Miller | MG270167L | Owner Manual | Miller MAXSTAR 210 User manual

Miller MAXSTAR 210 User manual
OM-270536E
2016−06−28
Processes
TIG (GTAW) Welding
Stick (SMAW) Welding
Description
120−480 Volt Models W/AutolineR
Arc Welding Power Source
R
Dynasty 210
Maxstar 210
R
CE And Non-CE Models
For product information,
Owner’s Manual translations,
and more, visit
www.MillerWelds.com
File: TIG (GTAW)
From Miller to You
Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.
That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They
will help you protect yourself against potential hazards on the worksite.
We’ve made installation and operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The
Miller is the first welding parts list will then help you to decide the
equipment manufacturer in exact part you may need to fix the problem.
the U.S.A. to be registered to
the ISO 9001 Quality System Warranty and service information for your
Standard.
particular model are also provided.
Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog or individual specification sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.
Mil_Thank 2009−09
Working as hard as you do
− every power source from
Miller is backed by the most
hassle-free warranty in the
business.
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Symboles utilisés . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . .
2-4. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-6. Informations relatives aux CEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Additional Safety Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Miscellaneous Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Static Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Selecting a Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Dimensions, Weights, And Mounting Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Selecting Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. Cooler Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6. Electrical Service Guide (Dynasty) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-7. Electrical Service Guide (Maxstar) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-8. Connecting Three-Phase Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-9. Connecting Single-Phase Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-10. Remote 14 Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-11. Simple Automation Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-12. Software Updates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − DYNASTY 210 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Dynasty 210 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Accessing Control Panel Menu: AC TIG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Accessing Control Panel Menu: DC TIG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4. Accessing Control Panel Menu: AC And DC Stick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-5. Accessing User Setup Menu: AC And DC TIG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-6. Accessing User Setup Menu: AC And DC Stick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − DYNASTY 210 DX OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. Dynasty 210 DX Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. Accessing Control Panel Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-3. Accessing User Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-4. AC Independent Expansion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-5. Selecting General (GEN) Tungsten To Change Programmable TIG Starting Parameters . . . . . . . . .
1
1
1
3
4
4
4
5
5
5
7
8
8
8
9
9
12
13
13
13
16
17
17
18
18
19
20
21
22
23
24
26
28
29
29
30
32
32
33
34
34
35
36
37
37
38
40
41
42
TABLE OF CONTENTS
SECTION 8 − MAXSTAR 210 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
43
8-1. Maxstar 210 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
43
8-2. Accessing Control Panel Menu: DC TIG HF And Lift Arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
44
8-3. Accessing Control Panel Menu: DC Stick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
45
8-4. Accessing User Setup Menu: DC TIG And Lift-Arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
46
8-5. Accessing User Setup Menu: DC Stick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
47
SECTION 9 − MAXSTAR 210 STR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
48
9-1. Maxstar 210 STR Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
48
9-2. Accessing Control Panel Menu: DC TIG Lift Arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
49
9-3. Accessing Control Panel Menu: DC Stick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
50
9-4. Accessing User Setup Menu: DC TIG Lift-Arc And DC Stick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
51
SECTION 10 − MAXSTAR 210 DX OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
53
10-1. Maxstar 210 DX Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
53
10-2. Accessing Control Panel Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
54
10-3. Accessing User Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
56
SECTION 11 − ADVANCED MENU FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
57
11-1. Accessing Tech Menu For Dynasty/Maxstar 210 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
57
11-2. Accessing Tech Menu For Dynasty/Maxstar 210DX Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
58
11-3. Sequencer And Weld Timer For DX Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
60
11-4. Output Control And Trigger Functions For DX Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
61
11-5. Lockout Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
64
11-6. Lockout Levels Defined . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
64
SECTION 12 − MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
65
12-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
65
12-2. Voltmeter/Ammeter Display Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
66
12-3. Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
67
12-4. Blowing Out Inside of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
68
12-5. Coolant Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
68
SECTION 13 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
69
13-1. Recommended Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
69
SECTION 14 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
70
SECTION 15 − HIGH FREQUENCY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
72
15-1. Welding Processes Requiring High Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
72
15-2. Installation Showing Possible Sources Of HF Interference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
72
15-3. Recommended Installation To Reduce HF Interference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
73
SECTION 16 − SELECTING AND PREPARING A TUNGSTEN FOR DC OR AC WELDING WITH INVERTER
MACHINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
74
16-1. Selecting Tungsten Electrode (Wear Clean Gloves To Prevent Contamination Of Tungsten) . . . . . .
74
16-2. Preparing Tungsten Electrode For DC Electrode Negative (DCEN) Welding
Or AC Welding With Inverter Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
74
SECTION 17 − TIG PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
75
17-1. Lift-Arc And HF TIG Start Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
75
17-2. Pulser Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
76
SECTION 18 − STICK WELDING (SMAW) GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
77
WARRANTY
COMPLETE PARTS LIST − Available at www.MillerWelds.com
DECLARATION OF CONFORMITY
for European Community (CE marked) products.
MILLER Electric Mfg. Co., 1635 Spencer Street, Appleton, WI 54914 U.S.A. declares that the
product(s) identified in this declaration conform to the essential requirements and provisions of
the stated Council Directive(s) and Standard(s).
Product/Apparatus Identification:
Product
Stock Number
DYNASTY 210 DX (AUTO-LINE 120-480 V) CPS
(CE)
MAXSTAR 210 DX (AUTO-LINE 120-480 V) (CE)
907686003
907684001
Council Directives:
• 2014/35/EU Low Voltage
• 2014/30/EU Electromagnetic Compatibility
• 2011/65/EU Restriction of the use of certain hazardous substances in electrical and electronic equipment
Standards:
• IEC 60974-1: 2012 Arc Welding Equipment – Part 1: Welding Power Sources
• IEC 60974-3: 2007 Arc Welding Equipment – Part 3: Arc Striking and Stabilizing Devices
• IEC 60974-10: 2007 Arc Welding Equipment – Part 10: Electromagnetic Compatibility Requirements
Signatory:
August 25, 2015
_____________________________________
___________________________________________
David A. Werba
Date of Declaration
MANAGER, PRODUCT DESIGN COMPLIANCE
273551A
EMF DATA SHEET FOR ARC WELDING POWER SOURCE
Product/Apparatus Identification
Product
DYNASTY 210 DX (AUTO-LINE 120-480 V) CPS (CE)
Stock Number
907686003
Compliance Information Summary
Applicable regulation
Directive 2014/35/EU
Reference limits
Directive 2013/35/EU, Recommendation 1999/519/EC
Applicable standards
IEC 62822-1:2016, IEC 62822-2:2016
Intended use
☒ for occupational use
☐ for use by laymen
Non-thermal effects need to be considered for workplace assessment
☒ YES
☐ NO
Thermal effects need to be considered for workplace assessment
☐ YES
☒ NO
☒
Data is based on maximum power source capability (valid unless firmware/hardware is changed)
☐
Data is based on worst case setting/program (only valid until setting options/welding programs are changed)
☐
Data is based on multiple settings/programs (only valid until setting options/welding programs are changed)
Occupational exposure is below the Exposure Limit Values (ELVs)
for health effects at the standardized configurations
☒ YES
☐ NO
(if NO, specific required minimum distances apply)
Occupational exposure is below the Exposure Limit Values (ELVs)
for sensory effects at the standardized configurations
☐ n.a
☒ YES
☐ NO
(if applicable and NO, specific measures are needed)
☐ n.a
☐ YES
☒ NO
(if applicable and NO, specific signage is needed)
Occupational exposure is below the Action Levels (ALs) at the
standardized configurations
EMF Data for Non-thermal Effects
Exposure Indices (EIs) and distances to welding circuit (for each operation mode, as applicable)
Head
Standardized distance
ELV EI @ standardized distance
Required minimum distance
Sensory Ef­
fects
10 cm
0.13
Health Ef­
fects
10 cm
0.12
Trunk
Limb (hand)
Limb (thigh)
10 cm
0.20
3 cm
0.11
3 cm
0.26
1 cm
1 cm
1 cm
1 cm
1 cm
Distance where all occupational ELV Exposure Indices fall below 0.20 (20%)
10 cm
Distance where all general public ELV Exposure Indices fall below 1.00 (100%)
Tested by:
275605-A
Tony Samimi
Date tested:
2016-02-18
120 cm
EMF DATA SHEET FOR ARC WELDING POWER SOURCE
Product/Apparatus Identification
Product
MAXSTAR 210 DX (AUTO-LINE 120-480 V) (CE)
Stock Number
907684001
Compliance Information Summary
Applicable regulation
Directive 2014/35/EU
Reference limits
Directive 2013/35/EU, Recommendation 1999/519/EC
Applicable standards
IEC 62822-1:2016, IEC 62822-2:2016
Intended use
☒ for occupational use
☐ for use by laymen
Non-thermal effects need to be considered for workplace assessment
☒ YES
☐ NO
Thermal effects need to be considered for workplace assessment
☐ YES
☒ NO
☒
Data is based on maximum power source capability (valid unless firmware/hardware is changed)
☐
Data is based on worst case setting/program (only valid until setting options/welding programs are changed)
☐
Data is based on multiple settings/programs (only valid until setting options/welding programs are changed)
Occupational exposure is below the Exposure Limit Values (ELVs)
for health effects at the standardized configurations
☒ YES
☐ NO
(if NO, specific required minimum distances apply)
Occupational exposure is below the Exposure Limit Values (ELVs)
for sensory effects at the standardized configurations
☐ n.a
☒ YES
☐ NO
(if applicable and NO, specific measures are needed)
☐ n.a
☒ YES
☐ NO
(if applicable and NO, specific signage is needed)
Occupational exposure is below the Action Levels (ALs) at the
standardized configurations
EMF Data for Non-thermal Effects
Exposure Indices (EIs) and distances to welding circuit (for each operation mode, as applicable)
Head
Standardized distance
ELV EI @ standardized distance
Required minimum distance
Sensory Ef­
fects
10 cm
0.09
Health Ef­
fects
10 cm
0.08
Trunk
Limb (hand)
Limb (thigh)
10 cm
0.13
3 cm
0.08
3 cm
0.17
1 cm
1 cm
1 cm
1 cm
1 cm
Distance where all occupational ELV Exposure Indices fall below 0.20 (20%)
5 cm
Distance where all general public ELV Exposure Indices fall below 1.00 (100%)
Tested by:
275606-A
Tony Samimi
Date tested:
2016-02-17
88 cm
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som 2015−09
7
Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.
1-1. Symbol Usage
DANGER! − Indicates a hazardous situation which, if
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or explained in the text.
NOTICE − Indicates statements not related to personal injury.
. Indicates special instructions.
This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the
hazards.
1-2. Arc Welding Hazards
The symbols shown below are used throughout this manual
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information
found in the Safety Standards listed in Section 1-5. Read and
follow all Safety Standards.
Only qualified persons should install, operate, maintain, and
repair this unit.
During operation, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic
wire welding, the wire, wire reel, drive roll housing,
and all metal parts touching the welding wire are
electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
D Do not touch live electrical parts.
D Wear dry, hole-free insulating gloves and body protection.
D Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
D Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
D Use AC output ONLY if required for the welding process.
D If AC output is required, use remote output control if present on
unit.
D Additional safety precautions are required when any of the following electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such
as floors, gratings, or scaffolds; when in cramped positions such
as sitting, kneeling, or lying; or when there is a high risk of unavoidable or accidental contact with the workpiece or ground. For these
conditions, use the following equipment in order presented: 1) a
semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most situations, use of a DC, constant voltage wire welder
is recommended. And, do not work alone!
D Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
D Properly install, ground, and operate this equipment according to
its Owner’s Manual and national, state, and local codes.
D Always verify the supply ground − check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
D When making input connections, attach proper grounding conductor first − double-check connections.
D Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
D Frequently inspect input power cord and ground conductor for
damage or bare wiring – replace immediately if damaged – bare
wiring can kill.
D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or repaired cables.
D Do not drape cables over your body.
D If earth grounding of the workpiece is required, ground it directly
with a separate cable.
D Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
D Do not touch electrode holders connected to two welding machines at the same time since double open-circuit voltage will be
present.
D Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
D Wear a safety harness if working above floor level.
D Keep all panels and covers securely in place.
D Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
D Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
D Do not connect more than one electrode or work cable to any
single weld output terminal. Disconnect cable for process not in
use.
D Use GFCI protection when operating auxiliary equipment in damp
or wet locations.
SIGNIFICANT DC VOLTAGE exists in inverter welding power sources AFTER removal of input power.
D Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
HOT PARTS can burn.
D Do not touch hot parts bare handed.
D Allow cooling period before working on
equipment.
D To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns.
OM- 270536 Page 1
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
D Keep your head out of the fumes. Do not breathe the fumes.
D If inside, ventilate the area and/or use local forced ventilation at the
arc to remove welding fumes and gases. The recommended way
to determine adequate ventilation is to sample for the composition
and quantity of fumes and gases to which personnel are exposed.
D If ventilation is poor, wear an approved air-supplied respirator.
D Read and understand the Safety Data Sheets (SDSs) and the
manufacturer’s instructions for adhesives, coatings, cleaners,
consumables, coolants, degreasers, fluxes, and metals.
D Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breathing air is safe.
D Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
D Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and while wearing an air-supplied
respirator. The coatings and any metals containing these elements
can give off toxic fumes if welded.
ARC RAYS can burn eyes and skin.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
D Wear an approved welding helmet fitted with a proper shade of
filter lenses to protect your face and eyes from arc rays and
sparks when welding or watching (see ANSI Z49.1 and Z87.1
listed in Safety Standards).
D Wear approved safety glasses with side shields under your
helmet.
D Use protective screens or barriers to protect others from flash,
glare and sparks; warn others not to watch the arc.
D Wear body protection made from durable, flame−resistant material (leather, heavy cotton, wool). Body protection includes
oil-free clothing such as leather gloves, heavy shirt, cuffless
trousers, high shoes, and a cap.
WELDING can cause fire or explosion.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.
D Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
D Do not weld where flying sparks can strike flammable material.
D Protect yourself and others from flying sparks and hot metal.
D Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
D Watch for fire, and keep a fire extinguisher nearby.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
D Do not weld on containers that have held combustibles, or on
closed containers such as tanks, drums, or pipes unless they are
properly prepared according to AWS F4.1 and AWS A6.0 (see
Safety Standards).
D Do not weld where the atmosphere can contain flammable dust,
gas, or liquid vapors (such as gasoline).
D Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock, sparks, and fire
hazards.
D Do not use welder to thaw frozen pipes.
OM-270536 Page 2
D Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
D Wear body protection made from durable, flame−resistant material
(leather, heavy cotton, wool). Body protection includes oil-free
clothing such as leather gloves, heavy shirt, cuffless trousers, high
shoes, and a cap.
D Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
D After completion of work, inspect area to ensure it is free of sparks,
glowing embers, and flames.
D Use only correct fuses or circuit breakers. Do not oversize or bypass them.
D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
for hot work and have a fire watcher and extinguisher nearby.
D Read and understand the Safety Data Sheets (SDSs) and the
manufacturer’s instructions for adhesives, coatings, cleaners,
consumables, coolants, degreasers, fluxes, and metals.
FLYING METAL or DIRT can injure eyes.
D Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
D Wear approved safety glasses with side
shields even under your welding helmet.
BUILDUP OF GAS can injure or kill.
D Shut off compressed gas supply when not in use.
D Always ventilate confined spaces or use
approved air-supplied respirator.
ELECTRIC AND MAGNETIC FIELDS (EMF)
can affect Implanted Medical Devices.
D Wearers of Pacemakers and other Implanted
Medical Devices should keep away.
D Implanted Medical Device wearers should consult their doctor
and the device manufacturer before going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating
operations.
NOISE can damage hearing.
Noise from some processes or equipment can
damage hearing.
D Wear approved ear protection if noise level is high.
CYLINDERS can explode if damaged.
Compressed gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
D Protect compressed gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames, sparks, and arcs.
D Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
D Keep cylinders away from any welding or other electrical circuits.
D Never drape a welding torch over a gas cylinder.
D Never allow a welding electrode to touch any cylinder.
D Never weld on a pressurized cylinder − explosion will result.
D Use only correct compressed gas cylinders, regulators, hoses,
and fittings designed for the specific application; maintain them
and associated parts in good condition.
D Turn face away from valve outlet when opening cylinder valve. Do
not stand in front of or behind the regulator when opening the valve.
D Keep protective cap in place over valve except when cylinder is in
use or connected for use.
D Use the right equipment, correct procedures, and sufficient number of persons to lift and move cylinders.
D Read and follow instructions on compressed gas cylinders,
associated equipment, and Compressed Gas Association (CGA)
publication P-1 listed in Safety Standards.
1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
D Do not install or place unit on, over, or near
combustible surfaces.
D Do not install unit near flammables.
D Do not overload building wiring − be sure power supply system is
properly sized, rated, and protected to handle this unit.
FALLING EQUIPMENT can injure.
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
D Use equipment of adequate capacity to lift and
support unit.
D If using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit.
D Keep equipment (cables and cords) away from moving vehicles
when working from an aerial location.
D Follow the guidelines in the Applications Manual for the Revised
NIOSH Lifting Equation (Publication No. 94−110) when manually lifting heavy parts or equipment.
OVERUSE can cause OVERHEATING
MOVING PARTS can injure.
D Keep away from moving parts such as fans.
D Keep all doors, panels, covers, and guards
closed and securely in place.
D Have only qualified persons remove doors, panels, covers, or
guards for maintenance and troubleshooting as necessary.
D Reinstall doors, panels, covers, or guards when maintenance is
finished and before reconnecting input power.
READ INSTRUCTIONS.
D Read and follow all labels and the Owner’s
Manual carefully before installing, operating, or
servicing unit. Read the safety information at
the beginning of the manual and in each
section.
D Use only genuine replacement parts from the manufacturer.
D Perform installation, maintenance, and service according to the
Owner’s Manuals, industry standards, and national, state, and
local codes.
D Allow cooling period; follow rated duty cycle.
D Reduce current or reduce duty cycle before
starting to weld again.
D Do not block or filter airflow to unit.
H.F. RADIATION can cause interference.
FLYING SPARKS can injure.
D Wear a face shield to protect eyes and face.
D Shape tungsten electrode only on grinder with
proper guards in a safe location wearing proper
face, hand, and body protection.
D
D Sparks can cause fires — keep flammables away.
D
STATIC (ESD) can damage PC boards.
D Put on grounded wrist strap BEFORE handling
boards or parts.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards.
D
D
D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
D Have only qualified persons familiar with
electronic equipment perform this installation.
The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
If notified by the FCC about interference, stop using the
equipment at once.
Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
MOVING PARTS can injure.
ARC WELDING can cause interference.
D Keep away from moving parts.
D Keep away from pinch points such as drive
rolls.
WELDING WIRE can injure.
D Do not press gun trigger until instructed to do
so.
D Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
BATTERY EXPLOSION can injure.
D Do not use welder to charge batteries or jump
start vehicles unless it has a battery charging
feature designed for this purpose.
D
D
D
D
D Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
D Be sure all equipment in the welding area is
electromagnetically compatible.
To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment.
Be sure this welding machine is installed and grounded
according to this manual.
If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
OM- 270536 Page 3
1-4. California Proposition 65 Warnings
Welding or cutting equipment produces fumes or gases
which contain chemicals known to the State of California to
cause birth defects and, in some cases, cancer. (California
Health & Safety Code Section 25249.5 et seq.)
This product contains chemicals, including lead, known to
the state of California to cause cancer, birth defects, or other
reproductive harm. Wash hands after use.
1-5. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Safe Practices for Welding and Cutting Containers that have Held Combustibles, American Welding Society Standard AWS A6.0, from Global
Engineering Documents (phone: 1-877-413-5184,
website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website:
www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way, Suite
103, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS
(phone: 800-463-6727, website: www.csagroup.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org).
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—
phone for Region 5, Chicago, is 312-353-2220, website:
www.osha.gov).
Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30329-4027 (phone: 1-800-232-4636, website:
www.cdc.gov/NIOSH).
1-6. EMF Information
Electric current flowing through any conductor causes localized electric
and magnetic fields (EMF). The current from arc welding (and allied processes including spot welding, gouging, plasma arc cutting, and
induction heating operations) creates an EMF field around the welding
circuit. EMF fields can interfere with some medical implants, e.g. pacemakers. Protective measures for persons wearing medical implants
have to be taken. For example, restrict access for passers−by or conduct individual risk assessment for welders. All welders should use the
following procedures in order to minimize exposure to EMF fields from
the welding circuit:
1. Keep cables close together by twisting or taping them, or using a
cable cover.
2. Do not place your body between welding cables. Arrange cables
to one side and away from the operator.
3. Do not coil or drape cables around your body.
OM-270536 Page 4
4. Keep head and trunk as far away from the equipment in the
welding circuit as possible.
5. Connect work clamp to workpiece as close to the weld as
possible.
6. Do not work next to, sit or lean on the welding power source.
7. Do not weld whilst carrying the welding power source or wire
feeder.
About Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recommended.
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION
fre_som_2015−09
7
Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives
aux précautions de sécurité et au mode opératoire.
2-1. Symboles utilisés
DANGER! − Indique une situation dangereuse qui si on
l’évite pas peut donner la mort ou des blessures graves.
Les dangers possibles sont montrés par les symboles
joints ou sont expliqués dans le texte.
Indique une situation dangereuse qui si on l’évite pas
peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou
sont expliqués dans le texte.
AVIS − Indique des déclarations pas en relation avec des blessures
personnelles.
. Indique des instructions spécifiques.
Ce groupe de symboles veut dire Avertissement! Attention! DANGER
DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
CHAUDES. Consulter les symboles et les instructions ci-dessous y
afférant pour les actions nécessaires afin d’éviter le danger.
2-2. Dangers relatifs au soudage à l’arc
Les symboles représentés ci-dessous sont utilisés dans ce manuel pour attirer l’attention et identifier les dangers possibles. En
présence de l’un de ces symboles, prendre garde et suivre les
instructions afférentes pour éviter tout risque. Les instructions
en matière de sécurité indiquées ci-dessous ne constituent
qu’un sommaire des instructions de sécurité plus complètes
fournies dans les normes de sécurité énumérées dans la Section 2-5. Lire et observer toutes les normes de sécurité.
Seul un personnel qualifié est autorisé à installer, faire fonctionner, entretenir et réparer cet appareil.
Pendant le fonctionnement, maintenir à distance toutes les
personnes, notamment les enfants de l’appareil.
UNE DÉCHARGE ÉLECTRIQUE peut
entraîner la mort.
Le contact d’organes électriques sous tension peut
provoquer des accidents mortels ou des brûlures
graves. Le circuit de l’électrode et de la pièce est sous
tension lorsque le courant est délivré à la sortie. Le
circuit d’alimentation et les circuits internes de la
machine sont également sous tension lorsque l’alimentation est sur Marche. Dans le mode de soudage avec
du fil, le fil, le dérouleur, le bloc de commande du
rouleau et toutes les parties métalliques en contact
avec le fil sont sous tension électrique. Un équipement
installé ou mis à la terre de manière incorrecte ou
impropre constitue un danger.
D Ne pas toucher aux pièces électriques sous tension.
D Porter des gants isolants et des vêtements de protection secs et
sans trous.
D S’isoler de la pièce à couper et du sol en utilisant des housses ou
des tapis assez grands afin d’éviter tout contact physique avec la
pièce à couper ou le sol.
D Ne pas se servir de source électrique à courant électrique dans les
zones humides, dans les endroits confinés ou là où on risque de
tomber.
D Se servir d’une source électrique à courant électrique UNIQUEMENT si le procédé de soudage le demande.
D Si l’utilisation d’une source électrique à courant électrique s’avère
nécessaire, se servir de la fonction de télécommande si l’appareil
en est équipé.
D D’autres consignes de sécurité sont nécessaires dans les conditions suivantes : risques électriques dans un environnement
humide ou si l’on porte des vêtements mouillés ; sur des structures
métalliques telles que sols, grilles ou échafaudages ; en position
coincée comme assise, à genoux ou couchée ; ou s’il y a un risque
élevé de contact inévitable ou accidentel avec la pièce à souder ou
le sol. Dans ces conditions, utiliser les équipements suivants,
dans l’ordre indiqué : 1) un poste à souder DC à tension constante
(à fil), 2) un poste à souder DC manuel (électrode) ou 3) un poste à
souder AC à tension à vide réduite. Dans la plupart des situations,
l’utilisation d’un poste à souder DC à fil à tension constante est recommandée. En outre, ne pas travailler seul !
D Couper l’alimentation ou arrêter le moteur avant de procéder à l’installation, à la réparation ou à l’entretien de l’appareil. Déverrouiller
l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de sécurité).
D Installez, mettez à la terre et utilisez correctement cet équipement
conformément à son Manuel d’Utilisation et aux réglementations
nationales, gouvernementales et locales.
D Toujours vérifier la terre du cordon d’alimentation. Vérifier et
s’assurer que le fil de terre du cordon d’alimentation est bien
raccordé à la borne de terre du sectionneur ou que la fiche du
cordon est raccordée à une prise correctement mise à la terre.
D En effectuant les raccordements d’entrée, fixer d’abord le conducteur de mise à la terre approprié et contre-vérifier les connexions.
D Les câbles doivent être exempts d’humidité, d’huile et de graisse;
protégez−les contre les étincelles et les pièces métalliques
chaudes.
D Vérifier fréquemment le cordon d’alimentation et le conducteur de
mise à la terre afin de s’assurer qu’il n’est pas altéré ou dénudé −,
le remplacer immédiatement s’il l’est −. Un fil dénudé peut entraîner la mort.
D L’équipement doit être hors tension lorsqu’il n’est pas utilisé.
D Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante ou mal épissés.
D Ne pas enrouler les câbles autour du corps.
D Si la pièce soudée doit être mise à la terre, le faire directement
avec un câble distinct.
D Ne pas toucher l’électrode quand on est en contact avec la pièce,
la terre ou une électrode provenant d’une autre machine.
D Ne pas toucher des porte électrodes connectés à deux machines
en même temps à cause de la présence d’une tension à vide doublée.
D N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-lechamp les pièces endommagées. Entretenir l’appareil conformément à ce manuel.
D Porter un harnais de sécurité si l’on doit travailler au-dessus du sol.
D S’assurer que tous les panneaux et couvercles sont correctement
en place.
D Fixer le câble de retour de façon à obtenir un bon contact métalmétal avec la pièce à souder ou la table de travail, le plus près possible de la soudure.
D Isoler la pince de masse quand pas mis à la pièce pour éviter le
contact avec tout objet métallique.
D Ne pas raccorder plus d’une électrode ou plus d’un câble de
masse à une même borne de sortie de soudage. Débrancher le
câble pour le procédé non utilisé.
D Utiliser une protection différentielle lors de l’utilisation d’un équipement auxiliaire dans des endroits humides ou mouillés.
Il reste une TENSION DC NON NÉGLIGEABLE dans
les sources de soudage onduleur UNE FOIS
l’alimentation coupée.
D Arrêter les convertisseurs, débrancher le courant électrique et
décharger les condensateurs d’alimentation selon les instructions
indiquées dans la partie Entretien avant de toucher les pièces.
OM-270536 Page 5
LES PIÈCES CHAUDES peuvent
provoquer des brûlures.
D Ne pas toucher à mains nues les parties chaudes.
D Prévoir une période de refroidissement avant
de travailler à l’équipement.
D Ne pas toucher aux pièces chaudes, utiliser les outils recommandés et porter des gants de soudage et des vêtements épais pour
éviter les brûlures.
LES FUMÉES ET LES GAZ peuvent
être dangereux.
Le soudage génère des fumées et des gaz. Leur
inhalation peut être dangereux pour votre santé.
D Eloigner votre tête des fumées. Ne pas respirer les fumées.
D À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au
niveau de l’arc pour l’évacuation des fumées et des gaz de
soudage. Pour déterminer la bonne ventilation, il est recommandé
de procéder à un prélèvement pour la composition et la quantité
de fumées et de gaz auxquels est exposé le personnel.
D Si la ventilation est médiocre, porter un respirateur anti-vapeurs
approuvé.
D Lire et comprendre les fiches de données de sécurité et les instructions du fabricant concernant les adhésifs, les revêtements, les
nettoyants, les consommables, les produits de refroidissement, les
dégraisseurs, les flux et les métaux.
D Travailler dans un espace fermé seulement s’il est bien ventilé ou
en portant un respirateur à alimentation d’air. Demander toujours à
un surveillant dûment formé de se tenir à proximité. Des fumées et
des gaz de soudage peuvent déplacer l’air et abaisser le niveau
d’oxygène provoquant des blessures ou des accidents mortels.
S’assurer que l’air de respiration ne présente aucun danger.
D Ne pas souder dans des endroits situés à proximité d’opérations
de dégraissage, de nettoyage ou de pulvérisation. La chaleur et
les rayons de l’arc peuvent réagir en présence de vapeurs et former des gaz hautement toxiques et irritants.
D Ne pas souder des métaux munis d’un revêtement, tels que l’acier
galvanisé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait été enlevé dans la zone de soudure, que l’endroit soit
bien ventilé, et en portant un respirateur à alimentation d’air. Les
revêtements et tous les métaux renfermant ces éléments peuvent
dégager des fumées toxiques en cas de soudage.
LES RAYONS DE L’ARC peuvent
provoquer des brûlures dans les
yeux et sur la peau.
Le rayonnement de l’arc du procédé de soudage génère
des rayons visibles et invisibles intenses (ultraviolets e
infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la
peau. Des étincelles sont projetées pendant le soudage.
D Porter un casque de soudage approuvé muni de verres filtrants
approprié pour protéger visage et yeux pour protéger votre visage
et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1
et Z87.1 énuméré dans les normes de sécurité).
D Porter des lunettes de sécurité avec écrans latéraux même sous
votre casque.
D Avoir recours à des écrans protecteurs ou à des rideaux pour
protéger les autres contre les rayonnements les éblouissements
et les étincelles ; prévenir toute personne sur les lieux de ne pas
regarder l’arc.
D Porter un équipement de protection pour le corps fait d’un matériau
résistant et ignifuge (cuir, coton robuste, laine). La protection du
corps comporte des vêtements sans huile comme par ex. des
gants de cuir, une chemise solide, des pantalons sans revers, des
chaussures hautes et une casquette.
LE SOUDAGE peut provoquer un
incendie ou une explosion.
Le soudage effectué sur des conteneurs fermés tels
que des réservoirs, tambours ou des conduites peut
provoquer leur éclatement. Des étincelles peuvent
être projetées de l’arc de soudure. La projection d’étincelles, des
pièces chaudes et des équipements chauds peut provoquer des incendies et des brûlures. Le contact accidentel de l’électrode avec des
objets métalliques peut provoquer des étincelles, une explosion, un surOM-270536 Page 6
chauffement ou un incendie. Avant de commencer le soudage, vérifier
et s’assurer que l’endroit ne présente pas de danger.
D Déplacer toutes les substances inflammables à une distance de
10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir
soigneusement avec des protections homologués.
D Ne pas souder dans un endroit là où des étincelles peuvent tomber
sur des substances inflammables.
D Se protéger et d’autres personnes de la projection d’étincelles et
de métal chaud.
D Des étincelles et des matériaux chauds du soudage peuvent
facilement passer dans d’autres zones en traversant de petites
fissures et des ouvertures.
D Surveiller tout déclenchement d’incendie et tenir un extincteur à
proximité.
D Le soudage effectué sur un plafond, plancher, paroi ou séparation
peut déclencher un incendie de l’autre côté.
D Ne pas effectuer le soudage sur des conteneurs fermés tels que
des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été
préparés correctement conformément à AWS F4.1 et AWS A6.0
(voir les Normes de Sécurité).
D Ne pas souder là où l’air ambiant pourrait contenir des poussières,
gaz ou émanations inflammables (vapeur d’essence, par exemple).
D Brancher le câble de masse sur la pièce le plus près possible de la
zone de soudage pour éviter le transport du courant sur une
longue distance par des chemins inconnus éventuels en provoquant des risques d’électrocution, d’étincelles et d’incendie.
D Ne pas utiliser le poste de soudage pour dégeler des conduites gelées.
D En cas de non utilisation, enlever la baguette d’électrode du porteélectrode ou couper le fil à la pointe de contact.
D Porter un équipement de protection pour le corps fait d’un matériau
résistant et ignifuge (cuir, coton robuste, laine). La protection du
corps comporte des vêtements sans huile comme par ex. des
gants de cuir, une chemise solide, des pantalons sans revers, des
chaussures hautes et une casquette.
D Avant de souder, retirer toute substance combustible de vos poches telles qu’un allumeur au butane ou des allumettes.
D Une fois le travail achevé, assurez−vous qu’il ne reste aucune
trace d’étincelles incandescentes ni de flammes.
D Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
Ne pas augmenter leur puissance; ne pas les ponter.
D Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et
NFPA 51B pour les travaux à chaud et avoir de la surveillance et un
extincteur à proximité.
D Lire et comprendre les fiches de données de sécurité et les instructions du fabricant concernant les adhésifs, les revêtements, les
nettoyants, les consommables, les produits de refroidissement,
les dégraisseurs, les flux et les métaux.
DES PIECES DE METAL ou DES
SALETES peuvent provoquer des
blessures dans les yeux.
D Le soudage, l’écaillement, le passage de la pièce à
la brosse en fil de fer, et le meulage génèrent des étincelles et des
particules métalliques volantes. Pendant la période de refroidissement des soudures, elles risquent de projeter du laitier.
D Porter des lunettes de sécurité avec écrans latéraux ou un écran
facial.
LES ACCUMULATIONS DE GAZ
risquent de provoquer des blessures
ou même la mort.
D Fermer l’alimentation du gaz comprimé en cas
de non utilisation.
D Veiller toujours à bien aérer les espaces confinés ou se servir d’un
respirateur d’adduction d’air homologué.
Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM)
peuvent affecter les implants médicaux.
D Les porteurs de stimulateurs cardiaques et
autres implants médicaux doivent rester à
distance.
D Les porteurs d’implants médicaux doivent consulter leur médecin
et le fabricant du dispositif avant de s’approcher de la zone où se
déroule du soudage à l’arc, du soudage par points, du gougeage,
de la découpe plasma ou une opération de chauffage par
induction.
LE BRUIT peut endommager l’ouïe.
Le bruit des processus et des équipements peut
affecter l’ouïe.
D Porter des protections approuvées pour les
oreilles si le niveau sonore est trop élevé.
LES BOUTEILLES peuvent exploser
si elles sont endommagées.
Les bouteilles de gaz comprimé contiennent du
gaz sous haute pression. Si une bouteille est
endommagée, elle peut exploser. Du fait que
les bouteilles de gaz font normalement partie du procédé de
soudage, les manipuler avec précaution.
D Protéger les bouteilles de gaz comprimé d’une chaleur excessive,
des chocs mécaniques, des dommages physiques, du laitier, des
flammes ouvertes, des étincelles et des arcs.
D Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte-bouteilles pour les empêcher de tomber ou
de se renverser.
D Tenir les bouteilles éloignées des circuits de soudage ou autres
circuits électriques.
D Ne jamais placer une torche de soudage sur une bouteille à gaz.
D Une électrode de soudage ne doit jamais entrer en contact avec
une bouteille.
D Ne jamais souder une bouteille pressurisée − risque d’explosion.
D Utiliser seulement des bouteilles de gaz comprimé, régulateurs,
tuyaux et raccords convenables pour cette application spécifique;
les maintenir ainsi que les éléments associés en bon état.
D Tourner le dos à la sortie de vanne lors de l’ouverture de la vanne
de la bouteille. Ne pas se tenir devant ou derrière le régulateur lors
de l’ouverture de la vanne.
D Le couvercle du détendeur doit toujours être en place, sauf lorsque
la bouteille est utilisée ou qu’elle est reliée pour usage ultérieur.
D Utiliser les équipements corrects, les bonnes procédures et suffisamment de personnes pour soulever et déplacer les bouteilles.
D Lire et suivre les instructions sur les bouteilles de gaz comprimé,
l’équipement connexe et le dépliant P-1 de la CGA (Compressed Gas
Association) mentionné dans les principales normes de sécurité.
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance
Risque D’INCENDIE OU D’EXPLOSION.
D Ne pas placer l’appareil sur, au-dessus ou
à proximité de surfaces inflammables.
D Ne pas installer l’appareil à proximité de produits inflammables.
D Ne pas surcharger l’installation électrique − s’assurer que
l’alimentation est correctement dimensionnée et protégée avant
de mettre l’appareil en service.
LA CHUTE DE L’ÉQUIPEMENT peut
provoquer des blessures.
D Utiliser l’anneau de levage uniquement pour
soulever l’appareil, NON PAS les chariots, les
bouteilles de gaz ou tout autre accessoire.
D Utiliser un équipement de levage de capacité suffisante pour lever
l’appareil.
D En utilisant des fourches de levage pour déplacer l’unité, s’assurer
que les fourches sont suffisamment longues pour dépasser du
côté opposé de l’appareil.
D Tenir l’équipement (câbles et cordons) à distance des véhicules
mobiles lors de toute opération en hauteur.
D Suivre les consignes du Manuel des applications pour l’équation
de levage NIOSH révisée (Publication Nº94–110) lors du levage
manuelle de pièces ou équipements lourds.
L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.
D Prévoir une période de refroidissement ; respecter le cycle opératoire nominal.
D Réduire le courant ou le facteur de marche
avant de poursuivre le soudage.
D Ne pas obstruer les passages d’air du poste.
LES ÉTINCELLES PROJETÉES
peuvent provoquer des blessures.
D Porter un écran facial pour protéger le visage et
les yeux.
D Affûter l’électrode au tungstène uniquement à
la meuleuse dotée de protecteurs. Cette manœuvre est à exécuter dans un endroit sûr lorsque l’on porte l’équipement homologué de protection du visage, des mains et du corps.
D Les étincelles risquent de causer un incendie − éloigner toute
substance inflammable.
LES CHARGES ÉLECTROSTATIQUES peuvent endommager les circuits imprimés.
D Établir la connexion avec la barrette de terre
avant de manipuler des cartes ou des pièces.
D Utiliser des pochettes et des boîtes antistatiques pour stocker, déplacer ou expédier des cartes de circuits imprimes.
Les PIÈCES MOBILES peuvent
causer des blessures.
D Ne pas s’approcher des organes mobiles.
D Ne pas s’approcher des points de coincement
tels que des rouleaux de commande.
LES FILS DE SOUDAGE peuvent
provoquer des blessures.
D Ne pas appuyer sur la gâchette avant d’en
avoir reçu l’instruction.
D Ne pas diriger le pistolet vers soi, d’autres
personnes ou toute pièce mécanique en engageant le fil de
soudage.
L’EXPLOSION DE LA BATTERIE
peut provoquer des blessures.
D Ne pas utiliser l’appareil de soudage pour
charger des batteries ou faire démarrer des
véhicules à l’aide de câbles de démarrage,
sauf si l’appareil dispose d’une fonctionnalité
de charge de batterie destinée à cet usage.
Les PIÈCES MOBILES peuvent
causer des blessures.
D S’abstenir de toucher des organes mobiles tels
que des ventilateurs.
D Maintenir fermés et verrouillés les portes,
panneaux, recouvrements et dispositifs de protection.
D Lorsque cela est nécessaire pour des travaux d’entretien et de dépannage, faire retirer les portes, panneaux, recouvrements ou
dispositifs de protection uniquement par du personnel qualifié.
D Remettre les portes, panneaux, recouvrements ou dispositifs de
protection quand l’entretien est terminé et avant de rebrancher
l’alimentation électrique.
LIRE LES INSTRUCTIONS.
D Lire et appliquer les instructions sur les
étiquettes et le Mode d’emploi avant l’installation, l’utilisation ou l’entretien de l’appareil.
Lire les informations de sécurité au début du
manuel et dans chaque section.
D N’utiliser que les pièces de rechange recommandées par le
constructeur.
D Effectuer l’installation, l’entretien et toute intervention selon les
manuels d’utilisateurs, les normes nationales, provinciales et de
l’industrie, ainsi que les codes municipaux.
OM-270536 Page 7
LE
RAYONNEMENT
HAUTE
FRÉQUENCE
(H.F.)
risque
de
provoquer des interférences.
LE SOUDAGE À L’ARC risque de
provoquer des interférences.
D L’énergie électromagnétique risque de
provoquer des interférences pour l’équipement
électronique sensible tel que les ordinateurs et
l’équipement commandé par ordinateur tel que
les robots.
D Le rayonnement haute fréquence (H.F.) peut
provoquer des interférences avec les équipements de radio−navigation et de communication, les services
de sécurité et les ordinateurs.
D Demander seulement à des personnes qualifiées familiarisées avec
des équipements électroniques de faire fonctionner l’installation.
D L’utilisateur est tenu de faire corriger rapidement par un électricien
qualifié les interférences résultant de l’installation.
D Si le FCC signale des interférences, arrêter immédiatement l’appareil.
D Effectuer régulièrement le contrôle et l’entretien de l’installation.
D Maintenir soigneusement fermés les portes et les panneaux des
sources de haute fréquence, maintenir les éclateurs à une distance correcte et utiliser une terre et un blindage pour réduire les
interférences éventuelles.
D Veiller à ce que tout l’équipement de la zone de soudage soit compatible électromagnétiquement.
D Pour réduire la possibilité d’interférence, maintenir les câbles de
soudage aussi courts que possible, les grouper, et les poser aussi
bas que possible (ex. par terre).
D Veiller à souder à une distance de 100 mètres de tout équipement
électronique sensible.
D Veiller à ce que ce poste de soudage soit posé et mis à la terre
conformément à ce mode d’emploi.
D En cas d’interférences après avoir pris les mesures précédentes,
il incombe à l’utilisateur de prendre des mesures supplémentaires
telles que le déplacement du poste, l’utilisation de câbles blindés,
l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone
de travail.
2-4. Proposition californienne 65 Avertissements
Les équipements de soudage et de coupage produisent des
fumées et des gaz qui contiennent des produits chimiques
dont l’État de Californie reconnaît qu’ils provoquent des malformations congénitales et, dans certains cas, des cancers.
(Code de santé et de sécurité de Californie, chapitre 25249.5
et suivants)
Ce produit contient des produits chimiques, notamment du
plomb, dont l’État de Californie reconnaît qu’ils provoquent
des cancers, des malformations congénitales ou d’autres
problèmes de procréation. Se laver les mains après
utilisation.
2-5. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Safe Practices for Welding and Cutting Containers that have Held Combustibles, American Welding Society Standard AWS A6.0, from Global
Engineering Documents (phone: 1-877-413-5184,
website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website:
www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way, Suite
103, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS
(phone: 800-463-6727, website: www.csagroup.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org).
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—
phone for Region 5, Chicago, is 312-353-2220, website:
www.osha.gov).
Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30329-4027 (phone: 1-800-232-4636, website:
www.cdc.gov/NIOSH).
2-6. Informations relatives aux CEM
Le courant électrique qui traverse tout conducteur génère des champs
électromagnétiques (CEM) à certains endroits. Le courant issu d’un
soudage à l’arc (et de procédés connexes, y compris le soudage par
points, le gougeage, le découpage plasma et les opérations de
chauffage par induction) crée un champ électromagnétique (CEM)
autour du circuit de soudage. Les champs électromagnétiques produits
peuvent causer interférence à certains implants médicaux, p. ex. les
stimulateurs cardiaques. Des mesures de protection pour les porteurs
d’implants médicaux doivent être prises: Limiter par exemple tout accès
aux passants ou procéder à une évaluation des risques individuels pour
les soudeurs. Tous les soudeurs doivent appliquer les procédures
suivantes pour minimiser l’exposition aux CEM provenant du circuit de
soudage:
1. Rassembler les câbles en les torsadant ou en les attachant avec
du ruban adhésif ou avec une housse.
2. Ne pas se tenir au milieu des câbles de soudage. Disposer les
OM-270536 Page 8
câbles d’un côté et à distance de l’opérateur.
3. Ne pas courber et ne pas entourer les câbles autour de votre
corps.
4. Maintenir la tête et le torse aussi loin que possible du matériel du
circuit de soudage.
5. Connecter la pince sur la pièce aussi près que possible de la
soudure.
6. Ne pas travailler à proximité d’une source de soudage, ni
s’asseoir ou se pencher dessus.
7. Ne pas souder tout en portant la source de soudage ou le
dévidoir.
En ce qui concerne les implants médicaux :
Les porteurs d’implants doivent d’abord consulter leur médecin avant
de s’approcher des opérations de soudage à l’arc, de soudage par
points, de gougeage, du coupage plasma ou de chauffage par induction. Si le médecin approuve, il est recommandé de suivre les
procédures précédentes.
. A complete Parts List is available at www.MillerWelds.com
SECTION 3 − DEFINITIONS
3-1. Additional Safety Symbols And Definitions
. Some symbols are found only on CE products.
Warning! Watch Out! There are possible hazards as shown by the symbols.
Safe1 2012−05
Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves.
Safe2 2012−05
Protect yourself from electric shock by insulating yourself from work and ground.
Safe3 2012−05
Disconnect input plug or power before working on machine.
Safe5 2012−05
Keep your head out of the fumes.
Safe6 2012−05
Use forced ventilation or local exhaust to remove the fumes.
Safe8 2012−05
Use ventilating fan to remove fumes.
Safe10 2012−05
Keep flammables away from welding. Do not weld near flammables.
Safe12 2012−05
Welding sparks can cause fires. Have a fire extinguisher nearby, and have a watchperson ready to use it.
Safe14 2012−05
Do not weld on drums or any closed containers.
Safe16 2012−05
OM-270536 Page 9
. A complete Parts List is available at www.MillerWelds.com
Do not remove or paint over (cover) the label.
Safe20 2012−05
When power is applied failed parts can explode or cause other parts to explode.
Safe26 2012−05
Flying pieces of parts can cause injury. Always wear a face shield when servicing unit.
Safe27 2012−05
Always wear long sleeves and button your collar when servicing unit.
Safe28 2012−05
After taking proper precautions as shown, connect power to unit.
Safe29 2012−05
Disconnect input plug or power before working on machine.
Safe30 2012−05
Do not use one handle to lift or support unit.
Safe31 2012−05
Do not discard product (where applicable) with general waste.
Reuse or recycle Waste Electrical and Electronic Equipment (WEEE) by disposing at a designated collection
facility.
Contact your local recycling office or your local distributor for further information.
Safe37 2012−05
Environmental Protection Use Period (China)
Safe123 2016−06
Wear hat and safety glasses. Use ear protection and button shirt
collar. Use welding helmet with correct shade of filter. Wear complete
body protection.
Safe38 2012−05
Become trained and read the instructions before working on the
machine or welding.
Safe40 2012−05
OM-270536 Page 10
. A complete Parts List is available at www.MillerWelds.com
V
V
>60s
= < 60°
Hazardous voltage remains on input capacitors after power is turned
off. Do not touch fully charged capacitors. Always wait 60 seconds
after power is turned off before working on unit, OR check input capacitor voltage, and be sure it is near 0 before touching any parts.
V
Safe42 2012−05
Always lift and support unit using both handles. Keep angle of lifting
device less than 60 degrees.
Use a proper cart to move unit.
Safe44 2012−05
Welding current creates an electric and magnetic field (EMF)
around the welding circuit and welding equipment.
Safe72 2012−06
Notes
OM-270536 Page 11
. A complete Parts List is available at www.MillerWelds.com
3-2. Miscellaneous Symbols And Definitions
A
Amperage
Alternating
Current
Panel−Local
Gas Input
Recall From
Memory
Gas Tungsten Arc
Welding (GTAW)
Gas Output
Arc Force (DIG)
Shielded Metal
Arc Welding
(SMAW)
V
Volts
I2
X
Voltage Output
Rated Welding
Current
Duty Cycle
Final Slope
Final Amperage
Line Connection
U2
U1
Pulse Percent
On Time
Conventional
Load Voltage
Initial Slope
Primary Voltage
Contactor Control
(Stick)
Circuit Breaker
Remote
Lift-Arc Start
(GTAW)
Protective Earth
(Ground)
Postflow Timer
IP
I1max
I1eff
U0
Hertz
HF Impulse
Starting (GTAW)
Direct Current
Voltage Input
3 Phase Static
Frequency
Converter-Transfo
rmer-Rectifier
Hz
Degree Of
Protection
Pulser On-Off
Rated Maximum
Supply Current
TIG Weld Amps
And Peak Amps
While Pulsing
Maximum
Effective Supply
Current
Pulse Frequency
Rated No Load
Voltage (OCV)
Background Amps
Pulse Background
Amperage
Process
Preflow Timer
S
Seconds
Pulser
Increase/
Decrease Of
Quantity
Normal Trigger
Operation
(GTAW)
Sequence
Two-Step Trigger
Operation
(GTAW)
Output
Off
Four-Step Trigger
Operation
(GTAW)
Adjust
Positive
On
Negative
OM-270536 Page 12
Initial Amperage
Percent
S
Suitable For
Areas Of
Increased Shock
Hazard
. A complete Parts List is available at www.MillerWelds.com
SECTION 4 − SPECIFICATIONS
4-1. Serial Number And Rating Label Location
The serial number and rating information for the power source is located on the top of the machine. Use the rating labels to determine input power
requirements and/or rated output. For future reference, write serial number in space provided on back cover of this manual.
4-2. Specifications
A. Dynasty
. Do not use information in unit specifications table to determine electrical service requirements. See Sections 5-6, 5-8 and 5-9 for information on
connecting input power.
Welding Amperage Range
Max Open Circuit Voltage (Uo)
Low Open-Circuit Voltage (Uo)
Rated Peak Striking Voltage
(Up)
1-210*
80
8-15***
15KV**
*Welding range for Stick process is 5-210 amperes. For TIG, the amperage range is tungsten diameter dependent (see Sections 8-4 and/or
10-3) depending on model.
** Arc starting device is designed for manual guided operations.
*** Low open-circuit voltage while in TIG Lift Arct, or while in Stick with low open-circuit voltage selected.
Current Draw (A)
At Rate Input Voltages (V)
Output Ratings
Process
STICK
Current
(A)
Voltage (V)
Duty
Cycle
210
28.4
30%
160
125
210
26.4
25
18.4
Input Power
Phase
208V
240V
400V
480V
kW
kVA
1
40
34
20
17
8.3
8.3
3
23
20
12
10
8.0
8.4
1
29
25
15
12
6.0
6.0
3
17
15
9
7
5.8
6.1
1
22
18
11
9
4.4
4.5
3
13
11
7
6
4.5
4.6
1
28
24
14
12
5.8
5.8
3
16
14
9
7
5.8
6.0
1
22
19
12
10
4.6
4.6
3
13
11
7
6
4.6
4.8
60%
100%
60%
TIG
175
17
100%
Power Draw (W)
Idle OCV
Idle w/ Output
Off
0
1
83
83
91
96
3
93
96
101
111
1
23
25
32
35
3
29
29
43
42
1
9
11
19
25
3
13
14
28
39
77.5
Standby
OM-270536 Page 13
. A complete Parts List is available at www.MillerWelds.com
4-2. Dynasty Specifications (Continued)
Current Draw (A)
At Rated Input Voltage (V)
Output Ratings
Process
Input Power
Current
(A)
Voltage (V)
Duty
Cycle
Phase
120V
kW
kVA
100
24
40%
1
31
3.7
3.7
90
23.6
60%
1
28
3.3
3.3
75
23
100%
1
23
2.7
2.7
150
16
40%
1
33
3.9
3.9
125
15
60%
1
26
3.1
3.2
100
14
100%
1
21
2.4
2.5
STICK
TIG
Power Draw (W)
Idle OCV
0
77.5
1
85
Idle w/ Output
Off
1
24
Standby
1
8
B. Maxstar
. Do not use information in unit specifications table to determine electrical service requirements. See Sections 5-7, 5-8 and 5-9 for information on
connecting input power.
Welding Amperage
Range
Max Open Circuit
Voltage (Uo)
Low Open-Circuit
Voltage (Uo)
Rated Peak Striking
Voltage (Up)
IP Rating
1-210*
80
8-15***
15KV**
23
*Welding range for Stick process is 5-210 amperes. For TIG, the amperage range is tungsten diameter dependent (see Sections 8-4 and/or
10-3) depending on model.
** Arc starting device is designed for manual guided operations.
*** Low open-circuit voltage while in TIG Lift Arct, or while in Stick with low open-circuit voltage selected.
Current Draw (A)
At Rated Input Voltage (V)
Output Ratings
Process
Current
(A)
Voltage (V)
Duty
Cycle
210
28.4
30%
STICK
160
125
210
26.4
25
18.4
Input Power
Phase
208V
240V
400V
480V
kW
kVA
1
36
30
18
15
7.3
7.4
3
21
18
10
9
7.1
7.4
1
26
22
13
11
5.3
5.3
3
15
13
8
6
5.2
5.5
1
19
16
10
8
3.9
4.0
3
11
10
6
5
3.9
4.1
1
24
20
12
10
4.9
4.9
3
14
12
7
6
4.9
5.2
1
19
17
10
8
4.0
4.0
3
12
10
6
5
4.0
4.2
60%
100%
60%
TIG
175
OM-270536 Page 14
17
100%
. A complete Parts List is available at www.MillerWelds.com
4-2. Maxstar Specifications (Continued)
Power Draw (W)
Idle OCV
0
1
83
83
91
96
3
93
96
101
111
1
23
25
32
35
3
29
29
43
42
1
9
11
19
25
3
13
14
28
39
77.5
Idle w/ Output
Off
Standby
Current Draw (A)
At Rated Input Voltage (V)
Output Ratings
Process
STICK
TIG
Input Power
Current
(A)
Voltage (V)
Duty
Cycle
Phase
120V
kW
kVA
100
24
40%
1
25
3.0
3.0
90
23.6
60%
1
23
2.8
2.8
75
23
100%
1
19
2.3
2.3
150
16
40%
1
27
3.3
3.3
125
15
60%
1
22
2.6
2.6
100
14
100%
1
17
2.0
2.0
Power Draw (W)
Idle OCV
0
77.5
1
85
Idle w/ Output
Off
1
24
Standby
1
8
Notes
OM-270536 Page 15
. A complete Parts List is available at www.MillerWelds.com
4-3. Duty Cycle And Overheating
Duty Cycle is percentage of 10 minutes that unit can weld at rated load
without overheating.
If unit overheats, output stops, a
Help message is displayed (see
Section 12-2), and cooling fan runs.
Wait fifteen minutes for unit to cool.
Reduce amperage or voltage, or
duty cycle before welding.
NOTICE − Exceeding duty cycle
can damage machine or torch and
void warranty.
TIG ( 208V Input)
Output Amperes
200
STICK ( 208V Input)
150
TIG (120V Input)
STICK (120V Input)
100
50
0
10
20
30
40
50
60
70
80
90 100
% Duty Cycle
Overheating
A or V
0
15
Minutes
OR
Reduce Duty Cycle
247 219-B
OM-270536 Page 16
. A complete Parts List is available at www.MillerWelds.com
4-4. Static Characteristics
The static (output) characteristics of the welding power source can be described as drooping during the SMAW and GTAW processes. Static
characteristics are also affected by control settings (including software), electrode, shielding gas, weldment material, and other factors. Contact
the factory for specific information on the static characteristics of the welding power source.
4-5. Environmental Specifications
A. IP Rating
IP Rating
Operating Temperature Range
Storage Temperature Range
14 to 104 °F (-10 to 40°C)
-4 to 131 °F (-20 to 55°C)
IP23
This equipment is designed for outdoor use. It
may be stored, but is not intended to be used
for welding outside during precipitation unless
sheltered.
IP23 2014−06
B. Information On Electromagnetic Compatibility (EMC)
!
This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low−
voltage supply system. There can be potential difficulties in ensuring electromagnetic compatibility in those locations, due to conducted as well as radiated disturbances.
This equipment complies with IEC61000-3-11 and IEC 61000−3−12 and can be connected to public low-voltage systems provided that the public
low-voltage system impedance Zmax at the point of common coupling is less than 52 mW (or the short−circuit power Ssc is greater than 3.1 MVA).
It is the responsibility of the installer or user of the equipment to ensure, by consultation with the distribution network operator if necessary, that
the system impedance complies with the impedance restrictions.
ce-emc 1 2014-07
C. China EEP Hazardous Substance Information
质
量
China EEP Hazardous Substance Information
质
Hazardous Substance
部 Component Name
(适)
(if applicable)
铅
Pb
Hg
镉
Cd
铬
Cr6
苯
PBB
苯醚
PBDE
黄铜铜部
Brass and Copper Parts
X
O
O
O
O
O
装
Coupling Devices
X
O
O
O
O
O
!装
Switching Devices
O
O
X
O
O
O
"#"#配
Cable and Cable
Accessories
X
O
O
O
O
O
$
Batteries
X
O
O
O
O
O
%表&'*SJ/T 11364 规,-..
This table is prepared in accordance with China SJ/T 11364.
O:
表2该
质5该部7 8质9: 量85GB/T26572规, 限量要>?@.
Indicates that the concentration of the Hazardous Substance in all homogeneous materials of the part is below the relevant threshold of China
GB/T 26572.
X:
表2该
质AC5该部 DE8质9: 量超FGB/T26572规, 限量要>.
Indicates that the concentration of the Hazardous Substance in at least one homogeneous material of the part is above the relevant threshold of
China GB/T 26572.
HIKL限'*SJ/Z11388 规,N,.
The EFUP value of this EEP is defined in accordance with China SJ/Z 11388.
EEP_2016−06
OM-270536 Page 17
. A complete Parts List is available at www.MillerWelds.com
SECTION 5 − INSTALLATION
5-1. Selecting a Location
Movement, Location, and Airflow
!
Special installation may be
required where gasoline or
volatile liquids are present −
see NEC Article 511 or CEC
Section 20.
1
Carry Strap
3
Use strap to carry power source
only. Do not use to lift power source
when attached to cart/cooler.
1
2
Lift Handle
Use lift handle to move and lift welder/cart/cooler.
18 in. (460 mm)
!
Do not use lift handle to lift
unit when gas cylinder and
accessories are connected.
3
Line Disconnect Device
Locate unit near correct input
power supply.
3
2
18 in. (460 mm)
18 in. (460 mm)
18 in. (460 mm)
!
Do not move or operate unit where it could tip.
805 497-A / 805 503-B loc_dynasty 2015-04
OM-270536 Page 18
. A complete Parts List is available at www.MillerWelds.com
5-2. Dimensions, Weights, And Mounting Options
A. Welding Power Source
Dimensions
A
B
A
C
13-5/8 in. (346 mm)
8-5/8 in. (219 mm)
22-1/2 in. (569 mm) − Dynasty and Maxstar CE
19-1/2 in. (495 mm) − Maxstar (non CE)
Weight
C
B
Maxstar: 38 lb (17.2 kg)
Maxstar CE: 42 lb (18.8 kg)
Dynasty: 47 lb (21.3 kg)
Ref. 805 497-A
w/CPS 50 lb (22.7 kg)
B. Welding Power Source With Cart And Cooler
Dimensions
A
A
B
C
33-1/2 in. (851 mm)
B
19-1/2 in. (493 mm)
C
41-1/2 in. (1052 mm)
Weight Empty
Dynasty: 137 lb (62.1 kg)
805 503-B
OM-270536 Page 19
. A complete Parts List is available at www.MillerWelds.com
C. Mounting Options
Dimensions
A
B
15-7/16 in. (392 mm)
C
E
1
A
D
B
9-19/32 in. (244 mm) Center-To-Center
C
5/16 in. (8 mm)
D
17-15/32 in. (444 mm)
E
3-3/4 in. (95 mm)
F
13/64 in. (5 mm)
1. Mounting Hardware
Remove hardware to separate power source from cooler.
Reinstall hardware.
2. Mounting Bracket
2
Use bracket to mount power source to cooler. Bracket is
included with cooler.
F
3.Mounting Bracket (Maxstar) (Not Shown)
Use bracket to mount power source to cooler. Purchase
bracket separately as Part No. 301312.
. Mounting bracket may be purchased separately to mount
805 505-A
machine to another surface. Space bracket according to
dimensions shown.
804 642-C
5-3. Selecting Cable Sizes*
NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source
is 100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine
cable size.
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit Not Exceeding
100 ft (30 m) or Less****
200 ft
(60 m)
10 − 60% Duty Cycle
60 − 100% Duty Cycle
10 − 100% Duty Cycle
AWG (mm2)
AWG (mm2)
AWG (mm2)
100
4 (20)
4 (20)
4 (20)
3 (30)
150
3 (30)
3 (30)
2 (35)
1 (50)
200
3 (30)
2 (35)
1 (50)
1/0 (60)
250
2 (35)
1 (50)
1/0 (60)
2/0 (70)
Welding Amperes***
* This
150 ft
(45 m)
chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2 for metric use
*** Select weld cable size for pulsing application at peak amperage value.
****For distances longer than 100 ft (30 m) and up to 200 ft (60 m), use direct current (DC) output only. For distances longer than those shown
in this guide, call a factory applications rep. at 920-735-4505 (Miller) or 1-800-332-3281 (Hobart).
Ref. S-0007-L 2015−02 (TIG)
OM-270536 Page 20
. A complete Parts List is available at www.MillerWelds.com
5-4. Connections
!
Turn off power before connecting to weld output terminals.
!
Do not use worn, damaged,
undersized, or repaired
cables.
Dynasty Connections
1
2
Remote Control Receptacle
(See Section 5-10)
Gas Out To Torch Connection
Requires an 11/16 in. Wrench.
3
4
5
Work Lead Connection
TIG Torch Or Stick Electrode
Holder Connection
Main Power Switch
Use switch to energize/de-energize machine.
Rear Panel
Dynasty Front Panel
6
5
7
7
8
6
1
Included with optional dedicated
Coolmate 1.3 power supply receptacle (Dynasty only).
2
8
3
Optional Coolmate 1.3
Dedicated Power Supply
Receptacle (Dynasty Only)
Supplementary Protector For
Coolmate 1.3 Dedicated
Power Supply
Gas In Connection
Fitting has 5/8-18 in. right hand
threads, and usually requires an
11/16 in. Wrench. Maximum psi is
125. (Not included with Maxstar
STR models.)
4
9
Work Lead Connection For
TIG Welding. Stick Electrode
Holder Connection For Stick
Welding
10 TIG Torch Connection For
TIG Welding / Work Lead
Connection For Stick Welding
Maxstar Front Panel
1
2
9
10
Tools Needed:
Ref.805 496-A
OM-270536 Page 21
. A complete Parts List is available at www.MillerWelds.com
5-5.
Cooler Connections
Cart and cooler are optional equipment.
1
Coolmate 1.3 Power
Receptacle
Cooler Power Cord
1
2
Provides 115 VAC to power cooler.
3
Electrode Weld Output
Terminal (−Weld Output
Terminal On Maxstar Models)
2
Connect TIG torch to electrode
weld output terminal.
4
Gas Out Connection
Connect TIG torch gas hose to gas
out fitting.
5
Work Weld Output Terminal
(+Weld Output Terminal On
Maxstar Models)
Connect work lead to work weld
output terminal.
6
Water-Out (To Torch)
Connection
Connect torch water supply (blue)
hose to the coolers water-out connection.
7
Water-In (From Torch)
Connection
Connect torch water return (red)
hose to the coolers water-in connection.
4
5
6
3
7
Tools Needed:
GTAW Or Where
HF* Is Used
Application
1-1/4
Gal
11/16 in. (21 mm for CE units)
Low Conductivity Coolant
No. 043 810**;
Distilled Or Deionized Water
OK Above 32° F (0° C)
Coolant
*HF: High Frequency Current
**Coolant 043 810, a 50/50 solution, protect to -37° F (-38°C) and resist algae growth.
NOTICE − Use of any coolant other than those listed in the table voids the warranty
on any parts that come in contact with the coolant (pump, radiator, etc.).
OM-270536 Page 22
805 504-C
. A complete Parts List is available at www.MillerWelds.com
5-6. Electrical Service Guide (Dynasty)
Elec Serv 2015−05
A. Electrical Service Guide For Three-Phase Operation
Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommendations are for a dedicated circuit sized for the rated output and duty cycle of the welding power source.
In dedicated circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating
of the circuit protection device. All components of the circuit must be physically compatible. See NEC articles 210.21, 630.11, and
630.12.
. Actual input voltage should not fall below 108 volts AC or rise above 528 volts AC. If actual input voltage is outside this range, unit may not operate
according to specifications.
Three-Phase
Input Voltage (V)
208
240
400
480
Rated Maximum Supply Current I1max (A)
23
20
11.8
9.8
13.2
11.4
6.8
5.7
25
25
10
10
35
30
15
15
14
14
14
14
52 (16)
69 (21)
195 (60)
284 (86)
14
14
14
14
Maximum Effective Supply Current I1eff (A)
Max Recommended Standard Fuse Rating In Amperes
1
Time Delay Fuses 2
Normal Operating Fuses 3
Min Input Conductor Size In AWG
4
Max Recommended Input Conductor Length In Feet (Meters)
Min Grounding Conductor Size In AWG 4
Reference: 2014 National Electrical Code (NEC) (including article 630)
1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.
2 “Time-Delay” fuses are UL class “RK5” . See UL 248.
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps and
above).
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table
310.15(B)(16). If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable
requirements.
B. Electrical Service Guide For Single-Phase Operation (Dynasty)
Elec Serv 2015−05
Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommendations are for a dedicated circuit sized for the rated output and duty cycle of the welding power source.
In dedicated circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating
of the circuit protection device. All components of the circuit must be physically compatible. See NEC articles 210.21, 630.11, and
630.12.
. Actual input voltage should not fall below 108 volts AC or rise above 528 volts AC. If actual input voltage is outside this range, unit may not operate
according to specifications.
Single-Phase
Input Voltage (V)
120
208
240
400
480
Rated Maximum Supply Current I1max (A)
33
40
34.3
19.8
16.6
22.7
22.3
19.1
11.5
9.5
40
50
40
20
20
50
60
50
30
25
10
10
12
14
14
46
(14)
65
(20)
53
(16)
98
(30)
140
(43)
10
10
12
14
14
Maximum Effective Supply Current I1eff (A)
Max Recommended Standard Fuse Rating In Amperes
1
Time Delay Fuses 2
Normal Operating Fuses 3
Min Input Conductor Size In AWG
4
Max Recommended Input Conductor Length In Feet (Meters)
Min Grounding Conductor Size In AWG 4
Reference: 2014 National Electrical Code (NEC) (including article 630)
1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.
2 “Time-Delay” fuses are UL class “RK5” . See UL 248.
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps and
above).
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table
310.15(B)(16). If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable
requirements.
OM-270536 Page 23
. A complete Parts List is available at www.MillerWelds.com
5-7. Electrical Service Guide (Maxstar)
Elec Serv 2015−05
A. Electrical Service Guide For Three-Phase Operation
Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommendations are for a dedicated circuit sized for the rated output and duty cycle of the welding power source.
In dedicated circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating
of the circuit protection device. All components of the circuit must be physically compatible. See NEC articles 210.21, 630.11, and
630.12.
. Actual input voltage should not fall below 108 volts AC or rise above 528 volts AC. If actual input voltage is outside this range, unit may not operate
according to specifications.
Three-Phase
Input Voltage (V)
208
240
400
480
Rated Maximum Supply Current I1max (A)
20.5
17.7
10.4
8.7
11
10
6
5
25
20
10
10
30
25
15
15
14
14
14
14
58 (18)
78 (24)
221 (67)
319 (97)
14
14
14
14
Maximum Effective Supply Current I1eff (A)
Max Recommended Standard Fuse Rating In Amperes
1
Time Delay Fuses 2
Normal Operating Fuses 3
Min Input Conductor Size In AWG
4
Max Recommended Input Conductor Length In Feet (Meters)
Min Grounding Conductor Size In AWG 4
Reference: 2014 National Electrical Code (NEC) (including article 630)
1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.
2 “Time-Delay” fuses are UL class “RK5” . See UL 248.
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps and
above).
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table
310.15(B)(16). If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable
requirements.
B. Electrical Service Guide For Single-Phase Operation (Maxstar)
Elec Serv 2015−05
Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommendations are for a dedicated circuit sized for the rated output and duty cycle of the welding power source.
In dedicated circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating
of the circuit protection device. All components of the circuit must be physically compatible. See NEC articles 210.21, 630.11, and
630.12.
. Actual input voltage should not fall below 108 volts AC or rise above 528 volts AC. If actual input voltage is outside this range, unit may not operate
according to specifications.
Single-Phase
Input Voltage (V)
120
208
240
400
480
Rated Maximum Supply Current I1max (A)
27.4
35.8
29.9
17.6
14.6
17.3
20
17
10
8
30
40
35
20
15
40
50
45
25
20
12
12
12
14
14
33
(10)
44
(13)
60
(18)
111
(34)
160
(49)
12
12
12
14
14
Maximum Effective Supply Current I1eff (A)
Max Recommended Standard Fuse Rating In Amperes
1
Time Delay Fuses 2
Normal Operating Fuses 3
Min Input Conductor Size In AWG
4
Max Recommended Input Conductor Length In Feet (Meters)
Min Grounding Conductor Size In AWG 4
Reference: 2014 National Electrical Code (NEC) (including article 630)
1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.
2 “Time-Delay” fuses are UL class “RK5” . See UL 248.
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps and
above).
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table
310.15(B)(16). If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable
requirements.
OM-270536 Page 24
. A complete Parts List is available at www.MillerWelds.com
229895
Notes
MATERIAL THICKNESS GAUGE
OM-270536 Page 25
. A complete Parts List is available at www.MillerWelds.com
5-8. Connecting Three-Phase Input Power
3
= GND/PE Earth Ground
4
7
2
L1
3
L2
5
L3
6
1
Tools Needed:
input2 2012−05 − 803 766-C / Ref. 805 496-A
OM-270536 Page 26
. A complete Parts List is available at www.MillerWelds.com
5-8.
Connecting Three-Phase Input Power (Continued)
!
Installation must meet all National and
Local Codes − have only qualified persons make this installation.
!
Disconnect and lockout/tagout input
power before connecting input conductors from unit. Follow established
procedures regarding the installation
and removal of lockout/tagout
devices.
!
Always connect green or green/yellow conductor to supply grounding
terminal first, and never to a line terminal.
NOTICE − The Auto-Line circuitry in this unit
automatically adapts the power source to the
primary voltage being applied. Check input
voltage available at site. This unit can be connected to any input power between 120−480
VAC without removing cover to relink the
power source.
See rating label on unit and check input voltage available at site.
For Three-Phase Operation
1
2
3
4
Input Power Cord.
Disconnect Device (switch shown in
the OFF position)
Green Or Green/Yellow Grounding
Conductor
Disconnect Device Grounding Terminal
5
6
Input Conductors (L1, L2 And L3)
Disconnect Device Line Terminals
Connect green or green/yellow grounding
conductor to disconnect device grounding
terminal first.
Connect input conductors L1, L2, and L3 to
disconnect device line terminals.
7
Overcurrent Protection
Select type and size of overcurrent protection
using Section 5-6 (fused disconnect switch
shown).
Close and secure door on disconnect device.
Follow established lockout/tagout procedures to put unit in service.
input2 2012−05
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-270536 Page 27
. A complete Parts List is available at www.MillerWelds.com
5-9. Connecting Single-Phase Input Power
1
8
=GND/PE Earth Ground
!
Installation must meet all National
and Local Codes − have only qualified persons make this installation.
!
Disconnect and lockout/tagout input power before connecting input
conductors from unit. Follow established procedures regarding
the installation and removal of
lockout/tagout devices.
!
Always connect green or green/
yellow conductor to supply
grounding terminal first, and never
to a line terminal.
10
NOTICE − The Auto-Line circuitry in this
unit automatically adapts the power
source to the primary voltage being applied. Check input voltage available at
site. This unit can be connected to any input power between 120−480 VAC without
removing cover to relink the power
source.
7
L1 9
L2
1
See rating label on unit and check input
voltage available at site.
3
1
1
6
2
3
2
3
6
5
4
4
5
Black And White Input Conductor
(L1 And L2)
Red Input Conductor
Green Or Green/Yellow Grounding
Conductor
Insulation Sleeving
Electrical Tape
Insulate and isolate red conductor as
shown.
6 Input Power Cord.
7 Disconnect Device (switch shown in
the OFF position)
8 Disconnect Device Grounding
Terminal
9 Disconnect Device Line Terminals
Connect green or green/yellow grounding
conductor to disconnect device grounding
terminal first.
Connect input conductors L1 and L2 to
disconnect device line terminals.
10 Overcurrent Protection
Select type and size of overcurrent
protection using Section 5-6 (fused disconnect switch shown).
Close and secure door on disconnect
device. Follow established lockout/tagout
procedures to put unit in service.
Tools Needed:
input1 2012−05 − 803 766-C / Ref. 805 496-A
OM-270536 Page 28
. A complete Parts List is available at www.MillerWelds.com
5-10. Remote 14 Receptacle Information
Socket
15 VOLTS DC
OUTPUT
CONTACTOR
A
B
K
J
I
REMOTE
OUTPUT
CONTROL
H
C L N
D M
G
E F
Output
Signals
A
Contactor control +15 volts DC, referenced to G.
B
Contact closure to A completes 15 volts DC
contactor control circuit and enables output.
C
Output to remote control; +10 volts DC output to
remote control.
D
Remote control circuit common.
E
0 to +10 volts DC input command signal from
remote control.
*Reconfigurable as input for Output Enable (Weld
Stop) − used to remotely stop the weld outside the
normal welding cycle. Connection to the D socket
must be maintained at all times. If the connection
is broken, output stops, and Auto Stop is displayed.
F
Current feedback; +1 volt DC per 100 amperes.
H
Voltage feedback; +1 volt DC per 10 volts output.
I*
Valid arc indication closed to socket G with valid
arc. Electrical specifications: open collector transistor (see Section 5-11 for connection example).
J*
Arc length control lockout closed to socket G during Initial and Final Amperage and Slope, and during the background time of a <=10 Hz pulse waveform. Electrical specifications: open collector transistor (see Section 5-11 for connection example).
**
Touch Sense Detection closed to Socket G, with
Modbus’s Touch Sense enabled and machine not
triggered for weld output.
G
Return for all output signals: F, H, I, J and A.
K
Chassis
805 497-A
COMMON
CHASSIS
Serial
Communication
Bus
Socket Information
L**
Modbus Common (RS485 Common)
M**
Modbus D1 (RS485 B+)
N**
Modbus D0 (RS485 A-)
Sockets G and K are electrically isloated from each other.
. If a remote hand control, like the RHC-14, is connected to the Remote 14 receptacle, some current value above min. must be set on the remote
control before the Panel or Remote contactor is turned on. Failure to do so will cause current to be controlled by the panel control, and the remote
hand control will not function.
*Available with optional Automation Expansion memory card.
**Available with optional Modbus Expansion memory card. Modbus serial communication provides access to all front panel parameters and
machine functionality. See Owner’s Manual 265415 for a list of Modbus registers. Modbus expansion also includes functionality of Automation
and AC Independent Amplitude (Dynasty only) Expansions.
5-11. Simple Automation Application
CR1
Coil resistance plus R
should be chosen to
limit current to 75 mA
CR1
+
Pin I, J: Collector
R
To User Equipment
−
User supplied power
up to 27 volts DC
peak
Pin G: Emitter
OM-270536 Page 29
. A complete Parts List is available at www.MillerWelds.com
5-12. Software Updates
A. Reasons For Downloads Of Software Updates
• To get the latest feature and software improvements with future software updates.
• For all circuit board replacements, a software update is required to ensure proper unit operation.
• A software update is required to ensure proper software expansion operation of all purchased feature expansions.
B. Requirements
. A computer with an SD memory card port, or SD
memory card reader is required to download software updates.
The SD logo is a registered trademark of SD-3C LLC.
C. How To Download Software Updates
1. On your web browser, go to http://www.millerwelds.com/products/tig/tigsoftware.php
2. Select System Installation Instructions (PDF) and follow the instructions.
1
2
OM-270536 Page 30
. A complete Parts List is available at www.MillerWelds.com
D. Software Installation
1
2
. Software updates
up to three minutes. Do Not remove card while LED is blinking
green.
Card Requirements:
After successfully reading from or
writing to the card, the LED
switches from blinking to continuous green, and the meters illuminate. The machine is now ready for
use.
may reset
machine back to default values.
Full size memory card required.
1
2
Memory Card Port
Indicator LED
Insert card containing new software into port while machine is on,
(but not while welding). Inserting
card while welding will interrupt the
welding process.
LED indicator blinks green when
machine is reading from or writing
to the card, and the meter displays
go blank. The update time may vary
Troubleshooting:
Indicator LED is blinking red: Error
updating software, or software is
not compatible. Try removing and
inserting card.
Indicator LED is continuous red:
Cannot read card. Card might be
bad.
Dynasty 210 DX Shown
805 496-A
Notes
OM-270536 Page 31
. A complete Parts List is available at www.MillerWelds.com
SECTION 6 − DYNASTY 210 OPERATION
6-1. Dynasty 210 Controls
1
4
3
5
2
6
7
247 222-A
8
1 Standby Button
Use to turn machine on and off for daily operation.
2 Amperage Adjustment Control
Use control to change preset amperage
value. If a remote control is used, preset
amperage value is the maximum amperage
output available. This control also functions
as a parameter change control while in the
menu mode (see Sections 6-2 thru 6-6).
3 Memory Card Port And Indicator
This port is used to add features to the machine and update software to the boards
within the machine. Indicator is lit while card
is being accessed (see Section 5-12D).
4 Volt Meter
Displays actual rectified average voltage
when voltage is present at the weld output
terminals. It is also used to display parameter descriptions while in the menu.
5 Ammeter
Displays actual amperage while welding
and preset amperage while idle. It is also
used to display parameter selection options while in the menu.
6 Menu Button
Press button to scroll through available
parameters for the selected process. Hold
button to enter set-up mode (see Sections
6-2 thru 6-6).
7
Output ON Indicator
Blue indicator illuminates when output is
on.
8
Process Selector
Use to select one of the following processes:
• AC TIG - Used for welding aluminum.
• DC TIG - (DCEN) Used for welding mild
and stainless steel.
• DC Stick - (DCEP) Used for welding
steels.
• AC Stick - Used for welding steels if arc
blow is a problem while using DC Stick.
The memory card port uses an SD
memory card.
The SD logo is a registered trademark
of SD-3C LLC.
OM-270536 Page 32
. A complete Parts List is available at www.MillerWelds.com
6-2. Accessing Control Panel Menu: AC TIG
1
Menu Button
Press Menu button to cycle through
parameters that can be set.
2
3
1
4
2
3
4
Parameter Display
Setting Display
Encoder
Rotate Encoder to adjust parameter
setting.
. Parameter automatically returns
to amperage setting 15 seconds
after Encoder is inactive.
150A
BAL
FREQ
POST
75%
120H
AUTO
*PRO−SET provides PROfessionally developed SETtings for the weld process.
To use PRO−SET, press the menu button
to display the parameter and adjust the
encoder until PRO−SET flashes on the
display. PRO−SET flashes one time and
reveals the professional setting for the
parameter.
Amperage Control:
Controls the average AC welding
amperage output. Limits the maximum output of a remote amperage
device.
[BAL] Balance Control:* (% EN)
Controls Oxide Cleaning
Increasing setting reduces oxide cleaning. Range is
60 to 80%. (See tips below)
[FREQ]* Frequency Control:
Increasing setting narrows arc width. Range is 70 to
150 Hertz. (See tips below)
[POST] Post Flow Control:
Controls the length of time gas flows after welding
stops. Range is AUTO, OFF − 50T (seconds).
AUTO calculates the time based on the maximum
amperage of each welding cycle. The minimum time
is 8 seconds. Auto = maximum amperage/10.
TIP: AC Balance controls the cleaning
action. If floating black spots appear in
the puddle, the balance setting is too high.
Turn the balance down until puddle becomes clear.
TIP: AC Frequency controls the width of
the arc cone. For thin fillet welds (less
than 1/4 in.) set the frequency to 120 Hz.
This frequency setting provides a focused
stable arc and produces a narrow weld.
For outside corner or groove welds on
heavy material, a wide weld may be required. Lower the frequency to between
70 and100 Hz. This frequency setting produces a wider weld.
247 222-A
OM-270536 Page 33
. A complete Parts List is available at www.MillerWelds.com
6-3. Accessing Control Panel Menu: DC TIG
1
Menu Button
Press Menu button to cycle through parameters that can be set.
2
3
2
3
4
4
1
Parameter Display
Setting Display
Encoder
Rotate Encoder to adjust parameter setting.
. Parameter automatically returns to am-
perage setting 15 seconds after Encoder is inactive.
Amperage Control:
150A
Controls the welding amperage output. Limits the
maximum output of a remote amperage device.
[PPS]* Pulse Control:
Reduces heat input to minimize distortion and increase travel speed. Set PPS (pulses per second).
The range is OFF−250 PPS. The Background Amperage and Peak Amperage Time are not adjustable. Background Amperage equals 25% of
Peak amperage. Peak amperage Time equals 40%.
[POST] Post Flow Control:
Controls the length of time gas flows after welding
stops. Range is AUTO, OFF−50T (seconds). AUTO
calculates the time based on the maximum amperage of each weld cycle. The minimum time is eight
seconds. Auto = maximum amperage/10.
PPS OFF
POST AUTO
*PRO−SET: provides PROfessionally developed
SETtings for the welding process. To use PRO−SET,
press the menu button to display the parameter and
adjust the encoder until PRO−SET flashes on the
display. PRO−SET flashes one time and reveals the
professional setting for the parameter.
6-4. Accessing Control Panel Menu: AC And DC Stick
1
Menu Button
Press Menu button to cycle through
parameters that can be set.
2
3
4
2
3
4
Parameter Display
Setting Display
Encoder
Rotate Encoder to adjust parameter
setting.
1
150A
. Parameter automatically returns
to amperage setting 15 seconds
after Encoder is inactive.
Amperage Control:
Controls the average welding amperage output.
Limits the maximum output of a remote amperage
device.
[DIG]* Arc Force Control:
Controls the amount of additional amperage at low
voltage (short arc length) conditions. Adjust the
force of the arc for different joint configurations and
electrodes. Range is OFF−100%. Features PRO−
SET values for 6010 and 7018 electrodes.
In AC, the user will be setting the rectified average
value of the AC current. [AC AV]will be displayed.
Or
DIG
OM-270536 Page 34
30%
*PRO−SET provides PROfessionally developed
SETtings for the weld process. To use PRO−SET,
press the menu button to display the parameter and
adjust the encoder until PRO−SET flashes on the
display. PRO−SET flashes one time and reveals the
professional setting for the parameter.
. A complete Parts List is available at www.MillerWelds.com
6-5. Accessing User Setup Menu: AC And DC TIG
1
2
3
Press and hold Menu button for approximately two seconds to access
machine configuration menus. Use
Menu button to cycle through parameters that can be set.
1
4
Menu Button
2
3
4
Parameter Display
Setting Display
Encoder
Rotate Encoder to adjust parameter setting.
. To exit menu, press and hold
USER
Menu button until Menu Off is
displayed.
MENU
Or
Arc Starting Method Selection:
STRT
TUNG
RMT
HF
3/32
STD
247 222-A
[STRT] [HF]
Is a non-contact starting method.
[STRT] [LIFT]
Is a contact starting method (see Section17-1).
Tungsten Diameter Selection:
Each tungsten size has preset starting parameters
specific to that diameter for optimized starting.
Range is 0.020 in.−1/8 in. or 0.5 mm−3.2 mm
Trigger Mode Selection:
[RMT] [STD]
Typically used with a remote foot or hand control.
RMT STD requires a maintained contact closure to
enable weld output. Amperage can be controlled
with a remote potentiometer, or it can be set at the
control panel.
[RMT] [HOLD]
Remote control required. Allows the operator to weld
without holding the trigger closed. To start the weld,
operator presses and releases trigger. To stop the
weld, the operator again presses and releases the
trigger. In this mode, only the output contactor is controlled by the remote control. Amperage must be set
on the control panel.
[OUT] [ON]
Output on. (Lift Only)
!
Weld output terminals are energized at all
times when displays read [OUT] [ON].
No remote control or trigger required. Amperage can
be controlled at the control panel or with a remote potentiometer. Blue output on LED illuminates to indicate output is on.
OM-270536 Page 35
. A complete Parts List is available at www.MillerWelds.com
6-6. Accessing User Setup Menu: AC And DC Stick
1
2
3
Press and hold Menu button for approximately 2 seconds to access
machine configuration menus. Use
Menu button to cycle through parameters that can be set.
1
4
Menu Button
2
3
4
Parameter Display
Setting Display
Encoder
Rotate Encoder to adjust parameter setting.
. To exit menu, press and hold
USER
Menu button until Menu Off is
displayed.
MENU
Or
HOTS
ON
Arc Starting Method Selection:
OUT
ON
[HOTS OFF]
[HOTS] [ON]
Provides additional amperage while striking the
electrode to prevent the electrode from sticking.
No additional starting amperage to assist in starting
the electrode.
Trigger Mode Selection:
[RMT] [STD]
Typically used with a remote foot or hand control.
RMT STD requires a maintained contact closure to
enable weld output. Amperage can be controlled
with a remote potentiometer, or it can be set at the
control panel.
[OUT] [ON]
!
Weld output terminals are energized at all
times when displays read [OUT] [ON].
No remote control or trigger required. Amperage
can be controlled at the control panel or with a
remote potentiometer. Blue output on LED illuminates to indicate output is on.
247 222-A
OM-270536 Page 36
. A complete Parts List is available at www.MillerWelds.com
SECTION 7 − DYNASTY 210 DX OPERATION
7-1.
Dynasty 210 DX Controls
4
1
3
5
2
6
227 220-C
. For all front panel switch pad controls:
press switch pad to turn on light and enable function.
. Green on nameplate indicates a TIG
function, Gray indicates a Stick function.
1
Standby Button
Use to turn machine on and off for daily operation.
2
Encoder Control
Use encoder control in conjunction with applicable front panel function switch pads to
change values for that function.
3 Memory Card Port And Indicator
This port is used to add features to the machine and update software to the boards
within the machine. Indicator is lit while card
is being accessed.
4 Volt Meter
Displays actual rectified average voltage
when voltage is present at the weld output
terminals. It is also used to display parameter descriptions while in the menu.
5 Ammeter
Displays actual amperage while welding and
preset amperage while idle. It is also used to
display parameter selection options while in
the menu.
6
Amperage Control
Use this control in conjunction with the encoder to set the average weld amperage or
peak amperage if the Pulser is active.
OM-270536 Page 37
. A complete Parts List is available at www.MillerWelds.com
7-2.
Accessing Control Panel Menu
1
2
3
4
2
3
4
1
Amperage Button
Parameter Display
Setting Display
Encoder
Rotate Encoder to adjust parameter setting.
Amperage Control
Controls the welding amperage
output. Limits the maximum output
of a remote amperage device.
150A
150A
247 220-C
Polarity Selection
Select output type AC or DC. With DC selected, the electrode will be negative (DCEN) for TIG, and
positive (DCEP) for Stick.
Process Selection
TIG HF Impulse − is a non-contact arc starting method for AC and DC TIG welding (see Section 17-1).
TIG Lift-Arc − Is a contact arc starting method for AC and DC TIG welding (see Section 17-1).
Stick − Select AC or DC Stick (SMAW) welding.
Trigger Mode Selection (See Section 11-4 for additional trigger function options).
[RMT] [STD]
Typical setting for a remote foot or hand control. RMT STD requires a maintained contact closure to
enable weld output. Amperage can be controlled with a remote potentiometer, or it can be set at the
control panel.
[RMT] 2T [HOLD]
Remote control required. Allows the operator to weld without holding the trigger closed. To start the
weld, operator presses and releases trigger. To stop the weld, the operator again presses and releases the trigger. In this mode, only the output contactor is controlled by the remote control. Amperage must be set on the control panel. (see Section 11-4).
[OUT] [ON]
Output on. (Lift Only)
!
Weld output terminals are energized at all times when displays read [OUT] [ON].
No remote control or trigger required. Amperage can be controlled at the control panel or with a remote
potentiometer. Blue output on LED illuminates to indicate output is on.
OM-270536 Page 38
. A complete Parts List is available at www.MillerWelds.com
. *PRO−SET provides PROfessionally developed SETtings for the weld process
PRO−SET flashes one time and reveals the professional setting for the parameter.
PPS
100
Pulse Control
Pulsing is available in the TIG process. Controls can
be adjusted while welding.
Reduces heat input to minimize distortion and increase travel speed. Range is 01. to 500 (pulses per
second).
Press switch pad to enable pulser.
[PPS]* Pulses Per Second: Range is 0.1− 500.
PK T
BK A
INTL
ISLP
40%
25%
20A
OFF
[PK T]* Peak Amperage Time: Range is 5−95%
[BK A]* Background Amperage Time: Range is 5−
95% of peak amperage value.
. See Section 17-2 for additional Pulser
information, or visit
http:/www.millerwelds.com/resources/
improving−your−skills/
Sequencer Control
The welding output can be programmed to specific amperages and durations for repetitive applications. Sequencer is only available in the
TIG process. Sequencer is disabled if a remote
control with variable amperage is connected to
the machine.
[INTL] Initial Amperage: Range is min − 210
amps.
[ISLP] Initial Slope Time: Range is OFF − 50.0T
(seconds).
[FSLP] Final Slope Time: Range is OFF −
50.0T (seconds).
FSLP
OFF
FNL
10A
[FNL] Final Amperage: Range is min − 210
amps.
(See Sections 11-2 and 11-3 for setting weld
time.)
Gas/DIG Control
[PRE] Preflow Time:
Controls length of time gas flows prior to arc start.
Range is OFF−25T (seconds).
[POST] Post Flow Time:
PRE
0.2T
POST
AUTO
DIG
30%
Increasing setting increases length of time gas
flows after welding stops. Range is OFF − 50T
(seconds). AUTO calculates the time based on
the maximum amperage of each welding cycle.
The minimum time is 8 seconds. Auto = maximum
amperage/10.
[DIG]* Arc Force Control:
Controls the amount of additional amperage at
low voltage (short arc length) conditions. Adjust
the force of the arc for different joint configurations and electrodes. Range is OFF − 100%.
PRO-Set values available for both 6010 and 7018
electrodes
Range, 0−100%
AC Waveshape Control
BAL
75%
FREQ
120H
[BAL] Balance Control (%EN) TIG Only:
Controls oxide cleaning. Increasing the setting
reduces cleaning. Range is BALL, 50 − 99%.
Stick is fixed at 50%. “BALL” sets the Balance to
30%. This is to allow the operator to form a ball on
the tip of the tungsten. It is not for normal welding
operation. (See tips in Section 6-2).
[FREQ] AC Frequency (Hz):
Controls arc width. Increasing the setting narrows the arc width. Range is 20 to 400 Hz. (See
tips in Section 6-2).
OM-270536 Page 39
. A complete Parts List is available at www.MillerWelds.com
7-3.
Accessing User Setup Menu
1
2
3
4
5
3
4
To access the User Functions,
press and hold the Amperage (A)
and the Gas/DIG controls until
[USER] [MENU] is displayed. To
scroll through the user menu functions, press and release the Gas/
DIG control.
1
5
Amperage Button
Gas/Dig Button
Parameter Display
Setting Display
Encoder
Rotate Encoder to adjust parameter setting.
To exit user menu, press Amperage
and Gas/DIG controls at the same
time and then release, or turn power
off.
USER MENU
247 220-C
Tungsten Diameter Selection
2
TUNG
RMT
ENEP
AC
HOTS
3/32
2T
SAME
SOFT
ON
Each tungsten size has preset starting parameters specific to that diameter for optimized starting. Range is
0.020−1/8 in. or 0.5−3.2 mm. To manually set starting
parameters, see Section 7-5.
Output Trigger Mode Functions
See Section 11-4 to reconfigure RMT functions.
Independent Amplitude Control (CE Models Only)
[ENEP] [SAME] - standard mode of operation for controlling AC amperage setting.
[ENEP] [INDP] - for AC TIG welding allows the user to set
the EP current amplitude independently from the EN current amplitude. When [ON], the user can set the EP
waveshape (sine, square, triangle) independently from
the EN waveshape (see Section 7-4).
AC Waveshape Selection:
Use Encoder to select between advanced squarewave
[ADVS], soft squarewave [SOFT], sine wave [SINE], or
triangle wave [TRI]. The default is Soft.
Application: Use advance squarewave when a more focused arc is required for better directional control. Use
soft squarewave when a softer arc with a more fluid
puddle is desired. Use sine wave to simulate a conventional power source. Use triangular waveshape when the
effects of peak amperage with reduced overall heat input
is required to help control distortion on thin materials.
Arc Starting Mode Selection (Stick)
[HOTS] [ON]
Provides additional amperage while striking the electrode to prevent the electrode from sticking.
[HOTS] [OFF]
No additional starting amperage to assist in starting the
electrode.
OM-270536 Page 40
. A complete Parts List is available at www.MillerWelds.com
7-4. AC Independent Expansion
. AC Independent Expansion is available on
DX models with SD expansion card and on
CE models with feature enable through the
user menu (see Section 7-3).
A. AC Independent Amplitude
1
AC Waveshape Control
Press switch pad until desired function is selected.
4
EN
EP
3
150 A
150 A
2
3
4
Encoder Control (Set Value)
Ammeter (Displays Value)
Voltmeter (Parameter Selection)
EN Amperage [EN] - Use with AC TIG only to select electrode negative amperage value.
EP Amperage [EP] - Use with AC TIG only to select
electrode positive amperage value.
2
. Both Balance and AC Frequency LEDs light
5
when either EN or EP Amperage is selected.
5
Amperage Control
Average Amperage Control: Setting EN Amperage, EP Amperage, Balance, and Frequency values creates an average amperage. The operator
can change the average amperage value while
maintaining the same EN amperage to EP amperage ratio at the existing balance and frequency. To
change the average amperage value, press the
Amperage switch pad and turn the Encoder control.
The changing average value is displayed on the
ammeter. Example: If EN Amperage is 150, EP Amperage is 100, Balance is 75%, and Frequency is
120, the average amperage is 138 amps. If you
press the Amperage switch pad and turn the Encoder control until 69 amps is displayed, the EN amperage is now 75 and EP amperage is now 50. The
balance remains 75%, and the frequency is still
120, and the 1.5 to 1 EN amperage to EP amperage
ratio is maintained.
1
B. AC Independent Waveshape
3
1
5
4
. See Section 7-3 for additional information
on Accessing User Setup Menu. The
[ACEN], [ACEP] option replaces the [AC]
option.
USER
1
2
3
MENU
Amperage (A) Control
Gas/DIG Control
Parameter Display
Press Gas/DIG switch pad until [ACEN] is displayed. Press the A switch pad to toggle between [ACEN] and [ACEP].
4
5
Setting Display
Encoder Control
Use Encoder to select between advanced
squarewave [ADVS], soft squarewave
[SOFT], sine wave [SINE], or triangle wave
[TRI]. The default is [SOFT].
ACEN
SOFT
ACEP
SOFT
2
OM-270536 Page 41
. A complete Parts List is available at www.MillerWelds.com
7-5. Selecting General (GEN) Tungsten To Change Programmable TIG Starting Parameters
1
2
3
Encoder Control
Parameter Display
Amperage Button
Once inside the machine set up
menu, tungsten parameter values
can be manually changed by pressing the Amperage switch pad to
step through each adjustable parameter. Turn encoder to change the
value.
2
1
TUNG
GEN
3
Available Parameter Settings
Current (A)
Start Amperage
Preset Amperage Minimum
Start Time
Start Slope Time
Parameter
• Start Output Polarity (POL)
• Start Amperage (STRT)
• Start Time (TIME)
• Start Slope (SSLP)
• Preset Minimum Amperage (PMIN)
OM-270536 Page 42
Default AC
Default DC
Range
• EP (Electrode Positive)
• EN (Electrode Negative)
• EP / EN
• 30 A
• 25 A
• 5−200 A
• 120 ms
• 120 ms
• 0−250 ms
• 120 ms
• 100 ms
• 0−250 ms
• 10 A
• 10 A
• 1 (DC) 2 (AC) −25 A
. A complete Parts List is available at www.MillerWelds.com
SECTION 8 − MAXSTAR 210 OPERATION
8-1. Maxstar 210 Controls
1
3
4
5
2
6
5
HF START
LIFT ARC
Hold for Setup
Schedule 1
Schedule 2
247 218-B
8
. For all front panel switch pad controls:
press switch pad to turn on light and enable function.
. Green on nameplate indicates a TIG
function, Gray indicates a Stick function.
1
Memory Card Port And Indicator
This port is used to add features to the machine and update software to the boards
within the machine, Indicator is lit while card
is being accessed.
4
Volt Meter
Standby Switch
Use to turn machine on and off for daily operation.
2
3
Amperage Adjustment Control
Use control to change preset amperage
value. If a remote control is used, preset amperage value is the maximum amperage output available. This control also functions as
a parameter change control while in the
menu mode (see Section 8-2 thru 8-5).
Displays actual voltage when voltage is
present at the weld output terminals. It is also
used to display parameter descriptions
while in the menu.
5
Ammeter
Displays actual amperage while welding and
preset amperage while idle. It is also used to
display parameter selection options while in
the menu.
6 Menu Button
Press button to scroll through available
parameters for the selected process. Hold
button at desired parameter to enter set-up
mode (see Section 8-2 thru 8-5).
7 Output On Indicator
Blue indicator illuminates when output is on.
8 Process Selector Control
Use control to select one of the following processes:
• DC TIG HF − Use for welding mild and
stainless steel. Non contact arc starting.
• DC TIG Lift − Use when HF could interfere
with surrounding equipment.
DC Stick (2 positions) − Used for welding
steels.
. Two schedules allow the user to have
two sets of parameters active and easily
selectable at one time.
OM-270536 Page 43
. A complete Parts List is available at www.MillerWelds.com
8-2. Accessing Control Panel Menu: DC TIG HF And Lift Arc
1
Menu Button
Press Menu button to cycle through
parameters that can be set.
2
3
4
1
2
3
4
Parameter Display
Setting Display
Encoder
Rotate Encoder to adjust parameter setting.
. Parameter
automatically returns to amperage setting 15
seconds after Encoder is inactive.
110A
Or
HF START
LIFT ARC
Hold for Setup
Schedule 1
Schedule 2
Amperage Control:
110A
PPS
OFF
POST
AUTO
Controls the welding amperage output. Limits the
maximum output of a remote amperage device.
[PPS]* Pulse Control:
Reduces heat input to minimize distortion and increase
travel speed. Set PPS (pulses per second). The range
is OFF−250 PPS. The Background Amperage and Peak
Amperage Time are not adjustable. Background Amperage equals 25% of Peak amperage. Peak amperage
Time equals 40%.
[POST] Post Flow Control:
Controls the length of time gas flows after welding
stops. Range is AUTO, OFF−50T (seconds). AUTO
calculates the time based on the maximum amperage
of each weld cycle. The minimum time is 8 seconds.
Auto equals maximum amperage/10.
*PRO−SET provides PROfessionally developed
SETtings for the weld process. To use PRO−SET,
press the menu button to display the parameter and
adjust the encoder until PRO−SET flashes on the display. PRO−SET flashes one time and reveals the professional setting for the parameter.
247 218-B
OM-270536 Page 44
. A complete Parts List is available at www.MillerWelds.com
8-3. Accessing Control Panel Menu: DC Stick
1
Menu Button
Press Menu button to cycle through
parameters that can be set.
2
3
4
1
2
3
4
Parameter Display
Setting Display
Encoder
Rotate Encoder to adjust parameter setting.
. Parameter
automatically returns to amperage setting 15
seconds after Encoder is inactive.
110A
HF START
LIFT ARC
Hold for Setup
Schedule 1
Or
Schedule 2
Amperage Control:
110A
Controls the welding amperage output. Limits the
maximum output of a remote amperage device.
[DIG]* Arc Force Control:
DIG
30%
Controls the amount of additional amperage at low
voltage (short arc length) conditions. Adjust the
force of the arc for different joint configurations and
electrodes. Range is OFF−100%. Features
PRO-Set values for both 6010 and 7018 electrodes
*PRO−SET provides PROfessionally developed
SETtings for the weld process. To use PRO−SET,
press the menu button to display the parameter and
adjust the encoder until PRO−SET flashes on the display. PRO−SET flashes one time and reveals the professional setting for the parameter.
247 218-B
OM-270536 Page 45
. A complete Parts List is available at www.MillerWelds.com
8-4. Accessing User Setup Menu: DC TIG And Lift-Arc
1
2
3
Press and hold Menu button for approximately 2 seconds to access
machine configuration menus. Use
Menu button to cycle through parameters that can be set.
1
4
Menu Button
2
3
4
Parameter Display
Setting Display
Encoder
Rotate Encoder to adjust parameter setting.
. To exit menu, press and hold
USER
Menu button until Menu Off is
displayed.
MENU
Or
HF START
LIFT ARC
Hold for Setup
Schedule 1
Schedule 2
Tungsten Diameter Selection:
TUNG
3/32
RMT
STD
Each tungsten size has preset starting parameters
specific to that diameter for optimized starting.
Range is 0.020 in.−1/8 in. or 0.5 mm−3.2 mm. To
manually set starting parameters, see Section 7-5.
Trigger Mode Selection (See Section for 11-4 for
additional trigger function options).
[RMT] [STD]
Typical setting for a remote foot or hand control.
RMT STD requires a maintained contact closure to
enable weld output. Amperage can be controlled
with a remote potentiometer, or it can be set at the
control panel.
[RMT] [HOLD]
Remote control required. Allows the operator to
weld without holding the trigger closed. To start the
weld, operator presses and releases trigger. To stop
the weld, the operator again presses and releases
the trigger. In this mode, only the output contactor is
controlled by the remote control. Amperage must be
set on the control panel. (see Section 11-4).
[OUT] [ON]
Output on. (Lift only)
!
Weld output terminals are energized at all
times when displays read [OUT] [ON].
No remote control or trigger required. Amperage
can be controlled at the control panel or with a remote potentiometer. Blue output on LED illuminates
to indicate output is on. Not valid with HF start.
247 218-B
OM-270536 Page 46
. A complete Parts List is available at www.MillerWelds.com
8-5. Accessing User Setup Menu: DC Stick
1
2
3
Press and hold Menu button for approximately 2 seconds to access
machine configuration menus. Use
Menu button to cycle through parameters that can be set.
1
4
Menu Button
2
3
4
Parameter Display
Setting Display
Encoder
Rotate Encoder to adjust parameter setting.
. To exit menu, press and hold
USER
Menu button until Menu Off is
displayed.
MENU
HF START
LIFT ARC
Hold for Setup
Schedule 1
HOTS
OUT
Or
Schedule 2
ON
Arc Starting Mode Selection:
ON
[HOTS] [OFF]
[HOTS] [ON]
Provides additional amperage while striking the electrode to prevent the electrode from sticking.
No additional starting amperage to assist in starting the
electrode.
Trigger Mode Selection:
[RMT] [STD]
Typical setting for a remote foot or hand control.
RMT STD requires a maintained contact closure to
enable weld output. Amperage can be controlled
with a remote potentiometer, or it can be set at the
control panel.
[OUT] [ON]
!
Weld output terminals are energized at all
times when displays read [OUT] [ON].
No remote control or trigger required. Amperage can
be controlled at the control panel or with a remote potentiometer. Blue output on LED illuminates to indicate output is on.
247 218-B
OM-270536 Page 47
. A complete Parts List is available at www.MillerWelds.com
SECTION 9 − MAXSTAR 210 STR OPERATION
9-1. Maxstar 210 STR Controls
1
3
4
5
2
6
5
271 723-A
8
. For all front panel switch pad controls:
press switch pad to turn on light and enable function.
. Green on nameplate indicates a TIG
function, Gray indicates a Stick function.
1
Memory Card Port And Indicator
This port is used to add features to the machine and update software to the boards
within the machine, Indicator is lit while card
is being accessed.
4
Volt Meter
Standby Switch
Use to turn machine on and off for daily operation.
2
3
Amperage Adjustment Control
Use control to change preset amperage
value. If a remote control is used, preset amperage value is the maximum amperage output available. This control also functions as
a parameter change control while in the
menu mode (see Section 8-2 thru 8-5).
OM-270536 Page 48
6
7
5
Ammeter
Displays actual amperage while welding and
preset amperage while idle. It is also used to
display parameter selection options while in
the menu.
Output On Indicator
Blue indicator illuminates when output is on.
8
Displays actual voltage when voltage is
present at the weld output terminals. It is also
used to display parameter descriptions
while in the menu.
Menu Button
Press button to scroll through available
parameters for the selected process. Hold
button at desired parameter to enter set-up
mode (see Section 8-2 thru 8-5).
Process Selector Control
Use control to select one of the following processes:
• DC TIG Lift (2 positions) − Use for welding
mild and stainless steel.
DC Stick (2 positions) − Used for welding
steels.
. Two schedules allow the user to have
two sets of parameters active and easily
selectable at one time.
. A complete Parts List is available at www.MillerWelds.com
9-2. Accessing Control Panel Menu: DC TIG Lift Arc
1
Menu Button
Press Menu button to cycle through
parameters that can be set.
2
3
4
1
2
3
4
Parameter Display
Setting Display
Encoder
Rotate Encoder to adjust parameter setting.
. Parameter
automatically returns to amperage setting 15
seconds after Encoder is inactive.
150A
NOT
VALD
. STR models have no DC TIG Lift Arc menu selection.
[NOT] [VALD] is displayed when Menu button is pressed.
271 723-A
OM-270536 Page 49
. A complete Parts List is available at www.MillerWelds.com
9-3. Accessing Control Panel Menu: DC Stick
1
Menu Button
Press Menu button to cycle through
parameters that can be set.
2
3
4
1
2
3
4
Parameter Display
Setting Display
Encoder
Rotate Encoder to adjust parameter setting.
. Parameter
automatically returns to amperage setting 15
seconds after Encoder is inactive.
110A
Or
Amperage Control:
110A
Controls the welding amperage output. Limits the
maximum output of a remote amperage device.
[DIG]* Arc Force Control:
DIG
30%
Controls the amount of additional amperage at low
voltage (short arc length) conditions. Adjust the
force of the arc for different joint configurations and
electrodes. Range is OFF−100%. Features
PRO-Set values for both 6010 and 7018 electrodes
*PRO−SET provides PROfessionally developed
SETtings for the weld process. To use PRO−SET,
press the menu button to display the parameter and
adjust the encoder until PRO−SET flashes on the display. PRO−SET flashes one time and reveals the professional setting for the parameter.
271 723-A
OM-270536 Page 50
. A complete Parts List is available at www.MillerWelds.com
9-4. Accessing User Setup Menu: DC TIG Lift-Arc And DC Stick
1
2
3
Press and hold Menu button for approximately 2 seconds to access
machine configuration menus. Use
Menu button to cycle through parameters that can be set.
1
4
Menu Button
2
3
4
Parameter Display
Setting Display
Encoder
Rotate Encoder to adjust parameter setting.
. To exit menu, press and hold
USER
OUT
Menu button until Menu Off is
displayed.
MENU
ON
Trigger Mode Selection
[RMT] [STD]
Typical setting for a remote foot or hand control.
RMT STD requires a maintained contact closure to
enable weld output. Amperage can be controlled
with a remote potentiometer, or it can be set at the
control panel.
[OUT] [ON]
Output on.
!
Weld output terminals are energized at all
times when displays read [OUT] [ON].
No remote control or trigger required. Amperage
can be controlled at the control panel or with a remote potentiometer. Blue output on LED illuminates
to indicate output is on.
271 723-A
OM-270536 Page 51
. A complete Parts List is available at www.MillerWelds.com
229895
Notes
MATERIAL THICKNESS GAUGE
OM-270536 Page 52
. A complete Parts List is available at www.MillerWelds.com
SECTION 10 − MAXSTAR 210 DX OPERATION
10-1.
Maxstar 210 DX Controls
4
1
3
5
2
6
227 220-C
. For all front panel switch pad controls:
press switch pad to turn on light and enable function.
. Green on nameplate indicates a TIG
function, Gray indicates a Stick function.
1
Standby Button
Use to turn machine on and off for daily operation.
2 Encoder Control
Use encoder control in conjunction with applicable front panel function switch pads to
change values for that function.
3 Memory Card Port And Indicator
This port is used to add features to the machine and update software to the boards
within the machine. Indicator is lit while card
is being accessed.
4 Volt Meter
Displays actual voltage when voltage is
present at the weld output terminals. It is also
used to display parameter descriptions
while in the menu.
5
Ammeter
Displays actual amperage while welding and
preset amperage while idle. It is also used to
display parameter selection options while in
the menu.
6
Amperage Control
Use this control in conjunction with the encoder to set the weld amperage or peak amperage if the Pulser is active.
OM-270536 Page 53
. A complete Parts List is available at www.MillerWelds.com
10-2.
Accessing Control Panel Menu
1
2
3
4
2
3
4
1
Amperage Button
Parameter Display
Setting Display
Encoder
Rotate Encoder to adjust parameter setting.
The Amperage Control controls the
welding amperage output, and limits the maximum output of a remote
amperage device.
150A
150A
247 220-C
Process Selection:
TIG HF Impulse − is a non-contact arc starting method for TIG welding (see Section 17-1).
TIG Lift-Arc − Is a contact arc starting method for TIG welding (see Section 17-1).
Stick − Select for DC Stick (SMAW) welding. Electrode polarity is determined by the welding
cable connections.
Trigger Mode Selection: (See Section for 11-4 for additional trigger function options).
[RMT] [STD]
Typical setting for a remote foot or hand control. RMT STD requires a maintained contact closure to enable weld output. Amperage can be controlled with a remote potentiometer, or it can
be set at the control panel.
[RMT] 2T [HOLD]
Remote control required. Allows the operator to weld without holding the trigger closed. To
start the weld, operator presses and releases trigger. To stop the weld, the operator again
presses and releases the trigger. In this mode, only the output contactor is controlled by the
remote control. Amperage must be set on the control panel. (see Section 11-4).
[OUT] [ON]
Output on. (Lift only)
!
Weld output terminals are energized at all times when displays read [OUT] [ON].
No remote control or trigger required. Amperage can be controlled at the control panel or with
a remote potentiometer. Blue output on LED illuminates to indicate output is on.
OM-270536 Page 54
. A complete Parts List is available at www.MillerWelds.com
. *PRO−SET provides PROfessionally developed SETtings for the weld process. PRO−SET flashes
one time and reveals the professional setting for the parameter.
PPS
PK T
100
40%
Pulse Control
Pulsing is available while in the TIG process.
Controls can be adjusted while welding.
Reduces heat input to minimize distortion and increase travel speed. Range is 01. to 500 (pulses
per second).
Press switch pad to enable pulser.
[PPS]* Pulses Per Second: Range is 0.1 to 500.
[PK T]* Peak Amperage Time: Range is 5 to 95%.
BK A
25%
[BK A]* Background Amperage Time: Range is
5 to 95% of peak amperage value.
. See Section 17-2 for additional Pulser information, or visit
http:/www.millerwelds.com/resources/improving−your−skills/
INTL
20A
ISLP
OFF
FSLP
OFF
[ISLP] Initial Slope Time: Range is OFF to 25T
(seconds).
10A
[FNL] Final Amperage: Range is min to 210
amps.
FNL
Sequencer Control
The welding output can be programmed to specific amperages and durations for repetitive applications. Sequencer is only available in the TIG
process. Sequencer is disabled if a remote control with variable amperage is connected to the
machine.
[INTL] Initial Amperage: Range is min to 210
amps.
[FSLP] Final Slope Time: Range is OFF to 25T
(seconds).
(See Sections 11-2 and 11-3 for setting weld
time.)
Gas/DIG Control
[PRE] Preflow Time:
PRE
0.2T
Controls length of time gas flows prior to arc start.
Range is OFF to 50T (seconds).
[POST] Post Flow Time:
POST
AUTO
DIG
30%
Increasing setting increases length of time gas
flows after welding stops. Range is OFF to 50T
(seconds). AUTO calculates the time based on
the maximum amperage of each welding cycle.
The minimum time is eight seconds. Auto equals
maximum amperage divided by 10.
[DIG]* Arc Force Control:
Controls the amount of additional amperage at
low voltage (short arc length) conditions. Adjust
the force of the arc for different joint configurations and electrodes. Range is OFF to 100%.
PRO-Set values available for both 6010 and
7018 electrodes.
OM-270536 Page 55
. A complete Parts List is available at www.MillerWelds.com
10-3.
Accessing User Setup Menu
1
2
3
4
5
3
4
1
5
Amperage Button
Gas/Dig Button
Parameter Display
Setting Display
Encoder
To access the User functions,
press and hold the Amperage (A)
and the Gas/DIG controls until
USER MENU is displayed. To scroll
through the user menu functions,
press and release the Gas/DIG
control.
Rotate Encoder to adjust parameter setting.
. Parameter
automatically returns to amperage setting 15
seconds after Encoder is inactive.
USER MENU
To exit user menu, press and release Amperage and Gas/DIG controls at the same time, or turn power
off.
2
247 220-C
TUNG
RMT
HOTS
3/32
2T
Tungsten Diameter Selection:
Each tungsten size has preset starting parameters specific to
that diameter for optimized starting. Range is 0.020−1/8 in. or
0.5−3.2 mm. To manually set starting parameters, see Section
7-5.
Output Trigger Mode Functions:
See Section 11-4 to reconfigure RMT functions.
ON
Arc Starting Mode Selection:
[HOTS] [ON]
Provides additional amperage while striking the electrode to prevent the electrode from sticking.
[HOTS] [OFF]
No additional starting amperage to assist in starting the electrode.
OM-270536 Page 56
. A complete Parts List is available at www.MillerWelds.com
SECTION 11 − ADVANCED MENU FUNCTIONS
11-1. Accessing Tech Menu For Dynasty/Maxstar 210 Models
1
2
3
4
1
Menu Button
Press and hold Menu button for approximately four seconds to scroll
past User Menu to Tech Menu. Use
Menu button to cycle through parameters that can be set.
2
3
4
Parameter Display
Setting Display
Encoder
Rotate Encoder to adjust parameter setting.
TECH
MENU
. Dynasty 210 shown, Maxstar
menus are the same. Menu order may vary.
To exit tech menu, press and hold
menu button approximately one
second, or turn power off.
. Settings in the Tech Menu are
global, meaning they may pertain to all or some of the process.
ARC
ERR
SLEP
STUC
OCV
COOL
SOFT
T/CY
LOG
OFF
OFF
NORM
AUTO
RSET
WARE
SERL
NUM
MACH
[ARC] [T/CY] Arc Timer: Monitors hours, minutes, and cycles of
valid arc on. To view, rotate encoder. To reset, rotate encoder until
[RESET] [YES] is displayed. Press Menu button to display [RESET]
[Done]. Displays turn to [000] [000].
[ERR] [LOG] Error Log: Use to view last eight logged error events.
Each event may list multiple Error Codes. See Section 12-3.
[SLEP] Sleep Timer: Turns power off after the machine exceeds the
programmed idle time without operation. Press the Standby button to
turn power on. To set or change time, rotate encoder to desired time.
Timer range: 1, 5, 10, 20, 30, 45 minutes or one hour.
[STUC] Stick Stuck: Detects if the electrode is stuck or shorted to
the workpiece. Turns weld output off to aid in freeing the electrode.
To turn on, rotate encoder. Not recommended for air carbon arc or
large diameter electrodes.
[OCV] Open Circuit Voltage: Allows user to select between Normal (NORM) and Low open circuit voltage. Low reduces open
circuit voltage to between 8 and 12 volts. To select, turn encoder.
[COOL] Cooler Power (Optional): Selects between [OFF] and
[AUTO]. [OFF] disables the power supply to the receptacle. [AUTO] provides power to the receptacle when the TIG process is
active.
[MACH] [RESET] Machine Reset: Resets all machine values
back to factory defaults. To reset, turn encoder to [RESET] [YES].
Then press Menu button. [RESET] [DONE] will be displayed when
the reset is complete and factory defaults have been restored.
[SOFT] [WARE] Software Number: Software number and revision will be displayed.
[SERL] [NUM] Serial Number: If serial number displayed does
not match serial number of machine, see Section 12-3.
OM-270536 Page 57
. A complete Parts List is available at www.MillerWelds.com
11-2. Accessing Tech Menu For Dynasty/Maxstar 210DX Models
1
2
3
4
5
1
Press and hold Amperage and
Gas/Dig buttons for approximately
two seconds to scroll past User
Menu to Tech Menu. Use Gas/Dig
button to cycle through parameters
that can be set.
3
4
5
TECH MENU
Amperage Button
Gas/Dig Button
Parameter Display
Setting Display
Encoder
Rotate Encoder to adjust parameter setting.
. Dynasty 210DX shown. Maxstar menus are the same.
Menu order may vary.
To exit tech menu, press Amperage
and Gas/DIG controls at the same
time.
2
ARC
T/CY
COOL
ERR
LOG
LOCK
AUTO
OFF
SLEP
STUC
OFF
OFF
EXPC
OFF
OCV
NORM
RSET
WELD
MACH
SOFT
TMRS
WARE
SERL
NUM
OFF
247 220-A
OM-270536 Page 58
. A complete Parts List is available at www.MillerWelds.com
[ARC] [T/CY] Arc Timer: Monitors hours, minutes, and cycles of valid arc on. To view these different elements, rotate encoder. To reset, rotate encoder until [RESET] [YES] is displayed. Press Menu button to display [RESET] [Done]. Displays turn to [000] [000].
[ERR] [LOG] Error Log: Use to view last eight logged error events. Each event may list multiple Error Codes. See Section 12-3.
[SLEP] Sleep Timer: Turns power off after the machine exceeds the programmed idle time without operation. Press the Standby button
to turn power on. To set or change time, rotate encoder to desired time. Timer range: 1, 5, 10, 20, 30, 45 minutes or one hour.
[STUC] Stick Stuck: Detects if the electrode is stuck or shorted to the workpiece. Turns weld output off to aid in freeing the electrode. To
turn on, rotate encoder. Not recommended for air carbon arc or large diameter electrodes.
[OCV] Open Circuit Voltage: Allows user to select between Normal (NORM) and Low open circuit voltage. Low reduces open circuit voltage
to between 8 and 12 volts. To select, turn encoder.
[WELD] [TMRS] Weld Timers: [ON] enable and [OFF] disable the feature. See Section 11-3 for information on setting weld timers. Weld
Timers work with or without Sequencer feature.
[COOL] Cooler Auxiliary Power (Optional): Selects between [OFF] and [AUTO]. [OFF] disables the power supply to the receptacle. [AUTO] provides power to the receptacle when the TIG process is active.
[LOCK]: Limits user control and adjustability of machine. See Section 11-5 For instructions and operation.
[EXPC] External Pulse Control Commands: Turn on when it is desired to control machine from an external source. When command is
on, a
command voltage of 0− 10 volts DC equals off − 210 amps.
[MACH] [RESET] Machine Reset:: Resets all machine values back to factory defaults. To reset, turn encoder to [RESET] [YES]. Then
press Amperage button. [RESET] [DONE] will be displayed when the reset is complete and factory defaults have been restored.
[SOFT] [WARE] Software Number: Software number and revision will be displayed.
[SERL] [NUM] Serial Number: If serial number displayed does not match serial number of machine, see Section 12-3.
OM-270536 Page 59
. A complete Parts List is available at www.MillerWelds.com
11-3. Sequencer And Weld Timer For DX Model
Sequencer Control With Weld Timers ON
INTL
20A
INTL
OFF
This function is available while using the TIG
process, but is disabled if a remote foot or fingertip control is connected while in the RMT
STD mode. When active, the sequencer controls the following parameters of the weld
cycle:
Initial Amperage
Range is 2−210 amps AC,1−210 amps DC
ISLP
FSLP
OFF
Initial Time*
Range is OFF to 25.0T (seconds)
Initial Slope Time
Range is OFF to 50.0T (seconds)
OFF
Final Slope Time
Range is OFF to 50.0T (seconds)
Final Amperage
FNL
FNL
10A
OFF
Range is 2−210 amps AC,1−210 amps DC
Final Time*
Range is OFF to 25.0T (seconds)
. When a remote switch is connected to the
welding power source, use the remote switch
to control the weld cycle. Amperage is controlled by the welding power source.
*enabled features with weld timer On (see Section
11-2).
WELD
OM-270536 Page 60
OFF
Weld Timer
With Weld Timer enabled, press Amperage (A)
button, and turn encoder to set weld time. Range
is Off or 0.1−99.9 and 100−999 (sec) (see Section
11-2).
. A complete Parts List is available at www.MillerWelds.com
11-4. Output Control And Trigger Functions For DX Models
A. Remote (Standard), 2T, And 4TE Torch Trigger Operation
Current (A)
Main Amps
Initial Slope
Final Slope
Initial Amps
Final Amps
Time
Postflow
Preflow
Standard
P&H
R
Foot Or Finger
Remote Control
R
Maintained Switch
P&H = Push trigger and hold
R = Release trigger.
. When a foot or finger remote current control is connected to the welding power source, initial amps, initial
slope, final slope and final amps are controlled by the remote control, not by the welding power source.
Remote 2T
P&R
P&R
P&R = Push trigger and release.
. If torch trigger is held more than 3 seconds, operation reverts to RMT STD (Remote Standard) mode.
Remote 4TE
P/R
P/R
P/R
P/R
P/R
P/R = Push and release trigger; Push and releasing during final slope will break the arc and go to postflow
. For first torch trigger push & release, if trigger is held more than 3 seconds, trigger cycle ends.
. When a remote switch is connected to the welding power source, use the remote switch to control the weld cycle.
Amperage is controlled by the welding power source.
Application:
Use 4T Momentary trigger method when the functions of a remote current control are desired, but only a remote on/off
control is available.
OM-270536 Page 61
. A complete Parts List is available at www.MillerWelds.com
B.
3T Specific Trigger Method
Current (A)
Remote Trigger Operation
*
*
*
*
*
*
A
Preflow
*
B
Initial Amps /Initial Slope
C
Main Amps
D
Final Slope /Final Amps
E
Postflow
* Arc can be extinguished at any time by pressing and releasing both initial and final switches, or by lifting the torch and breaking the arc.
1 3T (Specific Trigger Operation)
Sequencer is required to reconfigure for 3T.
3T requires a specific type of remote control with two independent momentarycontact switches. One will be designated
initial switch, and it must be connected between Remote 14 receptacle pins A and B.
The second will be designated as the final
switch, and it must be connected between
Remote 14 receptacle pins D and E.
2 Encoder Control
To select 3T, turn Encoder control.
Definitions:
Initial slope rate is the rate of amperage
change determined by the initial amperage,
initial slope time, and main amperage.
Final slope rate is the rate of amperage
change determined by the main amperage, final slope time, and final amperage.
OM-270536 Page 62
Operation:
A. Press and release initial switch within 3/4
second to start shielding gas flow. To stop
the preflow sequence before preflow time
elapses (25 seconds), press and release
final switch. The preflow timer will reset
and the weld sequence can be started
again.
. If an initial switch closure is not made
again before preflow time ends, gas flow
stops, the timer resets, and an initial
switch press and release is necessary to
start the weld sequence again.
B. Press initial switch to start arc at initial
amps. Holding switch will change amperage at initial slope rate (release switch to
weld at desired amperage level).
C. When main amperage level is reached,
initial switch can be released.
D. Press and hold the final switch to decrease amperage at final slope rate (release switch to weld at desired amperage
level).
E. When final amperage has been reached,
the arc extinguishes and shielding gas
flows for the time set on the Postflow control.
Application:
With the use of two remote switches instead
of potentiometers, 3T gives the operator the
ability to infinitely increase, decrease, or
pause and hold amperage within the range
determined by the initial, main, and final amperages.
. A complete Parts List is available at www.MillerWelds.com
C. 4T And 4TL Specific Trigger Method
4T Application:
Use 4T trigger method when the
functions of a remote current control are desired, but only a remote
on/off control is available.
4T allows the operator to toggle between weld current and final current.
4T Torch Trigger Operation
Current (A)
. When a remote switch is con-
nected to the welding power
source, use the remote switch
to control the weld cycle. Amperage is controlled by the
welding power source.
Main Amps
Initial Slope
Final Slope
Initial Amps
The ability to change current levels
without either initial slope or final
slope, gives the operator the opportunity to adjust filler metal without
breaking the arc.
Postflow
Preflow
P/H
4TL Application:
Final Amps
R
P/H
P/R
P/R
R
4TL (mini logic) allows the operator
to toggle between initial slope or
main amps and initial amps. Final
Amperage is not available. Final
slope always slopes to minimum
amperage and ends the cycle.
P/H = Push and hold trigger; R = Release trigger; P/R
= Push trigger and release in less than 3/4 seconds
. When a remote switch is con-
nected to the welding power
source, use the remote switch
to control the weld cycle. Amperage is controlled by the
welding power source.
4TL Torch Trigger Operation
Current (A)
Main Amps
Final Slope
Initial Slope
*
Initial Amps
P/H
R
*
*
*
Preflow
P/R P/R
P/R
Postflow
P/R
P/R
P/H
P/H = Push and hold trigger; R = Release trigger; P/R = Push trigger and release in less than 3/4 seconds
* = Arc can be extinguished at final slope rate at any time by pushing and holding trigger
OM-270536 Page 63
. A complete Parts List is available at www.MillerWelds.com
11-5.
Lockout Functions
See Section 11-2 for information on how
to access Lockout Functions.
There are four (1−4) different lockout
levels. Each successive level allows the
operator more flexibility.
1
. Before activating lockout levels, be
sure that all procedures and parameters are established. Parameter
adjustment is limited while lockout
levels are active.
To turn On lockout feature, proceed as
follows:
LOCK
CODE
1
2
OFF
2
Encoder Control
Amperage (A) Control
Press Amperage (A) control to toggle
between the lock off and code off displays. Toggle control until [CODE] [OFF]
is displayed
Turn encoder to select a lockout code
number. Select a number between 1 and
999. The number will appear on the amperage, right, display.
. Remember (write
down) this code
number, as you will need this number
to turn this feature off, or make
changes to your settings.
Toggle Amperage control until [LOCK] is
displayed. You may now select a lockout
level. See table below for the degree of
adjustability associated with each lock
level. Exit Advanced Functions according to Section 11-2.
To turn Off lockout feature, proceed as
follows:
Toggle Amperage control until Code is
displayed.
Use encoder control to enter the same
code number that was used to turn on the
lockout feature.
Press the Amperage control. The amperage meter display will turn to [OFF]. Lockout is now off. Exit Advanced Functions
according to Section 11-2.
11-6. Lockout Levels Defined
Degree Of Adjustability
Minimum Adjustability
Lock Level 1
Adjustable
Locked
Lock Level 2
Adjustable
Panel Amps
Locked
Panel Amps
Maximum Adjustability
Lock Level 3
Adjustable
Locked
Panel Amps +/- 10%
Lock Level 4
Adjustable
Locked
Remote Amps
(min−panel)
Panel Amps +/- 10%
Polarity (Dyn Only)
Polarity (Dyn Only)
Polarity (Dyn Only)
Polarity (Dyn Only)
Process
Process
Process
Process
Output
Output
Output
Pulser (on/off only)
Pulser (on/off only)
Output
Pulser
Pulser
Sequencer
Sequencer
Sequencer
Sequencer
Gas/DIG
Gas/DIG
Gas/DIG
Gas/DIG
Waveshape
Waveshape
Waveshape
Waveshape
OM-270536 Page 64
. A complete Parts List is available at www.MillerWelds.com
SECTION 12 − MAINTENANCE AND TROUBLESHOOTING
12-1. Routine Maintenance
!
Disconnect power before maintaining.
. Maintain more often during severe conditions.
A. Welding Power Source
n = Check
Z = Change
~ = Clean
* To be done by Factory Authorized Service Agent
Δ = Repair
l = Replace
Δ = Repair
l = Replace
Every
3
Months
nl Labels
n l Gas Hoses
Every
3
Months
nΔ lCables And Cords
Every
6
Months
!
Do not remove case when blowing out inside of unit
~:During heavy service, clean monthly.
B. Optional Cooler
n = Check
Z = Change
~ = Clean
* To be done by Factory Authorized Service Agent
Every
3
Months
~Coolant Strainer,
durning heavy service,
clean more frequently.
~ Blow out heat exchanger fins.
nCheck coolant level. Top off with
distilled or deionized water if necessary.
Every
6
Months
nlHoses
nl Labels
Every
12
Months
ZReplace coolant.
OM-270536 Page 65
. A complete Parts List is available at www.MillerWelds.com
12-2. Voltmeter/Ammeter Display Messages
1
4
Release Trigger
Latching Errors:
RELE
ASE
CHEK
INPT
TRIG
GER
WELD
CABL
SEE
O.M.
COOL
PWR
2
Un Short Output
UN S
HORT
5
OUTP
Not Valid
UT
NOT
3
Over Temperature Error
OVER
}
Latching Errors:
VALD
6
Lock Level
TEMP
LOCK
LEV1
7
Software Not Valid
. All directions are in reference to the
front of the unit. All circuitry referred to
is located inside the unit.
1
[RELE] [ASE] / [TRIG] [GER]
Remote 14 receptacle contactor control
(Pins A−B) must be opened before proceeding.
2
[UN S] [HORT] / [OUTP] [UT]
Short on weld output connections must be
removed before proceeding. See Section
12-3 if display shows after weld output connections have been verified as not having
a short.
3
[OVER] [TEMP]
Over temperature condition has occurred.
Error will clear after temperatures reach acceptable levels.
OM-270536 Page 66
SOFT
WARE
NOT
VALD
4 Latching Errors:
When one of the following errors occurs,
the Standby LED flashes. To clear error,
press Standby button or turn off power. See
Section 12-3 if error does not clear or happens frequently.
[CHEK] [INPT] Check Input
High or low voltage has been sensed. Have
a qualified person check input voltage.
[WELD] [CABL] Weld Cable
An error relate to the weld cables has been
sensed. Straighten out or shorten weld
cables.
[SEE] [O.M.] See Owner’s Manual: See
Section 12-3.
[COOL] [PWR] Cooler Power
An error related to the CoolMate 1.3 Power
has occurred. When error will not clear or
occurs frequently, cooler can be plugged into a nearby 115 volt AC receptacle, or machine can be used without the Cooler
Power, turn Cooler Power off (see Section
11-1).
5
[NOT] [VALD]
Message is displayed when attempting an
incompatible setup; i.e., pressing AC
Waveshape while in DC.
6
[LOCK] [LEV1], 2, 3, 4
Is displayed when attempting adjustments
that are incompatible with the active selected lock level.
7
[SOFT] [WARE] [NOT] [VALD]
A software compatibility error has been detected. A software update is required (see
Section 5-12 Software Updates). See Section 12-3 if display shows after a software
update is performed.
. A complete Parts List is available at www.MillerWelds.com
12-3. Troubleshooting Table
Trouble
No weld output; unit completely
inoperative.
Remedy
Place line disconnect switch in On position (see Section 5-8 or 5-9).
Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 5-8 or 5-9).
Check for proper input power connections (see Section 5-8 or 5-9).
No weld output; meter display On.
If using remote control, be sure correct process is enabled to provide output control at Remote 14
receptacle (see Section 5-10 as applicable).
Input voltage outside acceptable range of variation (see Section 5-6).
Check, repair, or replace remote control.
Unit overheated. Allow unit to cool with fan On (see Section 4-3).
Erratic or improper weld output.
Use proper size and type of weld cable (see Section 5-3).
Clean and tighten all weld connections (see Section 12-1).
Fan not operating.
Check for and remove anything blocking fan movement.
Have Factory Authorized Service Agent check fan motor.
Wandering arc.
Use proper size tungsten (see Section 16).
Use properly prepared tungsten (see Section 16).
Reduce gas flow rate.
Tungsten electrode oxidizing and not re- Shield weld zone from drafts.
maining bright after conclusion of weld.
Increase postflow time.
Check and tighten all gas fittings (see Section 12-1A).
Water in torch. Refer to torch manual.
Blank Display.
Verify Power to machine.
A software update may be required (see Section 5-12, Software Updates). Contact factory if display remains blank after a software update is performed.
Error message [ERR] [LOG] is dis- Contact a Factory Authorized Service Agent for an explanation of the error code.
played.
Latching Errors see Section 12-2.
Contact a Factory Authorized Service Agent if error does not clear or happens frequently.
Error message [SEE] [O.M.] is dis- Contact a Factory Authorized Service Agent.
played.
Tech Menu (See Section 11) Contact a Factory Authorized Service Agent.
[SERL][NUM] is selected, and serial
number displayed does not match serial
number of machine.
Error message [UN S] [HORT] / [OUTP] Contact a Factory Authorized Service Agent if display shows after weld output connections have been
[UT] is displayed.
verified as not having a short.
Error message [SOFT] [WARE] [NOT] Contact a Factory Authorized Service Agent if display shows after a software update is performed.
[VALD] is displayed.
OM-270536 Page 67
. A complete Parts List is available at www.MillerWelds.com
12-4. Blowing Out Inside of Unit
!
Do not remove case when
blowing out inside of unit.
To blow out unit, direct airflow
through front and back louvers as
shown.
805 497-A
12-5. Coolant Maintenance
!
Disconnect input power before maintaining.
1
Coolant Filter
Unscrew housing to clean filter.
Changing coolant: Drain coolant by
tipping unit to the front, or use suction pump. Fill with clean water and
run for 10 minutes. Drain and refill
with coolant.
1
.
Application
If replacing hoses, use hoses
compatible with ethylene glycol, such as Buna-n, Neoprene, or Hypalon. Oxy-acetylene hoses are not compatible
with any product containing
ethylene glycol.
GTAW Or Where
HF* Is Used
Low Conductivity Coolant No. 043 810**; Distilled Or Deionized Water
OK Above 32° F (0° C)
Tools Needed:
T25 Torx
805 502-A
Coolant
*HF: High Frequency Current
**Coolant 043 810, a 50/50 solution, protects to -37° F (-38°C) and resist algae growth.
NOTICE − Use of any coolant other than that listed in the table voids the warranty on any parts that come in contact with the coolant (pump,
radiator, etc.).
OM-270536 Page 68
. A complete Parts List is available at www.MillerWelds.com
SECTION 13 − PARTS LIST
13-1. Recommended Spare Parts
Dia.
Mkgs.
Part
No.
Description
Quantity
Recommended Spare Parts
. . . . . . . . . . . . . . . . 239494 . . . . Screen, Filter Lp Cyl 100x100x0.0045 SST a . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 043810 . . . . Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-270536 Page 69
SECTION 14 − ELECTRICAL DIAGRAMS
255980-E
Figure 14-1. Circuit Diagram For Dynasty 210
OM-270536 Page 70
255 981-F
Figure 14-2. Circuit Diagram For Maxstar 210
OM-270536 Page 71
SECTION 15 − HIGH FREQUENCY
15-1. Welding Processes Requiring High Frequency
1
High-Frequency Voltage
TIG − helps arc jump air gap
between torch and workpiece and/
or stabilize the arc.
1
Work
TIG
high_freq 5/10 − S-0693
15-2. Installation Showing Possible Sources Of HF Interference
Weld Zone
11, 12
50 ft
(15 m)
10
14
9
8
7
3
2
13
1
4
5
6
Best Practices
Not Followed
Sources of Direct High-Frequency
Radiation
1 High-Frequency Source (welding
power source with built-in HF or
separate HF unit)
2 Weld Cables
3 Torch
4 Work Clamp
5 Workpiece
6 Work Table
OM-270536 Page 72
Sources of Conduction of High
Frequency
7 Input Power Cable
8 Line Disconnect Device
9 Input Supply Wiring
Sources of Reradiation of High
Frequency
10 Ungrounded Metal Objects
11 Lighting
12 Wiring
13 Water Pipes and Fixtures
14 External Phone and Power Lines
S-0694
15-3. Recommended Installation To Reduce HF Interference
7
Weld Zone
3
50 ft
(15 m)
50 ft
(15 m)
5
1
6
2
8
4
8
Ground all metal objects and all wiring in
welding zone using
#12 AWG wire.
Nonmetal
Building
Ground
workpiece if
required by
codes.
9
Best Practices Followed
Metal Building
8
8
11
10
Ref. S-0695 / Ref. S-0695
1
High-Frequency Source (welding
power source with built-in HF or
separate HF unit)
Ground metal machine case (clean paint
from around hole in case, and use case
screw), work output terminal, line disconnect device, input supply, and worktable.
2 Center Point of Welding Zone
Midpoint between high-frequency source
and welding torch.
3 Welding Zone
A circle 50 ft (15 m) from center point in all
directions.
4 Weld Output Cables
Keep cables short and close together.
5
Conduit Joint Bonding and Grounding
Electrically join (bond) all conduit sections
using copper straps or braided wire.
Ground conduit every 50 ft (15 m).
6
Water Pipes and Fixtures
Ground water pipes every 50 ft (15 m).
7
External Power or Telephone Lines
Locate high-frequency source at least 50 ft
(15 m) away from power and phone lines.
8
Grounding Rod
Consult the National Electrical Code for
specifications.
Metal Building Requirements
9
Metal Building Panel Bonding
Methods
Bolt or weld building panels together, install
copper straps or braided wire across
seams, and ground frame.
10 Windows and Doorways
Cover all windows and doorways with
grounded copper screen of not more than
1/4 in (6.4 mm) mesh.
11 Overhead Door Track
Ground the track.
OM-270536 Page 73
SECTION 16 − SELECTING AND PREPARING A TUNGSTEN
FOR DC OR AC WELDING WITH INVERTER MACHINES
gtaw_Inverter_2013-10
Whenever possible and practical, use DC weld output instead of AC weld output.
16-1. Selecting Tungsten Electrode (Wear Clean Gloves To Prevent Contamination Of Tungsten )
. Not all tungsten electrode manufacturers use the same colors to identify tungsten type. Contact the tungsten electrode manufacturer or reference
the product packaging to identify the tungsten you are using.
Amperage Range - Gas Type♦ - Polarity
Electrode Diameter
(DCEN) − Argon
AC − Argon
Direct Current Electrode Negative
Balance Control @ 65% Electrode Negative
(For Use With Aluminum)
(For Use With Mild Or Stainless Steel)
2% Ceria, 1.5% Lanthanum, Or 2% Thorium Alloy Tungstens
.010 in. (.25 mm)
Up to 25
Up to 20
.020 in. (.50 mm)
15-40
15-35
.040 in. (1 mm)
25-85
20-80
1/16 in. (1.6 mm)
50-160
50-150
3/32 in. (2.4 mm)
130-250
135-235
1/8 in. (3.2 mm)
250-400
225-360
5/32 in. (4.0 mm)
400-500
300-450
3/16 in (4.8 mm)
500-750
400-500
1/4 in. (6.4 mm)
750-1000
600-800
♦Typical argon shielding gas flow rates are 11 to 35 CFH (cubic feet per hour).
Figures listed are a guide and are a composite of recommendations from American Welding Society (AWS) and electrode manufacturers.
16-2. Preparing Tungsten Electrode For DC Electrode Negative (DCEN) Welding
Or AC Welding With Inverter Machines
Grinding the tungsten electrode produces dust and flying sparks which can cause injury and start fires.
Use local exhaust (forced ventilation) at the grinder or wear an approved respirator. Read MSDS for safety
information. Consider using tungsten containing ceria, lanthana, or yttria instead of thoria. Grinding dust
from thoriated electrodes contains low-level radioactive material. Properly dispose of grinder dust in an
environmentally safe way. Wear proper face, hand, and body protection. Keep flammables away.
Radial Grinding
Causes Wandering Arc
2-1/2 Times
Electrode Diameter
1
3
2
1
Grinding Wheel
Grind end of tungsten on fine grit, hard
abrasive wheel before welding. Do not use
wheel for other jobs or tungsten can become
contaminated causing lower weld quality.
2
Tungsten Electrode
A 2% ceriated tungsten is recommended.
4
Wrong Tungsten
Preparation
Ideal Tungsten Preparation − Stable Arc
3
Flat
Diameter of this flat determines amperage
capacity.
4
Straight Ground
Grind lengthwise, not radial.
OM-270536 Page 74
SECTION 17 − TIG PROCEDURES
gtaw_Inverter_2011-06
. For additional resources on welding, visit http://www.millerwelds.com/resources/improving−your−skills
17-1. Lift-Arc And HF TIG Start Procedures
Lift-Arc Start
When Lift-Arct button light is On,
start arc as follows:
1
TIG Electrode
2
Workpiece
Touch tungsten electrode to workpiece at weld start point, enable output and shielding gas with torch trigger, foot control, or hand control. Hold
electrode to workpiece for 1-2 seconds, and slowly lift electrode. Arc is
formed when electrode is lifted.
Lift-Arc Start Method
1
“Touch”
1−2
Seconds
2
Normal open-circuit voltage is not
present before tungsten electrode
touches workpiece; only a low sensing voltage is present between electrode and workpiece. The solid-state
output contactor does not energize
until after electrode is touching workpiece. This allows electrode to touch
workpiece without overheating,
sticking, or getting contaminated.
Application:
Lift-Arc is used for the DCEN or AC
GTAW process when HF Start method is not permitted, or to replace the
scratch method.
HF Start
When HF Start button light is On, start
arc as follows:
Do NOT Strike Like A Match!
High frequency turns on to help start
arc when output is enabled. High frequency turns off when arc is started,
and turns on whenever arc is broken
to help restart arc.
Application:
HF start is used for the DCEN GTAW
process when a non-contact arc starting method is required.
OM-270536 Page 75
17-2.
Pulser Control
1
3
2
Pulser Control
Pulsing is available while using the TIG process. Controls can be adjusted while welding.
Press switch pad to enable pulser.
ON - When illuminated, this LED indicates the pulser is
on.
Press switch pad until desired parameter LED is illuminated.
To turn Pulser off, press and release switch pad until the
On LED turns off.
2
3
Encoder Control (Set Value)
Ammeter (Displays Value)
See Section 7-2 or 10-2 for all Pulser parameter ranges.
PPS - Pulse frequency or pulses per second, is the number of pulse cycles per second. Pulse frequency helps
reduce heat input, part warpage, and helps weld bead
cosmetics. The higher the PPS setting, the smoother the
ripple effect, the narrower the weld bead, and the more
cooling you get. By setting PPS on the lower end, the
pulse is slower, and the weld bead wider. This slow pulsing helps agitate the weld puddle to help release gas
trapped in the weldment, and help reduce porosity (very
useful in aluminum welding). Some beginners use a
slower pulse rate (2-4 pps) to help them with their timing
on adding filler material. An experienced welder may
have the PPS setting much higher, depending on their
personal preferences, and on what they are trying to accomplish.
1
4
Percent (%) Peak Time
Control Setting
Pulsed Output Waveforms
PPS
Peak 50%/Background 50%
Balanced 50%
Peak Amp
Bkg Amp
More Time At
Peak Amperage
(80%)
More Time At
Background
Amperage
(20%)
PEAK t - (PEAK t) is the percentage of time in each cycle,
spent at peak amperage (main amperage). Peak amperage is set with the Amperage control (see Section 10-1).
If one pulse per second is being used, and peak time is
set at 50%, one-half second is spent at peak amperage,
and the other 50%, or one-half second, is spent at the
background amperage. Increasing peak time increases
time spent at peak amperage, which increases heat input
into the part. A good starting point for peak time is about
50-60%. To find a good ratio, you will have to experiment
a bit, but the idea is to decrease heat input into the part,
and increase the cosmetics of the weld.
BKGND A - (Background amps) is set as a percentage
of the peak amps setting. If peak amps is set at 200, and
background amps at 50%, your background amps is 100
amps when the machine pulses on the background side
of the cycle. The lower background amperage helps reduce heat input. Increasing or decreasing background
amps increases or decreases the overall average amperage, which helps determine how fluid your puddle is
on the background side of the pulse cycle. Overall, you
want your puddle to shrink to about one-half the size, but
still remain fluid. To start with, set background amps at
about 20-30% for stainless/carbon steel, or at about
35-50% for aluminum alloys.
4
Pulsed Output Waveforms
Example shows affect changing the Peak Time control
has on the pulsed output waveform.
Application:
Pulsing refers to the alternating raising and lowering of
the weld output at a specific rate. The raised portions of
the weld output are controlled in width, height, and frequency, forming pulses of weld output. These pulses and
the lower amperage level between them (called the background amperage) alternately heat and cool the molten
weld puddle. The combined effect gives the operator better control of penetration, bead width, crowning, undercutting, and heat input. Controls can be adjusted while
welding.
Pulsing can also be used for filler material addition technique training.
. Function is enabled, when LED is lit
OM-270536 Page 76
SECTION 18 − STICK WELDING (SMAW) GUIDELINES
6013
7014
7018
7024
Ni-Cl
308L
DEEP
ALL
DEEP
6013
EP,EN
ALL
LOW
GENERAL
7014
EP,EN
ALL
MED
7018
EP
ALL
MED
SMOOTH, EASY,
FAST
LOW HYDROGEN,
STRONG
7024
EP,EN
NI-CL
EP
FLAT
HORIZ
FILLET
ALL
308L
EP
ALL
USAGE
ALL
EP
AC
EP
6011
DC*
6010
ELECTRODE
450
400
350
300
AMPERAGE
RANGE
250
200
150
PENETRATION
3/32
1/8
5/32
3/16
7/32
1/4
1/16
5/64
3/32
1/8
5/32
3/16
7/32
1/4
3/32
1/8
5/32
3/16
7/32
1/4
3/32
1/8
5/32
3/16
7/32
1/4
3/32
1/8
5/32
3/16
7/32
1/4
3/32
1/8
5/32
3/16
3/32
1/8
5/32
POSITION
6010
&
6011
100
50
DIAMETER
ELECTRODE
18-1. Electrode and Amperage Selection Chart
MIN. PREP, ROUGH
HIGH SPATTER
LOW
SMOOTH, EASY,
FASTER
LOW
CAST IRON
LOW
STAINLESS
*EP = ELECTRODE POSITIVE (REVERSE POLARITY)
EN = ELECTRODE NEGATIVE (STRAIGHT POLARITY)
Ref. S-087 985-A
. For additional resources on welding, visit http://www.millerwelds.com/resources/improving−your−skills
OM-270536 Page 77
Effective January 1, 2016
(Equipment with a serial number preface of MG or newer)
Warranty Questions?
Call
1-800-4-A-MILLER
for your local
Miller distributor.
Your distributor also gives
you ...
Service
You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
Support
Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
LIMITED WARRANTY − Subject to the terms and conditions below, 5. 6 Months — Parts
Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its original
* Batteries
retail purchaser that new Miller equipment sold after the effective
* Bernard Guns (No Labor)
date of this limited warranty is free of defects in material and
* Tregaskiss Guns (No Labor)
workmanship at the time it is shipped by Miller. THIS WARRANTY IS
EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS 6. 90 Days — Parts
* Accessory (Kits)
OR IMPLIED, INCLUDING THE WARRANTIES OF
MERCHANTABILITY AND FITNESS.
* Canvas Covers
* Induction Heating Coils and Blankets, Cables, and
Within the warranty periods listed below, Miller will repair or replace
Non-Electronic Controls
any warranted parts or components that fail due to such defects in
* M-Guns
material or workmanship. Miller must be notified in writing within
thirty (30) days of such defect or failure, at which time Miller will
* MIG Guns and Subarc (SAW) Torches
provide instructions on the warranty claim procedures to be
* Remote Controls and RFCS-RJ45
followed. If notification is submitted as an online warranty claim, the
* Replacement Parts (No labor)
claim must include a detailed description of the fault and the
* Roughneck Guns
troubleshooting steps taken to identify failed components and the
* Spoolmate Spoolguns
cause of their failure.
Miller shall honor warranty claims on warranted equipment listed
below in the event of such a failure within the warranty time periods.
All warranty time periods start on the delivery date of the equipment
to the original end-user purchaser, and not to exceed twelve months
after the equipment is shipped to a North American distributor or
eighteen months after the equipment is shipped to an International
distributor.
1.
2.
3.
4.
5 Years Parts — 3 Years Labor
* Original Main Power Rectifiers Only to Include SCRs,
Diodes, and Discrete Rectifier Modules
3 Years — Parts and Labor
* Auto-Darkening Helmet Lenses (Except Classic
Series) (No Labor)
* Engine Driven Welder/Generators
(NOTE: Engines are Warranted Separately by the
Engine Manufacturer.)
* Inverter Power Sources (Unless Otherwise Stated)
* Plasma Arc Cutting Power Sources
* Process Controllers
* Semi-Automatic and Automatic Wire Feeders
* Transformer/Rectifier Power Sources
2 Years — Parts and Labor
* Auto-Darkening Helmet Lenses − Classic Series Only
(No Labor)
* Fume Extractors − Capture 5, Filtair 400 and Industrial
Collector Series
1 Year — Parts and Labor Unless Specified
* Automatic Motion Devices
* CoolBelt and CoolBand Blower Unit (No Labor)
* Desiccant Air Dryer System
* External Monitoring Equipment and Sensors
* Field Options
(NOTE: Field options are covered for the remaining
warranty period of the product they are installed in,
or for a minimum of one year — whichever is
greater.)
* RFCS Foot Controls (Except RFCS-RJ45)
* Fume Extractors − Filtair 130, MWX and SWX Series
* HF Units
* ICE/XT Plasma Cutting Torches (No Labor)
* Induction Heating Power Sources, Coolers
(NOTE: Digital Recorders are Warranted Separately
by the Manufacturer.)
* LiveArc Welding Performance Management System
* Load Banks
* Motor-Driven Guns (except Spoolmate Spoolguns)
* PAPR Blower Unit (No Labor)
* Positioners and Controllers
* Racks
* Running Gear/Trailers
* Spot Welders
* Subarc Wire Drive Assemblies
* Water Coolant Systems
* TIG Torches (No Labor)
* Wireless Remote Foot/Hand Controls and Receivers
* Work Stations/Weld Tables (No Labor)
Miller’s True Blue® Limited Warranty shall not apply to:
1.
2.
3.
Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, relays, work
station table tops and welding curtains, or parts that
fail due to normal wear. (Exception: brushes and
relays are covered on all engine-driven products.)
Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
covered by the manufacturer’s warranty, if any.
Equipment that has been modified by any party other than
Miller, or equipment that has been improperly installed,
improperly operated or misused based upon industry
standards, or equipment which has not had reasonable
and necessary maintenance, or equipment which has
been used for operation outside of the specifications for
the equipment.
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
TRAINED AND EXPERIENCED IN THE USE AND
MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in appropriate
cases, (3) the reasonable cost of repair or replacement at an
authorized Miller service station; or (4) payment of or credit for the
purchase price (less reasonable depreciation based upon actual
use) upon return of the goods at customer’s risk and expense.
Miller’s option of repair or replacement will be F.O.B., Factory at
Appleton, Wisconsin, or F.O.B. at a Miller authorized service facility
as determined by Miller. Therefore no compensation or
reimbursement for transportation costs of any kind will be allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT,
INDIRECT,
SPECIAL,
INCIDENTAL
OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF PROFIT),
WHETHER BASED ON CONTRACT, TORT OR ANY OTHER
LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY
IMPLIED WARRANTY, GUARANTY OR REPRESENTATION AS
TO PERFORMANCE, AND ANY REMEDY FOR BREACH OF
CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH,
BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION,
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF
DEALING, INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY
MILLER.
Some states in the U.S.A. do not allow limitations of how long an
implied warranty lasts, or the exclusion of incidental, indirect,
special or consequential damages, so the above limitation or
exclusion may not apply to you. This warranty provides specific
legal rights, and other rights may be available, but may vary from
state to state.
In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein, and to
the extent that they may not be waived, the limitations and
exclusions set out above may not apply. This Limited Warranty
provides specific legal rights, and other rights may be available, but
may vary from province to province.
miller_warr 2016-01
Owner’s Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
(Date which equipment was delivered to original customer.)
Distributor
Address
City
State
Zip
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
For International Locations Visit
www.MillerWelds.com
Welding Process Handbooks
To locate a Distributor or Service Agency visit
www.millerwelds.com or call 1-800-4-A-Miller
Contact the Delivering Carrier to:
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
ORIGINAL INSTRUCTIONS − PRINTED IN USA
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
© 2016 Miller Electric Mfg. Co.
2016−01
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