Miller DYNASTY 350 ALL OTHER CE AND NON-CE MODELS User manual

OM-216 869AA
2011−11
Processes
TIG (GTAW) Welding
Stick (SMAW) Welding
Description
208/575 Volt Models W/Auto-Linet
380/575 Volt Three-Phase
W/Auto-Linet (CE)
Arc Welding Power Source
Dynasty 350, 700
R
Maxstar 350, 700
R
Including Optional Cart And Cooler
CE And Non-CE Models
File: TIG (GTAW)
Visit our website at
www.MillerWelds.com
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.
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
Dynasty 350
Maxstar 350
Dynasty 700
Maxstar 700
Stock Number
907204021
907334021
907101021
907103021
Council Directives:
 2006/95/EC Low Voltage
 2004/108/EC Electromagnetic Compatibility
Standards:




IEC 60974­1: 2005 Arc Welding Equipment – Welding Power Sources
IEC 60974­3: 2007 Arc Welding Equipment – Arc Striking and Stabilizing Devices
IEC 60974­10: 2007 Arc Welding Equipment – Electromagnetic Compatibility Requirements
EN 50445 Product family standard to demonstrate compliance of equipment for resistance welding, arc
welding and allied processes with the basic restrictions related to human exposure to electromagnetic fields
(0 Hz – 300Hz) BS EN 50445:2008.
US Signatory:
_____________________________________
November 30, 2010
____________________________________
David A. Werba
Date of Declaration
MANAGER, PRODUCT DESIGN COMPLIANCE
241512­E
TABLE OF CONTENTS
WARRANTY
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 (CE Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Warning Label Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. WEEE Label (For Products Sold Within The EU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Important Information Regarding CE Products (Sold Within The EU) . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Tipping Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8. Dimensions, Weights And Base Mounting Hole Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-9. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-10. Connecting Input Power For 350 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-11. Connecting Input Power For 700 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-12. Weld Output Terminals And Selecting Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-13. Remote 14 Receptacle Information (Used Without Automation Connection) . . . . . . . . . . . . . . . . . . . .
4-14. Automation Connection (For 28-Pin Receptacle If Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-15. Remote Memory Select Inputs (For 28-Pin Receptacle If Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-16. Typical Automation Application For Valid Arc Length Control Lockout And Final Slope Indication . . .
4-17. 115 Volts AC Duplex Receptacle, Supplementary Protector CB1, And Power Switch . . . . . . . . . . . .
4-18. Gas Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-19. TIG HF Impulse/ Lift-Arc Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-20. Cooler Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-21. Dynasty Stick Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-22. Maxstar Stick Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Encoder Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Amperage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Ammeter And Parameter Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. Voltmeter And Selected Parameter Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6. Polarity Control (Dynasty Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-7. Process Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-8. Lift-Arc And HF TIG Start Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-9. Output Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
3
4
4
4
5
5
5
7
8
9
9
11
11
13
14
15
15
16
16
18
20
22
22
23
24
28
30
33
34
35
38
39
39
40
40
41
42
42
43
43
44
44
44
45
45
46
46
47
TABLE OF CONTENTS
5-10. Pulser Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
48
5-11. Sequencer Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
49
5-12. Gas/DIG Controls (Preflow/Post Flow/DIG/Purge) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
50
5-13. AC Waveshape (Dynasty Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
51
5-14. Memory (Program Storage Locations 1-9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
52
5-15. Factory Parameter Defaults And Range And Resolution For 350 Models . . . . . . . . . . . . . . . . . . . . . .
53
5-16. Factory Parameter Defaults And Range And Resolution For 700 Models . . . . . . . . . . . . . . . . . . . . . .
54
5-17. Resetting Unit To Factory Default Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
56
5-18. Software And Revision Viewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
56
5-19. Arc Timer/Counter Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
57
SECTION 6 − ADVANCED FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
58
6-1. Accessing Advanced Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
58
6-2. Programmable TIG Start Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
59
6-3. Programmable TIG Start Parameters For Models With Advanced Automation
Capabilities . . . . .
64
6-4. Output Control And Trigger Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
66
6-5. AC Waveshape Selection (Dynasty Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
71
6-6. Independent Amplitude Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
72
6-7. Spot Enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
72
6-8. Stick Open-Circuit Voltage (OCV) Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
72
6-9. Stick Stuck Check Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
73
6-10. Lockout Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
74
6-11. Pulse Welding Display Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
76
6-12. DC Meter Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
76
SECTION 7 − MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
77
7-2. Blowing Out Inside of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
78
7-3. Coolant Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
78
7-4. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
79
SECTION 8 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
82
SECTION 9 − HIGH FREQUENCY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
95
9-1. Welding Processes Requiring High Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
95
9-2. Installation Showing Possible Sources Of HF Interference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
95
9-3. Recommended Installation To Reduce HF Interference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
96
SECTION 10 − SETUP GUIDES FOR (GTAW) TIG WELDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
97
10-1. Typical GTAW Setups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
97
SECTION 11 − SELECTING AND PREPARING A TUNGSTEN FOR DC OR AC WELDING WITH INVERTER
MACHINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
99
11-1. Selecting Tungsten Electrode (Wear Clean gloves To Prevent Contamination Of Tungsten) . . . . . . .
99
11-2. Preparing Tungsten Electrode For DC Electrode Negative (DCEN) Welding Or AC Welding With
Inverter Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
99
SECTION 12 − GUIDELINES FOR TIG WELDING (GTAW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
100
12-1. Positioning The Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
12-2. Torch Movement During Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
12-3. Positioning Torch Tungsten For Various Weld Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
SECTION 13 − SETUP GUIDES FOR (SMAW) STICK WELDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
102
13-1. Front Panel Display For Stick DCEP (Direct Current Electrode Positive) . . . . . . . . . . . . . . . . . . . . . . . 102
SECTION 14 − STICK WELDING (SMAW) GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
103
SECTION 15 − PARTS LIST FOR 350 MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
110
SECTION 16 − PARTS LIST FOR 700 MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
120
SECTION 17 − PARTS LIST FOR COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
130
SECTION 18 − PARTS LIST FOR CART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
132
WARRANTY
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som 2011−01
7
Protect yourself and others from injury — read and follow these precautions.
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.
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 for damage or bare wiring −
replace cord immediately if damaged − bare wiring can kill.
D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or poorly spliced cables.
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 and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
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.
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-216 869 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.
D If ventilation is poor, wear an approved air-supplied respirator.
D Read and understand the Material Safety Data Sheets (MSDSs)
and the manufacturer’s instructions for metals, consumables,
coatings, cleaners, and degreasers.
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 protective clothing made from durable, flame-resistant
material (leather, heavy cotton, or wool) and foot protection.
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 closed containers such as tanks, drums, or pipes,
unless they are properly prepared according to AWS F4.1 (see
Safety Standards).
D Do not weld where the atmosphere may 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-216 869 Page 2
D Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
D Wear oil-free protective garments 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.
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.
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.
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 maintenance and service according to the Owner’s
Manuals, industry standards, and national, state, and local
codes.
OVERUSE can cause OVERHEATING
H.F. RADIATION can cause interference.
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.
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 Sparks can cause fires — keep flammables away.
D
D
D
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.
ARC WELDING can cause interference.
MOVING PARTS can injure.
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.
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.
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-216 869 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.)
Battery posts, terminals and related accessories contain lead
and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other
reproductive harm. Wash hands after handling.
For Gasoline Engines:
Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive harm.
For Diesel Engines:
Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.
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,
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).
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, 4221 Walney Road, 5th Floor,
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, Ontario, Canada L4W 5NS (phone:
800-463-6727, website: www.csa-international.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).
U.S. Consumer Product Safety Commission (CPSC), 4330 East West
Highway, Bethesda, MD 20814 (phone: 301-504-7923, website:
www.cpsc.gov).
Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30333 (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). Welding current creates an EMF field
around the welding circuit and welding equipment. EMF fields may interfere with some medical implants, e.g. pacemakers. Protective
measures for persons wearing medical implants have to be taken. For
example, access restrictions for passers−by or 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-216 869 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_2011−01
7
Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes.
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.
NOTE − 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.
D
Seul un personnel qualifié est autorisé à installer, faire fonctionner, entretenir et réparer cet appareil.
D
Pendant le fonctionnement, maintenir à distance toutes les
personnes, notamment les enfants de l’appareil.
D
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,
D
D
D
D
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 !
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).
Installer le poste correctement et le mettre à la terre convenablement selon les consignes du manuel de l’opérateur et les normes
nationales, provinciales et locales.
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.
En effectuant les raccordements d’entrée, fixer d’abord le conducteur de mise à la terre approprié et contre-vérifier les connexions.
Les câbles doivent être exempts d’humidité, d’huile et de graisse;
protégez−les contre les étincelles et les pièces métalliques
chaudes.
Vérifier fréquemment le cordon d’alimentation afin de s’assurer
qu’il n’est pas altéré ou à nu, le remplacer immédiatement s’il l’est.
Un fil à nu peut entraîner la mort.
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.
OM-216 869 Page 5
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.
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.
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 surchauffement 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.
LES FUMÉES ET LES GAZ peuvent
être dangereux.
D Se protéger et d’autres personnes de la projection d’étincelles et
de métal chaud.
Le soudage génère des fumées et des gaz. Leur
inhalation peut être dangereux pour votre santé.
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 Eloigner votre tête des fumées. Ne pas respirer les fumées.
D Surveiller tout déclenchement d’incendie et tenir un extincteur à
proximité.
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.
D Le soudage effectué sur un plafond, plancher, paroi ou séparation
peut déclencher un incendie de l’autre côté.
D Si la ventilation est médiocre, porter un respirateur anti-vapeurs
approuvé.
D Lire et comprendre les spécifications de sécurité des matériaux
(MSDS) et les instructions du fabricant concernant les métaux, les
consommables, les revêtements, les nettoyants et les dégraisseurs.
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 intense
(ultraviolets et infrarouges) susceptibles de provoquer des brûlure
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 des vêtements confectionnés avec des matières résistantes et ignifuges (cuir, coton lourd ou laine) et des bottes de
protection.
OM-216 869 Page 6
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 (voir les normes de sécurité).
D Ne soudez pas si l’air ambiant est chargé de particules, gaz, ou vapeurs 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 des vêtements de protection dépourvus d’huile tels que des
gants en cuir, une chemise en matériau lourd, des pantalons sans
revers, des chaussures hautes et un couvre chef.
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 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.
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 Détourner votre visage du détendeur-régulateur lorsque vous
ouvrez la soupape de la bouteille.
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.
OM-216 869 Page 7
Les PIÈCES MOBILES peuvent
causer des blessures.
LE
RAYONNEMENT
HAUTE
FRÉQUENCE
(H.F.)
risque
de
provoquer des interférences.
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.
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’entretien en respectant les manuels d’utilisation, les
normes industrielles et les codes nationaux, d’état et locaux.
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.
LE SOUDAGE À L’ARC risque de
provoquer des interférences.
D
D
D
D
D
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.
Veiller à ce que tout l’équipement de la zone de soudage soit
compatible électromagnétiquement.
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).
Veiller à souder à une distance de 100 mètres de tout équipement électronique sensible.
Veiller à ce que ce poste de soudage soit posé et mis à la terre
conformément à ce mode d’emploi.
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)
Les batteries, les bornes et autres accessoires contiennent
du plomb et des composés à base de plomb, produits chimiques dont l’État de Californie reconnaît qu’ils provoquent des
cancers et des malformations congénitales ou autres
problèmes de procréation. Se laver les mains après manipulation.
Ce produit contient des produits chimiques, notamment du
plomb, dont l’État de Californie reconnaît qu’ils provoquent
OM-216 869 Page 8
des cancers, des malformations congénitales ou d’autres
problèmes de procréation. Se laver les mains après
utilisation.
Pour les moteurs à essence :
Les gaz d’échappement des moteurs contiennent des produits chimiques dont l’État de Californie reconnaît qu’ils
provoquent des cancers et des malformations congénitales
ou autres problèmes de procréation.
Pour les moteurs diesel :
Les gaz d’échappement des moteurs diesel et certains de
leurs composants sont reconnus par l’État de Californie comme provoquant des cancers et des malformations
congénitales ou autres problèmes de procréation.
2-5. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
de Global Engineering Documents (téléphone : 1-877-413-5184, site
Internet : www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, de Global
Engineering Documents (téléphone : 1-877-413-5184, site internet :
www.global.ihs.com).
National Electrical Code, NFPA Standard 70, de National Fire Protection Association, Quincy, MA 02269 (téléphone : 800-344-3555, site
Internet : www.nfpa.org et www.sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
de Compressed Gas Association, 4221 Walney Road, 5th Floor, Chantilly, VA 20151 (téléphone : 703-788-2700, site Internet :
www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, de Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (téléphone :
800-463-6727, site internet : www.csa-international.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, de American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (téléphone : 212-642-4900,
site Internet : www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, de National Fire Protection Association,
P.O. Box 9101, Quincy, MA 02269-9101 (téléphone : 617-770-3000,
site Internet : 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, de U.S. Government Printing
Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA
15250-7954 (téléphone : 1-866-512-1800) (il y a 10 bureaux
régionaux−le téléphone de la région 5, Chicago, est 312-353-2220, site
Internet : www.osha.gov).
U.S. Consumer Product Safety Commission (CPSC), 4330 East West
Highway, Bethesda, MD 20814 (téléphone : 301-504-7923, site internet : www.cpsc.gov).
Applications Manual for the Revised NIOSH Lifting Equation, The
National Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30333 (télé[hone : 1-800-232-4636, site internet:
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 de soudage
crée un CEM autour du circuit et du matériel de soudage. Les CEM
peuvent créer des interférences avec certains implants médicaux
comme des stimulateurs cardiaques. Des mesures de protection pour
les porteurs d’implants médicaux doivent être prises: par exemple, des
restrictions d’accès pour les passants ou une évaluation individuelle
des risques pour les soudeurs. Tous les soudeurs doivent appliquer les
procédures suivantes pour minimiser l’exposition aux CEM provenant
du circuit de soudage:
4. Maintenir la tête et le torse aussi loin que possible du matériel 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
câbles d’un côté et à distance de l’opérateur.
3. Ne pas courber et ne pas entourer les câbles autour de votre
corps.
En ce qui concerne les implants médicaux :
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.
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.
OM-216 869 Page 9
OM-216 869 Page 10
SECTION 3 − DEFINITIONS (CE Models Only)
3-1.
Warning Label Definitions
Warning! Watch Out! There are possible
hazards as shown by the symbols.
1
Electric shock from welding electrode
or wiring can kill.
2
2.1
2.2
1.1 Wear dry insulating gloves. Do not
touch electrode with bare hand. Do
not wear wet or damaged gloves.
2.3
3
1.2 Protect yourself from electric shock by
insulating yourself from work and
ground.
3.1
1.3 Disconnect input plug or power before
working on machine.
2
3.2
1
Breathing welding fumes can be
hazardous to your health.
Keep your head out of the fumes.
Use forced ventilation or local exhaust
to remove the fumes.
Use ventilating fan to remove fumes.
Welding sparks can cause explosion
or fire.
Keep flammables away from welding.
Do not weld near flammables.
Welding sparks can cause fires. Have
a fire extinguisher nearby, and have a
watchperson ready to use it.
3
4
3.3 Do not weld on drums or any closed
containers.
4
Arc rays can burn eyes and injure
skin.
4.1 Wear hat and safety glasses. Use ear
protection and button shirt collar. Use
welding helmet with correct shade of
filter. Wear complete body protection.
5
Become trained and read the
instructions before working on the
machine or welding.
6
Do not remove or paint over (cover)
the label.
1
2
3
4
5
5
Warning! Watch Out! There
are possible hazards as
shown by the symbols.
Electric shock from wiring can
kill.
Read the Owner’s Manual
before working on this
machine.
Disconnect input plug or
power before working on
machine.
Become trained and read the
instructions before working on
the machine or welding.
OM-216 869 Page 11
Warning! Watch Out! There are
possible hazards as shown by the
symbols.
1
2
1
2
4
3
5
3
4
5
6
7
6
9
8
7
8
9
1
2
3
4
Electric shock from wiring can
kill.
Disconnect input plug or
power before working on
machine.
Hazardous voltage remains
on input capacitors after
power is turned off. Do not
touch fully charged
capacitors.
Always wait 5 minutes 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.
When power is applied failed
parts can explode or cause
other parts to explode.
Flying pieces of parts can
cause injury. Always wear a
face shield when servicing
unit.
Always wear long sleeves and
button your collar when
servicing unit.
After taking proper
precautions as shown,
connect power to unit.
5
S-180 663
1
6
Warning! Watch Out! There are
possible hazards as shown by the
symbols.
2
Electric shock from wiring can kill.
3
Disconnect input plug or power before
working on machine.
OM-216 869 Page 12
4
5
6
7
7
Moving parts, such as fans, can cut
fingers and hands and cause injury.
Keep away from moving parts.
Wear safety glasses with side shields.
Read the Owner’s Manual before
working on this machine.
Read the labels on the welding power
8
9
8
9
source, wire feeder, or other major
equipment for welding safety
information.
Recycle or dispose of used coolant in
an environmentally safe way.
Do not remove or paint over (cover)
the label.
1
2
3
100 h. std.
4
=
6
5
7
043 810 (HF)
043 809 (AL)
S-178 910
4/96
1
2
3
4
Warning! Watch Out! There are
possible hazards as shown by the
symbols.
Disconnect input plug or power before
working on machine.
Wear safety glasses with side shields.
Plugged filter or hoses cause
overheating and damage.
5
Read Owner’s Manual.
6
Check and clean filter every 100
hours; also check condition of hoses.
7
Use Low Conductivity Coolant No. 043
810 for High-Frequency assisted or
Gas Tungsten Arc Welding
applications. Use Aluminum Protecting
Coolant No. 043 809 where coolant
contacts aluminum parts or for Gas
Metal Arc Welding applications or
where High Frequency is not used.
3-2. WEEE Label (For Products Sold Within The EU)
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.
OM-216 869 Page 13
3-3.
Symbols And Definitions
A
Amperes
Output
V
Volts
Input
Output
Supplementary
Protector
Remote
Protective Earth
(Ground)
Postflow Timer
Preflow Timer
On
Off
Positive
Alternating
Current
Gas Input
Gas Output
Duty Cycle
Direct Current
Line Connection
X
U1
U0
Primary Voltage
Rated No Load
Voltage (Average)
IP
Degree Of
Protection
Polarity Control
Remote Standard
Hz
Gas Tungsten Arc
Welding (GTAW)
Shielded Metal Arc
Welding (SMAW)
3 Phase Static Frequency
Converter-Transformer-Rectifier
I1max
Rated Maximum
Supply Current
Lift-Arc (GTAW)
S
Seconds
Negative
I2
U2
I1eff
Rated Welding
Current
Conventional Load
Voltage
Maximum Effective
Supply Current
Initial Amperage
Increase/Decrease
Of Quantity
Gas/DIG Control
Percent
Hertz
Recall From
Memory
Arc Force (DIG)
Impulse Starting
(GTAW)
Final Slope
Final Amperage
Pulse Percent
On Time
Initial Slope
AC Waveshape
Control
Pulser
EP Amperage
Pulse Frequency
Work
Electrode
EN Amperage
Unit may be used
in environments
with increased
hazard of electric
shock
Sequence
Background Amperage
Water (Coolant) Input
Water (Coolant)
Output
Circulating Unit
With Coolant Pump
OM-216 869 Page 14
Process
f
AC Frequency
SECTION 4 − INSTALLATION
4-1. Important Information Regarding CE Products (Sold Within The EU)
A. Information On Electromagnetic Fields (EMF)
!
This equipment shall not be used by the general public as the EMF limits for the general public might be exceeded during welding.
This equipment is built in accordance with EN 60974−1 and is intended to be used only in an occupational environment (where the general public
access is prohibited or regulated in such a way as to be similar to occupational use) by an expert or an instructed person.
Wire feeders and ancillary equipment (such as torches, liquid cooling systems and arc striking and stabilizing devices) as part of the welding
circuit may not be a major contributor to the EMF. See the Owner’s Manuals for all components of the welding circuit for additional EMF exposure
information.
S
S
The EMF assessment on this equipment was conducted at 0.5 meter.
At a distance of 1 meter the EMF exposure values were less than 20% of the permissible values.
The weld cable occupational exposure assessment was performed at the center of a radius of a curved weld cable under worst-case conditions.
The following special conditions apply to the operation of this equipment:
S
Use mechanized welding operations when welding with AC or pulsed DC processes and power source settings are above 350 A.
B. Information On Electromagnetic Compatibility (EMC) (Dynasty 350)
!
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 IEC 61000−3−12 provided that the short−circuit power Ssc is greater than or equal to 4, 141, 791 at the interface
point between the user’s supply and the public system. 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 equipment is connected only to a supply with a short−circuit power Ssc greater than
or equal to 4,141, 791.
C. Information On Electromagnetic Compatibility (EMC) (Maxstar 350)
!
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 IEC 61000−3−12 provided that the short−circuit power Ssc is greater than or equal to 1, 340, 274 at the interface
point between the user’s supply and the public system. 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 equipment is connected only to a supply with a short−circuit power Ssc greater than
or equal to 1, 340, 274.
D. Information On Electromagnetic Compatibility (EMC) (Dynasty 700)
!
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 IEC 61000−3−12 provided that the short−circuit power Ssc is greater than or equal to 9, 394, 172 at the interface
point between the user’s supply and the public system. 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 equipment is connected only to a supply with a short−circuit power Ssc greater than
or equal to 9, 394, 172.
E. Information On Electromagnetic Compatibility (EMC) (Maxstar 700)
!
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 IEC 61000−3−12 provided that the short−circuit power Ssc is greater than or equal to 3, 259, 047 at the interface
point between the user’s supply and the public system. 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 equipment is connected only to a supply with a short−circuit power Ssc greater than
or equal to 3, 259, 047.
OM-216 869 Page 15
4-2. Serial Number And Rating Label Location
The serial number and rating information for the power source is located on the front 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.
4-3. Specifications
A. Dynasty 350 Models
Input
Power
Three
Phase
Single
Phase
Rated Welding
IP
Rating
Output
Amperage
Range
250 A @ 30 Volts,
100% Duty Cycle
300 A @ 32 Volts,
60% Duty Cycle
23
5−350
Max
OpenCircuit
Voltage
DC (Uo)
Rated Peak
Striking
Voltage
(Up)
75
15 KV**
10−15
Amperes Input at Rated Load Output 50/60 Hz
208 V
230 V
380 V
400 V
460 V
575 V
KVA
29
26
16
15
13
10
10.3
KW
9.9
*(.06)
36
32
19
18
16
13
12.7
12.1
*(.06)
35
180 A @ 27.2
Volts, 100% Duty
Cycle
23
5−350
225 A @ 29 Volts,
60% Duty Cycle
75
32
−−
−−
15
12
7.4
15 KV**
10−15
6.8
*(.06)
47
43
−−
−−
21
16
9.8
9.1
*(.06)
*While idling
** 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 (see Section 6-8).
Normal open-circuit voltage (75 volts) is present while in Stick with normal open-circuit voltage selected (see Section 6-8).
. This unit is equipped with Auto-Linet. Auto-Line is an internal inverter power source circuit that automatically links the power source to any
primary input voltage from 190 to 625 volts, single-or-three-phase, 50 or 60 hertz. Also adjusts for voltage spikes within the entire range.
B. Maxstar 350 Models
Input
Power
Three
Phase
Single
Phase
Rated Welding
IP
Rating
Output
Amperage
Range
250 A @ 30
Volts, 100% Duty
Cycle
300 A @ 32
Volts, 60% Duty
Cycle
180 A @ 27.2
Volts, 100% Duty
Cycle
225 A @ 29
Volts, 60% Duty
Cycle
23
5−350
Max
OpenCircuit
Voltage
DC (Uo)
75
Rated Peak
Striking
Voltage
(Up)
Amperes Input at Rated Load Output 50/60 Hz
208 V
230 V
380 V
400 V
460 V
575 V
KVA
KW
27
24
15
14
12
9
9.7
9.3
*(.06)
15 KV**
33
10−15
30
18
17
15
12
12
11.5
*(.06)
32
29
−−
−−
14
11
6.4
6
*(.06)
23
5−350
75
15 KV**
10−15
43
39
−−
−−
19
14
8.6
8.2
*(.06)
*While idling
** 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 (see Section 6-8).
Normal open-circuit voltage (75 volts) is present while in Stick with normal open-circuit voltage selected (see Section 6-8).
. This unit is equipped with Auto-Linet. Auto-Line is an internal inverter power source circuit that automatically links the power source to any
primary input voltage from 190 to 625 volts, single-or-three-phase, 50 or 60 hertz. Also adjusts for voltage spikes within the entire range.
OM-216 869 Page 16
C. Dynasty 700 Models
Input
Power
Three
Phase
Single
Phase
Rated Welding
IP
Rating
Output
Amperage
Range
500 A @ 40
Volts, 100% Duty
Cycle
23
600 A @ 44
Volts, 60% Duty
Cycle
360 A @ 34
Volts, 100% Duty
Cycle
450 A @ 38
Volts, 60% Duty
Cycle
5−700
Max
OpenCircuit
Voltage
DC (Uo)
75
10−15
Rated Peak
Striking
voltage
(Up)
Amperes Input at Rated Load Output 50/60 Hz
208 V
230 V
380 V
400 V
460 V
575 V
KVA
75
68
41
39
34
27
27
KW
26
*(.08)
15 KV **
98
88
53
51
43
33
35
34
*(.08)
82
74
−−
−−
37
30
17
16
*(.08)
23
5−700
75
10−15
15 KV **
119
105
−−
−−
50
38
24
22
*(.08)
*While idling
** 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 (see Section 6-8).
Normal open-circuit voltage (75 volts) is present while in Stick with normal open-circuit voltage selected (see Section 6-8).
. This unit is equipped with Auto-Linet. Auto-Line is an internal inverter power source circuit that automatically links the power source to any
primary input voltage from 190 to 625 volts, single-or-three-phase, 50 or 60 hertz. Also adjusts for voltage spikes within the entire range.
D. Maxstar 700 Models
Input
Power
Three
Phase
Single
Phase
Rated Welding
Output
IP
Rating
Amperage
Range
500 A @ 40
Volts, 100% Duty
Cycle
600 A @ 44
Volts, 60% Duty
Cycle
360 A @ 34
Volts, 100% Duty
Cycle
450 A @ 38
Volts, 60% Duty
Cycle
23
5−700
Max
OpenCircuit
Voltage
DC (Uo)
75
10−15
Rated Peak
Striking
Voltage
(Up)
Amperes Input at Rated Load Output 50/60 Hz
208 V
230 V
380 V
400 V
460 V
575 V
KVA
67
60
36
35
30
24
24
KW
23
*(.08)
15 KV**
89
80
49
46
40
31
32
31
*(.08)
77
70
−−
−−
35
28
16
15
*(.08)
23
5−700
75
15 KV**
10−15
108
95
−−
−−
45
35
22
21
*(.08)
*While idling
** 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 (see Section 6-8).
Normal open-circuit voltage (75 volts) is present while in Stick with normal open-circuit voltage selected (see Section 6-8).
. This unit is equipped with Auto-Linet. Auto-Line is an internal inverter power source circuit that automatically links the power source to any
primary input voltage from 190 to 625 volts, single-or-three-phase, 50 or 60 hertz. Also adjusts for voltage spikes within the entire range.
OM-216 869 Page 17
4-4.
Duty Cycle And Overheating
Duty Cycle is the percentage of 10
minutes that unit can weld at rated
load without overheating.
700
If unit overheats, output stops, a
Help message is displayed (see
Section 7-4), and cooling fan runs.
Wait fifteen minutes for unit to cool.
Reduce amperage or voltage, or
duty cycle before welding.
700 3 Phase
NOTICE − Exceeding duty cycle
can damage unit and void warranty.
Output Amperes
600
500
700 1 Phase
400
350 3 Phase
300
350 1 Phase
200
100
0
10
20
30
40
50
60 70 80 90 100
%Duty Cycle
Overheating
0
A or V
15
Minutes
Notes
OM-216 869 Page 18
OR
Reduce Duty Cycle
Notes
OM-216 869 Page 19
4-5. Volt-Ampere Curves
Dynasty 350 DC
Dynasty 350 AC
80
80
70
70
60
60
TIG Max
TIG Min
30
AC Volts
DC Volts
50
40
Stick Max
DIG Min
Stick Min DIG Max
20
Stick Max
50
Stick Min
40
30
TIG Max
20
10
0
TIG Min
10
0
0
50 100 150 200 250 300 350 400
DC Amperes
50 100 150 200 250 300 350 400
0
AC Amperes
215 138-A / 215 139-A
Maxstar 350 DC
80
70
Stick Max
DIG Max
60
50
40
Stick Min DIG Max
30
20
TIG Min
10
0
0
50 100 150
TIG Max
200 250 300 350 400
224 527-A
OM-216 869 Page 20
Volt-ampere curves show minimum and maximum voltage and
amperage output capabilities of
unit. Curves of other settings fall between curves shown.
90
Dynasty 700 DC
80
90
70
80
70
40
Stick Max
DIG Max
30
10
0
0
Stick Min DIG Max
AC Volts
50
Stick Max
60
TIG Min
50
40
TIG Max
30
Stick Min
20
TIG Min
10
TIG Max
100 200 300 400 500 600 700 800 900
DC Amperes
0
0
100
200
300 400 500
AC Amperes
600 700
800
213 342-A / 213 344-A
Maxstar 700 DC
80
70
60
DC Volts
DC Volts
60
20
Dynasty 700 AC
100
50
40
30
Stick Max
DIG Max
Stick Min DIG Max
20
10
TIG Min
0
0
100
TIG Max
200 300 400 500 600 700
DC Amperes
800 900
215 126-A
OM-216 869 Page 21
4-6. Selecting A Location
!
Falling Unit Can Cause Injury.
Use equipment of adequate capacity to lift
and support unit.
Movement
1
2
Lifting Eye
Lifting Forks
Use lifting eye or lifting forks to move unit.
Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
1
If using lifting forks, extend forks beyond opposite side of unit.
3
Line Disconnect Device
Locate unit near correct input power supply.
OR
2
!
Special installation may be required
where gasoline or volatile liquids are
present − see NEC Article 511 or CEC
Section 20.
Location And Airflow
3
1
18 in. (460 mm)
18 in. (460 mm)
Ref. 117 264-C / 803 900-B / 223 259-A / 223 275-A
4-7. Tipping Warnings
!
OM-216 869 Page 22
Do not move or operate unit
where it could tip.
4-8. Dimensions, Weights And Base Mounting Hole Layout
. Overall dimensions (A, B, and C) include lifting eye, handles, hardware, etc.
A. Welding Power Source
Dimensions
A
A
B
C
D
G
F
C
24-3/4 in (654 mm) −
350 Amp Models
34-5/8 in (879 mm) −
700 Amp Models
B
13-3/4 in. (349 mm)
C
22 in. (559 mm)
D
20-1/2 in. (521 mm)
E
1 in. (25 mm)
F
11-3/4 in. (298 mm)
G
1/2 in. Dia. (13 mm Dia.)
4 Holes
E
803 914-A
Weight
Weight
135.5 lb (61.5 kg)
198 lb (89.8 kg)
B. Welding Power Source With Cart And Cooler
Dimensions
A
350 Models
700 Models
45-1/8 in. (1146 mm)
55-1/8 in. (1400 mm)
A
B
B
23-1/8 in. (587 mm)
C
41-3/4 in. (1060 mm)
C
Weight For 350 Models
Weight For 700 Models
268.5 lb (121.8 Kg)
331 lb (150 Kg)
804 642-B
OM-216 869 Page 23
4-9. Electrical Service Guide
A. Dynasty 350 Models
. Actual input voltage should not be 10% less than minimum (5% for 380 volt CE models) and/or 10% more than maximum input voltages listed
in table. If actual input voltage is outside this range, output may not be be available.
NOTICE − INCORRECT INPUT POWER can damage this welding power source. Phase to ground voltage shall not exceed +10% of rated input
voltage.
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.
Three-Phase
Input Voltage (V)
208
230
380
400
460
575
Input Amperes (A) At Rated Output - 300 amps @ 32 volts
36
32
19
18
16
13
40
35
20
20
20
15
50
45
30
25
25
20
10
10
12
14
14
14
88
(27)
107
(33)
177
(54)
127
(39)
168
(51)
262
(80)
10
10
12
14
14
14
Max Recommended Standard Fuse Rating In
Amperes1
Time-Delay Fuses2
Normal Operating
Fuses3
Min Input Conductor Size In AWG4
Max Recommended Input Conductor Length In Feet (Meters)
Min Grounding Conductor Size In AWG4
1
2
3
4
Reference: 2011 National Electrical Code (NEC) (including article 630)
If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.
“Time-Delay” fuses are UL class “RK5” . See UL 248.
“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).
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.
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.
Single-Phase
Input Voltage (V)
208
230
460
575
Input Amperes (A) At Rated Output - 225 amps @ 29 volts
47
43
21
16
50
50
25
20
70
60
30
25
Max Recommended Standard Fuse Rating In
Amperes1
Time-Delay Fuses2
Normal Operating
Min Input Conductor Size In
Fuses3
AWG4
Max Recommended Input Conductor Length In Feet (Meters)
Min Grounding Conductor Size In AWG4
8
8
12
14
88
(27)
108
(33)
172
(52)
174
(53)
8
10
12
14
Reference: 2011 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-216 869 Page 24
B. Maxstar 350 Models
. Actual input voltage should not be 10% less than minimum (5% for 380 volt CE models) and/or 10% more than maximum input voltages listed
in table. If actual input voltage is outside this range, output may not be be available.
NOTICE − INCORRECT INPUT POWER can damage this welding power source. Phase to ground voltage shall not exceed +10% of rated input
voltage.
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.
Three-Phase
Input Voltage (V)
208
230
380
400
460
575
Input Amperes (A) At Rated Output - 300 amps @ 32 volts
33
30
18
17
15
12
Time-Delay Fuses2
40
35
20
20
15
15
Normal Operating Fuses3
50
45
25
25
20
20
AWG4
10
10
14
14
14
14
93
(28)
113
(35)
121
(37)
134
(41)
177
(54)
276
(84)
10
10
14
14
14
14
Max Recommended Standard Fuse Rating In Amperes1
Min Input Conductor Size In
Max Recommended Input Conductor Length In Feet (Meters)
Min Grounding Conductor Size In AWG4
Reference: 2011 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.
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.
Single-Phase
Input Voltage (V)
208
230
460
575
Input Amperes (A) At Rated Output - 225 amps @ 29 volts
43
39
19
14
Time-Delay Fuses2
50
45
20
15
Normal Operating Fuses3
60
60
30
20
Max Recommended Standard Fuse Rating In
Min Input Conductor Size In
Amperes1
AWG4
Max Recommended Input Conductor Length In Feet (Meters)
Min Grounding Conductor Size In AWG4
8
10
14
14
99
(30)
79
(24)
124
(38)
194
(59)
10
10
14
14
Reference: 2011 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-216 869 Page 25
C. Dynasty 700 Models
. Actual input voltage should not be 10% less than minimum (5% for 380 volt CE models) and/or 10% more than maximum input voltages listed
in table. If actual input voltage is outside this range, output may not be be available.
NOTICE − INCORRECT INPUT POWER can damage this welding power source. Phase to ground voltage shall not exceed +10% of rated input
voltage.
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.
Three-Phase
Input Voltage (V)
208
230
380
400
460
575
Input Amperes (A) At Rated Output - 600 amps @ 44 volts
98
88
53
51
44
33
110
100
60
60
50
40
150
125
80
80
70
50
4
4
8
8
8
10
118
(36)
144
(44)
160
(49)
177
(54)
235
(72)
240
(73)
6
6
8
8
8
10
Max Recommended Standard Fuse Rating In
Amperes1
Time-Delay Fuses2
Normal Operating
Fuses3
Min Input Conductor Size In AWG4
Max Recommended Input Conductor Length In Feet (Meters)
Min Grounding Conductor Size In AWG4
Reference: 2011 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.
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.
Single-Phase
Input Voltage (V)
208
230
460
575
Input Amperes (A) At Rated Output - 450 amps @ 38 volts
119
105
50
38
Time-Delay Fuses2
125
125
60
50
Normal Operating Fuses3
175
150
80
60
Max Recommended Standard Fuse Rating In Amperes1
Min Input Conductor Size In
AWG4
Max Recommended Input Conductor Length In Feet (Meters)
Min Grounding Conductor Size In AWG4
3
4
8
8
107
(33)
107
(33)
178
(54)
279
(85)
6
6
8
10
Reference: 2011 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-216 869 Page 26
D. Maxstar 700 Models
. Actual input voltage should not be 10% less than minimum (5% for 380 volt CE models) and/or 10% more than maximum input voltages listed
in table. If actual input voltage is outside this range, output may not be be available.
NOTICE − INCORRECT INPUT POWER can damage this welding power source. Phase to ground voltage shall not exceed +10% of rated input
voltage.
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.
Three-Phase
Input Voltage (V)
208
230
380
400
460
575
Input Amperes (A) At Rated Output - 600 amps @ 44 volts
89
80
49
46
40
31
110
100
60
50
50
40
125
125
70
70
60
50
4
6
8
8
8
10
129
(39)
101
(31)
175
(53)
194
(59)
257
(78)
263
(80)
6
6
8
8
10
10
Max Recommended Standard Fuse Rating In
Amperes1
Time-Delay Fuses2
Normal Operating
Fuses3
Min Input Conductor Size In AWG4
Max Recommended Input Conductor Length In Feet (Meters)
Min Grounding Conductor Size In AWG4
Reference: 2011 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.
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.
Single-Phase
Input Voltage (V)
208
230
460
575
Input Amperes (A) At Rated Output - 450 amps @ 38 volts
108
95
45
35
Max Recommended Standard Fuse Rating In Amperes1
Min Input Conductor Size In
Time-Delay Fuses2
125
110
50
45
Normal Operating Fuses3
150
150
70
60
AWG4
Max Recommended Input Conductor Length In Feet (Meters)
Min Grounding Conductor Size In AWG4
4
4
8
10
94
(29)
115
(35)
189
(58)
194
(59)
6
6
8
10
Reference: 2011 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-216 869 Page 27
4-10.
Connecting Input Power For 350 Models
A. Connecting Three-Phase Input Power
3
!
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.
!
Always connect green or green/
yellow conductor to supply
grounding terminal first, and never
to a line terminal.
4
. The Auto-Line circuitry in this unit au-
tomatically 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 208 and 575 VAC
without removing cover to relink the
power source.
7
2
For Three-Phase Operation
1
2
3
4
L1
3
L2
L3
6
5
5
6
Input Power Cord.
Disconnect Device (switch shown in
the OFF position)
Green Or Green/Yellow Grounding
Conductor
Disconnect Device Grounding
Terminal
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
1
Over-Current Protection
Select type and size of over-current
protection using Section 4-9 (fused disconnect switch shown).
Close and secure door on disconnect
device. Remove lockout/tagout device,
and place switch in the On position.
Tools Needed:
Ref. 804 746-B
OM-216 869 Page 28
B. Connecting Single-Phase Input Power
1
8
!
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.
!
Always connect green or green/
yellow conductor to supply
grounding terminal first, and never
to a line terminal.
. The Auto-Line circuitry in this unit au-
=GND/PE Earth Ground
tomatically 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 208 and 575 VAC
without removing cover to relink the
power source.
10
7
1
9
L1
L2
2
3
1
4
5
1
3
2
6
3
6
5
4
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 Over-Current Protection
Select type and size of over-current
protection using Section 4-9 (fused disconnect switch shown).
Close and secure door on disconnect
device. Remove lockout/tagout device,
and place switch in the On position.
Tools Needed:
Ref. 804 746-B / 803 766-A
OM-216 869 Page 29
4-11.
Connecting Input Power For 700 Models
A. Connecting Three-Phase Input Power For Maxstar 700 Models
6
5
4
3
2
!
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.
!
Make input power connections to the
welding power source first.
!
Always connect green or green/yellow
conductor to supply grounding terminal
first, and never to a line terminal.
See rating label on unit and check input voltage
available at site (see Section 4-6).
1
Select size and length of conductors using
Section 4-9. Conductors must comply with national, state, and local electrical codes. If applicable,
use lugs of proper amperage capacity and correct
hole size.
1
3
Welding Power Source Input Power Connections
7
= GND/PE Earth Ground
9
2
Strain Relief
Route conductors (cord) through strain relief and
tighten screws.
11
3
4
8
Machine Grounding Terminal
Green Or Green/Yellow Grounding
Conductor
Connect green or green/yellow grounding conductor to welding power source grounding terminal first.
5
6
10
4
Input Power Conductors (Customer
Supplied Cord)
Welding Power Source Line Terminals
(Switch S1)
Input Conductors L1 (U), L2 (V) And L3 (W)
Connect input conductors L1 (U), L2 (V) and L3
(W) to welding power source line terminals.
6
7
Cable Tie (CE Only)
Secure wires with supplied cable tie.
Install cover.
Disconnect Device Input Power Connections
8
9
Disconnect Device (switch shown in OFF
position)
Disconnect Device (Supply) Grounding
Terminal
Connect green or green/yellow grounding conductor to disconnect device grounding terminal
first.
10 Disconnect Device Line Terminals
Connect input conductors L1 (U), L2 (V) And L3
(W) to disconnect device line terminals.
11 Over-Current Protection
Select type and size of over-current protection using Section 4-9 (fused disconnect switch shown).
Close and secure door on line disconnect device.
Remove lockout/tagout device, and place switch
in the On position.
Tools Needed:
805 473-A
OM-216 869 Page 30
B. Connecting Three-Phase Input Power For Dynasty 700 Models
7
6
5
!
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.
!
Make input power connections to the
welding power source first.
!
Always connect green or green/yellow conductor to supply grounding
terminal first, and never to a line terminal.
4
2
See rating label on unit and check input voltage available at site (see Section 4-6).
1
1
3
Select size and length of conductors using
Section 4-9. Conductors must comply with
national, state, and local electrical codes. If
applicable, use lugs of proper amperage
capacity and correct hole size.
3
Welding Power Source Input Power Connections
8
10
2
= GND/PE Earth Ground
Strain Relief
Route conductors (cord) through strain relief
and tighten screws.
12
3
4
9
Machine Grounding Terminal
Green Or Green/Yellow Grounding
Conductor
Connect green or green/yellow grounding
conductor to welding power source grounding terminal first.
5
Ferrite Core F9 (CE Only)
. For Dynasty models, wrap green/yellow
11
4
Input Power Conductors (Customer
Supplied Cord)
grounding conductor through supplied
ferrite F9 4 times as shown.
6
6
7
Welding Power Source Line Terminals
(Switch S1)
Input Conductors L1 (U), L2 (V) And L3
(W)
Connect input conductors L1 (U), L2 (V) and
L3 (W) to welding power source line
terminals.
8
Cable Tie (CE Only)
Secure wires with supplied cable tie.
Install cover.
Disconnect Device Input Power Connections
9
Disconnect Device (switch shown in
OFF position)
10 Disconnect Device (Supply) Grounding
Terminal
Connect green or green/yellow grounding
conductor to disconnect device grounding
terminal first.
11 Disconnect Device Line Terminals
Connect input conductors L1 (U), L2 (V) And
L3 (W) to disconnect device line terminals.
12 Over-Current Protection
Select type and size of over-current protection using Section 4-9 (fused disconnect
switch shown).
Tools Needed:
805 470-B
Close and secure door on line disconnect device. Remove lockout/tagout device, and
place switch in the On position.
OM-216 869 Page 31
C. Connecting Single-Phase Input Power
6
5
2
!
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.
!
Make input power connections to
the welding power source first.
!
Always connect green or green/
yellow conductor to supply
grounding terminal first, and never
to a line terminal.
4
See rating label on unit and check input
voltage available at site (see Section 4-6).
2
1
1
Select size and length of conductors using
Section 4-9. Conductors must comply with
national, state, and local electrical codes.
If applicable, use lugs of proper amperage
capacity and correct hole size.
3
1
Input Power Conductors (Customer
Supplied Cord)
Welding Power Source Input Power
Connections
2
8
=GND/PE Earth Ground
3
4
10
7
Strain Relief
Route conductors (cord) through strain relief and tighten screws.
Machine Grounding Terminal
Green Or Green/Yellow Grounding
Conductor
Connect green or green/yellow grounding
conductor to welding power source
grounding terminal first.
5
Welding Power Source Line
Terminals (Switch S1)
Input Conductors L1 (U) And L2 (V)
9
6
6
Connect input conductors L1 (U) And L2
(V) to welding power source line terminals.
Install cover.
4
Disconnect Device
Connections
7
8
Input
Power
Disconnect Device (switch shown in
OFF position)
Disconnect Device (Supply)
Grounding Terminal
Connect green or green/yellow grounding
conductor to disconnect device grounding
terminal first.
9
Disconnect Device Line Terminals
Connect input conductors L1 (U) And L2
(V) to disconnect device line terminals.
10 Over-Current Protection
Select type and size of over-current
protection using Section 4-9 (fused disconnect switch shown).
Close and secure door on line disconnect
device. Remove lockout/tagout device,
and place switch in the On position.
Tools Needed:
Ref. 803 927-D
OM-216 869 Page 32
4-12. Weld Output Terminals And 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
Weld Output
Terminals
!
Turn off power before connecting to weld output terminals.
!
Do not use worn, damaged, undersized, or poorly spliced
cables.
Work
* This
200 ft
(60 m)
10 − 60% Duty
Cycle
60 − 100% Duty
Cycle
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)
300
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
350
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
400
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
500
2/0 (70)
3/0 (95)
4/0 (120)
2x2/0 (2x70)
600
3/0 (95)
4/0 (120)
2x2/0 (2x70)
2x3/0 (2x95)
700
4/0 (120)
2x2/0 (2x70)
2x3/0 (2x95)
2x4/0 (2x120)
800
4/0 (120)
2x2/0 (2x70)
2x3/0 (2x95)
2x4/0 (2x120)
900
2x2/0 (2x70)
2x3/0 (2x95)
2x4/0 (2x120)
3x3/0 (3x95)
Welding
Amperes***
Electrode
150 ft
(45 m)
100 ft (30 m) or Less****
10 − 100% Duty Cycle
AWG (mm2)
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-J 2011−07 (TIG)
. Proceed to Section 4-13 For Additional Installation Instructions. A Dynasty 700 is illustrated in Sections 4-13 through 7-4. Location of controls
and components is similar for all models covered in this manual.
OM-216 869 Page 33
4-13.
Remote 14 Receptacle Information (Used Without Automation Connection)
Socket*
A
B
K
J
A
Contactor control, 15 volts DC.
B
Contact closure to A completes 15 volts DC
contactor control circuit, and enables output.
C
+10 volts DC.
D
Remote control circuit common.
E
0 to +10 volts DC input command signal
from remote control.
F
Current feedback; +1 volt DC per 100 amperes.
AMPERAGE
VOLTAGE
H
Voltage feedback; +1 volt DC per 10 output
receptacle volts.
CHASSIS
K
Chassis common.
GND
G
+15 volts DC (A) common.
15 VOLTS DC
I
Socket Information
H
C L N
M
D
G
E F
REMOTE
OUTPUT
CONTROL
A/V
803 900-A / 218 716-A
* The remaining sockets are not used.
. 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.
OM-216 869 Page 34
4-14.
Automation Connection (For 28-Pin Receptacle If Present)
A. Basic Automation Mode
Use this mode when only the basic functions of the automation board are required. These functions include Start/Stop,
Valid Arc Indication, Gas Control, High Frequency Arc Start Disable, and Remote Memory Select. The welding power
source functions as a standard unit. Automation 2 mode should be used when an externally controlled pulse waveform
is needed, or if the welder’s amperage is affected by noise injected into the cabling between the remote equipment and
the welder.
2
3
7
8
14
20
1
6
5
4
13
12
11
10
9
19
18
17
16
15
25
28
24 23
27
22
21
26
803 900-A / 218 716-A
Pin
Signal
Direction
1
Input
Start/Stop = Maintained connection to pin 8 starts the weld cycle. Opening connection stops weld cycle. For momentary closure operation, set unit to 2T, A momentary closure greater than 100 ms, but less than 3/4 of a second starts and
stops weld output.
3
Input
Gas Control = This input is used to control the gas flow outside the settings of the preflow and/or postflow set on the
machine. Connection to pin 8 turns on gas.
4
Output
Valid Arc Indication = Paired with Pin 9. This output is used to signal external fixtures that the machine has detected a
valid arc. Pin is closed to pin 9 when the output is on and there is less than 65 load volts. Electrical specifications:
Open collector transistor maximum values 27volts DC peak @ 75mA. (See Section 4-16 for typical application).
5
Output
Scaled Actual Welding Voltage = +1 volt DC per 10 volts of output w/reference to pin 11.
6
Output
Scaled Actual Welding Amperage = +1 volt DC per 100 amperes of output w/reference to pin 11.
7
Output
+15volts DC with respect to pin 11 (Pin A of 14 pin)
8
Output
Reference PIN = This pin is the signal reference for pins 1,2,3,10,15,16
9
Output
Valid Arc Indication Reference = Paired with Pin 4. Connect to user’s external voltage supply common. (See Section
4-16 for typical application).
10
Input
11
Output
Amperage Control Reference = for pins 5,6,7,17 and 18. (Pin D of 14 pin)
12
Output
Welders Chassis = Earth ground. Connected only if common potentials are needed between user equipment and the
welder.
13
Output
Arc Length Control Lockout = Paired with Pin 14. Used to send signal to an automatic voltage control to ignore the
voltage during certain situations. Pin is closed to pin 14 when weld cycle is in Initial Amperage, Initial Slope, Final
Slope, Final Amperage, and Pulsed Background time. Electrical specifications: Open collector transistor maximum values 27 volts DC peak @ 75mA. (See Section 4-16 for typical application)
14
Output
Arc Length Control Lockout Reference = Paired with Pin 13. Connect to user’s external voltage supply common
(See Section 4-17 for typical application).
15
Input
Memory Select = Used to select between memory numbers. Used in conjunction with pin 10 and 16.(See Sections 4-15
and 5-14.)
16
Input
Memory Select = Used to select between memory numbers. Used in conjunction with pin 10 and 15.(See Sections
4-15 and 5-14.)
17
Input
Amperage Control = 0 to +10 volts DC with respect to pin 11. The 10 volts represents the amperage value set on machines meter. (Pin E of 14 pin)
Pin Information For 28-Pin Receptacle RC28
Memory Select = Used to select between memory numbers. Used in conjunction with pin 15 and 16. (See Sections
4-14 and 5-14. )
Continued on next page
OM-216 869 Page 35
Continued from previous page Section A
18
Output
+10 volts DC = with respect to pin 11 for use with an external potentiometer to vary the signal into pin 17 (Pin C of 14
pin)
19
Input
23
Output
Final Slope Sequence Indication = Paired with Pin 24. Pin is closed to pin 24 when in Final Slope. Electrical specifications: Open collector transistor maximum values 27 volts DC peak @ 75mA. (See Section 4-16 for typical application).
24
Output
Final Slope Sequence Indication Reference = Paired with pin 23. Connect to user’s external voltage supply common.
(See Section 4-16 for typical application).
High Frequency Arc Start Disable = Disables the arc starter from being activated when connected to pin 8.
All other pins not used.
B. Welder Controlled Automation Mode (Pin 20 Connected To Pin 8) Automation 1
Use this mode when only the basic functions of the automation board are required, or if the welder needs to control the
initial and final weld timers. These functions include Start/Stop, Valid Arc Indication, Gas Control, High Frequency Arc
Start Disable, Remote Memory Select, and Emergency weld stop. The welding power source functions as a standard
unit. Automation 2 mode should be used when an externally controlled pulse waveform is needed, or if the welder’s
amperage is affected by noise injected into the cabling between the remote equipment and the welder.
2
3
7
8
14
20
1
6
5
4
13
12
11
10
9
19
18
17
16
15
25
28
24 23
27
22
21
26
803 900-A / 218 716-A
Pin
Signal
Direction
1
Input
Start/Stop = Maintained connection to pin 8 starts the weld cycle. Opening connection stops weld cycle. For momentary closure operation, set unit to 2T. A momentary closure greater than 100 ms, but less than 3/4 of a second starts and
stops weld output.
2
Input
Emergency Weld Stop = Used to remotely stop the weld outside the normal welding cycle (i.e. light curtains or external
E-Stop). Connection to pin 8 must be maintained at all times. If the connection is broken, output stops, Postflow begins,
and AUTO STOP will be displayed on the meters.
3
Input
Gas Control = This input is used to control the gas flow outside the settings of the preflow and/or postflow set on the
machine. Connection to pin 8 turns on gas.
4
Output
Valid Arc Indication = Paired with Pin 9. This output is used to signal external fixtures that the machine has detected a
valid arc. Pin is closed to pin 9 when the output is on and there is less than 65 load volts. Electrical specifications:
Open collector transistor maximum values 27 volts DC peak @ 75mA. (See Section 4-16 for typical application).
5
Output
Scaled Actual Welding Voltage = +1 volt DC per 10 volts of output w/reference to pin 11.
6
Output
Scaled Actual Welding Amperage = +1 volt DC per 100 amperes of output w/reference to pin 11.
7
Output
+15 volts DC = with respect to pin 11 (Pin A of 14 pin)
8
Output
Reference PIN= This pin is the signal reference for pins 1,2,3,10,15,16
9
Output
Valid Arc Indication Reference = Paired with Pin 4. Connect to user’s external voltage supply common. (See Section
4-16 for typical application).
10
Input
11
Output
Amperage Control Reference = for pins 5,6,7,17 and 18. (Pin D of 14 pin)
12
Output
Welders Chassis = Earth ground. Connected only if common potentials are needed between user equipment and the
welder.
13
Output
Arc Length Control Lockout = Paired with Pin 14. Used to send signal to an automatic voltage control to ignore the
voltage during certain situations. Pin is closed to pin 14 when the weld cycle is in Initial Amperage, Initial Slope, Final
Slope, Final Amperage, and Pulsed Background time. Electrical specifications: Open collector transistor maximum values 27volts DC peak @ 75mA. (See Section 4-16 for typical application)
Pin Information For 28-Pin Receptacle RC28
Memory Select = Used to select between memory numbers. Used in conjunction with pins 15 and 16. (See Sections
4-14 and 5-14. )
Continued on next page
OM-216 869 Page 36
Continued from previous page Section B.
14
Output
Arc Length Control Lockout Reference = Paired with Pin 13. Connect to user’s external voltage supply common
(See Section 4-16 for typical application).
15
Input
Memory Select = Used to select between memory numbers. Used in conjunction with pin 10 and 16.(See Sections
4-15 and 5-14.)
16
Input
Memory Select = Used to select between memory numbers. Used in conjunction with pin 10 and 15.(See Sections 4-15
and 5-14.)
17
Input
Amperage Control = 0 to +10 volts DC with respect to pin 11. The 10 volts represents the amperage value set on machines meter. (Pin E of 14 pin)
18
Output
19
Input
High Frequency Arc Start Disable = Disables the arc starter from being activated when connected to pin 8.
20
Input
Welder Control Select = Connect to pin 8 to activate this mode.
23
Output
Final Slope Sequence Indication = Paired with Pin 24. Pin is closed to pin 24 when in Final Slope. Electrical specifications: Open collector transistor maximum values 27 volts DC peak @ 75mA. (See Section 4-16 for typical application).
24
Output
Final Slope Sequence Indication Reference = Paired with pin 23. Connect to user’s external voltage supply common.
(See Section 4-16 for typical application).
+10 volts DC = with respect to pin 11 for use with an external potentiometer to vary the signal into pin 17 (Pin C of 14
pin)
All other pins not used.
C. User Controlled Automation Mode (Pin 25 Connected To Pin 8) Automation 2
This mode includes all the basic functions of the automation board, plus gives the welder the option to control the pulse
or AC waveforms, or to minimize the noise that can be injected into the welder from the control and cables. These
functions include Start/Stop, Valid Arc Indication, Gas Control, High Frequency Arc Start Disable, and Emergency
weld stop.
2
3
7
8
14
20
1
6
5
4
13
12
11
10
9
19
18
17
16
15
25
28
24 23
27
22
21
26
803 900-A / 218 716-A
Pin
Signal
Direction
1
Input
Start/Stop = Maintained connection to pin 8 starts the weld cycle. Opening connection stops weld cycle. For momentary
closure operation, set unit to 2T. A momentary closure greater than 100 ms, but less than 3/4 of a second starts and
stops weld output.
2
Input
Emergency Weld Stop = Used to remotely stop the weld outside the normal welding cycle (i.e. light curtains or external E-Stop). Connection to pin 8 must be maintained at all times. If the connection is broken, output stops, Postflow begins, and AUTO STOP will be displayed on the meters.
3
Input
Gas Control = This input is used to control the gas flow outside the settings of the preflow and/or postflow set on the
machine. Connection to pin 8 turns on gas.
4
Output
Valid Arc Indication = Paired with Pin 9. This output is used to signal external fixtures that the machine has detected a
valid arc. Pin is closed to pin 9 when the output is on and there is less than 65 load volts. Electrical specifications:
Open collector transistor maximum values 27 volts DC peak @ 75mA. (See Section 4-16 for typical application).
5
Output
Scaled Actual Welding Voltage = +1 volt DC per 10 volts of output w/reference to pin 11.
6
Output
Scaled Actual Welding Amperage = +1 volt DC per 100 amperes of output w/reference to pin 11.
7
Output
+15 volts DC = with respect to pin 11 (Pin A of 14 pin)
8
Output
Reference PIN = This pin is the signal reference for pins 1,2,3,10,15,16
9
Output
Valid Arc Indication Reference = Paired with Pin 4. Connect to user’s external voltage supply common. (See Section
4-16 for typical application).
Pin Information For 28-Pin Receptacle RC28
Continued on next page
OM-216 869 Page 37
Continued from previous page Section C.
11
Output
Control Reference for pins 5 and 6.
12
Output
Welders Chassis = Earth ground. Connected only if common potentials are needed between user equipment and the
welder.
19
Input
High Frequency Arc Start Disable = Disables the arc starter from being activated when connected to pin 8.
21
Input
Isolated EN Amperage Common = Paired with Pin 22.
22
Input
Isolated EN Amperage Command = Paired with pin 21. Sets output amperage value for a Maxstar and the EN (penetration) amperage value for a Dynasty. Value should be between .3 to 10V corresponding to the minimum to maximum of
the machine.
25
Input
User Controlled Automation Select = Connect to pin 8 to active this mode.
26
Input
Isolated EP Amperage Command (Dynasty models only) = Paired with Pin 27. Sets EP(cleaning) output amperage
value. Value should be between .3 to 10 volts corresponding to the minimum to maximum of the machine.
27
Input
Isolated EP Amperage Common (Dynasty models only) = Paired with Pin 26.
28
Input
AC waveform Generation (Dynasty models only) - User controlled polarity(EN or EP), frequency (20-400 HZ) and
balance of an AC waveform. When this pin is not connected to pin 8 the weld output is EN. When this pin is connected to
pin 8 the weld output is EP. Alternating between connection and disconnection at different intervals creates the frequency and balance of the waveform.
All other pins not used.
4-15. Remote Memory Select Inputs (For 28-Pin Receptacle If Present)
28-Pin Receptacle RC28
Socket Designations 0 = No Connection / 1 = Connected To Ground (Pin 8)
3
Function
8
4
9
14
15
20
25
21
28
OM-216 869 Page 38
10
16
15
Off
0
0
0
Memory 1
0
0
1
Memory 2
0
1
0
Memory 3
0
1
1
Memory 4
1
0
0
Memory 5
1
0
1
Memory 6
1
1
0
Memory 7
1
1
1
1
26
4-16. Typical Automation Application For Valid Arc Length Control Lockout And Final
Slope Indication
CR1
Coil resistance plus R
should be chosen to
limit current to 75 mA
R
CR1
+
−
Typical 28-Pin Output
To User Equipment
User supplied power
up to 27 volts DC peak
Collector
Pins 4, 13, 23
Pins 9, 14, 24
Emitter
4-17.
115 Volts AC Duplex Receptacle, Supplementary Protector CB1, And Power
Switch
1
AC Duplex Receptacle
Receptacle RC2 supplies 115 V 10
A of single-phase power.
2
3
Supplementary Protector CB1
CB1 protects duplex receptacle
from overload. If circuit breaker
opens, the receptacle does not
work. Press button to reset
protector.
1
3
Power On/Off Switch
2
803 901-A
OM-216 869 Page 39
4-18.
Gas Connections
1
Gas Fitting
Fittings have 5/8-18 right-hand
threads.
2
Cylinder Valve
Open valve slightly so gas flow
blows dirt from valve. Close valve.
1
4
3
2
3
4
Regulator/Flowmeter
Flow Adjust
Typical flow rate is 15 cfh (cubic feet
per hour).
Connect customer supplied gas
hose between regulator/flowmeter
and gas fitting on rear of unit.
Tools Needed:
11/16, 1-1/8 in.
803 901-A
4-19.
TIG HF Impulse/ Lift-Arc Connections
!
Turn off power before making connections.
1
Electrode Weld Output
Terminal
Connect TIG torch to electrode
weld output terminal.
5
2
Gas Out Connection
Connect torch gas hose to gas out
fitting.
3
Work Weld Output Terminal
Connect work lead to work weld
output terminal.
4
4
1
Remote 14 Receptacle
If desired, connect remote control
to Remote 14 receptacle (see Section 4-13).
5
Gas In Connection
Connect gas hose from gas supply
to gas in fitting (see Section 4-18).
2
3
Tools Needed:
11/16 in. (21 mm for CE units)
803 915-B
OM-216 869 Page 40
4-20.
Cooler Connections
Cart and cooler are optional equipment.
1
2
1
AC Duplex Receptacle
115 VAC Cord
Provides 115 vac to power cooler.
2
3
Electrode Weld Output
Terminal (−Weld Output
Terminal On Maxstar Models)
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-in (blue) hose
to welding power source water-out
connection.
7
Water-In (From Torch)
Connection
Connect torch water-out (red) hose
to welding power source water-in
connection.
4
3
5
7
804 753-B
6
Tools Needed:
GTAW Or Where
HF* Is Used
Application
3-1/2
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-216 869 Page 41
4-21.
Dynasty Stick Connections
!
Turn off power before making
connections.
. Connections shown are for
Dynas-
ty models.
1
Work Weld Output Terminal
Connect work lead to work weld output
terminal.
3
2
2
Electrode Weld Output Terminal
Connect electrode holder to electrode
weld output terminal.
3
Remote 14 Receptacle
If desired, connect remote control to Remote 14 receptacle (see Section 4-13).
1
803 916-C
4-22.
Maxstar Stick Connections
!
Turn off power before making
connections.
. Connections shown are for
Max-
star models.
1
+ Weld Output Terminal
Connect electrode lead to positive (+)
weld output terminal.
2
− Weld Output Terminal
Connect work lead to negative (−) weld
output terminal.
3
2
3
Remote 14 Receptacle
If desired, connect remote control to Remote 14 receptacle (see Section 4-13).
1
803 916-C
OM-216 869 Page 42
SECTION 5 − OPERATION
5-1.
Controls
2
3
1
13
11
12
4
5
8
7
6
9
10
. Polarity
And AC Waveshape Controls
Are Available On Dynasty Models Only.
226 868-B / Ref. 803 901-A
14
Rear Panel
. For all front panel switch pad controls:
press switch pad to turn on light and enable normal function.
. Green on nameplate
indicates a TIG
function, Gray indicates a normal Stick
function.
1
2
Encoder Control
Ammeter And Parameter Display
See Section 5-4.
3
Voltmeter And Selected Parameter
Display
See Section 5-5.
4 Polarity Control (Dynasty Only)
See Section 5-6.
5 Process Controls
See Section 5-7.
6 Output Controls
See Section 5-9.
7 Pulser Controls
See Section 5-10.
8 Sequencer Controls
See Section 5-11.
9 Gas/DIG Controls
See Section 5-12.
10 AC Waveshape (Dynasty Only)
See Section 5-13.
11 Amperage And Spot Time Control
For Amperage Control see Section 5-3.
For Spot Time Control see Section 6-7.
12 Memory
See Section 5-14.
13 Memory Display
Displays active memory.
14 Power Switch
Use switch to turn unit On/Off.
OM-216 869 Page 43
5-2.
Encoder Control
1
1
5-3.
Encoder Control
Use control in conjunction with applicable front panel function switch
pad to set values for that function.
Amperage Control
1
2
3
3
A (Amperage Control)
Encoder Control
Ammeter
2 See Section 5-15 for Amperage
control range.
1
Press Amperage switch pad, and
turn Encoder control to set weld
amperage, or peak amperage
when Pulser function is active (see
Section 5-10).
. See Section 5-13 for AC functions.
5-4.
Ammeter And Parameter Display
1
1
OM-216 869 Page 44
Ammeter
Ammeter displays actual amperage while welding. It also displays
adjustable parameters for all functions
5-5.
Voltmeter And Selected Parameter Display
1
1
5-6.
Volt Meter
Displays output or open circuit voltage. Also displays word abbreviations for selected parameters.
Polarity Control (Dynasty Models Only)
1
Polarity Control
Press switch pad until desired LED
is illuminated.
DC - Select DC for DC welding. Machines electrode output is DCEN
for TIG, and DCEP for Stick.
AC - Select AC for AC welding.
1
Notes
OM-216 869 Page 45
5-7.
Process Control
1
Process Control
Press switch pad until desired process LED is illuminated:
TIG HF Impulse - is a pulsed HF
(see Section 5-8) arc starting method that can be used with either AC
or DC TIG welding. Make connections according to Section 4-19.
TIG Lift-Arct - is an arc starting
method in which the electrode must
come in contact with the workpiece
(see Section 5-8). This method can
be used with either AC or DC TIG
welding. Make connections according to Section 4-19.
1
Stick (SMAW) - This method can
be used with either AC or DC Stick
welding. Make connections according to Section 4-21.
5-8. Lift-Arc And HF TIG Start Procedures
Lift-Arc Start
When Lift-Arct button light is On,
start arc as follows:
Lift-Arc Start Method
1
“Touch”
1−2
Seconds
2
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.
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 a properly prepared electrode (see Section 11-2) to
touch workpiece without overheating,
sticking, or getting contaminated.
Application:
Do NOT Strike Like A Match!
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:
High frequency turns on to 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,
or the AC GTAW process when a
non-contact arc starting method is
required.
OM-216 869 Page 46
5-9.
Output Control
2
1
1
Output Control
Press switch pad until desired parameter
LED is illuminated.
RMT STD (Remote Standard)
Application: Use Remote Trigger (Standard) with a foot pedal or finger amperage
control (see Section 6-4A).
. When a foot or finger remote current
control is connected, initial amps, initial slope, final slope, and final amps
are controlled by the remote control.
NOTE: If an On/Off type trigger is used, it
must be a maintained switch. All Sequencer functions become active, and must be
set by the operator.
RMT 2T HOLD
Application: Use Remote Trigger Hold
(2T) for long extended welds.
If a foot or finger current control is connected to the welding power source, only
trigger input is functional (see Section
6-4B).
. This switch function can be reconfigured for 3T, 4T, 4T Momentary, or
Mini Logic control See Sections 6-4C,
D, E, or F)
ON
Output will energize two seconds after being selected.
Application: Use Output On for Stick
(SMAW) welding, or for Lift-Arc without the
use of a remote control (see Section
6-4G).
2
On LED
Blue On LED is lit whenever Output is on.
Notes
OM-216 869 Page 47
5-10.
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 5-15 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 5-3).
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-216 869 Page 48
5-11.
Sequencer Controls
1
4
Sequencer Control
Sequencing is available while using
the TIG process, but is disabled if a
remote foot or finger current control
is connected to the Remote receptacle while in the RMT STD mode.
3
2
Press switch pad until desired parameter LED is illuminated.
2
Encoder Control (Set Value)
Turn control to set values for the sequencer parameters.
5
3
Ammeter (Displays Value)
See Section 5-15 for all Sequencer
parameter ranges.
4
Voltmeter
Displays word abbreviations of selected parameters.
INITIAL A (Initial Amperage) [INTL]
- Use control to select a starting amperage that is different from the
weld amperage.
1
Application:
Initial Amperage can be used to assist in preheating cold material prior
to depositing filler material, or to ensure a soft start.
INITIAL t (Initial Time) [INTL]
(Available with Automation option Only) - Press control again
and turn Encoder to set amount of
time needed at the beginning of the
weld.
INITIAL SLOPE t (Initial Slope
Time) [ISLP] Use control to set
amount of time that it takes to slope
from initial amperage to weld
amperage. To disable, set to 0.
5
Amperage Switch Pad
Weld Time (Available with Automation option Only) - Press
Amperage switch pad twice. Set
desired weld time.
Spot Time - Press amperage
switch twice. Set desired spot time.
FINAL SLOPE t (Final Slope Time)
[FSLP] - Use control to set amount
of time it takes to slope from weld
amperage to final amperage. To
disable, set to 0.
Application:
Final Slope should be used while
welding materials that are crack
sensitive, and/or to eliminate the
crater at the end of the weld.
FINAL A (Final Amperage) [FNL] Used to set amperage to which
weld amperage slopes to.
FINAL t (Final Time) [FNL] (Available with Automation option
Only) - Press control again and turn
Encoder to set Final Amperage
time.
OM-216 869 Page 49
5-12.
Gas/DIG Controls (Preflow/Post Flow/DIG/Purge)
1
4
Gas/DIG Controls
Press switch pad until desired function
LED is illuminated.
3
2
3
Encoder Control (Set Value)
Ammeter (Displays Value)
See Section 5-15 for all Adjust parameter
ranges.
4
2
Voltmeter
Displays word abbreviations of selected
parameters.
PREFLOW [PRE] - If the TIG HF process
is active (see Section 5-7) and Preflow is
shown on the control panel, use control to
set length of time gas flows before arc initiation.
Application: Preflow is used to purge
the weld area and aids in arc starts.
POST FLOW [POST] - If the TIG process
is active (see Section 5-7), use control to
set length of time gas flows after welding
stops.
1
AUTO POST FLOW - Creates a post
flow time scaled at 1 second per 10 amps
of the peak weld amperage for a given
weld cycle. Auto post flow is limited to a
8 second minimum, or to the maximum
preset post flow time.
Application:
Postflow is required to cool tungsten and
weld, and to prevent contamination of
tungsten and weld. Increase postflow
time if tungsten or weld are dark in appearance.
DIG - If Stick process is active (see Section 5-7), use control to set amount of
DIG. When set at 0, short-circuit amperage at low arc voltage is the same as normal welding amperage.
When setting is increased, short-circuit
amperage at low arc voltage increases.
Application:
Control helps arc starting or making vertical or overhead welds by increasing amperage at low arc voltage, and reduces
electrode sticking while welding.
PURGE [PURG] - To activate the gas
valve and start the purge function, push
and hold the Gas/DIG switch pad for the
desired amount of time. To set from 1 to
50 seconds of purge time, hold the Gas/
DIG switch pad while turning the encoder
control. Default is 0.
While Purge is active, [PURG] is shown
in the left display, and purge time is
shown in the right display.
Pressing any switch pad will end the
purge display, but gas will continue to flow
until the preset time has timed out.
Application: Purge is used to clear the
gas lines.
OM-216 869 Page 50
5-13.
AC Waveshape (Dynasty Models Only)
1
4
AC Waveshape Control
Press switch pad until desired function LED is
illuminated.
3
2
3
Encoder Control (Set Value)
Ammeter (Displays Value)
See Section 5-15 for all AC Waveshape parameter ranges.
EN Amperage [EN] - Use with AC TIG only to
select electrode negative amperage value.
2
EP Amperage [EP] - Use with AC TIG only to
select electrode positive amperage value.
5
Note: See Section 6-1 to set same Amplitude
control [ENEP].
EN Amperage and EP Amperage allow the operator the ability to control the amount of amperage in the negative and positive half cycles
independently. A 1.5 to 1 ratio of EN to EP is a
good starting point. This provides cleaning action, but directs more energy into the workpiece
and provides faster travel speeds and deeper
penetration.
4
1
f
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 300, EP Amperage is 150, Balance is 60%, and Frequency is
120, the average amperage is 240 amps. If you
press the Amperage switch pad and turn the
Encoder control until 480 amps is displayed,
the EN amperage is now 600 and EP amperage is now 300. The balance remains 60%, and
the frequency is still 120, and the 2 to 1 EN amperage to EP amperage is maintained.
Balance [BAL] - AC Balance control is enabled
only in AC TIG to set percentage of time polarity
is electrode negative. Set control at about 75%,
and fine tune from there.
5
Voltmeter
Displays word abbreviations of selected parameters.
Application:
When welding on oxide forming materials such
as aluminum or magnesium, excess cleaning
is not necessary. To produce a good weld, only
0.10 in (2.5mm) of etched zone along the weld
toes is required.
Use AC Balance to control the etch zone width.
Joint configuration, set-up, process variables,
and oxide thickness may affect setting.
AC Frequency [FREQ] - Use control to set AC
frequency (cycles per second).
Application:
AC Frequency controls arc width and directional control. As AC frequency decreases, the arc
becomes wider and less focused, limiting directional control. As AC frequency increases,
the arc becomes narrower and more focused,
increasing directional control. Travel speed
can increase as AC frequency increases.
OM-216 869 Page 51
5-14.
Memory (Program Storage Locations 1-9)
1
2
3
Memory (Program Storage
1-9) Switch Pad
Polarity Switch Pad (Dynasty
Only)
Process Switch Pad
To create, change, or recall a
welding parameters program,
proceed as follows:
1
First, press Memory switch pad until
the desired program storage location (1-9) is displayed.
Second, press Polarity switch pad
until the desired polarity, AC or DC,
LED is illuminated
1st
Third, press Process switch pad until desired process, TIG HF Impulse,
TIG Lift Arc, or Stick, LED is illuminated.
2
The program at the chosen location,
for the desired polarity and process,
is now the active program.
2nd
Fourth, change or set all desired parameters (see Section 5-15 for
parameters).
3rd
3
. Polarity And AC Waveshape Controls Are Available On Dynasty Models Only.
TIG (HF or Lift)
AC
And
Stick
Memory Locations
1−9
And
TIG (HF or Lift)
DC
And
Stick
For Dynasty Models, each memory location (1 thru 9) can store parameters
for both polarities (AC and DC), and each polarity can store parameters for
both process (TIG and Stick) for a total of 36 programs.
Memory Locations
TIG (HF or Lift)
1−9
DC
And
Stick
For Maxstar Models, each memory location (1 thru 9) can store parameters
for both process (TIG and Stick) for a total of 18 programs.
OM-216 869 Page 52
5-15.
Factory Parameter Defaults And Range And Resolution For 350 Models
Parameter
(DYNASTY ONLY)
Default
Range And Resolution
MEMORY
1
1−9
POLARITY
AC
AC / DC
PROCESS
TIG HF Impulse
TIG HF Impulse / TIG Lift / Stick
OUTPUT
RMT STD
RMT STD / RMT 2T / ON
**RMT 2T
2T
RMT 2T can be reconfigured for: 2T / 3T / 4T / Mini Logic
/ 4T Momentary (see Section 6-4)
3 − 350 Amps
A MAIN / PEAK
(DYNASTY ONLY)
AC TIG
150 A
(DYNASTY ONLY)
AC STICK
110 A
3− 350 Amps
DC TIG
150 A
3 − 350 Amps
DC STICK
110 A
3 − 350 Amps
*Spot
OFF
ON/OFF
*Spot Time
0T
0 − 999 Seconds
**Weld Time
0T
0 − 999 Seconds
PULSER
Off
ON / OFF
PPS
100 Hz
DC: 0.1 - 5000 PPS
AC: 0.1 − 500 PPS
PEAK t
40%
5 − 95 Percent
BKGND A
25%
5 − 95 Percent
INITIAL A
20 A
3 − 350 Amps
SEQUENCER
**Initial Time
0 T
0.0 − 25.0 Seconds
INITIAL SLOPE t
0T
0.0 − 50.0 Seconds
FINAL SLOPE t
0T
0.0 − 50.0 Seconds
FINAL A
5A
3 − 350 Amps
**Final Time
0T
0.0 − 25.0 Seconds
ADJUST
(DYNASTY ONLY)
PREFLOW
0.2 T
0.0 − 25.0 Seconds
POST FLOW
Auto
Auto 1 − 50 Seconds
DIG
30%
0 − 100 Percent
*Waveform
Soft Square
Soft Square, Advanced Square, Sine, Triangle
EN Amps
150A
3 - 350 Amps
EP Amps
150A
3 - 350 Amps
BALANCE
75%
30 − 99 Percent
AC WAVESHAPE
FREQUENCY
120 Hz
20 − 400 Hertz
EN/EP
Independent
Same/Independent
OM-216 869 Page 53
Factory Parameter Defaults And Range And Resolution For 350 Models (Continued)
*TIG Start parameters for each program (1-9)
DC:
*Tungsten
.094
***Polarity (DYNASTY ONLY)
EN
EP / EN
60 A
3 − 200 Amps
***Time
1 ms
1 − 200 Milliseconds
***Start Slope Time
40 ms
0 − 250 Milliseconds
5A
3 − 25 Amps
*Tungsten
.094
GEN, .020, .040, .062, .094, .125, .156, .187
***Polarity
EP
EP / EN
***Amperage
130 A
3 − 200 Amps
***Time
20 ms
1 − 200 Milliseconds
***Start Slope Time
20 ms
0 − 250 Milliseconds
5A
3 − 25 Amps
***Amperage
***Preset Amperage Minimum
GEN, .020, .040, .062, .094, .125, .156, .187
AC: (DYNASTY ONLY)
***Preset Amperage Minimum
*TIG Start parameters for Advanced Automation
DC:
**OFF
OFF
ON
**Amperage
50 A
3 − 200 Amps
30 ms
10 − 200 Milliseconds
OFF
ON
**Time
AC: (DYNASTY ONLY)
**OFF/ON
**Amperage
**Time
30 A
3 − 200 Amps
30 ms
10 − 200 Milliseconds
* Parameter adjusted using an Advanced Function configuration only (See Section 6).
** Parameter used with the automation option only.
*** Parameter adjust in GEN setting only (see Section 6-2).
5-16.
Factory Parameter Defaults And Range And Resolution For 700 Models
(DYNASTY ONLY)
Parameter
Default
Range And Resolution
MEMORY
1
1−9
POLARITY
AC
AC / DC
PROCESS
TIG HF Impulse
TIG HF Impulse / TIG Lift / Stick
OUTPUT
RMT STD
RMT STD / RMT 2T / ON
**RMT 2T
2T
RMT 2T can be reconfigured for: 2T / 3T / 4T / Mini Logic
/ 4T Momentary / Spot (see Section 6-4)
500 A
5 − 700 Amps
A MAIN / PEAK
(DYNASTY ONLY)
AC TIG
(DYNASTY ONLY)
AC STICK
110 A
5 − 700 Amps
DC TIG
500 A
5 − 700 Amps
DC STICK
110 A
5 − 700 Amps
*Spot
Off
On/Off
Spot Time
0T
0.0 − 999 Seconds
**Weld Time
0T
0.0 − 999 Seconds
PULSER
Off
ON / OFF
PPS
100 Hz
DC: 0.1 − 5000 PPS
AC: 0.1 − 500 PPS
OM-216 869 Page 54
PEAK t
40%
5 − 95 Percent
BKGND A
25%
5 − 95 Percent
Factory Parameter Defaults And Range And Resolution For 700 Models (Continued)
SEQUENCER
INITIAL A
20 A
5 − 700 Amps
**Initial Time
0 T
0.0 − 25.0 Seconds
INITIAL SLOPE t
0T
0.0 − 50.0 Seconds
FINAL SLOPE t
0T
0.0 − 50.0 Seconds
FINAL A
5A
5 − 700 Amps
**Final Time
0T
0.0 − 25.0 Seconds
ADJUST
PREFLOW
0.2 T
0.0 − 25.0 Seconds
POST FLOW
Auto
Auto 1 − 50.0 Seconds @ 1 Second Resolution
DIG
30%
0 − 100 Percent
*Waveform
Soft Square
Soft Square, Advanced Square, Sine, Triangle
EN Amps
500A
5 - 700 Amps
EP Amps
500A
5 - 700 Amps
BALANCE
75%
30 − 99 Percent
(DYNASTY ONLY) AC WAVESHAPE
FREQUENCY
120 Hz
20 − 400 Hertz
*EN/EP
Independent
Same/Independent
*Tungsten
.094
GEN, .040, .062, .094, .125, .156, .187, .250
***Polarity (DYNASTY ONLY)
EN
EP / EN
*TIG Start parameters for each program (1-9)
DC:
***Amperage
60 A
5 − 200 Amps
***Time
1 ms
1 − 200 Milliseconds
**Start Slope Time
40 ms
0 − 250 Milliseconds
5A
5 − 25 Amps
.094
GEN, .040, .062, .094, .125, .156, .187, .250
***Preset Amperage Minimum
AC: (DYNASTY ONLY)
*Tungsten
***Polarity
EP
EP / EN
***Amperage
130 A
5 − 200 Amps
***Time
20 ms
1 − 200 Milliseconds
***Start Slope Time
20 ms
0 − 250 Milliseconds
***Preset Amperage Minimum
5 ms
5 − 25 Amps
*TIG Start parameters for Advanced Automation
DC:
**OFF
OFF
ON
**Amperage
50 A
5 − 200 Amps
30 ms
10 − 200 Milliseconds
**Time
AC: (DYNASTY ONLY)
**OFF/ON
OFF
ON
**Amperage
30 A
5 − 200 Amps
30 ms
10 − 200 Milliseconds
Time
* Parameter adjusted using an Advanced Function configuration only (See Section 6).
** Parameter used with the automation option only
*** Parameter adjust in GEN setting only (see Section 6-2).
OM-216 869 Page 55
5-17.
Resetting Unit To Factory Default Settings
1
2
3
4
Process Switch Pad
Output Switch Pad
Gas/DIG Switch Pad
Power Switch
To reset the active memory, polarity,
and process to original factory settings, lockout feature must be off
(see Section 6-10). Turn power on
and then press and hold the Process, Output, and Gas/DIG switch
pads before the machine name
clears the meters.
4
1
2
3
V
Rear Panel
5-18.
Software And Revision Viewing
1
2
Power Switch
Process Switch Pad
To access software numbers, turn
power on and then press and hold
Process switch pad until machine
name clears. First [SOFT][NUM]
will appear for two seconds followed by the software number for
five seconds.
1
V
2
OM-216 869 Page 56
Rear Panel
5-19.
Arc Timer/Counter Display
3/4
1234 Hour
1
f
1
2
And
V
Rear Panel
1 Output And Amperage Controls
2 Power Switch
To display the arc timer/counter, turn power
switch on, press and hold the Amperage
Control and Output switch pads until the
machine name clears the meters.
3
Arc Timer Display
The arc time will be displayed for 5 seconds
as [0-9999][Hours] then [0-59][Mins].
4 Arc Counter
After 5 seconds, the arc count will be displayed for the next 5 seconds as
[0cy] to [9999][99cy].
OM-216 869 Page 57
SECTION 6 − ADVANCED FUNCTIONS
6-1.
Accessing Advanced Functions
3
1
f
2
1 Amperage Switch Pad
2 Gas/Dig
3 Encoder Control
To access the advanced functions, press
and hold the Amperage (A) switch pad and
then press the Gas/Dig switch pad. To
scroll through the advanced functions,
press and release the Gas/Dig switch pad.
Use the Encoder control to change parameters for each function.
Advanced Functions:
or Mini Logic
 AC Waveshape Selection with Dynasty
models only (see Section 6-5) − Allows
you to set a soft, sine, triangle, or advanced AC waveshape for each memory
location if desired.
 Independent Amplitude Selection with
Dynasty models only (see Section 6-6) −
Allows you to set the amplitude of the AC
waveshape equal for both the positive
and negative half of the weld cycle, or
have independent settings.
 Programmable TIG Start Parameters
(see Section 6-2 or 6-3) − Allows you to
set tungsten size, amps, time, polarity,
and preset amperage minimum to customize arc starts for different tungstens.
 Spot Enable (see Section 6-7) − Allows
you to turn the spot function on and be
available for all programs.
 Output Remote Hold And Trigger Functions (see Section 6-4) − For reconfiguring RMT 2T Hold for 3T, 4T Momentary,
 Stick OCV Selection (see Section 6-8) −
Allows you to select either low or normal
OCV (open circuit voltage).
OM-216 869 Page 58
 Stick Stuck Check Selection (See Section 6-9) − With Stick Stuck Check on and
the welding electrode (rod) stuck, output
is turned off in an attempt to save the rod
for reuse.
 Lockout Functions (see Section 6-10) −
Allows you to turn the lockout function on
and off and adjust the lockout levels.
 Meter Displays (see Section 6-11) − Allows you to set meters to display weld
voltage and amperage, or blank meters
while pulse welding. Also allows you to
select amperage preset of peak or average amperage for DC TIG pulse.
 DC Meter Calibration (See Section 6-12)
− Allows voltage/amperage calibration of
DC meter.
To exit advanced functions, press and hold
the Amperage (A) switch pad and then
press the Gas/Dig switch pad.
6-2.
Programmable TIG Start Parameters
. Each memory and polarity selection has their own programmable parameters.
A.
Tungsten Selection
3
2
TUNG .094
1
Current (A)
Start Amperage
Preset Amperage Minimum
Start Time
Start Slope
Time
1
Amperage Switch Pad
2
Encoder Control
3
Amps Meter
Preset TIG Start Parameters
Use Encoder control to select a tungsten
size from the following: .020, .040, .062
(1/16 in.), .094 (3/32 in.), or .125 (1/8 in.),
.156 (5/32 in.), .187 (3/16 in.), [.250 (1/4 in.)
700 Models only], (.094 is the default).
When one of the listed tungsten sizes is selected, the following TIG starting parameters are preset: Amperage, Start Time, Start
Slope Time, and Preset Amperage Minimum. There are a separate set of parameters
for AC and DC (to select polarity see Section C).
If it is necessary or desired to manually set
the TIG starting parameters, turn the encoder until GEN is displayed on the amps
meter and Amperage (A) switch pad LED
turns on (see Section B).
OM-216 869 Page 59
B.
Selecting GEN
1
2
3
2
1
TUNG GEN
3
If [GEn] is selected and displayed on
the amps meter, the TIG starting
parameters for a .094 tungsten are
the default, and for AC polarity they
are: Start Polarity = EP, Start Amperage = 120 A, Start Time = 20 ms,
Start Slope Time = 10 ms, Preset
Minimum Amps = 5 A. For DC polarity they are: Start Polarity = EN,
Start Amperage = 60 A, Start Time
= 1 ms, Start Slope Time = 40 ms,
Preset Minimum Amps = 5 A.
These parameters can be manually
changed by pressing the Amperage switch pad to step through
each adjustable parameter. To
change parameters, see Sections
C, D, E, F, and G.
GEN Default AC TIG Start Parameter Relationships
Current (A)
Start Amperage
120 Amps
Preset Amperage Minimum
5 Amps
Start Time 20 ms
Start Slope Time
10 ms
GEN Default DC TIG Start Parameter Relationships
Current (A)
Start Amperage
60 Amps
Preset Amperage Minimum
5 Amps
Start Time 1 ms
Start Slope Time
40 ms
OM-216 869 Page 60
Encoder Control
Amps Meter
Amperage Switch Pad
C.
Changing Programmable TIG Start Polarity (Dynasty Models Only)
3
2
POL
En
1
Current (A)
Start
Polarity
1
2
3
Amperage Switch Pad
Encoder Control
Amps Meter
lows:
To adjust TIG Start Polarity proceed as fol-
D.
Press Amperage switch pad until the current Start Polarity, (SEL] [E−] or [SEL] [EP]
is displayed on meters, and can be ad-
justed (see Section 5-15) by turning the Encoder control.
To change Start Amperage, proceed to
Section D.
Changing Programmable TIG Start Amperage
3
2
STRT
20A
1
Current (A)
Start
Amperage
1
Amperage Switch Pad
2
Encoder Control
3
Amps Meter
To adjust TIG Start Amperage proceed as
follows:
amps meter, and can be adjusted (see Section 5-15) by turning the Encoder control.
Press Amperage switch pad until the current Start Amperage is displayed on the
To change Start Time, proceed to Section
E.
OM-216 869 Page 61
E. Changing Programmable Start Time
3
TIME
2
10m
1
Current (A)
Start Time
1
2
3
To
F.
Amperage Switch Pad
Encoder Control
Amps Meter
adjust Programmable Start Time pro-
ceed as follows:
Press Amperage switch pad until the current Start Time is displayed in milliseconds
on the amps meter, and can be adjusted by
turning the Encoder control (see Section
5-15).
To change Start Slope Time, proceed to
Section F.
Changing Start Slope Time
3
2
20m
SSLP
1
Current (A)
Start Slope Time
1
2
3
Amperage Switch Pad
Encoder Control
Amps Meter
To adjust Start Slope Time proceed as fol-
OM-216 869 Page 62
lows:
Press Amperage switch pad until the Start
Slope Time is displayed in milliseconds on
the amps meter, and can be adjusted (see
Section 5-15) by turning the Encoder control.
To change Preset Amperage Minimum,
proceed to Section G.
G.
Changing Preset Amperage Minimum
3
2
PMIN
5A
1
Current (A)
Preset Amperage Minimum
1
2
3
Amperage Switch Pad
Encoder Control
Amps Meter
To adjust Preset Amperage Minimum proceed as follows:
Press Amperage switch pad until the Preset Minimum Amperage is displayed on the
amps meter, and can be adjusted (see Section 5-15) by turning the Encoder control.
The preset amperage minimum can be independently set for AC and DC.
. Whatever amperage is selected as the
preset amperage minimum, is the minimum amperage that the machine will
provide in either AC or DC.
Notes
OM-216 869 Page 63
6-3.
A.
Programmable TIG Start Parameters For Models With Advanced Automation
Capabilities
OFF/ON (Start Amperage And Time) For Models W/Advanced Automation Capabilities
3
2
OFF
STAT
1
Current (A)
Start Amperage
Start Time
When pin 25 of the 28-pin automation connection receptacle (see Section 4-14) is selected, Advanced Automation TIG Start
Amperage and Start Time may be turned
on.
Off is the default setting. Use Encoder control to select On. When On is selected, the
Amperage switch pad LED turns on.
Dynasty models have a separate set of
parameters for AC and DC.
The AC and DC parameters are selected
remotely through pin 28 of the 28-pin auto-
OM-216 869 Page 64
mation receptacle where EP (electrode
positive = AC, and EN (electrode negative)
= DC
1
Amperage Switch Pad
2
Encoder Control
3
Amps Meter
Preset Advanced Automation TIG Start
Parameters
Default values for Advanced Automation
TIG Start Amperage and Start Time are as
follows: AC Start Amperage = 50A, AC
Start Time = 30ms. DC Start Amperage =
30A and DC Start Time = 30ms.
If it is necessary or desired to change the
Advanced Automation TIG Start Amperage
and Start Time values from the default values, press the amperage switch pad to step
through each adjustable parameter (see
Sections B and C).
B. Changing Programmable TIG Start Amperage For Models With Advanced Automation Capabilities
3
2
STRT
20A
1
Current (A)
Start
Amperage
1
2
3
Amperage Switch Pad
Encoder Control
Amps Meter
To adjust TIG Start Amperage proceed as
follows:
Press Amperage switch pad until the current start amperage is displayed. The current Start Amperage is displayed on the
amps meter, and can be adjusted (see Section 5-15) by turning the Encoder control.
To change Start Time, proceed to Section
C.
C. Changing Programmable Start Time For Models With Advanced Automation Capabilities
3
TIME
2
10m
1
Current (A)
Start
Time
1
Amperage Switch Pad
2
Encoder Control
3
Amps Meter
To adjust Programmable Start Time proceed as follows:
Press Amperage switch pad until the current start time is displayed. The current
Start Time is displayed in milliseconds on
the amps meter, and can be adjusted by
turning the Encoder control (see Section
5-15).
OM-216 869 Page 65
6-4.
Output Control And Trigger Functions
A. Remote (Standard) Torch Trigger Operation
Current (A)
Main Amps
Initial Slope
Final Slope
Initial Amps
Final Amps
Postflow
Preflow
P/H
R
Maintained Switch
R
Foot Or Finger
Remote Control
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.
B. Remote 2T Torch Trigger Operation
Current (A)
Main Amps
Initial Slope
Final Slope
Initial Amps
Final Amps
Postflow
Preflow
P/R
P/R = Push trigger and release.
OM-216 869 Page 66
P/R
. If torch trigger is held more than 3 seconds, operation reverts to RMT STD (Remote Standard) mode.
C.
3T Specific Trigger Method
1
RMT
2
3T
= 3T
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.
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.
OM-216 869 Page 67
D. 4T Specific Trigger Method
2
1
1
2
4T (Specific Trigger Operation)
Encoder Control
To select 4T, turn Encoder control.
RMT
4T
Torch trigger operation is as shown.
4T allows the operator to toggle between weld current and final
current.
= 4T
. 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:
Current (A)
Use 4T trigger method when the functions of a remote current
control are desired, but only a remote on/off control is available.
Torch Trigger Operation
Main Amps
Initial Slope
Final Slope
Initial Amps
Final Amps
Postflow
Preflow
P/H
R
P/R
P/R
P/H
R
P/H = Push and hold trigger; R = Release trigger; P/R = Push trigger and release in less than 3/4 seconds
E. Mini Logic Operation
1
2
1
2
Mini Logic Meter Display
Encoder Control
To select Mini Logic, turn Encoder control.
RMT
4TL
Torch trigger operation is as shown.
=
Mini Logic
Mini logic allows the operator to toggle between initial slope
or main amps and initial amps. Final Amperage is not available. Final slope will always slope to minimum amperage
and end the cycle.
. 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: This 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.
Torch Trigger Operation
Main Amps
Final Slope
Initial Slope
*
Initial Amps
Preflow
P/H
R
*
*
*
P/R
P/R
P/R
P/R
Postflow
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-216 869 Page 68
F. 4T Momentary Operation
1
1
2
2
4T Momentary Meter Display
Encoder Control
To select 4T Momentary, turn Encoder control.
RMT
4TE
= 4T Momentary Main
4T Momentary torch trigger operation is as shown.
. 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:
Current (A)
Main Amps
Use 4T Momentary trigger method when the functions of a
remote current control are desired, but only a remote on/off
control is available.
Initial Slope
Final Slope
Initial Amps
*
Final Amps
Postflow
Preflow
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.
Notes
OM-216 869 Page 69
G. On Trigger Operation
Voltage (V)
ON
2 Sec
Current (A)
Stick
Touch Stick
Electrode
Lift Stick
Electrode
Current (A)
Lift
Main Amperage
Initial Amperage
Initial Slope
*Final Slope
Touch Current
Touch Tungsten
*Final Amperage
Lift Tungsten
Slightly
*Becomes active with Spot Time enabled.
OM-216 869 Page 70
Lift Tungsten
6-5.
AC Waveshape Selection (Dynasty Models Only)
1
1
AC Soft
= Advanced Squarewave
= Sine wave
1
Memory Switch Pad
Each memory location can select any of
four wave shapes.
2
2
Encoder
Use the Encoder, at any of the nine memory
locations, to select between advanced
squarewave [ADVS], soft squarewave
[SOFT] (default), sine wave [Sine], or
triangle wave [TRI].
. During normal operation, when EN or
EP Amperage is selected, the left parameter screen will display the active
waveshape [ADVS],, [Soft], [Sine], or
[TRI] and the independent amplitude
selection (see Section 6-6) as a reminder.
= Soft Squarewave
= Triangular wave
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.
OM-216 869 Page 71
6-6.
Independent Amplitude Selection
1
2
2
ENEP
6-7.
Same
1
Encoder Control
Ammeter Parameter Selection
To change between same [Same]
and independent [INDP] amplitude
adjustment, turn encoder control.
Application: Use same if it is desired to have the same amperage
set for both the electrode negative
(EN) and electrode positive (EP)
halves of the cycle. Use independent if you wish to set a different
amperage for each half of the weld
cycle for more control of the cleaning action and longer tungsten life
(see Section 5-13).
Spot Enable
1
2
3
2
Spot
Off
1
3
Encoder
Ammeter Parameter Selection
Amperage Switch Pad
Turn Encoder control to turn Spot
on and off. Once on, exit set-up and
press Amperage control switch pad
twice and turn Encoder control to
set spot time. The spot time default
is zero for each program. Spot Enable works in RMT STD and RMT
2T Hold only. When a foot control is
connected, amperage is controlled
at the machine, not by a remote
control.
Application: Used for tacking and
thin sheet joining.
6-8. Stick Open-Circuit Voltage (OCV) Selection
2
OCV
LOW
1
Encoder Control
played on the meters.
2
Meter Display
When Stick low OCV is selected, open-circuit voltage is between 9 and 14 volts.
When Stick normal OCV is selected, opencircuit voltage is approximately 72 volts.
Turn Encoder to change between low OCV
and normal OCV. Active selection is dis-
OM-216 869 Page 72
1
Application: For most Stick applications
use low open-circuit voltage. Use normal
open-circuit voltage for hard to start Stick
electrodes, or if required for your particular
application.
6-9. Stick Stuck Check Selection
2
STUC
1 Encoder Control
2 Ammeter Parameters Select Display
Turn Encoder to change between Stick
Stuck Check [ON and [OFF] meter display.
When Stick Stuck Check is on and the
welding electrode (rod) is stuck, output is
turned off.
1
ON
Application: For most Stick applications,
use Stick Stuck Check off. With Stick
Stuck Check on and the welding electrode
(rod) stuck, output is turned off in an attempt to save the rod for reuse. This allows
the operator time to un-stick the rod, or disconnect the rod holder from the rod without
arc occurring. Turn Stick Stuck Check on
when this function is desired.
. Some applications may require Stick
Stuck Check to be turned off. For example: Large stick electrodes operating at high amperages would require
Stick Stuck Check to be turned off.
Notes
OM-216 869 Page 73
6-10.
Lockout Functions
A. Accessing Lockout Capability
Toggle
1
2
Lock
OFF
Select Lockout Level
1, 2, 3, or 4
Toggle
Code
OFF
Select Code Number
1 to 999
See Section 5-1 for explanation of controls referred to in all of
Section 6-10.
thru [999]. IMPORTANT: remember this code number, as you will
need it to turn the lockout feature off.
There are four (1−4) different lockout levels. Each successive level
allows the operator more flexibility.
Toggle Amperage (A) switch pad until lock is displayed. You may now
select a lockout level.
. Before activating lockout levels, be sure that all procedures and
There are four lockout levels available. Turn Encoder control to select a lockout level (see Sections 6-10B for lockout level descriptions).
To turn On the lockout feature, proceed as follows:
1 Encoder Control
2 Amperage (A) Switch Pad
Press Amperage (A) switch pad to toggle between the lock and code
displays. Toggle switch pad until code is displayed.
Once the desired three digits have been entered and a lockout level
selected, exit advanced functions mode (see Section 6-1).
Turn Encoder control to select a lockout code number. The code
number will appear on the amp meter. Select any number from [1]
Press the Amperage (A) switch pad. The amperage (right) meter display will change to [OFF]. The lockout feature is now off.
parameters are established. Parameter adjustment is limited
while lockout levels are active.
OM-216 869 Page 74
To turn Off the lockout feature, proceed as follows:
Use Encoder control to enter the same code number that was used
to turn on the lockout feature.
B. Lockout Levels
Levels 1, 2, And 3
L3
Use Encoder Control To Adjust
Amperage 10% Of Preset
Value.
L2
Indicates which functions are available
for the corresponding lockout level.
L2
L2
L1
L3
Level 4
A
B
K
J
I
H
C L N
D M
G
E F
. Before
activating lockout levels, be
sure that all procedures and parameters are established. Parameter adjustment is limited while lockout levels are
active.
Level 1
When parameter change or selection is limited by lock level 1, [LOCK][LEV1] is displayed as a reminder.
Level 2
. Remote amperage control is not available in level 2.
. Remote amperage control is not avail-
Includes all the functions of level 1 plus
Memory, Polarity and Process Selection
(see Sections 5-6 and 5-7).
TIG Output Selection
When parameter change or selection is limited by lock level 2, [LOCK][LEV2] is displayed as a reminder.
able in level 1.
If either the TIG HF Impulse or TIG Lift Arc
process (see Section 5-7) was active when
lockout level 1 was activated, the operator
can choose between RMT STD (Remote
Standard) or RMT 2T HOLD (Remote 2T
Hold) (see Section 5-9). The On function is
also available if TIG Lift Arc was active.
Stick Output Selection
If the Stick process was active when lockout level 1 was activated, the operator can
choose between RMT STD or On.
Level 3
. Remote amperage control is not available in level 3.
Includes all the functions of levels 1 and 2
plus the following:
+10% adjustment of preset TIG or Stick
Weld Amps
Select desired process, TIG or Stick, and
use Encoder control to adjust amperage +/−
10% of preset amperage value, up to the
limits of the machine. If operator tries to go
beyond the 10%, the amperage (right) meter will display [LOCK][LEV3] as a reminder.
Pulser ON/Off Control
Gives operator the ability to turn on/off the
Pulser control.
When parameter change or selection is limited by lock level 3, [LOCK][LEV3] is displayed as a reminder.
Level 4
Includes all the functions of levels 1, 2, and
3 plus the following:
Remote Amperage Control
Allows operator to use remote amperage
control if desired. Remote control operates
from minimum to maximum of preset amperage value. Connect remote control device according to Section 4-13.
When parameter change or selection is limited by lock level 4, [LOCK][LEV4] is displayed as a reminder.
OM-216 869 Page 75
6-11. Pulse Welding Display Options
2
METR
1
2
Encoder Control
Ammeter Parameters Select Display
Turn Encoder to change between [V/A],
[OFF], and [AVG] pulse welding display
options.
[V/A]
Amperage preset displays peak amperage
for both AC and DC TIG pulser. While pulse
welding at one pulse per second and
above in DC TIG, meters display average
1
V/A
voltage and amperage. While pulse welding in AC TIG, meter display may not be
stable, and are for reference only.
[OFF]
Amperage preset displays peak amperage
for both AC and DC TIG pulser. Meters display [PULS] [WELD] while pulse welding.
Meter Hold function is disabled. While in a
non-pulse welding mode, weld voltage and
amperage display and meter hold capabilities are not effected.
[AVG]
Amperage preset displays average amperage for DC TIG pulser, and peak amperage for AC TIG pulser. While pulse
welding at one pulse per second and
above in DC TIG, meters display average
voltage and amperage. While pulse welding in AC TIG, meter display may not be
stable, and are for reference only.
6-12. DC Meter Calibration
2
MCAL
OA
MCAL
OV
1
Encoder Control
2
Ammeter Parameters Select Display
Amperage Calibration:
The amperage calibration range is 10 amps.
To calibrate the machine’s amperage meter to
a load bank’s amperage meter, add or subtract
the difference between the amperage found
on the machine’s amperage meter and the amperage meter on the load bank. For example:
OM-216 869 Page 76
4
MachineMeter LoadBankMeter SetMCAL
Amps
100 A
105 A
+5 A
100 A
95 A
−5 A
3 Amperage Switch Pad
4 Voltage Parameters Select Display
Voltage Calibration:
The voltage calibration range is 9.9 volts.
To calibrate voltage, press the Amperage
switch pad and [MCAL] [OV] will be displayed.
1
3
To calibrate the machine’s voltage meter to a
load bank’s voltage meter, add or subtract the
difference between the voltage found on the
machine’s voltage meter and the voltage meter on the load bank. For example:
MachineMeter LoadBankMeter SetMCAL
Volts
10.0 V
10.5 V
+0.5 V
10.0 V
9.5 V
−0.5 V
SECTION 7 − MAINTENANCE AND TROUBLESHOOTING
7-1. Routine Maintenance
!
Disconnect power before maintaining.
A. Welding Power Source
n = Check
Z = Change
~ = Clean
* To be done by Factory Authorized Service Agent
= Repair
l = Replace
Every
3
Months
nl Labels
~ Weld Terminals
n l Gas Hoses
Every
3
Months
n lCables And Cords
Every
6
Months
~:Durning heavy service, clean monthly.
B. 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.
= Repair
l = Replace
~ 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-216 869 Page 77
7-2. 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.
803 900-B
7-3. Coolant Maintenance
!
Disconnect input power before maintaining.
1
Coolant Filter
Unscrew housing to clean filter.
1
Changing coolant: Drain coolant by
tipping unit to rear, or use suction
pump. Fill with clean water and run
for 10 minutes. Drain and refill with
coolant (see section 4-20).
.
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.
Tools Needed:
m30 Torx
804 649-A / Ref. 801 194
OM-216 869 Page 78
7-4. Troubleshooting
A. Voltmeter/Ammeter And Cooler Help Displays
1
V
HELP
. All directions are in reference to the
A
30
Indicates a malfunction in the primary power circuit caused by an overcurrent condition in the primary IGBT switching circuit.
Contact a Factory Authorized Service
Agent if this display is shown.
w Help 32 Display
Indicates a short or open in the thermal
protection circuitry located on the left side of
the unit. Contact a Factory Authorized Service Agent if this display is shown.
w Help 34 Display
Indicates a short or open in the thermal
protection circuitry located on the right side
of the unit. Contact a Factory Authorized
Service Agent if this display is shown.
w Help 8 Display
Indicates a malfunction in the secondary
power circuit of the unit. There is a high
open circuit condition. Contact a Factory
Authorized Service Agent if this display is
shown.
w Help 14 Display
Unit not ready. Primary circuit bus not up to
full power.
w Help 16 Display
Secondary clamp voltage too high.
Straighten out or shorten weld cables. If this
does not correct the problem, contact a
Factory Authorized Service Agent.
2
w [LOW][LINE]
front of the unit. All circuitry referred to
is located inside the unit.
1
Typical Voltmeter/Ammeter
Numbered Help Displays - 30
Numbers are for 350 Models Or
Top Engine Of 700 Models. 40
Numbers Are For Bottom Engine
Of 700 Models.
w Help 30 Display
Indicates a short or open in the thermal
protection circuitry located in the input inductor of the unit. Contact a Factory Authorized Service Agent if this display is shown.
w Help 31 Display
Typical Voltmeter/Ammeter Worded
Help Displays. [TOP] or [BOT] will
display after the message to
identify the affected engine on 700
models.
w [Over][Temp]
On for two seconds then flashes:
[Sec] − Indicates the left side of the unit
has overheated. The unit has shut down to
allow the fan to cool it (see Section 4-4). Operation will continue when the unit has
cooled.
[PRI] − Indicates the right side of the
unit has overheated. The unit has shut
down to allow the fan to cool it (see Section
4-4). Operation will continue when the unit
has cooled.
[InD] − Indicates that the input inductor
has overheated. The unit has shut down to
allow the fans to cool it (see Section 4-4).
Operation will continue when the unit has
cooled.
Indicates that the input voltage is too low,
and the unit has automatically shut down.
Operation will continue when the voltage is
within the operating range (10%). Have an
electrician check the input voltage if this display is shown.
w [HIGH][LINE]
Indicates that the input voltage is too high,
and the unit has automatically shut down.
Operation will continue when the voltage is
within the operating range (10%). Have an
electrician check the input voltage if this display is shown.
w [REL][RMT]
Indicates that the torch trigger is depressed. Release trigger to continue.
w [not][VALD]
Indicates a non-allowable set-up on the
front panel.
w Help 20 Display
Indicates that the power supplies for the primary drives have failed. Contact a Factory
Authorized Service Agent if this display is
shown.
w
Help 21 Display
Indicates voltage or current feedback has
been detected with contactor off. Contact a
Factory Authorized Service Agent if this
display is shown.
w
Help 22 Display
Voltage and current not present with contactor on. Contact a Factory Authorized
Service Agent if this display is shown.
w
Help 24 Display
Indicates a power supply to the control and
interface board PC6 failure. Possible cause
is a short in Pin A or Pin B of the remote
control.
w [AUTO][STop]
Output disable open causing weld output to
stop, but gas continues to flow.
w [Out][LIMT]
Indicates a primary overpower condition.
Output current is decreased to limit primary
power draw. Depress any switch pad and
turn encoder or strike an arc to clear the last
help condition.
w [ADV][AUTO]
Indicates a non-allowable setup on the front
panel due to an Advanced Automation
selection being active (see Section 6).
w [LOCK][LEV 1] 2, 3, or 4
Indicates a non-allowable setup on the front
panel due to the current lockout selection
(see Section 6-10).
w [ERR][GND]
Turn Off input power and have qualified person inspect unit. To clear error, turn power
Off and back On.
Error is displayed only if option is installed
and error occurs.
Err GND indicates current is present on
green or green/yellow grounding conductor.
As a result, machine weld output is
disabled.
ERR GND may be caused by a live conductor contacting the chassis.
ERR GND may be caused by work clamp
not connected to work piece.
OM-216 869 Page 79
B. Troubleshooting Table
Trouble
No weld output; unit completely
inoperative.
Remedy
Place line disconnect switch in On position (see Section 4-10).
Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 4-10).
Check for proper input power connections (see Section 4-10).
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 Sections 5-1 and 4-13).
Input voltage outside acceptable range of variation (see Section 4-9).
Check, repair, or replace remote control.
Unit overheated and [Over][Temp] is displayed. Allow unit to cool with fan On (see Section 4-4).
Erratic or improper weld output.
Use proper size and type of weld cable (see Section 4-12).
Clean and tighten all weld and gas connections.
No 115 volts AC output at duplex
receptacle.
Reset circuit breaker CB1 (see Section 4-17).
Fan not operating. Fan only runs when
cooling is necessary.
Check for and remove anything blocking fan movement.
Have Factory Authorized Service Agent check fan motor.
Wandering arc
Use proper size tungsten (see Section 11-1).
Use properly prepared tungsten (see Section 11-2).
Reduce gas flow rate.
Tungsten electrode oxidizing and not re- Shield weld zone from drafts.
maining bright after conclusion of weld.
Increase postflow time (see Section 5-12).
Check and tighten all gas fittings.
Water in torch. Refer to torch manual.
OM-216 869 Page 80
Notes
OM-216 869 Page 81
SECTION 8 − ELECTRICAL DIAGRAM
Figure 8-1. Circuit Diagram For Dynasty 350 Models
OM-216 869 Page 82
243 217-D
OM-216 869 Page 83
Figure 8-2. Circuit Diagram For Maxstar 350 Models
OM-216 869 Page 84
243 215-D
OM-216 869 Page 85
Figure 8-3. Circuit Diagram For Dynasty 700 Models (Part 1 of 2)
OM-216 869 Page 86
243 218-D
OM-216 869 Page 87
Figure 8-4. Circuit Diagram For Dynasty 700 Models (Part 2 of 2)
OM-216 869 Page 88
243 218-D
OM-216 869 Page 89
Figure 8-5. Circuit Diagram For Maxstar 700 Models (Part 1 of 2)
OM-216 869 Page 90
243 216-D
OM-216 869 Page 91
Figure 8-6. Circuit Diagram For Maxstar 700 Models (Part 2 of 2)
OM-216 869 Page 92
243 216-D
OM-216 869 Page 93
228 525-B
Figure 8-7. Circuit Diagram For Cooler
OM-216 869 Page 94
SECTION 9 − HIGH FREQUENCY
9-1. 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
9-2. 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
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
OM-216 869 Page 95
9-3. 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.
OM-216 869 Page 96
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.
SECTION 10 − SETUP GUIDES FOR (GTAW) TIG WELDING
10-1. Typical GTAW Setups
A. AC − GTAW 1/8 in. Aluminum Setup (Dynasty Models Only)
This symbol indicates which functions should be active for aluminum welding.
226 868-B
. Some of the controls shown above may not be on your machine (Dynasty 350/700 illustrated).
 Turn power on (switch located on rear panel).
 Press Polarity switch pad until AC LED is lit.
 Press Process switch pad until TIG HF Impulse LED is lit.
 Press Output switch pad until RMT STD LED is lit.
 Press Adjust switch pad until Post Flow LED is lit.
 Turn Encoder control to set 15 seconds of Post Flow time.
 Press AC Waveshape switch pad until Balance LED is lit.
 Turn Encoder control to set desired Balance (65 - 80%).
 Press AC Waveshape switch pad until AC Frequency LED is lit.
 Turn Encoder control to set desired AC Frequency (100 - 150 Hz).
 Press AC Waveshape switch pad until EN Amperage or EP Amperage LED is lit.
 Turn Encoder control to set desired ratio: typically in the range of (75A EP / 100A EN) to (50A EP / 100A EN).
 Press Amperage A switch pad until LED is lit.
 Turn Encoder control to set desired amperage (125 - 160 amps).
 Pulser Controls (if applicable, see Section 5-10).
. The ammeter displays the parameter for any of the following units of measure when they are active: amperage, time, percentage,
or frequency. The corresponding LED, located directly below the ammeter, will also light up. The ammeter also displays actual
amperage while welding.
OM-216 869 Page 97
B. DC - GTAW 16 Gauge Mild Steel* And Stainless Steel Setup
226 868-B
This symbol indicates which functions should be active for stainless or mild steel welding.
. Some of the controls shown above may not be on your machine (Dynasty 350/700 illustrated).
 Turn power on (switch located on rear panel)
 Press Polarity switch pad until DC LED is lit (Dynasty Models Only)
 Press Process switch pad until TIG HF Impulse LED is lit
 Press Output switch pad until RMT STD LED is lit
 Press Adjust switch pad until Post Flow LED is lit
 Turn Encoder control to set 8 seconds of Post Flow time
 Press Amperage A switch pad until LED is lit
 Turn Encoder control to set desired amperage (50 - 80 amps for stainless steel) or (55 to 88 amps for mild steel*).
 Pulser Controls (if applicable, see Section 5-10).
. The ammeter displays the parameter for any of the following units of measure when they are active: amperage, time, percentage,
or frequency. The corresponding LED, located directly below the ammeter, will also light up. The ammeter also displays actual
amperage while welding.
OM 216 896 Page 98
SECTION 11 − SELECTING AND PREPARING A TUNGSTEN
FOR DC OR AC WELDING WITH INVERTER MACHINES
gtaw_Inverter_2011-06
Whenever possible and practical, use DC weld output instead of AC weld output.
11-1. 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. (1 mm)
Up to 25
Up to 20
.020 in. (1 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.
11-2. 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.
Wrong Tungsten
Preparation
4
Ideal Tungsten Preparation − Stable Arc
3
Flat
Diameter of this flat determines amperage
capacity.
4
Straight Ground
Grind lengthwise, not radial.
OM-216 869 Page 99
SECTION 12 − GUIDELINES FOR TIG WELDING (GTAW)
12-1. Positioning The Torch
!
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 cerium or lanthanum based tungsten instead of
thoriated. Thorium dust 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.
1
Workpiece
3
2
4
90
Make sure workpiece is clean before
welding.
1
2
Work Clamp
Place as close to the weld as possible.
3
4
5
6
10−15
4
5
6
10−25
5
6
Torch
Filler Rod (If Applicable)
Gas Cup
Tungsten Electrode
Select and prepare tungsten according
to Section 11.
Guidelines:
The inside diameter of the gas cup
should be at least three times the
tungsten diameter to provide adequate
shielding gas coverage. (For example,
if tungsten is 1/16 in. diameter, gas cup
should be a minimum of 3/16 in.
diameter.
Tungsten extension is the distance the
tungsten extends out gas cup of torch.
1/16 in.
3/16 in.
Bottom View Of Gas Cup
The tungsten extension should be no
greater than the inside diameter of the
gas cup.
Arc length is the distance from the
tungsten to the workpiece.
Ref. ST-161 892
OM-216 869 Page 100
12-2. Torch Movement During Welding
Tungsten Without Filler Rod
75
Welding direction
Form pool
Tilt torch
Move torch to front
of pool. Repeat process.
Tungsten With Filler Rod
75
Welding direction
Form pool
15
Tilt torch
Remove rod
Add filler metal
Move torch to front
of pool. Repeat process.
ST-162 002-B
12-3. Positioning Torch Tungsten For Various Weld Joints
“T” Joint
Butt Weld And Stringer Bead
20
90
70
75
20
10
15
Corner Joint
Lap Joint
20-40
90
75
75
15
15
30
ST-162 003 / S-0792
OM-216 869 Page 101
SECTION 13 − SETUP GUIDES FOR (SMAW) STICK WELDING
13-1. Front Panel Display For Stick DCEP (Direct Current Electrode Positive)
. Some of the controls shown above may not be on your machine (Dynasty 350/700 illustrated).
. Gray on nameplate indicates a Stick function (see Section 5-1 for description of controls).
This symbol indicates which functions should be active for Stick DCEP (Direct Current Electrode Positive) welding.
 Turn power on (switch located on rear panel)
 Press Polarity switch pad until DC LED is lit (Dynasty Models Only)
 Press Process switch pad until STICK LED is lit
 Press Output switch pad until ON LED is lit
 Press Amperage A switch pad until LED is lit
 Turn Encoder control to set desired amperage.
. The ammeter displays the parameter for any of the following units of measure when they
are active: amperage, time, percentage, or frequency. The corresponding LED, located
directly below the ammeter, will also light up. The ammeter also displays actual amperage while welding.
OM-216 869 Page 102
216 869-B
SECTION 14 − STICK WELDING (SMAW) GUIDELINES
14-1. Stick Welding Procedure
!
Weld current starts when
electrode touches workpiece.
!
Weld current can damage
electronic parts in vehicles.
Disconnect both battery
cables before welding on a
vehicle. Place work clamp
as close to the weld as
possible.
Equipment Needed:
Tools Needed:
. Always wear appropriate per1
Constant Current
Welding Power Source
sonal protective clothing.
Workpiece
Make sure workpiece is clean before welding.
2
3
Work Clamp
Electrode
A small diameter electrode requires less current than a large
one. Follow electrode manufacturer’s instructions when setting weld
amperage (see Section 14-2).
4
5
6
5
4
Insulated Electrode Holder
Electrode Holder Position
Arc Length
Arc length is the distance from the
electrode to the workpiece. A short
arc with correct amperage will give
a sharp, crackling sound.
2
7
3
Slag
Use a chipping hammer and wire
brush to remove slag. Remove
slag and check weld bead before
making another weld pass.
6
1
7
stick 2010−02 − 151 593
OM-216 869 Page 103
6013
7014
7018
7024
Ni-Cl
308L
ALL
DEEP
EP
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
EP
6011
AC
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
DC*
6010
ELECTRODE
450
400
350
300
AMPERAGE
RANGE
250
200
150
POSITION
6010
&
6011
100
50
DIAMETER
ELECTRODE
14-2. 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
14-3. Striking an Arc
1
2
3
Electrode
Workpiece
Arc
Scratch Technique
1
2
Drag electrode across workpiece
like striking a match; lift electrode
slightly after touching work. If arc
goes out, electrode was lifted too
high. If electrode sticks to workpiece, use a quick twist to free it.
Tapping Technique
Bring electrode straight down to
workpiece; then lift slightly to start
arc. If arc goes out, electrode was
lifted too high. If electrode sticks to
workpiece, use a quick twist to free
it.
3
1
2
3
S-0049 / S-0050
OM-216 869 Page 104
14-4. Positioning Electrode Holder
1
2
End View Of Work Angle
Side View Of Electrode Angle
1
10-30
90
2
90
Groove Welds
10-30
45
1
2
45
Fillet Welds
S-0060
14-5. Poor Weld Bead Characteristics
1
2
3
4
5
Large Spatter Deposits
Rough, Uneven Bead
Slight Crater During Welding
Bad Overlap
Poor Penetration
4
2
3
5
1
S-0053-A
14-6. Good Weld Bead Characteristics
1
2
3
Fine Spatter
Uniform Bead
Moderate Crater During
Welding
Weld a new bead or layer for each
1/8 in. (3.2 mm) thickness in metals
being welded.
2
3
4
5
4
5
No Overlap
Good Penetration into Base
Metal
1
S-0052-B
OM-216 869 Page 105
14-7. Conditions That Affect Weld Bead Shape
. Weld bead shape is affected
by
electrode angle,
arc
length, travel speed, and thickness of base metal.
Angle Too Small
Correct Angle
10 - 30
Angle Too Large
Electrode Angle
Drag
Spatter
Arc Length
Too Short
Normal
Too Long
Slow
Normal
Fast
Travel Speed
S-0061
14-8. Electrode Movement During Welding
. Normally,
2
1
1
2
3
3
a single stringer
bead is satisfactory for most
narrow groove weld joints;
however, for wide groove weld
joints or bridging across gaps,
a weave bead or multiple
stringer beads work better.
Stringer Bead − Steady
Movement Along Seam
Weave Bead − Side to Side
Movement Along Seam
Weave Patterns
Use weave patterns to cover a
wide area in one pass of the electrode. Do not let weave width exceed 2-1/2 times diameter of
electrode.
S-0054-A
OM-216 869 Page 106
14-9. Groove (Butt) Joints
1
Tack Welds
Prevent edges of joint from drawing together ahead of electrode by
tack welding the materials in position before final weld.
1
2
2
Square Groove Weld
Good for materials up to 3/16 in. (5
mm) thick.
3
1/16 in.
(1.6 mm)
Single V-Groove Weld
Good for materials 3/16 − 3/4 in.
(5-19 mm) thick. Cut bevel with
oxyacetylene or plasma cutting
equipment. Remove scale from
material after cutting. A grinder can
also be used to prepare bevels.
30
Create 30 degree angle of bevel on
materials in V-groove welding.
4
Good for materials thicker than
3/16 in. (5 mm).
4
3
Double V-Groove Weld
S-0062
14-10. Lap Joint
1
2
Electrode
Single-Layer Fillet Weld
Move electrode in circular motion.
3
30
Or Less
30
Or Less
1
1
Multi-Layer Fillet Weld
Weld a second layer when a heavier fillet is needed. Remove slag before making another weld pass.
Weld both sides of joint for maximum strength.
3
2
S-0063 / S-0064
14-11. Tee Joint
1
2
Electrode
Fillet Weld
Keep arc short and move at definite rate of speed. Hold electrode
as shown to provide fusion into the
corner. Square edge of the weld
surface.
For maximum strength weld both
sides of upright section.
1
2
45
Or
Less
1
2
3
3
Multi-Layer Deposits
Weld a second layer when a heavier fillet is needed. Use any of the
weaving patterns shown in Section
14-8. Remove slag before making
another weld pass.
S-0060 / S-0058-A / S-0061
OM-216 869 Page 107
14-12. Weld Test
1
2
3
Vise
Weld Joint
Hammer
Strike weld joint in direction shown.
A good weld bends over but does
not break.
3
3
2 To 3 in.
(51-76 mm)
1/4 in.
(6.4 mm)
2
1
2 To 3 in.
(51-76 mm)
2
1
S-0057-B
14-13. Troubleshooting
Porosity − small cavities or holes resulting from gas pockets in weld metal.
Possible Causes
Corrective Actions
Arc length too long.
Reduce arc length.
Damp electrode.
Use dry electrode.
Workpiece dirty.
Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before
welding.
Excessive Spatter − scattering of molten metal particles that cool to solid form near weld bead.
Possible Causes
Corrective Actions
Amperage too high for electrode.
Decrease amperage or select larger electrode.
Arc length too long or voltage too high.
Reduce arc length or voltage.
Incomplete Fusion − failure of weld metal to fuse completely with base metal or a preceeding
weld bead.
Possible Causes
Corrective Actions
Insufficient heat input.
Increase amperage. Select larger electrode and increase amperage.
Improper welding technique.
Place stringer bead in proper location(s) at joint during welding.
Adjust work angle or widen groove to access bottom during welding.
Momentarily hold arc on groove side walls when using weaving technique.
Keep arc on leading edge of weld puddle.
Workpiece dirty.
OM-216 869 Page 108
Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before
welding.
Lack Of Penetration − shallow fusion between weld metal and base metal.
Lack of Penetration
Good Penetration
Possible Causes
Corrective Actions
Improper joint preparation.
Material too thick. Joint preparation and design must provide access to bottom of groove.
Improper weld technique.
Keep arc on leading edge of weld puddle.
Insufficient heat input.
Increase amperage. Select larger electrode and increase amperage.
Reduce travel speed.
Excessive Penetration − weld metal melting through base metal and hanging underneath weld.
Excessive Penetration Good Penetration
Possible Causes
Corrective Actions
Excessive heat input.
Select lower amperage. Use smaller electrode.
Increase and/or maintain steady travel speed.
Burn-Through − weld metal melting completely through base metal resulting in holes where no
metal remains.
Possible Causes
Corrective Actions
Excessive heat input.
Select lower amperage. Use smaller electrode.
Increase and/or maintain steady travel speed.
Waviness Of Bead − weld metal that is not parallel and does not cover joint formed by base metal.
Possible Causes
Corrective Actions
Unsteady hand.
Use two hands. Practice technique.
Distortion − contraction of weld metal during welding that forces base metal to move.
Base metal moves
in the direction of
the weld bead.
Possible Causes
Corrective Actions
Excessive heat input.
Use restraint (clamp) to hold base metal in position.
Make tack welds along joint before starting welding operation.
Select lower amperage for electrode.
Increase travel speed.
Weld in small segments and allow cooling between welds.
OM-216 869 Page 109
SECTION 15 − PARTS LIST FOR 350 MODELS
. Hardware is common and
not available unless listed.
6
8
7
5
10
4
9
28
34
33
Maxstar Qty 2
Dynasty Qty 1
29
2
12
30
31
19
14
32
27
13
17
15
26
18
25
24
19
33
Dynasty
Only
20
16
21
3
1
22
23
Dynasty 350 illustrated
805 471-B
Figure 15-1. Main Assembly
OM-216 869 Page 110
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 15-1. Main Assembly
. . . 1 . . . . . . . . . . 224 519 . . LABEL, SIDE DYNASTY 350 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 1 . . . . . . . . . . 224 525 . . LABEL, SIDE MAXSTAR 350 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 2 . . . . . . . . . . 224 516 . . INSULATOR, SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 3 . . . . . . . . . . 216 878 . . PANEL, SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 4 . . . . . . . . . +213 056 . . WRAPPER, TOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 5 . . . . . . . . . . 203 990 . . LABEL, WARNING GENERAL PRECAUTIONARY WORDLESS . . . . . . . . .
. . . 5 . . . . . . . . . . 179 310 . . LABEL, WARNING GENERAL PRECAUTIONARY WORDLESS, (CE) . . . . .
. . . 6 . . . . . . . . . . 213 073 . . SEAL, LIFT EYE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 7 . . . . . . . . . . 213 058 . . LIFT EYE, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 8 . . . . T2 . . 251 337 . . XFMR, 665 115/24 18/18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 9 . . . . . . . . . . 155 436 . . LABEL, GROUND/PROTECTIVE EARTH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 10 . . . . . . . . . . 254 015 . . HOSE, NPRN BRD NO 1 X .250 ID X 23.000 . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 12 . . . . . . . Figure 15-3 . . PANEL, REAR W/COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 13 . . . . . . . . . . 222 760 . . BRACKET, FILTER BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 14 . . PC19 . 233 152 . . CIRCUIT CARD ASSY, FILTER (CE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 15 . . . . . . . Figure 15-5 . . HEAT SINK, PRIMARY ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 16 . . . . . . . Figure 15-4 . . WINDTUNNEL, RIGHT HAND W/COMPONENTS . . . . . . . . . . . . . . . . . . . . . .
. . . 17 . . . . . . . Figure 15-7 . . HEAT SINK, SECONDARY − DYNASTY 350 . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 17 . . . . . . . Figure 15-8 . . HEAT SINK, SECONDARY − MAXSTAR 350 . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 18 . . . PC7 . . 235 476 . . CIRCUIT CARD ASSY, HF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . PLG39 115 092 . . . . HOUSING PLUG+SKTS, (SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 19 . . . . . . . . . . 080 509 . . GROMMET, SCR NO 8/10 PANEL HOLE .312 SQ .375 HIGH . . . . . . . . . . . .
. . . 20 . . . . . . . . . . 213 074 . . CABLE, LEM 23 IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 21 . . . HD1 . . 182 918 . . TRANSDUCER,CURRENT 400A MODULE SUPPLY V +/− 15V . . . . . . . . .
. . . 22 . . . . . . . . . . 213 055 . . BASE, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 23 . . . . . . . Figure 15-2 . . PANEL, FRONT W/CMPNTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 215 120 . . CONNECTION KIT, DINSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 24 . . C6,C7 . 222 752 . . CAPACITOR ASSY, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 25 . . . . . . . Figure 15-6 . . WINDTUNNEL, LEFT HAND W/COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . .
. . . 26 . . . . . . . . . . 057 357 . . BUSHING,SNAP−IN NYL .937 ID X 1.125 MTG HOLE . . . . . . . . . . . . . . . . . .
. . . 27 . . . . . . . . . . 215 402 . . PANEL, TOP WINDTUNNEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 28 . . . PC8 . . 233 142 . . CIRCUIT CARD ASSY, CLAMP (DYNASTY ONLY) . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . PLG24 163 467 . . HOUSING PLUG+SKTS, (SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . PLG33 201 665 . . HOUSING PLUG+SKTS, (SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . PLG34 148 439 . . HOUSING PLUG PINS+SKTS, (SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . .
. . . 29 . . . PC5 . . 247 125 . . CIRCUIT CARD ASSY, AUX POWER W/PROGRAM . . . . . . . . . . . . . . . . . . . .
. . . . . . . . PLG19 131 052 . . HOUSING RCPT+SKTS, (SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . PLG21 115 091 . . HOUSING PLUG+SKTS, (SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . PLG22 131 054 . . HOUSING RCPT+SKTS, (SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . PLG23 115 093 . . HOUSING PLUG+SKTS, (SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 30 . . . . . . . . . . 226 878 . . BRACKET, HARNESS SUPPORT (MAXSTAR 700) . . . . . . . . . . . . . . . . . . . . .
. . . 31 . . . . . . . . . . 195 666 . . SCREW, 010−32X .50 TORX PANHD W/GNDRNG STL PLD . . . . . . . . . . . .
. . . 32 . . . . . . . . . . 213 248 . . LUG, UNIV W/SCREW 2/0−14 WIRE .266STD . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 33 . . F8, F9 131 447 . . CORE, TOROIDAL 1.332 ID X 1.932 OD X .625 THK . . . . . . . . . . . . . . . . . . .
. . . 34 . . . . . . . . . . 235496 . . CABLE TIE, 0.06−2.000 BUNDLE DIA TREE STYLE PUSH MOUNT
. . . . . . . . . . . . . . . . . . . . . . . . . . . MTG HOLE DIA .246−.276 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
2
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
9
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
2
1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-216 869 Page 111
. Hardware is common and
21
not available unless listed.
22
12
13
11
8
25
6
23
24
9
10
7
19
3
15
14
20
1
2
16
17
18
4
5
804 758-C
Figure 15-2. Panel, Front w/Components
Item
No.
Dia.
Mkgs.
Part
No.
213 339
... 1 ..........
... 2 ..........
... 3 ..........
... 4 ..........
... 5 ..........
... 6 ..........
... 7 ..........
... 7 ..........
... 8 ..........
... 9 ..........
. . . 10 . . . . . . . . . .
. . . 11 . . . . . . . . . .
. . . 11 . . . . . . . . . .
. . . 12 . . . PC6 . .
. . . . . . . . PLG2 .
. . . . . . . . PLG4 .
. . . . . . . . PLG6 .
. . . . . . . . PLG7 .
. . . 13 . . . RC1 . .
. . . 14 . . . . . . . . . .
. . . 15 . . . . . . . . . .
. . . 16 . . . . . . . . . .
. . . 17 . . . . . . . . . .
. . . 18 . . . . . . . . . .
. . . 19 . . . . . . . . . .
. . . 20 . . . FMT .
OM-216 869 Page 112
213 053
202 553
186 228
185 712
231 279
213 051
233 115
233 116
228 546
242 388
233 114
226 868
226 869
241 061
203 800
131 056
115 092
115 094
213 327
185 717
178 548
229 338
185 713
185 718
230 155
213 072
Description
Quantity
Figure 15-2. Panel, Front w/Components
. . PANEL, LOUVER COVER (ORDER SERIAL NO. CARD ALSO) . . . . . . . . . .
. . RECEPTACLE,TWIST LOCK BRASS POWER (FEMALE) . . . . . . . . . . . . . . .
. . O−RING, 0.739 ID X 0.070 H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . INSULATOR, BULKHEAD FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . FITTING, GAS−CLIP MOUNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PANEL, FRONT TOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PLATE, INDICATOR FRONT − DYNASTY 350 . . . . . . . . . . . . . . . . . . . . . . . . .
. . PLATE, INDICATOR FRONT − MAXSTAR 350 . . . . . . . . . . . . . . . . . . . . . . . . .
. . KNOB, POINTER 1.250 DIA X 6MM ID W/SPRING CLIP− 4.5MM FLAT . . .
. . BUSHING, FLG 375−32X.511 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PANEL, FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . NAMEPLATE/SWITCH MEMBRANE, DYNASTY 350/700 STH/FF . . . . . . . .
. . NAMEPLATE/SWITCH MEMBRANE, MAXSTAR 350/700 STH/FF . . . . . . . .
. . CIRCUIT CARD ASSY, CONTROL&INTERFACE W/PROGRAM . . . . . . . . .
. . HOUSING PLUG+SKTS, (SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HOUSING RCPT+SKTS, (SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HOUSING PLUG+SKTS, (SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HOUSING PLUG+SKTS, (SERVICE KIT) (Dynasty 350) . . . . . . . . . . . . . . . . .
. . RECEPTACLE, W/LEADS & PLUG 14PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . NUT, M20−1.5 1.00HEX .19H BRS LOCKING . . . . . . . . . . . . . . . . . . . . . . . . . .
. . TERMINAL, CONNECTOR FRICTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . WASHER, DOMED LOAD .812 ID X 1.450 OD X .070 THK . . . . . . . . . . . . . .
. . INSULATOR, BULKHEAD REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . O−RING, 0.989 ID X 0.070 H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BRACKET, VALVE MTG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CIRCUIT CARD ASSY, CNTRL SPECTRUM 375 W/PGM NON-CE . . . . .
1
2
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
2
2
2
1
1
Item
No.
Dia.
Mkgs.
Part
No.
213 339
................
. . . 21 . . PC10 .
. . . 22 . . . . . . . . . .
. . . 23 . . . . . . . . . .
. . . 24 . . . . . . . . . .
. . . 25 . . . . . . . . . .
195516
233150
223263
218715
218713
079739
Description
Quantity
Figure 15-2. Panel, Front w/Components (continued)
. . KIT, AUTOMATION INTERFACE CONNECTION (INCLUDES) . . . . . . . . . . . .
. . . . CIRCUIT CARD ASSY, AUTOMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . RECEPTACLE, W/LEADS & PLUG 28 PIN . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CONN, CIRC MS/CPC 28PIN SIZE 17 PLUG CABLE PUSHIN . . . . . . . . . .
. . . . CONN, CIRC MS/AMP PIN PUSHIN 20-24GA SOLDER CUP . . . . . . . . . .
. . . . CONN, CIRC CPC CLAMP STR RLF SIZE 17-20 .703OD . . . . . . . . . . . . . .
1
1
1
1
28
1
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
Notes
OM-216 869 Page 113
. Hardware is common and
11
not available unless listed.
10
7
8
9
12
6
5
4
3
2
13
1
804 759-A
Figure 15-3. Panel, Rear w/Components
Item
No.
Dia.
Mkgs.
Part
No.
Description
215 128
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
2
2
3
4
5
6
7
8
9
10
11
12
12
13
. . . . . . . . . +215 129
. . . . . . . . . . 216 880
. . . . . . . . . . 246 180
. . . . . . . . . . 182 445
. . . GS1 . . 238 805
. . . CB1 . . 183 492
. . . RC2 . . 189 033
. . . . . . . . . . 115 516
. . . . . . . . . . 215 980
. . . . . . . . . . 137 761
. . . . . . . . . . 215 117
. . . . . . . . . . 217 297
. . . . . . . . . . 217 480
. . . . . . . . . . 219 842
. . . . S1 . . 244 920
Quantity
Figure 15-3. Panel, Rear w/Components
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
PANEL, REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CABLE, POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CABLE, POWER (CE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VALVE, 24VDC 2WAY,125 PSI CUSTOM PORT.054 ORF W/FR . . . . . . . . . .
SUPPLEMENTARY PROTECTOR, MAN RESET 1P 10A 250V FRIC . . . . .
RCPT, STR DX GND 2P3W 15A 125V (GRAY) . . . . . . . . . . . . . . . . . . . . . . . . .
RIVET, AL .187 DIA X .063−.125 GRIP BLK BLIND DOME . . . . . . . . . . . . . . .
BUSHING,STRAIN RELIEF .709/.984 ID X1.375 MTG HOLE . . . . . . . . . . . .
NUT, 750 NPT 1.31HEX .27H NYL BLK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NAMEPLATE, IDENT REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COVER, RECEPTACLE WEATHERPROOF DUPLEX RCPT . . . . . . . . . . . . .
LABEL, WARNING CORRECT CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . .
LABEL, WARNING INPUT CONNECTIONS/ELECTRIC SHOCK (CE) . . . .
SWITCH, TGL 3PST 40A 600VAC SCR TERM WIDE TGL . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-216 869 Page 114
. Hardware is common and
not available unless listed.
2
1
3
11
4
5
6
7
8
14
15
13
5
12
9
10
804 134-B
Figure 15-4. Wind Tunnel, Right Hand w/Components
Item
No.
Dia.
Mkgs.
Part
No.
Description
231 262
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
9
10
11
11
12
13
14
15
. . . . L1 . . 231 244
. . . . T3 . . 242 782
. . . . . . . . . +212 489
. . . . . . . . . . 195 666
. . . . . . . . . . 216 861
. . . . . . . . . . 170 647
. . . . . . . . . . 216 860
. . C4,C20 217 941
. . . . . . . . . . 207 418
. . . . C3 . . 216 700
. . . . . . . . . . 218 004
. . . . . . . . . . 219 844
. . . . . . . . . . 010 493
. . . . . . . . . . 218 566
. . . . L2 . . 213 348
. . . . . . . . . . 233 913
Quantity
Figure 15-4. Wind Tunnel, Right Hand w/Components
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
INDUCTOR, INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
XFMR, HF COUPLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PANEL, RIGHT WINDTUNNEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SCREW, 010−32X .50 TORX PANHD WGNDRNG STL PLD . . . . . . . . . . . . .
STAND−OFF, CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BUSHING, SNAP−IN NYL 1.312 ID X 1.500 MTG HOLE . . . . . . . . . . . . . . . . .
GROMMET, CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAPACITOR, ELCTLT 1800 UF 500 VDC CAN 2.52 DIA . . . . . . . . . . . . . . . . .
SCREW, K40X 20 PAN HD−PHL STL PLD PT THREAD FORMING . . . . . . .
CAPACITOR, POLYP MET FILM 16. UF 400 VAC 10% . . . . . . . . . . . . . . . . . .
LABEL, WARNING ELECTRIC SHOCK/EXPLODING PARTS . . . . . . . . . . . .
LABEL, WARNING ELECTRIC SHOCK/EXPLODING PARTS−WDLES (CE)
BUSHING, SNAP−IN NYL .625 ID X .875 MTG HOLE . . . . . . . . . . . . . . . . . . .
GASKET, INDUCTOR MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COIL, INDUCTOR (PRE−REGULATOR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SCREW,250- X .50 HEXWHD T-25 T/C SC ZC . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
3
2
1
2
2
2
1
1
1
1
1
1
2
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-216 869 Page 115
1
. Hardware is common and
not available unless listed.
2
3
4
5
6
8
804 135-C
Figure 15-5. Heat Sink, Primary Assembly
Item
No.
Dia.
Mkgs.
Part
No.
Description
219 344
... 1 ..........
. . . 2 . . . RM1 .
... 3 ..........
. . . 4 . . . RT1 . .
. . . 5 . MOD1,2
. . . 6 . . . PC1 . .
. . . . . . . . PLG11 .
. . . . . . . . PLG13
. . . . . . . . PLG15
... 8 ..........
213 346
205 751
207 451
213 353
217 625
233 146
201 665
131 056
164 899
200 565
Quantity
Figure 15-5. Heat Sink, Primary Assembly
..
..
..
..
..
..
..
..
..
..
HEAT SINK, POWER MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MODULE, POWER RESISTOR W/PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SCREW, 008−32X .50 PAN HD−PHL STL PLD SEMS . . . . . . . . . . . . . . . . . . .
THERMISTOR, NTC 30K OHM @ 25 DEG C 8IN LEAD . . . . . . . . . . . . . . . . .
KIT, INPUT/PRE−REGULATOR AND INVERTER MODULE . . . . . . . . . . . . . .
CIRCUIT CARD ASSY, POWER INTERCONNECT . . . . . . . . . . . . . . . . . . . . .
HOUSING PLUG+SKTS, (SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HOUSING RCPT+SKTS, (SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HOUSING PLUG PINS+SKTS, (SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . .
SCREW, M 5− .8X 35 PAN HD−PHL STL PLD SEMS . . . . . . . . . . . . . . . . . . . .
1
1
3
1
1
1
1
1
1
4
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-216 869 Page 116
3
1
4
5
2
. Hardware is common and
not available unless listed.
12
6
9
10
11
7
8
804 136-C
Figure 15-6. Wind Tunnel, Left Hand w/Components
Item
No.
Dia.
Mkgs.
Part
No.
Description
213 354
...
...
...
...
...
...
...
...
...
...
...
...
...
1
2
2
3
4
5
6
7
8
9
10
11
12
. . . . . . . . . . 170 647
. . . . . . . . . . 218 004
. . . . . . . . . . 219 844
. . . CR1 . . 206 258
. . . . . . . . . . 145 217
. . . . . . . . . +212 488
. . . . T1 . . 213 361
. . . . Z4 . . 213 513
. . . . Z1 . . 213 356
. . . . . . . . . . 010 493
. . . . . . . . . . 010 381
. . . . . . . . . . 227 746
. . . . . . . . . . 057 357
Figure 15-6. Wind Tunnel, Left Hand w/Components
..
..
..
..
..
..
..
..
..
..
..
..
..
Quantity
BUSHING, SNAP−IN NYL 1.312 ID X 1.500 MTG HOLE . . . . . . . . . . . . . . . . .
LABEL, WARNING ELECTRIC SHOCK/EXPLODING PARTS . . . . . . . . . . . .
LABEL, WARNING ELECTRIC SHOCK/EXPLODING PARTS−WDLES (CE)
RELAY, ENCL 24VDC SPST 30A/240VAC 4PIN FLANGE MTG . . . . . . . . . . .
SCREW, K40X 12 PAN HD−PHL STL PLD PT THREAD FORMING . . . . . . .
PANEL, LEFT WINDTUNNEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
XFMR, HF LITZ/LITZ W/BOOST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COIL, INDUCTOR (BOOST) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OUTPUT INDUCTOR ASSY, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BUSHING, SNAP−IN NYL .625 ID X .875 MTG HOLE . . . . . . . . . . . . . . . . . . .
CONNECTOR, RECTIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GASKET, INDUCTOR MOUNTING E55 FERRITE CORE . . . . . . . . . . . . . . .
BUSHING, SNAP−IN NYL .937 ID X 1.125 MTG HOLE . . . . . . . . . . . . . . . . . .
1
1
1
1
2
1
1
1
1
2
1
1
2
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-216 869 Page 117
. Hardware is common and
7
not available unless listed.
6
4
5
3
2
1
8
9
10
804 137-A
Figure 15-7. Heat Sink, Secondary − Dynasty 350
Item
No.
Dia.
Mkgs.
Part
No.
Description
219 345
. . . 1 . . . PC3 . .
. . . . . . . . PLG37
. . . . . . . . PLG38
... 2 ..........
... 3 ..........
. . . 4 . PM1 − 6
. . . 5 . . D1,D2 .
. . . 6 . . . RT2 . .
... 7 ..........
. . . 8 . . . SR1 . .
... 9 ..........
. . . 10 . . . PC9 . .
233 157
131 204
115 093
213 517
216 867
213 522
213 521
213 353
224 470
201 530
216 868
241 542
Quantity
Figure 15-7. Heat Sink, Secondary − Dynasty 350
..
..
..
..
..
..
..
..
..
..
..
..
CIRCUIT CARD ASSY, COMMUTATOR CONTROL . . . . . . . . . . . . . . . . . . . . .
HOUSING PLUG+SKTS, (SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HOUSING PLUG+SKTS, (SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BUS BAR, OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BUS BAR, POSITIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
KIT, IGBT (CONSISTS OF 3 IGBT’S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
KIT, ULTRA FAST DIODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
THERMISTOR, NTC 30K OHM @ 25 DEG C 8IN LEAD . . . . . . . . . . . . . . . . .
HEAT SINK, POWER MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
KIT, DIODE FAST RECOVERY BRIDGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BUS BAR, NEGATIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT CARD ASSEMBLY, DIODE SNUBBER . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
2
1
2
2
1
1
1
1
1
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-216 869 Page 118
1
. Hardware is common and
not available unless listed.
3
4
5
2
7
6
804 177-B
Figure 15-8. Heat Sink, Secondary − Maxstar 350
Item
No.
Dia.
Mkgs.
Part
No.
Description
221 730
...
...
...
...
...
...
...
1
2
3
4
5
6
7
..........
. . D1, D2
. . . SR1 . .
. . . RT2 . .
. . . PC3 . .
..........
. . . C12 . .
224 470
213 521
201 531
213 353
241 542
213 519
233 133
Quantity
Figure 15-8. Heat Sink, Secondary − Maxstar 350
..
..
..
..
..
..
..
HEAT SINK, POWER MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
KIT, ULTRA FAST DIODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
KIT, DIODE POWER MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
THERMISTOR, NTC 30K OHM @ 25 DEG C 8IN LEAD . . . . . . . . . . . . . . . . .
CIRCUIT CARD ASSY, DIODE SNUBBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BUS BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAPACITOR ASSY (CE ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
2
1
1
1
1
1
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-216 869 Page 119
SECTION 16 − PARTS LIST FOR 700 MODELS
. Hardware is common and
not available unless listed.
6
12
5
4
11
9
7
2
3
8
39
14
10
8
25
35
13
Maxstar
37
24 Dynasty
Only
36
1
26
27
33
37
38
17
18
29
16
34
24
Maxstar
Only
23
28
13Dynasty
15
19
37
21
22
30
22
21
38
20 8
18
19
31
17
3
37
8
32
1
28
Dynasty 700 illustrated
805 472-B
Figure 16-1. Main Assembly
OM-216 869 Page 120
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 16-1. Main Assembly
. . . 1 . . . . . . . . . . 223 785 . .
. . . 1 . . . . . . . . . . 223 784 . .
. . . 2 . . . . . . . . . . 213 071 . .
. . . 3 . . . . . . . . . . 213 057 . .
. . . 4 . . . . . . . . . +213 056 . .
. . . 5 . . . . . . . . . . 203 990 . .
. . . 5 . . . . . . . . . . 179 310 . .
. . . 6 . . . . . . . . . . 213 073 . .
. . . 7 PC8,PC18 233 142 . .
. . . . PLG24/PLG44 163 467 . . .
. . . . PLG33/PLG43 201 665 . . .
. . . . PLG34/PLG45 148 439 . . .
. . . 8 . . . . . . . . . . 080 509 . .
. . . 9 . . . . . . . . . . 221 708 . .
. . . 10 . . . . . . . . . . 010 493 . .
. . . 11 . . . . . . . . . . 213 058 . .
. . . 12 . . . . T2 . . 213 059 . .
. . . 13 . . . . . . . . . . 155 436 . .
. . . 14 . . . . . . . . . . 254 015 . .
. . . 15 . . . . . . . . . . 089 120 . .
. . . 16 . . . . . . . Figure 16-3 . .
. . . 17 . . . . . . . Figure 16-5 . .
. . . 18 . . . . . . . Figure 16-4 . .
. . . 19 . . . PC7 . . 235 476 . .
. . . . . . . . PLG39 115 092 . .
. . . 20 . . . . . . . . . . 213 055 . .
. . . 21 . . . . . . . . . . 213 074 . .
. . . 22 . . . HD1 . . 182 918 . .
. . . 23 . . . . . . . Figure 16-7 . .
. . . 23 . . . . . . . Figure 16-8 . .
. . . 24 . . . . . . . . . . 213 248 . .
. . . 25 . . . PC5 . . 247 125 . .
. . . . . . . . PLG19 131 052 . .
. . . . . . . . PLG21 115 091 . .
. . . . . . . . PLG22 131 054 . .
. . . . . . . . PLG23 115 093 . .
. . . . . . . . PLG41 131 054 . .
. . . 26 . . . . . . . . . . 215 402 . .
. . . 27 . . . . . . . . . . 057 357 . .
. . . 28 . . . . . . . Figure 16-6 . .
. . . 29 . . C6,C7 . 222 752 . .
. . . 30 . . . . . . . . . . 221 721 . .
. . . 31 . . . . C8 . . 221 707 . .
. . . 32 . . . . . . . Figure 16-2 . .
. . . . . . . . . . . . . . . . 215 120 . .
. . . 33 . . PC19 . 233 152 . .
. . . 33 . . PC19 . 246 265 . .
. . . 34 . . . . . . . . . . 222 760 . .
. . . 35 . . . . . . . . . . 226 878 . .
. . . 36 . . . . . . . . . . 195 666 . .
. . . 37 . . F8, F9 131 447 . .
. . . . . . F10, F11 . . . . . . . . . . .
LABEL, SIDE DYNASTY 700 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
LABEL, SIDE MAXSTAR 700 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
INSULATOR, SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
PANEL, SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
WRAPPER, TOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
LABEL, GENERAL PRECAUTIONARY STATIC . . . . . . . . . . . . . . . . . . . . . . . . . 1
LABEL, GENERAL PRECAUTIONARY WORDLESS EMF (CE) . . . . . . . . . . . 1
SEAL, LIFT EYE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
CIRCUIT CARD ASSY, CLAMP (DYNASTY 700 MODELS ONLY) . . . . . . . . . . . 2
HOUSING PLUG+SKTS,(SERVICE KIT) (DYNASTY 700 MODELS ONLY) 1
HOUSING PLUG+SKTS, (SERVICE KIT) (DYNASTY 700 MODELS ONLY) 1
HOUSING PLUG PINS+SKTS, (SERVICE KIT) (DYNASTY 700 MODELS ONLY)1
GROMMET, SCR NO 8/10 PANEL HOLE .312 SQ .375 HIGH . . . . . . . . . . . . 9
BRACKET, MTG PC BOARD (DYNASTY 700 MODELS ONLY) . . . . . . . . . . . 1
BUSHING, SNAP−IN NYL .625 ID X .875 MTG HOLE . . . . . . . . . . . . . . . . . . . 2
LIFT EYE, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
XFMR, 665 115/24 18/18 220 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
LABEL, GROUND/PROTECTIVE EARTH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
HOSE, NPRN BRD NO 1 X .250 ID X 23.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
CLAMP, HOSE .375 − .450 CLP DIA SLFTTNG GREEN . . . . . . . . . . . . . . . . . 2
PANEL, REAR W/COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
HEAT SINK, PRIMARY ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
WINDTUNNEL, RIGHT HAND W/COMPONENTS . . . . . . . . . . . . . . . . . . . . . . 2
CIRCUIT CARD ASSY, HF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
HOUSING PLUG+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
BASE, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
CABLE, LEM 23 IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
TRANSDUCER,CURRENT 400A MODULE SUPPLY V +/− 15V . . . . . . . . . 2
HEAT SINK, SECONDARY − DYNASTY 700 . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
HEAT SINK, SECONDARY − MAXSTAR 700 . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
LUG, UNIV W/SCREW 2/0−14 WIRE .266STD . . . . . . . . . . . . . . . . . . . . . . . . . 1
CIRCUIT CARD ASSY, AUX POWER W/PROGRAM . . . . . . . . . . . . . . . . . . . 1
HOUSING RCPT+SKTS, (SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
HOUSING PLUG+SKTS, (SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
HOUSING RCPT+SKTS, (SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
HOUSING PLUG+SKTS, (SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
HOUSING RCPT+SKTS, (SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
PANEL, TOP WINDTUNNEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
BUSHING,SNAP−IN NYL .937 ID X 1.125 MTG HOLE . . . . . . . . . . . . . . . . . . 1
WINDTUNNEL, LEFT HAND W/COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . 2
CAPACITOR ASSY, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
PANEL, WINDTUNNEL SEPARATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
CAPACITOR ASSY, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
PANEL, FRONT W/CMPNTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
CONNECTION KIT, DINSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
CIRCUIT CARD ASSY, FILTER (DYNASTY 700 ONLY) (CE) . . . . . . . . . . . . 1
CIRCUIT CARD ASSY, FILTER (MAXSTAR 700 ONLY) (CE) . . . . . . . . . . . . 1
BRACKET, FILTER BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
BRACKET, HARNESS SUPPORT (MAXSTAR 700 ONLY) . . . . . . . . . . . . . . . 1
SCREW, 010−32X .50 TORX PANHD W/GNDRNG STL PLD . . . . . . . . . . . . 2
CORE, TOROIDAL 1.332 ID X 1.932 OD X .625 THK
(DYNASTY 700 ONLY) (CE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
OM-216 869 Page 121
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 16-1. Main Assembly (continued)
. . . 38 . . F8, F9 237 542 . . CORE, TOROIDAL .540 ID X .875 OD X .500 THK (MAXSTAR 700 ONLY) (CE) 2
. . . 39 . . . . . . . . . . 235496 . . CABLE TIE, 0.06−2.000 BUNDLE DIA TREE STYLE PUSH MOUNT
. . . . . . . . . . . . . . . . . . . . . . . . . . . MTG HOLE DIA .246−.276 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
. Hardware is common and
22
not available unless listed.
23
13
12
9
10
14
11
24
6
25
8
26
20
18
15
16
17
19
21
1
2
3
4
7
5
1
804 138-C
Figure 16-2. Panel, Front w/Components
Item
No.
Dia.
Mkgs.
Part
No.
Description
221 408
...
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
8
..........
..........
..........
..........
..........
..........
..........
..........
..........
OM-216 869 Page 122
213 053
214 826
186 228
185 712
231 279
213 051
216 859
233 115
233 116
Quantity
Figure 16-2. Panel, Front w/Components
..
..
..
..
..
..
..
..
..
PANEL, LOUVER COVER (ORDER SERIAL NO. CARD ALSO) . . . . . . . . . .
RECEPTACLE, THREAD LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
O−RING, 0.739 ID X 0.070 H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSULATOR, BULKHEAD FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FITTING,GAS−CLIP MOUNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PANEL, FRONT TOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLATE, FRONT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLATE, INDICATOR FRONT − DYNASTY 700 . . . . . . . . . . . . . . . . . . . . . . . . .
PLATE, INDICATOR FRONT − MAXSTAR 700 . . . . . . . . . . . . . . . . . . . . . . . . .
2
2
2
2
1
1
1
1
1
Item
No.
Dia.
Mkgs.
Part
No.
221 408
... 9 ..........
. . . 10 . . . . . . . . . .
. . . 11 . . . . . . . . . .
. . . 12 . . . . . . . . . .
. . . 12 . . . . . . . . . .
. . . 13 . . . PC6 . .
. . . . . . . . PLG2 .
. . . . . . . . PLG4 .
. . . . . . . . PLG5 .
. . . . . . . . PLG6 .
. . . . . . . . PLG7 .
. . . 14 . . . RC1 . .
. . . 15 . . . . . . . . . .
. . . 16 . . . . . . . . . .
. . . 17 . . . . . . . . . .
. . . 18 . . . . . . . . . .
. . . 19 . . . . . . . . . .
. . . 20 . . . . . . . . . .
. . . 21 FMB,FMT
................
. . . 22 . . PC10 .
. . . 23 . . . . . . . . . .
. . . 24 . . . . . . . . . .
. . . 25 . . . . . . . . . .
. . . 26 . . . . . . . . . .
228 546
242 388
233 113
226 868
226 869
241 061
203 800
131 056
162 382
115 092
115 094
213 327
185 717
178 548
229 338
185 718
185 713
230 155
213 072
195516
233150
223263
218715
218713
079739
Description
Quantity
Figure 16-2. Panel, Front w/Components (continued)
. . KNOB, POINTER 1.250 DIA X 6MM ID W/SPRING CLIP− 4.5MM FLAT . .
. . BUSHING, FLG 375−32X.511 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PANEL, FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . NAMEPLATE/SWITCH MEMBRANE, DYNASTY 350/700 STH/FF . . . . . . . .
. . NAMEPLATE/SWITCH MEMBRANE, MAXSTAR 350/700 STH/FF . . . . . . . .
. . CIRCUIT CARD ASSY, CONTROL&INTERFACE W/PROGRAM . . . . . . . . . . . .
. . HOUSING PLUG+SKTS, (SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HOUSING RCPT+SKTS, (SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HOUSING PLUG+SKTS, (SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HOUSING PLUG+SKTS, (SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HOUSING PLUG+SKTS, (SERVICE KIT) (Dynasty 700 Models Only) . . . . .
. . RECEPTACLE, W/LEADS & PLUG 14PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . NUT, M20−1.5 1.00HEX .19H BRS LOCKING . . . . . . . . . . . . . . . . . . . . . . . . . .
. . TERMINAL, CONNECTOR FRICTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . WASHER, DOMED LOAD .812 ID X 1.450 OD X .070 THK . . . . . . . . . . . . . .
. . O−RING, 0.989 ID X 0.070 H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . INSULATOR, BULKHEAD REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BRACKET, VALVE MTG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . FAN, MUFFIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . KIT, AUTOMATION INTERFACE CONNECTION (INCLUDES) . . . . . . . . . . . .
. . . . CIRCUIT CARD ASSY, AUTOMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . RECEPTACLE, W/LEADS & PLUG 28 PIN . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CONN, CIRC MS/CPC 28PIN SIZE 17 PLUG CABLE PUSHIN . . . . . . . . . .
. . . . CONN, CIRC MS/AMP PIN PUSHIN 20-24GA SOLDER CUP . . . . . . . . . .
. . . . CONN, CIRC CPC CLAMP STR RLF SIZE 17-20 .703OD . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
1
1
1
1
2
1
2
2
2
1
2
1
1
1
1
28
1
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
Notes
OM-216 869 Page 123
9
. Hardware is common and
not available unless listed.
5
6
8
7
10
4
3
2
11
1
804 139-A
Figure 16-3. Panel, Rear w/Components
Item
No.
Dia.
Mkgs.
Part
No.
221 409
. . . 1 . . . . . . . . . +213 054
. . . 2 . . . GS1 . . 238805
. . . 3 . . . CB1 . . 183 492
. . . 4 . . . RC2 . . 189 033
. . . 5 . . . . . . . . . . 115 516
. . . 6 . . . . . . . . . . 010 467
. . . 7 . . . . . . . . . . 137 761
. . . 8 . . . . . . . . . . 215 117
. . . 9 . . . . . . . . . . 217 297
. . . 10 . . . . . . . . . . 221 164
. . . 10 . . . . . . . . . . 219 842
. . . 11 . . . . S1 . . 246 846
. . . . . . . . . . . . . . . . 249 816
Description
Quantity
Figure 16-3. Panel, Rear w/Components
. . PANEL, REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . VALVE, 24VDC 2WAY,125 PSI CUSTOM PORT.054 ORF W/FR . . . . . . . . . .
. . SUPPLEMENTARY PROTECTOR, MAN RESET 1P 10A 250V FRIC . . . . .
. . RCPT, STR DX GND 2P3W 15A 125V (GRAY) . . . . . . . . . . . . . . . . . . . . . . . . .
. . RIVET, AL .187 DIA X .063−.125 GRIP BLK BLIND DOME . . . . . . . . . . . . . . .
. . CONN, CLAMP CABLE 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . NUT, 750 NPT 1.31HEX .27H NYL BLK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . NAMEPLATE, IDENT REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . COVER, RECEPTACLE WEATHERPROOF DUPLEX RCPT . . . . . . . . . . . . .
. . LABEL, WARNING ELECTRIC SHOCK/INPUT POWER CONNECT . . . . . .
. . LABEL, WARNING INPUT CONNECTIONS/ELECTRIC SHOCK (CE) . . . .
. . SWITCH, TGL ASSY (INCLUDES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . SWITCH, TGL 3 PST 85A 600VAC SCR TERM WIDE TGL . . . . . . . . . . . .
1
1
1
1
1
1
1
1
1
1
1
1
1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-216 869 Page 124
. Hardware is common and
not available unless listed.
2
1
3
11
4
5
6
7
8
14
15
13
5
12
9
10
804 134-B
Figure 16-4. Wind Tunnel, Right Hand w/Components
Item
No.
Dia.
Mkgs.
Part
No.
Description
213 345
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
9
10
11
11
12
13
14
15
. . . . L1 . . 231 244
. . T3, T4 . 242 782
. . . . . . . . . +212 489
. . . . . . . . . . 195 666
. . . . . . . . . . 216 861
. . . . . . . . . . 170 647
. . . . . . . . . . 216 860
. . C4,C20 217 941
. . . . . . . . . . 207 418
. . . . C3 . . 216 700
. . . . . . . . . . 218 004
. . . . . . . . . . 219 844
. . . . . . . . . . 010 493
. . . . . . . . . . 218 566
. . . . L2 . . 213 348
. . . . . . . . . . 233 913
Quantity
Figure 16-4. Wind Tunnel, Right Hand w/Components
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
INDUCTOR, INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
XFMR, COUPLING (TOP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PANEL, RIGHT WINDTUNNEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SCREW, 010−32X .50 TORX PANHD WGNDRNG STL PLD . . . . . . . . . . . . .
STAND−OFF, CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BUSHING, SNAP−IN NYL 1.312 ID X 1.500 MTG HOLE . . . . . . . . . . . . . . . . .
GROMMET, CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAPACITOR, ELCTLT 1800 UF 500 VDC CAN 2.52 DIA . . . . . . . . . . . . . . . . .
SCREW, K40X 20 PAN HD−PHL STL PLD PT THREAD FORMING . . . . . . .
CAPACITOR, POLYP MET FILM 16. UF 400 VAC 10% . . . . . . . . . . . . . . . . . .
LABEL, WARNING ELECTRIC SHOCK/EXPLODING PARTS . . . . . . . . . . . .
LABEL, WARNING ELECTRIC SHOCK/EXPLODING PARTS−WDLES (CE)
BUSHING, SNAP−IN NYL .625 ID X .875 MTG HOLE . . . . . . . . . . . . . . . . . . .
GASKET, INDUCTOR MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COIL, INDUCTOR (PRE−REGULATOR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SCREW,250- X .50 HEXWHD T-25 T/C SC ZC . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
3
2
1
2
2
2
1
1
1
1
1
1
2
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-216 869 Page 125
1
. Hardware is common and
not available unless listed.
2
3
4
5
6
8
804 135-C
Figure 16-5. Heat Sink, Primary Assembly
Item
No.
Dia.
Mkgs.
Part
No.
Description
219 344
... 1 ..........
. . . 2 . . . RM1 .
... 3 ..........
. . . 4 . RT1,RT3
. . . 5 . MOD1,2
. . . 6 . PC1,PC2
. . . . . . . . PLG11 .
. . . . . . . . PLG13
. . . . . . . . PLG15
. . . . . . . . PLG26
. . . . . . . . PLG27
. . . . . . . . PLG46
... 8 ..........
213 346
205 751
207 451
213 353
217 625
233 146
210 050
131 056
164 899
158 719
131 056
210 050
200 565
Quantity
Figure 16-5. Heat Sink, Primary Assembly
..
..
..
..
..
..
..
..
..
..
..
..
..
HEAT SINK, POWER MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MODULE, POWER RESISTOR W/PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SCREW, 008−32X .50 PAN HD−PHL STL PLD SEMS . . . . . . . . . . . . . . . . . . .
THERMISTOR, NTC 30K OHM @ 25 DEG C 8IN LEAD . . . . . . . . . . . . . . . . .
KIT, INPUT/PRE−REGULATOR AND INVERTER MODULE . . . . . . . . . . . . . .
CIRCUIT CARD ASSY, POWER INTERCONNECT . . . . . . . . . . . . . . . . . . . . .
HOUSING PLUG+SKTS, (SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HOUSING RCPT+SKTS, (SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HOUSING PLUG PINS+SKTS, (SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . .
HOUSING PLUG+SKTS, (SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HOUSING RCPT+SKTS, (SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HOUSING PLUG+SKTS, (SERVICE KIT) (DYNASTY 700 MODELS ONLY)
SCREW, M 5− .8X 35 PAN HD−PHL STL PLD SEMS . . . . . . . . . . . . . . . . . . . .
1
1
3
1
1
1
1
1
1
1
1
1
4
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-216 869 Page 126
3
1
4
5
2
. Hardware is common and
not available unless listed.
12
6
9
10
11
7
8
804 136-C
Figure 16-6. Wind Tunnel, Left Hand w/Components
Item
No.
Dia.
Mkgs.
Part
No.
Description
213 354
...
...
...
...
...
...
...
...
...
...
...
...
...
1
2
2
3
4
5
6
7
8
9
10
11
12
. . . . . . . . . . 170 647
. . . . . . . . . . 218 004
. . . . . . . . . . 219 844
. . . CR1 . . 206 258
. . . . . . . . . . 145 217
. . . . . . . . . +212 488
. . . . T1 . . 213 361
. . . . Z4 . . 213 513
. . . . Z1 . . 213 356
. . . . . . . . . . 010 493
. . . . . . . . . . 010 381
. . . . . . . . . . 227 746
. . . . . . . . . . 057 357
Figure 16-6. Wind Tunnel, Left Hand w/Components
..
..
..
..
..
..
..
..
..
..
..
..
..
Quantity
BUSHING, SNAP−IN NYL 1.312 ID X 1.500 MTG HOLE . . . . . . . . . . . . . . . . .
LABEL, WARNING ELECTRIC SHOCK/EXPLODING PARTS . . . . . . . . . . . .
LABEL, WARNING ELECTRIC SHOCK/EXPLODING PARTS (CE) . . . . . . . .
RELAY, ENCL 24VDC SPST 30A/240VAC 4PIN FLANGE MTG . . . . . . . . . . .
SCREW, K40X 12 PAN HD−PHL STL PLD PT THREAD FORMING . . . . . . .
PANEL, LEFT WINDTUNNEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
XFMR, HF LITZ/LITZ W/BOOST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COIL, INDUCTOR (BOOST) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OUTPUT INDUCTOR ASSY, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BUSHING, SNAP−IN NYL .625 ID X .875 MTG HOLE . . . . . . . . . . . . . . . . . . .
CONNECTOR, RECTIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GASKET, INDUCTOR MOUNTING E55 FERRITE CORE . . . . . . . . . . . . . . .
BUSHING, SNAP−IN NYL .937 ID X 1.125 MTG HOLE . . . . . . . . . . . . . . . . . .
1
1
1
1
2
1
1
1
1
2
1
1
2
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-216 869 Page 127
. Hardware is common and
7
not available unless listed.
6
4
5
3
2
1
8
9
10
804 137-A
Figure 16-7. Heat Sink, Secondary − Dynasty 700
Item
No.
Dia.
Mkgs.
Part
No.
219 345
. . . 1 . PC3,PC4 233 157 . .
. . . . . PLG32/PLG38115 093 . .
. . . . . PLG31/PLG37131 024 . .
. . . 2 . . . . . . . . . . 213 517 . .
. . . 3 . . . . . . . . . . 216 867 . .
. . . 4 . PM1 − 6 213 522 . .
. . . 5 . . D1,D2 . 213 521 . .
. . . 6 . RT2,RT4 213 353 . .
. . . 7 . . . . . . . . . . 224 470 . .
. . . 8 . . . SR1 . . 201 530 . .
. . . 9 . . . . . . . . . . 216 868 . .
. . . 10 . . . PC9 . . 241 542 . .
Description
Quantity
Figure 16-7. Heat Sink, Secondary − Dynasty 700
CIRCUIT CARD ASSY, COMMUTATOR CONTROL . . . . . . . . . . . . . . . . . . . .
CIRCUIT CARD ASSY, COMMUTATOR CONTROL . . . . . . . . . . . . . . . . . . . . .
CIRCUIT CARD ASSY, COMMUTATOR CONTROL . . . . . . . . . . . . . . . . . . . . .
BUS BAR, OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BUS BAR, POSITIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
KIT, IGBT (CONSISTS OF 3 IGBT’S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
KIT, ULTRA FAST DIODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
THERMISTOR, NTC 30K OHM @ 25 DEG C 8IN LEAD . . . . . . . . . . . . . . . . .
HEAT SINK, POWER MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
KIT, DIODE FAST RECOVERY BRIDGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BUS BAR, NEGATIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT CARD ASSEMBLY, DIODE SNUBBER . . . . . . . . . . . . . . . . . . . . . . .
2
1
1
2
1
2
2
1
1
1
1
1
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-216 869 Page 128
1
. Hardware is common and
not available unless listed.
3
4
5
2
7
804 177-B
6
Figure 16-8. Heat Sink, Secondary − Maxstar 700
Item
No.
Dia.
Mkgs.
Part
No.
Description
221 730
...
...
...
...
...
...
...
1
2
3
4
5
6
7
..........
. . D1, D2
. . . SR1 . .
. RT2, RT4
. . . PC3 . .
..........
. C9, C10
224 470
213 521
201 531
213 353
241 542
213 519
221 707
Quantity
Figure 16-8. Heat Sink, Secondary − Maxstar 700
..
..
..
..
..
..
..
HEAT SINK, POWER MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
KIT, ULTRA FAST DIODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
KIT, DIODE POWER MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
THERMISTOR, NTC 30K OHM @ 25 DEG C 8IN LEAD . . . . . . . . . . . . . . . . .
CIRCUIT CARD ASSY, DIODE SNUBBER . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BUS BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAPACITOR ASSY (CE ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
2
1
1
1
1
1
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-216 869 Page 129
SECTION 17 − PARTS LIST FOR COOLER
. Hardware is common and
not available unless listed.
10
6
5
7
11
8
17
9
4
2
3
15
14
16
1
13
12
19
18
20
35
34
14
29
21
22
33
32
23
24
31
26
30
14
25
27
28
804 813-B
Figure 17-1. Main Assembly
OM-216 869 Page 130
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 17-1. Main Assembly
. . . 1 . . . . . . . . . . 228 551
. . . 2 . . . . . . . . . . 219 178
. . . 3 . . . . . . . . . +226 965
. . . 4 . . . . . . . . . . 228 519
. . . 5 . . . . . . . . . . 228 508
. . . 6 . . . . . . . . . . . . . 5523
. . . 7 . . . . . . . . . . 173 999
. . . 8 . . . . . . . . . . 134 795
. . . 9 . . . . . . . . . . 196 990
. . . 10 . . . . . . . . . . 173 263
. . . 11 . . . . . . . . . . 226 966
. . . 12 . . . . . . . . . . 166 608
. . . 13 . . . . . . . . . . 226 932
. . . . . . . . . . . . . . . . 231 286
. . . . . . . . . . . . . . . . 231 284
. . . . . . . . . . . . . . . . 228 518
. . . . . . . . . . . . . . . . 231 285
. . . 14 . . . . . . . . . . 228 529
. . . 15 . . . . . . . . . . 155 436
. . . 16 . . . . . . . . . . 163 562
. . . 17 . . . . . . . . . . 213 053
. . . 18 . . . . . . . . . . 230 151
. . . 19 . . . . . . . . . . 226 940
. . . 20 . . . . . . . . . . 230 155
. . . 21 . . . . . . . . . . 226 964
. . . 22 . . . . . . . . . . 226 931
. . . 23 . . . . . . . . . . 232 424
. . . 24 . . . . . . . . . . 231 341
. . . 25 . . . . . . . . . . 213 072
. . . 26 . . . . . . . . . . 204 369
. . . 27 . . . . . . . . . . 228 498
. . . 28 . . . . . . . . . . 196 312
. . . 29 . . . . . . . . . . 228 520
. . . 30 . . . . . . . . . . 215 667
. . . 31 . . . . . . . . . . 228 532
. . . 32 . . . . . . . . . . 231 286
. . . 33 . . . . . . . . . . 226 967
. . . 34 . . . . . . . . . . 236 084
. . . 35 . . . . . . . . . . 228 530
. . Plug, W/Leads Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Label, Caution Incorrect Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Panel, Side RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Hose, nprn brd no 1 X .250 ID X .455 OD X 9.000 . . . . . . . . . . . . . . . . . . . . . .
. . Pump, Coolant W/Fittings (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Ftg, Hose Brs Barbed Elbow M 3/8 TBG X 3/8 NPT . . . . . . . . . . . . . . . . . . .
. . . . Pump, Coolant 100 GPH W/V-Band CW Rotation . . . . . . . . . . . . . . . . . . . . .
. . . . Coupler, Drive Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Ftg, Brs Barbed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Motor, 1/4hp 115vac 50/60 Hz 1425/1725 RPM Dual . . . . . . . . . . . . . . . . . . . . .
. . Bracket, Motor Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Cap, Tank Screw−on W/Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Tank, Coolant (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Ftg, Hose Brs Elbow Barbed M 3/8 TBG X M 3/8 TBG . . . . . . . . . . . . . . . .
. . . . Bushing, Tank Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Tubing, PVC .375 ID X .500 OD X 6.125 Blk Angle . . . . . . . . . . . . . . . . . . .
. . . . Tubing, PVC .375 ID X .500 OD X 1.000 Blk . . . . . . . . . . . . . . . . . . . . . . . .
. . Hose, .375 ID X .650 OD X 19.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Label, Ground/Protective Earth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Light, Ind Wht Lens 125VAC Snap−in Neon Non−relampa . . . . . . . . . . . . . . . .
. . Panel, Louver Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Plate, Indicator Front Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Valve, Check Bidirectional Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Backet, Valve Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Panel, Side Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Base, Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Radiator, Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Plenum, Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Fan, Muffin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Cable, Power 5 Ft 16ga 3c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Panel, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Guard, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Filter, Assy W/Fittings (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Hose, .375 ID X .650 OD X 1.415 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Ftg, Hose Brs Elbow Barbed M 3/8 TBG X M 3/8 TBG . . . . . . . . . . . . . . . . .
. . . . Bracket, Mtg Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Hose, .375 ID X .650 OD X 10.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Hose, .375 ID X .650 OD X 8.375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
2
1
1
1
1
1
1
1
2
2
1
1
3
1
1
1
1
2
2
1
1
1
1
1
1
1
1
1
1
2
2
1
1
1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-216 869 Page 131
SECTION 18 − PARTS LIST FOR CART
. Hardware is common and
3
not available unless listed.
4
2
7
1
9
6
8
5
10
19
12
11
13
18
15
14
16
17
804 872-B
Figure 18-1. Main Assembly
Item
No.
Dia.
Mkgs.
Part
No.
300 244
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
. . . . . . . . . . . . . 226 927
. . . . . . . . . . . . +226 929
. . . . . . . . . . . . . 210 224
. . . . . . . . . . . . . 226 926
. . . . . . . . . . . . . 192 236
. . . . . . . . . . . . +226 930
. . . . . . . . . . . . . 199 403
. . . . . . . . . . . . . 191 875
. . . . . . . . . . . . . 226 919
. . . . . . . . . . . . . 226 920
. . . . . . . . . . . . . 602 250
. . . . . . . . . . . . . 209 869
. . . . . . . . . . . . . 121 614
. . . . . . . . . . . . . 226 925
. . . . . . . . . . . . . 226 923
. . . . . . . . . . . . . 216 594
. . . . . . . . . . . . . 191 884
. . . . . . . . . . . . . 228 585
. . . . . . . . . . . . . 235 506
Description
Quantity
Figure 18-1 Complete Cart Assembly.
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
Handle, Cart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Panel, Side Rail LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chain, Straight Link 1/0 X 27 Bright Zinc Pld . . . . . . . . . . . . . . . . . . . . .
Support, Bottle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Label, Caution Over Turning Can Cause Injury . . . . . . . . . . . . . . . . . . . . .
Panel, Side Rail RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Holder, Foot Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hanger, Cable/Torch
.........................................
Base, Cart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tray, Bottle Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Washer, Flat .812 ID x 1.469 OD x .134t Stl Pld Ansi .750 . . . . . . . . . .
Wheel, Poly−olefin 10 In Diax 2.000 wide x .750 . . . . . . . . . . . . . . . . . . .
Ring, Rtng Ext .750 Shaft X .085 Thk E Style Pld . . . . . . . . . . . . . . . . . .
Support, Base Drawer Slides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Caster, Swvl 4.00 In Polyolefin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Slide, Drawer Full Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drawer, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Base, Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
2
1
1
3
1
1
2
2
2
1
2
2
1
1
2
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
OM-216 869 Page 132
Effective January 1, 2011
(Equipment with a serial number preface of MB 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 6. 90 Days — Parts
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its
* Accessory (Kits)
original retail purchaser that new Miller equipment sold after the
* Canvas Covers
effective date of this limited warranty is free of defects in material
* Induction Heating Coils and Blankets, Cables, and
and workmanship at the time it is shipped by Miller. THIS
Non-Electronic Controls
WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
* M-Guns
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
* MIG Guns and Subarc (SAW) Guns
WARRANTIES OF MERCHANTABILITY AND FITNESS.
* Remote Controls and RFCS-RJ45
Within the warranty periods listed below, Miller will repair or replace
* Replacement Parts (No labor)
any warranted parts or components that fail due to such defects in
* Roughneck Guns
material or workmanship. Miller must be notified in writing within
* Spoolmate Spoolguns
thirty (30) days of such defect or failure, at which time Miller will
provide instructions on the warranty claim procedures to be
followed.
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
one year 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.
5 Years Parts — 3 Years Labor
* Original main power rectifiers only to include SCRs,
diodes, and discrete rectifier modules
3 Years — Parts and Labor
* Engine Driven Welding 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
* Smith 30 Series Flowgauge and Flowmeter
Regulators (No Labor)
* Transformer/Rectifier Power Sources
* Water Coolant Systems (Integrated)
2 Years — Parts
* Auto-Darkening Helmet Lenses (No Labor)
1 Year — Parts and Labor Unless Specified
* Automatic Motion Devices
* CoolBelt and CoolBand Blower Unit (No Labor)
* 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.)
* Flowgauge and Flowmeter Regulators (No Labor)
* RFCS Foot Controls (Except RFCS-RJ45)
* Fume Extractors
* HF Units
* ICE Plasma Cutting Torches (No Labor)
* Induction Heating Power Sources, Coolers, and
Electronic Controls/Recorders
* Load Banks
* Motor Driven Guns (w/exception of Spoolmate
Spoolguns)
* PAPR Blower Unit (No Labor)
* Positioners and Controllers
* Racks
* Running Gear/Trailers
* Spot Welders
* Subarc Wire Drive Assemblies
* Water Coolant Systems (Non-Integrated)
* Weldcraft-Branded TIG Torches (No Labor)
* Wireless Remote Foot/Hand Controls and Receivers
* Work Stations/Weld Tables (No Labor)
6 Months — Parts
* Batteries
* Bernard Guns (No Labor)
* Tregaskiss Guns (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 2011−01
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
 2011 Miller Electric Mfg. Co.
2011−01