welding applications.
Superior arc performance even on difficult to run
electrodes like E6010.
DX: When the job demands greater
control the DX provides pulse on/off,
pulse frequency, peak % time, background amperage, initial amperage,
initial slope time, final slope time and
final amperage control.
LX: Automation made simple. With the
Automation Interface Connector, the
integrator can quickly interface to the
output disable, weld start/stop, gas
start/stop inputs; valid arc, pulse lock
out, and end of weld sequence outputs.
Programmable HF start parameters
allows the operator to independently set
HF starting conditions based upon process
and memory selection.
HF start for non-contact arc starting that
eliminates tungsten or material
contamination.
Dynasty 300 LX
Dynasty 300 SD
Dynasty 300 DX
TIGRunner
Auto-Link ™ provides connection to 230 V or
460 V single- or three-phase power without
having to remove the covers and relink the
power source.
Lift-Arc™ start for TIG arc starting without the
use of high frequency.
Inverter-based, AC/DC power source has
state-of-the-art operator interface allowing
the user extra set-up capabilities in a
compact machine. Features more precise
control of output parameters than traditional
knobs and switches.
Power source is warranted for 3 years, parts and labor.
Original main power rectified parts are warranted for 5 years.
Miller Electric Mfg. Co.
International Headquarters
Web Site
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Phone: 920-735-4505
USA FAX: 920-735-4134
Canadian FAX: 920-735-4169
International FAX: 920-735-4125
www.MillerWelds.com
Specifications
(Subject to change without notice.)
For Multivoltage Units
Input
Power
Rated Output
at 40% Duty Cycle
Welding
Amperage
Range
Max. OpenCircuit
Voltage
Amps Input at Rated Output, 60 Hz
230 V
460 V
KVA
KW
ThreePhase
250 A at 30 VAC
5–300 A
95 VDC
26.3
17
14.2
10.5
200 A at 28 VDC
20.5
13.4
8.39
7.7
SinglePhase
250 A at 30 VAC
63
32.2
14.8
10.4
200 A at 28 VDC
44
25.8
11.9
8.1
Dimensions
Net Weight
H: 17 in (432 mm)
W: 12-1/2 in (318 mm)
D: 24 in (610 mm)
Without Aux. Power:
90 lb (41 kg)
Dimensions
Net Weight
H: 17 in (432 mm)
W: 12-1/2 in (318 mm)
D: 24 in (610 mm)
Without Aux. Power:
90 lb (41 kg)
With Aux. Power:
106 lb (48.1 kg)
With Aux. Power:
106 lb (48.1 kg)
For Single-Voltage Units
Rated Output at
40% Duty Cycle
Welding
Amperage Range
Max. OpenCircuit Voltage
Amps Input at Rated Output, 50 Hz
400 V
KVA
KW
250 A at 30 VAC
5–300 A
95 VDC
20.2
14.0
10.5
200 A at 28 VDC
5–300 A
95 VDC
15.1
10.5
7.5
Certified by Canadian Standards Association to both Canadian and U.S. Standards.
Conforms to European standards.
Control Panels
Dynasty 300 SD
Dynasty 300 DX/LX
6
1
6
1
2
2
7
7
1. Voltmeter
2. Ammeter
3. Polarity Control
4. Process Control
5. Output Control
6. Encoder Control
7. Amperage Control
8. AC Waveshape Control
9. Adjust Control
10. Sequencer Controls
11. Pulser Control
3
8
3
8
4
5
9
4
5
9
10
11
Dynasty 300 SD (CE)
Dynasty 300 DX/LX (CE)
6
1
6
1
2
2
7
7
8
3
3
8
4
5
9 4
10 5
9
10
11
Control Panel Parameter Values
A. Preflow (s)
B. Initial Time (s)
C. Initial Amperage (A)
D. Initial Slope Time (s)
E. Weld Amperage (A)
2
0.0 – 25
0.0 – 25 (LX only)
5 – 300
0.0 – 25
5 – 300
F. AC Frequency (Hz)
G. Balance Control (%EN)
H. Background Amperage (%)
I. Pulse Frequency (Hz)
J. Peak Percent Time (%)
20 – 250
50 – 90
0 –100
0.1 – 500
5 – 95
K. Final Slope Time (s)
L. Final Amperage (A)
M. Final Time (s)
N. Postflow Time (s)
O. Dig (%)
0 – 25
5 – 300
0.0 – 25 (LX only)
0.0 – 50
0 – 100
Performance Data
VOLT/AMP CURVE, AC
DUTY CYCLE CHART
100
1000
80
600
500
400
300
250
200
AC VOLTS
WELD AMPS
800
AC
DC
GTAW-MAX
40
GTAW-MIN
20
150
100
10
SMAW-MAX
60
SMAW-MIN
15
20
25
30
40
50 60
80
0
100
0
50
100
% DUTY CYCLE
150
200
250
300
350
AC AMPS
(250 HZ @ BALANCED)
VOLT/AMP CURVE, DC
100
DC VOLTS
80
SMAW-MAX
60
GTAW-MAX
40
DIG-MIN
GTAW-MIN
20
SMAW-MIN
DIG-MAX
0
0
50
100
150
200
250
300
350
DC AMPS
Included Accessories
Non-CE SD/DX Models Include:
(1) DA1820L torch adapter
(2) International-style connectors 35/50
TIGRunner Packages
®
CE SD/DX Models Include:
(2) International-style connectors 35/50
(1) 14-pin amphenol with clamp
(1) 5/8 in - 18 gas fitting
Non-CE LX Model Includes:
(1) DA1820L torch adapter
(2) International-style connectors 35/50
(1) 14-pin amphenol with clamp
(1) 10-pin amphenol with clamp
CE LX Model Includes:
(2) International-style connectors 35/50
(1) 14-pin amphenol with clamp
(1) 10-pin amphenol with clamp
(1) 5/8 in - 18 gas fitting
Dynasty 300 SD w/TIGRunner #903 840
Dynasty 300 DX w/TIGRunner #903 841
Includes Dynasty 300 SD or DX, Auxiliary
Power, Coolmate™ 3, Deluxe Carrying Cart
and Cylinder Rack, and Remote Foot Control
(completely assembled).
Dynasty 300 SD w/TIGRunner and Torch
#903 840-01-1
Dynasty 300 DX w/TIGRunner and Torch
#903 841-01-1
Includes Dynasty 300 SD or DX, Auxiliary
Power, Coolmate™ 3, Deluxe Carrying Cart
and Cylinder Rack, and Remote Foot Control
(completely assembled). Also a 25-ft
250-Amp, Water-Cooled DB20M25R
Diamondback Torch, Work Clamp,
10-ft Gas Hose, Regulator/Flowmeter,
Cable Cover, and an AK-4 Accessory Kit.
3
Genuine Miller Accessories
Remote Controls
RFCS-14 HD Foot Control #194 744
For all Miller solid-state power sources
after serial number JK674521. This new
design increases stability with a larger
base and durability with a heavier cord.
Maximum flexibility is accomplished with a
reconfigurable cord that can exit the front,
back or either side of the pedal. Foot pedal
provides remote current and contactor
control. Includes 20 ft (6 m) cord and
14-pin plug.
RFCS-14 Foot Control #043 554
For all Miller solid-state power sources
after serial number JK674521. Foot pedal
provides remote current and contactor
control. Includes 20 ft (6 m) cord and
14-pin plug.
4
RCCS-14 Remote Contactor and Current
Control #043 688 14-pin plug
For all Miller solid-state power sources
after serial number JK674521. North/south
rotary-motion fingertip control fastens
to TIG torch using two Velcro® straps.
Great for applications that require a finer
amperage control. Includes 26.5 ft (8 m)
control cord.
RCC-14 Remote Contactor and Current
Control #151 086 14-pin plug
For all Miller solid-state power sources
after serial number JK674521. Side-to-side
rotary-motion fingertip control fastens to
TIG torch using two Velcro® straps. Great
for production or contractors that need
quick ramp-up. Includes 26.5 ft (8 m)
control cord.
RMLS-14 Switch #129 337
For all Miller solid-state power sources
after serial number JK674521. Momentaryand maintained-contact rocker switch for
contactor control. Push forward for
maintained contact and backward for
momentary contact. Includes 26.5 ft (8 m)
cord and 14-pin plug.
RMS-14 On/Off Control #187 208
For all Miller solid-state power sources
after serial number JK674521. Momentarycontact switch for contactor control.
Rubber-covered pushbutton dome switch
ideal for repetitive on-off applications.
Includes 26.5 ft (8 m) cord and 14-pin plug.
Genuine Miller Accessories
(Continued)
Carts and Racks
Educational Resources
Gas Tungsten Arc (TIG) Welding Book
#170 555
To order, call the Miller Literature
Distribution Center at 1-920-751-2120, or
FAX 1-920-751-2121. A comprehensive,
86-page text on all aspects of the TIG process.
Deluxe Carrying Cart and Cylinder Rack
#043 867
Accommodates inverter power source,
cooler, and one gas cylinder. Includes
bottom drawer for miscellaneous items.
Running Gear/Cylinder Rack #042 537
Has adjustable handles and is slanted for
convenient access to power source front
panel controls. Carries two 160 lb (72.6 kg)
gas cylinders, or one gas cylinder and one
Coolmate V3 coolant system for TIG (GTAW)
welding. Can be used with the Dynasty™,
®
Maxstar®, Invision™ or XMT inverter power
supplies. Also accommodates Radiator,
Watermate™, or Coolmate™ coolant systems.
Inverter Rack #043 562
6-Rack 230/460 V
The XMT® 304 Rack conveniently houses
multiple power sources for multiple
welders. This is an ideal system for onsite
applications including construction and
ship building.
TIG Fundamentals Welding CD #196 567
To order, please call 1-800-934-5148, or
FAX 1-920-751-2121, or log on to our Web
site. An interactive CD designed for anyone
who’s looking to better understand the
TIG process.
TIG (GTAW) Torches
Diamondback™ TIG Torches
The NEW Diamondback line of ergonomically designed TIG torches from Miller
Electric complements the most popular
TIG power source line available today. The
Diamondback torch line includes both
air-cooled and water-cooled models. The
air-cooled models range in size from
125 to 200 A. The water-cooled models
include 250 and 350 A torches. All models
are standard with a rigid head. See
Diamondback TIG Torch Selector Guide.
TIG (GTAW) Torch Adapters
Universal Carrying Cart and Cylinder Rack
#042 934
Accommodates power source, plus one
gas cylinder up to 56 in (142.2 cm) high
measuring 6 to 9 in (15.2 to 22.8 cm) in
diameter. Also provides storage for
auxiliary items such as electrodes, helmets,
gloves, etc. Can also be used with XMT®,
Dynasty™ Series, Maxstar ® Series, and
Millermatic® 130 power sources.
DA-917F #194 720
Used to adapt a 1-piece 125 or 150 amp
air-cooled torch to an International-style
connector.
DA-1820L #190 219
Used to adapt a 250 or 350 amp watercooled torch to an International-style
connector.
DA-26R #194 724
Used to adapt a 1-piece 200 amp air-cooled
torch to an International-style connector.
5
Genuine Miller Accessories
(Continued)
Coolant Systems
For more information, see the Miller Coolant
Systems literature sheet, Index No. AY/7.2.
Coolmate V3
Coolmate™ 3
#043 007 115 VAC
#043 007-01-2 115 VAC, CE
#043 008 230 VAC
#043 008-01-2 230 VAC, CE
For use with water-cooled torches rated up
to 500 amps. Unique paddle-wheel indicator,
external filter and easy-fill spout.
Coolmate 4
Coolmate 3
Coolmate™ V3
#043 009 115 VAC
#043 009-01-2 115 VAC, CE
For use with water-cooled torches rated up
to 500 amps. Vertical design conveniently
mounts to Miller cylinder rack in place of
one cylinder.
Coolmate™ 4
#042 288 115 VAC
#042 288-01-5 115 VAC, CE
For use with water-cooled torches rated up
to 600 amps. Tough molded polyethylene
case with carrying handle.
Low-Conductivity Coolant #043 810
Sold in multiples of four in 1-gallon
recyclable plastic bottles. Primarily used
in TIG (high-frequency) applications, but
can also be used in MIG systems where
aluminum is not in the water path. Miller
coolants contain a base of ethylene glycol
and deionized water to protect against
freezing to -37°F (-38°C) or boiling to
227°F (108°C). Also contains a compound
that resists algae growth.
International-Style Connectors
(Will accept Dinse™ or other International connectors.)
Note: All Dynasty power sources are equipped with
International-style connectors for secondary
connections. (Power source is shipped with two
50-mm male International-style plugs for use with
#1 or #2 AWG size cable.)
Extension Kit for International-Style
Cable Connectors
International-Style Connector Kit
Used to adapt or extend weld and/or
work cables. Kit includes one male
International-style plug and one in-line
female International-style receptacle.
#042 418 50 mm
Accepts #1 or #2 AWG cable size. Required
if male plugs shipped with power source
must be replaced, if additional plugs
are needed.
Kit includes one International-style male
plug which attaches to the work and/or weld
cables and plugs into the International-style
receptacles on the power source.
6
Aluminum-Protecting Coolant #043 809
Sold in multiples of four in 1-gallon
recyclable plastic bottles. Primarily used in
MIG products, such as the water-cooled
XR, which has an aluminum drive housing,
or in any system where high frequency is
not used. Miller coolants contain a base of
ethylene glycol and deionized water to
protect against freezing to -37°F (-38°C) or
boiling to 227°F (108°C). Also contains a
compound that resists algae growth.
#042 419 50 mm
Accepts #1 or #2 AWG size cable.
International/Tweco®
Adapter #042 465
A one-piece adapter which
has an International-style
male plug (to power
source) on one end and a female Tweco
receptacle (for weld cable connection) on
other end.
International/Cam-Lok
Adapter #042 466
A one-piece adapter which
has an International-style
male plug (to power source) on one end
and a Cam-Lok receptacle (for weld cable
connection) on other end.
Typical Installations
TIG (GTAW) Basic Equipment
Remote
Control
Shielding
Gas Cylinder
TIG
Torch
Work
Stick Electrode
Stick (SMAW) Basic Equipment
Work
7
Ordering Information
Equipment and Options
Stock No.
Description
Qty.
#903 832
#903 834
#903 832-01-1
#903 834-01-1
#903 832-01-2
#903 834-01-2
#903 832-02-1
#903 834-02-1
#903 832-02-2
#903 834-02-2
#903 840
#903 840-01-1
#903 841
#903 841-01-1
Basic controls, 230/460 VAC, 50/60 Hz
Basic controls, 400 VAC, 50/60 Hz, CE
Basic controls w/115 V auxiliary power, 230/460 VAC, 50/60 Hz
Basic controls w/115 V auxiliary power, 400 VAC, 50/60 Hz, CE
Full feature controls, 230/460 VAC, 50/60 Hz
Full feature controls, 400 VAC, 50/60 Hz, CE
Full feature controls w/115 V auxiliary power, 230/460 VAC, 50/60 Hz
Full feature controls w/115 V auxiliary power, 400 VAC, 50/60 Hz, CE
Full feature controls w/115 V auxiliary power & required automation connections
Full feature controls w/115 V aux. power & required automation connections, CE
Basic controls w/TIGRunner package (see pg 3)
Basic controls w/TIGRunner & 250 A torch package (see pg 3)
Full feature controls w/TIGRunner package (see pg 3)
Full feature controls w/TIGRunner & 250 A torch package (see pg 3)
#194 720
#190 219
#194 724
DA-917F
DA-1820L
DA-26R
See Diamondback TIG Torch Selector Guide
See Parts Guide
Remote Controls
RFCS-14 HD
RFCS-14
RCCS-14
RCC-14
RMLS-14
RMS-14
#194 744
#043 554
#043 688
#151 086
#129 337
#187 208
Heavy-duty foot control
Foot control
North/south fingertip control
Side-to-side fingertip control
Momentary/maintained rocker control
Momentary rubber dome switch
Carts and Racks
Deluxe Carrying Cart and Cylinder Rack
Universal Carrying Cart and Cylinder Rack
Running Gear/Cylinder Rack
Inverter Rack
#043 867
#042 934
#042 537
#043 562
Educational Resources
Gas Tungsten Arc (TIG) Welding Book
TIG Fundamentals Welding CD
#170 555
#196 567
Power Source
Dynasty™ 300 SD
Dynasty™ 300 DX
Dynasty™ 300 LX w/Auxiliary Power
Dynasty™ 300 SD w/TIGRunner™
Dynasty™ 300 SD w/TIGRunner™ and Torch
Dynasty™ 300 DX w/TIGRunner™
Dynasty™ 300 DX w/TIGRunner™ and Torch
TIG Accessories
TIG Torch Adapters
Diamondback™ TIG Torches
Consumables, Tungsten
Gas Cylinder, Gas Hose and Fittings
Stick Accessories
Stick Electrodes
Coolant Systems
Coolmate™ 3
Coolmate™ V3
Coolmate™ 4
Aluminum-Protecting Coolant
Low-Conductivity Coolant
Cooling System Hoses
International-Style Connectors
International-Style Connector Kit
Extension Kit for International-Style
International/Tweco® Adapter
International/Cam-Lok Adapter
#043 007
#043 007-01-2
#043 008
#043 008-01-2
#043 009
#043 009-01-2
#042 288
#042 288-01-5
#043 809
#043 810
115 VAC
115 VAC, CE
230 VAC
230 VAC, CE
115 VAC
115 VAC, CE
115 VAC
115 VAC, CE
#042 418
#042 419
#042 465
#042 466
50 mm
50 mm
A one-piece adapter with International-style male plug
A one-piece adapter with International-style male plug
Date:
Total Quoted Price:
Distributed by:
Litho in USA
Price
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