Miller | LH400483L | Owner Manual | Miller DYNASTY 350 ALL OTHER CE AND NON-CE MODELS User manual

Miller DYNASTY 350 ALL OTHER CE AND NON-CE MODELS User manual
OM-216 869F
2007−09
Processes
TIG (GTAW) Welding
Stick (SMAW) Welding
Description
208/575 Volt Models W/Auto-Line
Arc Welding Power Source
Dynasty 350, 700
Maxstar 350, 700
Including Optional Cart And Cooler
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 9001:2000 Quality Warranty and service information for your
System 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 4/05
Working as hard as you do
− every power source from
Miller is backed by the most
hassle-free warranty in the
business.
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Symboles utilisés . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . .
2-4. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-6. Information EMF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − DEFINITIONS (CE Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Warning Label Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Manufacturer’s Rating Labels For Dynasty 350 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Manufacturer’s Rating Labels For Maxstar 350 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4. Manufacturer’s Rating Labels For Dynasty 700 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5. Manufacturer’s Rating Labels For Maxstar 700 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-6. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Duty Cycle and Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Tipping Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Dimensions, Weights And Base Mounting Hole Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8. Connecting Input Power For 350 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-9. Connecting Input Power For 700 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-10. Weld Output Terminals And Selecting Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-11. Remote 14 Receptacle Information (Used Without Automation Connection) . . . . . . . . . . . . . . . . . . . .
4-12. Automation Connection (For 28-Pin Receptacle If Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-13. Remote Memory Select Inputs (For 28-Pin Receptacle If Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-14. Automation Selections (For 28-Pin Receptacle If Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-15. Typical Automation Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-16. 115 Volts AC Duplex Receptacle, Supplementary Protector CB1, And Power Switch . . . . . . . . . . . .
4-17. Gas Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-18. TIG HF Impulse/ Lift-Arct Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-19. Cooler Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-20. Dynasty Stick Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-21. 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 (Dynastyt Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-7. Process Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-8. Lift-ArcE And HF TIG Start Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
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4
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5
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8
9
9
11
11
14
15
16
17
18
19
19
21
22
24
24
25
26
30
32
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TABLE OF CONTENTS
5-9. Output Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5-10. Pulser Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5-11. Sequencer Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5-12. Gas/DIG Controls (Preflow/Post Flow/DIG/Purge) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5-13. AC Waveshape (Dynasty Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
5-14. Memory (Program Storage Locations 1-9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5-15. Factory Parameter Defaults And Range And Resolution For 350 Models . . . . . . . . . . . . . . . . . . . . . . 52
5-16. Factory Parameter Defaults And Range And Resolution For 700 Models . . . . . . . . . . . . . . . . . . . . . . 53
5-17. Resetting Unit To Factory Default Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
5-18. Software And Revision Viewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
5-19. Arc Timer/Counter Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
SECTION 6 − ADVANCED FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
56
6-1. Accessing Advanced Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
6-2. Programmable TIG Start Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
6-3. Output Control And Trigger Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
6-4. AC Waveshape Selection (Dynasty Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
6-5. Independent Amplitude Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
6-6. Spot Enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
6-7. Stick Open-Circuit Voltage (OCV) Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
6-8. Lockout Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
6-9. Setting Unit So Meters Are Blank While Pulse Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
SECTION 7 − MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
68
7-2. Blowing Out Inside of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
7-3. Coolant Maintenance And Oiling Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
7-4. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
SECTION 8 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
72
SECTION 9 − HIGH FREQUENCY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
85
9-1. Welding Processes Requiring High Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
9-2. Incorrect Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
9-3. Correct Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
SECTION 10 − SELECTING AND PREPARING A TUNGSTEN FOR DC OR AC WELDING WITH INVERTER
MACHINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
87
10-1. Selecting Tungsten Electrode (Wear Clean gloves To Prevent Contamination Of Tungsten) . . . . . . . 87
10-2. Preparing Tungsten Electrode For DC Electrode Negative (DCEN) Welding Or AC Welding With Inverter
Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
SECTION 11 − GUIDELINES FOR TIG WELDING (GTAW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
88
11-1. Positioning The Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
11-2. Torch Movement During Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
11-3. Positioning Torch Tungsten For Various Weld Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
SECTION 12 − SETUP GUIDES FOR (GTAW) TIG WELDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
90
12-1. Typical GTAW Setups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
SECTION 13 − SETUP GUIDES FOR (SMAW) STICK WELDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
92
13-1. Front Panel Display For Stick DCEP (Direct Current Electrode Positive) . . . . . . . . . . . . . . . . . . . . . . 92
SECTION 14 − STICK WELDING (SMAW) GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
93
SECTION 15 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
WARRANTY
Declaration of Conformity for
European Community (CE) Products
This information is provided for units with CE certification (see rating label on unit).
Manufacturer:
European Contact:
Miller Electric Mg. Co.
1635 W. Spencer St.
Appleton, WI 54914 USA
Phone: (920) 734-9821
Mr. Danilo Fedolfi,
Managing Director
ITW Welding Products Italy S.r.l.
Via Privata Iseo 6/E
20098 San Giuliano
Milanese, Italy
Phone: 39(02)98290-1
Fax: 39(02)98290203
European Contact Signature:
Declares that this product:
Dynasty® 350
conforms to the following Directives and Standards:
Directives
Low Voltage Directive: 73/23/EEC
Electromagnetic Compatibility Directives: 89/336/EEC, 92/31/EEC, 2004/108/EC
Machinery Directives: 98/37EEC, 91/368/EEC, 92/31/EEC, 133/04, 93/68/EEC
CE Marking Directive: 93/68/EEC
Standards
Arc Welding Equipment − Part 1: Welding Power Sources. IEC 60974-1 Ed. 3, 2005-07
Arc Welding Equipment − Part 10: Electromagnetic Compatibility (EMC) Requirements.
IEC 60974-10 Ed. 1.1, 2004-10
Degrees of Protection Provided By Enclosures (IP Code): IEC 60529 Ed. 2.1, 2001-02
The product technical file is maintained by the responsible Business Unit(s) located at the manufacturing facility.
Additional Standards
Arc Welding Equipment − Part 3: Arc Striking And Stabilizing Devices. IEC 60974-3 Ed. 1, 2003-07
dec_stat_1/07
Declaration of Conformity for
European Community (CE) Products
This information is provided for units with CE certification (see rating label on unit).
Manufacturer:
European Contact:
Miller Electric Mg. Co.
1635 W. Spencer St.
Appleton, WI 54914 USA
Phone: (920) 734-9821
Mr. Danilo Fedolfi,
Managing Director
ITW Welding Products Italy S.r.l.
Via Privata Iseo 6/E
20098 San Giuliano
Milanese, Italy
Phone: 39(02)98290-1
Fax: 39(02)98290203
European Contact Signature:
Declares that the product:
Dynasty 700
conforms to the following Directives and Standards:
Directives
Low Voltage Directive: 73/23/EEC
Electromagnetic compatibility Directives: 89/336/EEC, 92/31/EEC
Machinery Directives: 98/37EEC, 91/368/EEC, 92/31/EEC, 133/04, 93/68/EEC
Standards
Arc Welding Equipment − Part 10: Electromagnetic Compatibility (EMC) Requirements.
IEC 60974-10 August 2002
Arc Welding Equipment − Part 1: Welding Power Sources. IEC 60974-1 Ed. 2.1
Degrees of Protection Provided By Enclosures (IP Code): IEC 60529 Ed. 2.1
Insulation Coordination For Equipment Within Low-Voltage Systems:
Part 1: Principles, Requirements And Tests. IEC 60664-1 Ed. 1.1
Arc Welding Equipment − Part 3: Arc Striking And Stabilizing Devices. IEC 60974-3 Ed. 1
dec_stat_1/07
Declaration of Conformity for
European Community (CE) Products
This information is provided for units with CE certification (see rating label on unit).
Manufacturer:
European Contact:
Miller Electric Mg. Co.
1635 W. Spencer St.
Appleton, WI 54914 USA
Phone: (920) 734-9821
Mr. Danilo Fedolfi,
Managing Director
ITW Welding Products Italy S.r.l.
Via Privata Iseo 6/E
20098 San Giuliano
Milanese, Italy
Phone: 39(02)98290-1
Fax: 39(02)98290203
European Contact Signature:
Declares that this product:
Maxstar®350
conforms to the following Directives and Standards:
Directives
Low Voltage Directive: 73/23/EEC
Electromagnetic Compatibility Directives: 89/336/EEC, 92/31/EEC, 2004/108/EC
Machinery Directives: 98/37EEC, 91/368/EEC, 92/31/EEC, 133/04, 93/68/EEC
CE Marking Directive: 93/68/EEC
Standards
Arc Welding Equipment − Part 1: Welding Power Sources. IEC 60974-1 Ed. 3, 2005-07
Arc Welding Equipment − Part 10: Electromagnetic Compatibility (EMC) Requirements.
IEC 60974-10 Ed. 1.1, 2004-10
Degrees of Protection Provided By Enclosures (IP Code): IEC 60529 Ed. 2.1, 2001-02
The product technical file is maintained by the responsible Business Unit(s) located at the manufacturing facility.
Additional Standards
Arc Welding Equipment − Part 3: Arc Striking And Stabilizing Devices. IEC 60974-3 Ed. 1, 2003-07
dec_stat_1/07
Declaration of Conformity for
European Community (CE) Products
This information is provided for units with CE certification (see rating label on unit).
Manufacturer:
European Contact:
Miller Electric Mg. Co.
1635 W. Spencer St.
Appleton, WI 54914 USA
Phone: (920) 734-9821
Mr. Danilo Fedolfi,
Managing Director
ITW Welding Products Italy S.r.l.
Via Privata Iseo 6/E
20098 San Giuliano
Milanese, Italy
Phone: 39(02)98290-1
Fax: 39(02)98290203
European Contact Signature:
Declares that the product:
Maxstar 700
conforms to the following Directives and Standards:
Directives
Low Voltage Directive: 73/23/EEC
Electromagnetic compatibility Directives: 89/336/EEC, 92/31/EEC
Machinery Directives: 98/37EEC, 91/368/EEC, 92/31/EEC, 133/04, 93/68/EEC
Standards
Arc Welding Equipment − Part 10: Electromagnetic Compatibility (EMC) Requirements.
IEC 60974-10 August 2002
Arc Welding Equipment − Part 1: Welding Power Sources. IEC 60974-1 Ed. 2.1
Degrees of Protection Provided By Enclosures (IP Code): IEC 60529 Ed. 2.1
Insulation Coordination For Equipment Within Low-Voltage Systems:
Part 1: Principles, Requirements And Tests. IEC 60664-1 Ed. 1.1
Arc Welding Equipment − Part 3: Arc Striking And Stabilizing Devices. IEC 60974-3 Ed. 1
dec_stat_1/07
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som _2007−04
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.
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.
When making input connections, attach proper grounding conductor first − double-check connections.
Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
Frequently inspect input power cord for damage or bare wiring −
replace cord immediately if damaged − bare wiring can kill.
Turn off all equipment when not in use.
Do not use worn, damaged, undersized, or poorly spliced cables.
Do not drape cables over your body.
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.
Do not touch live electrical parts.
Wear dry, hole-free insulating gloves and body protection.
Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
Use AC output ONLY if required for the welding process.
If AC output is required, use remote output control if present on
unit.
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!
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).
Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
If earth grounding of the workpiece is required, ground it directly
with a separate cable.
Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
Do not touch electrode holders connected to two welding machines at the same time since double open-circuit voltage will be
present.
Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
Wear a safety harness if working above floor level.
Keep all panels and covers securely in place.
Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
Do not connect more than one electrode or work cable to any
single weld output terminal.
SIGNIFICANT DC VOLTAGE exists in inverter-type
welding power sources after removal of input
power.
Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
HOT PARTS can cause severe burns.
Do not touch hot parts bare handed.
Allow cooling period before working on gun or
torch.
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.
Keep your head out of the fumes. Do not breathe the fumes.
If inside, ventilate the area and/or use local forced ventilation at the
arc to remove welding fumes and gases.
If ventilation is poor, wear an approved air-supplied respirator.
Read and understand the Material Safety Data Sheets (MSDSs)
and the manufacturer’s instructions for metals, consumables,
coatings, cleaners, and degreasers.
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.
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.
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.
Wear an approved welding helmet fitted with a proper shade of filter lenses to protect your face and eyes when welding or watching
(see ANSI Z49.1 and Z87.1 listed in Safety Standards).
Wear approved safety glasses with side shields under your
helmet.
Do not use welder to thaw frozen pipes.
Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
After completion of work, inspect area to ensure it is free of sparks,
glowing embers, and flames.
Use only correct fuses or circuit breakers. Do not oversize or bypass them.
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.
Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
Wear approved safety glasses with side
shields even under your welding helmet.
BUILDUP OF GAS can injure or kill.
Shut off shielding gas supply when not in use.
Always ventilate confined spaces or use
approved air-supplied respirator.
MAGNETIC FIELDS can affect Implanted
Medical Devices.
Wearers of Pacemakers and other Implanted
Medical Devices should keep away.
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.
Use protective screens or barriers to protect others from flash,
glare and sparks; warn others not to watch the arc.
NOISE can damage hearing.
Wear protective clothing made from durable, flame-resistant material (leather, heavy cotton, or wool) and foot protection.
Noise from some processes or equipment can
damage hearing.
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.
Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
Do not weld where flying sparks can strike flammable material.
Protect yourself and others from flying sparks and hot metal.
Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
Watch for fire, and keep a fire extinguisher nearby.
Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
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).
Do not weld where the atmosphere may contain flammable dust,
gas, or liquid vapors (such as gasoline).
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.
OM-216 869 Page 2
Wear approved ear protection if noise level is
high.
CYLINDERS can explode if damaged.
Shielding 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.
Protect compressed gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames, sparks, and arcs.
Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
Keep cylinders away from any welding or other electrical circuits.
Never drape a welding torch over a gas cylinder.
Never allow a welding electrode to touch any cylinder.
Never weld on a pressurized cylinder − explosion will result.
Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and
associated parts in good condition.
Turn face away from valve outlet when opening cylinder valve.
Keep protective cap in place over valve except when cylinder is in
use or connected for use.
Use the right equipment, correct procedures, and sufficient number of persons to lift and move cylinders.
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.
Do not install or place unit on, over, or near
combustible surfaces.
Do not install unit near flammables.
Do not overload building wiring − be sure power supply system is
properly sized, rated, and protected to handle this unit.
FALLING UNIT can cause injury.
MOVING PARTS can cause injury.
Keep away from moving parts such as fans.
Keep all doors, panels, covers, and guards
closed and securely in place.
Have only qualified persons remove doors, panels, covers, or
guards for maintenance as necessary.
Reinstall doors, panels, covers, or guards when maintenance is
finished and before reconnecting input power.
Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
Use equipment of adequate capacity to lift and
support unit.
If using lift forks to move unit, be sure forks are
long enough to extend beyond opposite side of
unit.
READ INSTRUCTIONS.
Read Owner’s Manual before using or servicing unit.
Use only genuine replacement parts from the
manufacturer.
OVERUSE can cause OVERHEATING
H.F. RADIATION can cause interference.
Allow cooling period; follow rated duty cycle.
Reduce current or reduce duty cycle before
starting to weld again.
Do not block or filter airflow to unit.
FLYING SPARKS can cause injury.
Wear a face shield to protect eyes and face.
Shape tungsten electrode only on grinder with
proper guards in a safe location wearing proper
face, hand, and body protection.
Sparks can cause fires — keep flammables away.
STATIC (ESD) can damage PC boards.
Put on grounded wrist strap BEFORE handling
boards or parts.
Use proper static-proof bags and boxes to
store, move, or ship PC boards.
ARC WELDING can cause interference.
MOVING PARTS can cause injury.
Keep away from moving parts.
Keep away from pinch points such as drive
rolls.
WELDING WIRE can cause injury.
Do not press gun trigger until instructed to do
so.
Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
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.
Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
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.
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).
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, 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, P.O. Box 9101, Quincy, MA 02269-9101 (phone:
617-770-3000, 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).
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 5060 Mississauga,
Ontario, Canada L4W 5NS (phone: 800-463-6727 or in Toronto
416-747-4044, 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 10036–8002 (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,
P.O. Box 9101, Quincy, MA 02269-9101 (phone: 617-770-3000, 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 Regional Offices—phone for
Region 5, Chicago, is 312-353-2220, website: www.osha.gov).
1-6. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
1. Keep cables close together by twisting or taping them, or using a
cable cover.
Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
2. Arrange cables to one side and away from the operator.
To reduce magnetic fields in the workplace, use the following
procedures:
OM-216 869 Page 4
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from operator as practical.
5. Connect work clamp to workpiece as close to the weld as possible.
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_2007−04
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.
Seul un personnel qualifié est autorisé à installer, faire fonctionner, entretenir et réparer cet appareil.
Pendant le fonctionnement, maintenir à distance toutes les
personnes, notamment les enfants de l’appareil.
UNE DÉCHARGE ÉLECTRIQUE peut
entraîner la mort.
Le contact d’organes électriques sous tension peut
provoquer des accidents mortels ou des brûlures
graves. Le circuit de l’électrode et de la pièce est
sous tension lorsque le courant est délivré à la
sortie. Le circuit d’alimentation et les circuits internes de la machine
sont également sous tension lorsque l’alimentation est sur Marche.
Dans le mode de soudage avec du fil, le fil, le dérouleur, le bloc de
commande du rouleau et toutes les parties métalliques en contact
avec le fil sont sous tension électrique. Un équipement installé ou mis
à la terre de manière incorrecte ou impropre constitue un danger.
(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.
Ne pas toucher aux pièces électriques sous tension.
L’équipement doit être hors tension lorsqu’il n’est pas utilisé.
Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante ou mal épissés.
Ne pas enrouler les câbles autour du corps.
Porter des gants isolants et des vêtements de protection secs et
sans trous.
Si la pièce soudée doit être mise à la terre, le faire directement
avec un câble distinct.
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.
Ne pas toucher l’électrode quand on est en contact avec la pièce,
la terre ou une électrode provenant d’une autre machine.
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.
Se servir d’une source électrique à courant électrique UNIQUEMENT si le procédé de soudage le demande.
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’autres consignes de sécurité sont nécessaires dans les conditions suivantes : risques électriques dans un environnement
humide ou si l’on porte des vêtements mouillés ; sur des structures
métalliques telles que sols, grilles ou échafaudages ; en position
coincée comme assise, à genoux ou couchée ; ou s’il y a un risque
élevé de contact inévitable ou accidentel avec la pièce à souder ou
le sol. Dans ces conditions, utiliser les équipements suivants,
dans l’ordre indiqué : 1) un poste à souder DC à tension constante
Ne pas toucher des porte électrodes connectés à deux machines
en même temps à cause de la présence d’une tension à vide doublée.
N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-lechamp les pièces endommagées. Entretenir l’appareil
conformément à ce manuel.
Porter un harnais de sécurité si l’on doit travailler au-dessus du sol.
S’assurer que tous les panneaux et couvercles sont correctement
en place.
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.
Isoler la pince de masse quand pas mis à la pièce pour éviter le
contact avec tout objet métallique.
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 quand on a
coupé l’alimentation.
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.
DES PIÈCES CHAUDES peuvent
provoquer des brûlures graves.
Ne pas toucher à mains nues les parties
chaudes.
Prévoir une période de refroidissement avant de
travailler à l’équipement.
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 in
cendie ou une explosion.
Le soudage effectué sur des conteneurs fermés tel
que des réservoirs, tambours ou des conduites peu
provoquer leur éclatement. Des étincelles peuven
être projetées de l’arc de soudure. La projection d’étincelles, des pièce
chaudes et des équipements chauds peut provoquer des incendies e
des brûlures. Le contact accidentel de l’électrode avec des objet
métalliques peut provoquer des étincelles, une explosion, un surchauf
fement ou un incendie. Avant de commencer le soudage, vérifier e
s’assurer que l’endroit ne présente pas de danger.
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.
Ne pas souder dans un endroit là où des étincelles peuvent tomber
sur des substances inflammables.
LES FUMÉES ET LES GAZ peuvent être
dangereux.
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.
Des étincelles et des matériaux chauds du soudage peuvent
facilement passer dans d’autres zones en traversant de petites
fissures et des ouvertures.
Eloigner votre tête des fumées. Ne pas respirer les fumées.
Surveiller tout déclenchement d’incendie et tenir un extincteur à
proximité.
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.
Le soudage effectué sur un plafond, plancher, paroi ou séparation
peut déclencher un incendie de l’autre côté.
Si la ventilation est médiocre, porter un respirateur anti-vapeurs
approuvé.
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).
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.
Ne soudez pas si l’air ambiant est chargé de particules, gaz, ou vapeurs inflammables (vapeur d’essence, par exemple).
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.
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.
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.
En cas de non utilisation, enlever la baguette d’électrode du porteélectrode ou couper le fil à la pointe de contact.
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 pro
voquer des brûlures dans les yeux e
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.
Porter un casque de soudage approuvé muni de verres filtrants
approprié pour protéger visage et yeux pendant le soudage
(voir ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité).
Porter des lunettes de sécurité avec écrans latéraux même sous
votre casque.
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.
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
Ne pas utiliser le poste de soudage pour dégeler des conduites gelées.
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.
Avant de souder, retirer toute substance combustible de vos poches telles qu’un allumeur au butane ou des allumettes.
Une fois le travail achevé, assurez−vous qu’il ne reste aucune
trace d’étincelles incandescentes ni de flammes.
Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
Ne pas augmenter leur puissance; ne pas les ponter.
Une fois le travail achevé, assurez−vous qu’il ne reste aucune
trace d’étincelles incandescentes ni de flammes.
Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
Ne pas augmenter leur puissance; ne pas les ponter.
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.
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.
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.
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.
Fermer l’alimentation du gaz protecteur en cas
de non-utilisation.
Veiller toujours à bien aérer les espaces confinés ou se servir d’un respirateur d’adduction
d’air homologué.
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.
LES CHAMPS MAGNETIQUES peuvent affecter des implants médicaux.
Porteur de simulateur cardiaque ou autre implants médicaux, rester à distance.
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.
Tenir les bouteilles éloignées des circuits de soudage ou autres
circuits électriques.
Ne jamais placer une torche de soudage sur une bouteille à gaz.
Une électrode de soudage ne doit jamais entrer en contact avec
une bouteille.
Ne jamais souder une bouteille pressurisée − risque d’explosion.
LE BRUIT peut endommager l’ouïe.
Utiliser seulement des bouteilles de gaz protecteur, régulateurs,
tuyaux et raccords convenables pour cette application spécifique ;
les maintenir ainsi que les éléments associés en bon état.
Le bruit des processus et des équipements peut
affecter l’ouïe.
Détourner votre visage du détendeur-régulateur lorsque vous
ouvrez la soupape de la bouteille.
Porter des protections approuvées pour les
oreilles si le niveau sonore est trop élevé.
Le couvercle du détendeur doit toujours être en place, sauf lorsque
la bouteille est utilisée ou qu’elle est reliée pour usage ultérieur.
LES BOUTEILLES peuvent exploser
si elles sont endommagées.
Utiliser les équipements corrects, les bonnes procédures et suffisamment de personnes pour soulever et déplacer les bouteilles.
Des bouteilles de gaz protecteur 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.
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.
Ne pas placer l’appareil sur, au-dessus ou
à proximité de surfaces inflammables.
Ne pas installer l’appareil à proximité de produits inflammables.
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’APPAREIL peut
blesser.
Utiliser l’anneau de levage uniquement pour
soulever l’appareil, NON PAS les chariots, les
bouteilles de gaz ou tout autre accessoire.
Utiliser un équipement de levage de capacité
suffisante pour lever l’appareil.
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.
L’EMPLOI EXCESSIF peut
CHAUFFER L’ÉQUIPEMENT.
LES ÉTINCELLES VOLANTES risquent de provoquer des blessures.
Porter un écran facial pour protéger le visage et
les yeux.
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.
Les étincelles risquent de causer un incendie − éloigner toute substance inflammable.
LES CHARGES ÉLECTROSTATIQUES peuvent endommager les
circuits imprimés.
Établir la connexion avec la barrette de terre
avant de manipuler des cartes ou des pièces.
Utiliser des pochettes et des boîtes antistatiques pour stocker, déplacer ou expédier des
cartes de circuits imprimes.
SUR-
Prévoir une période de refroidissement ; respecter le cycle opératoire nominal.
Réduire le courant ou le facteur de marche
avant de poursuivre le soudage.
Ne pas obstruer les passages d’air du poste.
DES ORGANES MOBILES peuvent
provoquer des blessures.
Ne pas s’approcher des organes mobiles.
Ne pas s’approcher des points de coincement
tels que des rouleaux de commande.
OM-216 869 Page 7
LES FILS DE SOUDAGE peuvent
provoquer des blessures.
LE RAYONNEMENT HAUTE FRÉQUENCE (H.F.) risque de provoquer
des interférences.
Ne pas appuyer sur la gâchette avant d’en
avoir reçu l’instruction.
Ne pas diriger le pistolet vers soi, d’autres personnes ou toute pièce mécanique en engageant le fil de soudage.
DES ORGANES MOBILES peuvent
provoquer des blessures.
S’abstenir de toucher des organes mobiles tels
que des ventilateurs.
Maintenir fermés et verrouillés les portes, panneaux, recouvrements et dispositifs de protection.
Seules des personnes qualifiées sont autorisées à enlever les
portes, panneaux, recouvrements ou dispositifs de protection
pour l’entretien.
Remettre les portes, panneaux, recouvrements ou dispositifs de
protection quand l’entretien est terminé et avant de rebrancher
l’alimentation électrique.
LIRE LES INSTRUCTIONS.
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.
Demander seulement à des personnes qualifiées familiarisées
avec des équipements électroniques de faire fonctionner l’installation.
L’utilisateur est tenu de faire corriger rapidement par un électricien
qualifié les interférences résultant de l’installation.
Si le FCC signale des interférences, arrêter immédiatement l’appareil.
LE SOUDAGE À L’ARC risque de
provoquer des interférences.
Lisez le manuel d’instructions avant l’utilisation
ou la maintenance de l’appareil.
N’utiliser que les pièces de rechange recommandées par le constructeur.
Effectuer régulièrement le contrôle et l’entretien de l’installation.
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.
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.
OM-216 869 Page 8
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).
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, 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, P.O. Box 9101, Quincy, MA 02269-9101 (téléphone :
617-770-3000, site Internet : www.nfpa.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).
Code for Safety in Welding and Cutting, CSA Standard W117.2, de
Canadian Standards Association, 5060 Mississauga, Ontario, Canada
L4W 5NS (téléphone : 800-463-6727 ou à Toronto 416-747-4044, 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,
11 West 43rd Street, New York, NY 10036-8002 (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).
2-6. Information EMF
Considérations sur le soudage et les effets de basse fréquence et des
champs magnétiques et électriques.
Le courant de soudage, pendant son passage dans les câbles de soudage, causera des champs électromagnétiques. Il y a eu et il y a encore
un certain souci à propos de tels champs. Cependant, après avoir examiné plus de 500 études qui ont été faites pendant une période de
recherche de 17 ans, un comité spécial ruban bleu du National
Research Council a conclu : « L’accumulation de preuves, suivant le
jugement du comité, n’a pas démontré que l’exposition aux champs
magnétiques et champs électriques à haute fréquence représente un
risque à la santé humaine ». Toutefois, des études sont toujours en
cours et les preuves continuent à être examinées. En attendant que les
conclusions finales de la recherche soient établies, il vous serait
souhaitable de réduire votre exposition aux champs électromagnétiques pendant le soudage ou le coupage.
Pour réduire les champs magnétiques sur le poste de travail, appliquer
les procédures suivantes :
1. Garder les câbles ensemble, les torsader, les scotcher, ou les
recouvrir d’une housse.
2. Disposer les câbles d’un côté et à distance de l’opérateur.
3. Ne pas courber pas et ne pas entourer pas les câbles autour de
votre corps.
4. Garder le poste de soudage et les câbles le plus loin possible de
vous.
5. Connecter la pince sur la pièce aussi près que possible de la
soudure.
En ce qui concerne les implants médicaux :
Les porteurs d’implants doivent d’abord consulter leur médecin avant
de s’approcher des opérations de soudage à l’arc, de soudage par
points, de gougeage, du coupage plasma ou de chauffage par induction. Si le médecin approuve, il est recommandé de suivre les
procédures précédentes.
OM-216 869 Page 9
OM-216 869 Page 10
A complete Parts List is available at www.MillerWelds.com
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.
1
1.1
2
2.1
3
3.1
3.2
1.2
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.
1.3
2.2
2.3
3.2
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.
4.1
5
3.3
6
OM-216 869 Page 11
A complete Parts List is available at www.MillerWelds.com
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
2
1
3
4
3
4
5
5
OM-216 869 Page 12
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.
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.
A complete Parts List is available at www.MillerWelds.com
1
2
3
4
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.
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
1
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.
2
3
100 h. std.
4
=
6
5
7
043 810 (HF)
043 809 (AL)
S-178 910
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.
4/96
OM-216 869 Page 13
A complete Parts List is available at www.MillerWelds.com
3-2.
Manufacturer’s Rating Labels For Dynasty 350 Models
For label location
see Section 4-4.
Manufacture’s Rating Label For
Dynasty 350 Non-CE Models
OM-216 869 Page 14
Manufacture’s Rating Label
For Dynasty 350 CE Models
A complete Parts List is available at www.MillerWelds.com
3-3.
Manufacturer’s Rating Labels For Maxstar 350 Models
For label location
see Section 4-4.
Manufacture’s Rating Label For
Maxstar 350 Non-CE Models
Manufacture’s Rating Label
For Maxstar 350 CE Models
OM-216 869 Page 15
A complete Parts List is available at www.MillerWelds.com
3-4.
Manufacturer’s Rating Labels For Dynasty 700 Models
For label location
see Section 4-4.
Manufacture’s Rating Label For
Dynasty 700 Non-CE Models
OM-216 869 Page 16
Manufacture’s Rating Label
Dynasty 700 Models
A complete Parts List is available at www.MillerWelds.com
3-5.
Manufacturer’s Rating Labels For Maxstar 700 Models
For label location
see Section 4-4.
Manufacture’s Rating Label For
Maxstar 700 Non-CE Models
Manufacture’s Rating Label
For Maxstar 700 CE Models
OM-216 869 Page 17
A complete Parts List is available at www.MillerWelds.com
3-6.
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 18
Process
f
AC Frequency
A complete Parts List is available at www.MillerWelds.com
SECTION 4 − INSTALLATION
4-1.
Specifications
A. Dynasty 350 Models
Input
Power
Three
Phase
Single
Phase
Rated Welding
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
5−350
Maximum
Open-CirOpen Cir
cuit Voltage DC
Amperes Input at Rated Load Output 50/60 Hz
208 V
230 V
380 V
400 V
460 V
575 V
KVA
KW
29
26
16
15
13
10
10.3
9.9
36
32
19
18
16
13
12.7
*(.06)
75∇
10−15♦
12.1
*(.06)
35
5−350
32
−−
−−
15
12
7.4
75∇
10−15♦
6.8
*(.06)
47
43
−−
−−
21
16
9.8
9.1
*(.06
*While idling
♦Low open-circuit voltage while in TIG Lift Arc, or while in Stick with low open-circuit voltage selected (see Section 6-7).
∇Normal open-circuit voltage (75 volts) is present while in Stick with normal open-circuit voltage selected (see Section 6-7).
Note: This unit is equipped with Auto-Line. 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
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
5−350
Maximum
Open-CirOpen Cir
cuit Voltage DC
Amperes Input at Rated Load Output 50/60 Hz
208 V
230 V
380 V
400 V
460 V
575 V
KVA
27
24
15
14
12
9
9.7
9.3
*(.06)
75∇
10−15♦
KW
33
30
18
17
15
12
12
11.5
*(.06)
32
5−350
29
−−
−−
14
11
6.4
10−15♦
6
*(.06)
75∇
43
39
−−
−−
19
14
8.6
8.2
*(.06)
*While idling
♦Low open-circuit voltage while in TIG Lift Arc, or while in Stick with low open-circuit voltage selected (see Section 6-7).
∇Normal open-circuit voltage (75 volts) is present while in Stick with normal open-circuit voltage selected (see Section 6-7).
Note: This unit is equipped with Auto-Line. 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 19
A complete Parts List is available at www.MillerWelds.com
C. Dynasty 700 Models
Rated Welding
Input
Power
Output
Amperage
Range
500 A @ 40 Volts,
100% Duty Cycle
Three
Phase
600 A @ 44 Volts, 60%
Duty Cycle
360 A @ 34 Volts,
100% Duty Cycle
Single
Phase
450 A @ 38 Volts, 60%
Duty Cycle
5−700
Maximum
Open-CirOpen Cir
cuit Voltage DC
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
26
*(.08)
75∇
10−15♦
KW
98
88
53
51
43
33
35
34
*(.08)
82
5−700
74
−−
−−
37
30
17
10−15♦
16
*(.08)
75∇
119
105
−−
−−
50
38
24
22
*(.08)
*While idling
♦Low open-circuit voltage while in TIG Lift Arc, or while in Stick with low open-circuit voltage selected (see Section 6-7).
∇Normal open-circuit voltage (75 volts) is present while in Stick with normal open-circuit voltage selected (see Section 6-7).
Note: This unit is equipped with Auto-Line. 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
Amperage
Range
Input
Power
Three
Phase
Single
Phase
Rated Welding Output
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
5−700
Maximum
OpenOpen
C
Circuit
Voltage
DC
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
23
*(.08)
75∇
10−15♦
KW
89
80
49
46
40
31
32
31
*(.08)
77
5−700
70
−−
−−
35
28
16
10−15♦
15
*(.08)
75∇
108
95
−−
−−
45
35
22
21
*(.08)
*While idling
♦Low open-circuit voltage while in TIG Lift Arc, or while in Stick with low open-circuit voltage selected (see Section 6-7).
∇Normal open-circuit voltage (75 volts) is present while in Stick with normal open-circuit voltage selected (see Section 6-7).
Note: This unit is equipped with Auto-Line. 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 20
A complete Parts List is available at www.MillerWelds.com
4-2.
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
OR
Reduce Duty Cycle
OM-216 869 Page 21
A complete Parts List is available at www.MillerWelds.com
4-3. Volt-Ampere Curves
Dynasty 350 AC
Dynasty 350 DC
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 22
A complete Parts List is available at www.MillerWelds.com
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 23
A complete Parts List is available at www.MillerWelds.com
4-4. 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
4
OR
2
Serial Number/Patent Label
Rating Label
Use rating label to determine input power
needs (see Section 3-2, 3-3, 3-4 or 3-5).
5
Line Disconnect Device
Locate unit near correct input power supply.
!
Location And Airflow
5
Special installation may be required
where gasoline or volatile liquids are
present − see NEC Article 511 or CEC
Section 20.
1
3
18 in (460 mm)
4
18 in (460 mm)
Ref. 117 264-C / 803 900-A / 223 259-A / 223 275-A
4-5. Tipping Warnings
!
OM-216 869 Page 24
Do not move or operate unit
where it could tip.
A complete Parts List is available at www.MillerWelds.com
4-6. 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
803 914-A
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
Weight
Weight
135.5 lb (61.5 kg)
198 lb (89.8 kg)
B. Welding Power Source With Cart And Cooler
Dimensions
A
A
B
C
350 Models
700 Models
45-1/8 in (1146 mm)
55-1/8 in (1400 mm)
B
23-1/8 in (587 mm)
C
41-3/4 in (1060 mm)
Weight For 350 Models
Weight For 700 Models
268.5 lb (121.8 Kg)
331 lb (150 Kg)
804 642-A
OM-216 869 Page 25
A complete Parts List is available at www.MillerWelds.com
4-7. 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 branch circuit sized for the rated output and duty cycle of the welding power source.
Three-Phase
Input Voltage
208
230
380
400
460
575
Input Amperes 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-Delay2
Normal
Operating3
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: 2005 National Electrical Code (NEC) (includes article 630)
If a circuit breaker is used in place of a fuse, use a circuit breaker with time-current curves comparable to the recommended fuse.
“Time-Delay” fuses are UL class “RK5” .
“Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amp), and UL class “H” (65 amp and
above).
Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table
310.16. 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 branch circuit sized for the rated output and duty cycle of the welding power source.
Single-Phase
Input Voltage
208
230
460
575
Input Amperes At Rated Output - 225 amps @ 29 volts
47
43
21
16
Time-Delay2
50
50
25
20
Normal Operating3
70
60
30
25
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
8
12
14
88
(27)
108
(33)
172
(52)
174
(53)
8
10
12
14
Reference: 2005 National Electrical Code (NEC) (includes article 630)
1 If a circuit breaker is used in place of a fuse, use a circuit breaker with time-current curves comparable to the recommended fuse.
2 “Time-Delay” fuses are UL class “RK5” .
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amp), and UL class “H” (65 amp 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
310.16. 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
A complete Parts List is available at www.MillerWelds.com
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 branch circuit sized for the rated output and duty cycle of the welding power source.
Three-Phase
Input Voltage
208
230
380
400
460
575
Input Amperes At Rated Output - 300 amps @ 32 volts
33
30
18
17
15
12
Time-Delay2
40
35
20
20
15
15
Normal Operating3
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: 2005 National Electrical Code (NEC) (includes article 630)
1 If a circuit breaker is used in place of a fuse, use a circuit breaker with time-current curves comparable to the recommended fuse.
2 “Time-Delay” fuses are UL class “RK5” .
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amp), and UL class “H” (65 amp 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
310.16. 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 branch circuit sized for the rated output and duty cycle of the welding power source.
Single-Phase
Input Voltage
208
230
460
575
Input Amperes At Rated Output - 225 amps @ 29 volts
43
39
19
14
Time-Delay2
50
45
20
15
Normal Operating3
60
60
30
20
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
8
10
14
14
99
(30)
79
(24)
124
(38)
194
(59)
10
10
14
14
Reference: 2005 National Electrical Code (NEC) (includes article 630)
1 If a circuit breaker is used in place of a fuse, use a circuit breaker with time-current curves comparable to the recommended fuse.
2 “Time-Delay” fuses are UL class “RK5” .
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amp), and UL class “H” (65 amp 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
310.16. 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
A complete Parts List is available at www.MillerWelds.com
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 branch circuit sized for the rated output and duty cycle of the welding power source.
Three-Phase
Input Voltage
208
230
380
400
460
575
Input Amperes At Rated Output - 600 amps @ 44 volts
98
88
53
51
44
33
Time-Delay2
110
100
60
60
50
40
Normal Operating3
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
Min Input Conductor Size In
AWG4
Max Recommended Input Conductor Length In Feet (Meters)
Min Grounding Conductor Size In AWG4
Reference: 2005 National Electrical Code (NEC) (includes article 630)
1 If a circuit breaker is used in place of a fuse, use a circuit breaker with time-current curves comparable to the recommended fuse.
2 “Time-Delay” fuses are UL class “RK5” .
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amp), and UL class “H” (65 amp 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
310.16. 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 branch circuit sized for the rated output and duty cycle of the welding power source.
Single-Phase
Input Voltage
208
230
460
575
Input Amperes At Rated Output - 450 amps @ 38 volts
119
105
50
38
125
125
60
50
175
150
80
60
Max Recommended Standard Fuse Rating In
Amperes1
Time-Delay2
Normal
Min Input Conductor Size In
Operating3
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: 2005 National Electrical Code (NEC) (includes article 630)
1 If a circuit breaker is used in place of a fuse, use a circuit breaker with time-current curves comparable to the recommended fuse.
2 “Time-Delay” fuses are UL class “RK5” .
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amp), and UL class “H” (65 amp 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
310.16. 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 28
A complete Parts List is available at www.MillerWelds.com
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 branch circuit sized for the rated output and duty cycle of the welding power source.
Three-Phase
Input Voltage
208
230
380
400
460
575
Input Amperes At Rated Output - 600 amps @ 44 volts
89
80
49
46
40
31
Time-Delay2
110
100
60
50
50
40
Normal Operating3
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
Min Input Conductor Size In
AWG4
Max Recommended Input Conductor Length In Feet (Meters)
Min Grounding Conductor Size In AWG4
Reference: 2005 National Electrical Code (NEC) (includes article 630)
1 If a circuit breaker is used in place of a fuse, use a circuit breaker with time-current curves comparable to the recommended fuse.
2 “Time-Delay” fuses are UL class “RK5” .
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amp), and UL class “H” (65 amp 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
310.16. 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 branch circuit sized for the rated output and duty cycle of the welding power source.
Single-Phase
Input Voltage
208
230
460
575
Input Amperes At Rated Output - 450 amps @ 38 volts
108
95
45
35
125
110
50
45
150
150
70
60
Max Recommended Standard Fuse Rating In
Amperes1
Time-Delay2
Normal
Min Input Conductor Size In
Operating3
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: 2005 National Electrical Code (NEC) (includes article 630)
1 If a circuit breaker is used in place of a fuse, use a circuit breaker with time-current curves comparable to the recommended fuse.
2 “Time-Delay” fuses are UL class “RK5” .
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amp), and UL class “H” (65 amp 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
310.16. 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 29
A complete Parts List is available at www.MillerWelds.com
4-8.
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 4-7 (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-A
OM-216 869 Page 30
A complete Parts List is available at www.MillerWelds.com
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 4-7 (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-A / 803 766-A
OM-216 869 Page 31
A complete Parts List is available at www.MillerWelds.com
4-9.
Connecting Input Power For 700 Models
A. Connecting Three-Phase Input Power
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.
6
4
2
See rating label on unit and check input voltage available at site (see Section 4-4).
1
1
Select size and length of conductors using
Section 4-7. Conductors must comply with
national, state, and local electrical codes. If
applicable, use lugs of proper amperage
capacity and correct hole size.
3
3
8
Input Power Conductors (Customer
Supplied Cord)
= GND/PE Earth Ground
Welding Power Source Input Power Connections
2
Strain Relief
10
Route conductors (cord) through strain relief
and tighten screws.
7
3
4
Machine Grounding Terminal
Green Or Green/Yellow Grounding
Conductor
Connect green or green/yellow grounding
conductor to welding power source grounding terminal first.
5
9
6
6
4
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.
Install cover.
Disconnect Device Input Power Connections
7
8
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), L2 (V) And
L3 (W) to disconnect device line terminals.
10 Over-Current Protection
Select type and size of over-current protection using Section 4-7 (fused disconnect
switch shown).
Tools Needed:
Close and secure door on line disconnect device. Remove lockout/tagout device, and
place switch in the On position.
803 927-A
OM-216 869 Page 32
A complete Parts List is available at www.MillerWelds.com
B. Connecting Single-Phase Input Power
6
!
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.
5
2
4
2
See rating label on unit and check input
voltage available at site (see Section 4-4).
1
1
1
Select size and length of conductors using
Section 4-7. Conductors must comply with
national, state, and local electrical codes.
If applicable, use lugs of proper amperage
capacity and correct hole size.
3
8
=GND/PE Earth Ground
Welding Power Source Input Power
Connections
2
10
6
4
Strain Relief
Route conductors (cord) through strain relief and tighten screws.
7
9
Input Power Conductors (Customer
Supplied Cord)
3
4
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
Welding Power Source Line
Terminals (Switch S1)
Input Conductors L1 (U) And L2 (V)
Connect input conductors L1 (U) And L2
(V) to welding power source line terminals.
Install cover.
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 4-7 (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-A
OM-216 869 Page 33
A complete Parts List is available at www.MillerWelds.com
4-10. Weld Output Terminals And Selecting Cable Sizes*
NOTICE − ARC WELDING can cause Electromagnetic Interference.
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.
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.
Electrode
100 ft (30 m) or Less
200 ft
(60 m)
250 ft
(70 m)
300 ft
(90 m)
350 ft
400 ft
(105 m) (120 m)
Welding
Amps***
10 − 60%
Duty
Cycle
60 − 100%
Duty
Cycle
100
4 (20)
4 (20)
4 (20)
3 (30)
2 (35)
1 (50)
1/0 (60)
1/0 (60)
150
3 (30)
3 (30)
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
3/0 (95)
200
3 (30)
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
4/0 (120)
250
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 2/0
(2x70)
300
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 3/0
(2x95)
350
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
400
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
2 ea. 4/0
(2x120)
500
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
3 ea. 3/0
(3x95)
3 ea. 3/0
(3x95)
600
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
3 ea. 3/0
(3x95)
3 ea. 4/0
(3x120)
3 ea. 4/0
(3x120)
700
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
3 ea. 3/0
(3x95)
3 ea. 4/0
(3x120)
3 ea. 4/0
(3x120)
4 ea. 4/0
(4x120)
800
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
3 ea. 4/0
(3x120)
3 ea. 4/0
(3x120)
4 ea. 4/0
(4x120)
4 ea. 4/0
(4x120)
900
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
3 ea. 3/0
(3x95)
W k
Work
* This
150 ft
(45 m)
10 − 100% Duty Cycle
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
S-0007-E−
***Select weld cable size for pulsing application at peak amperage value.
Proceed to Section 4-11 For Additional Installation Instructions. A Dynasty 700 is illustrated in Sections 4-11 through 7-4. Location of controls and
components is similar for all models covered in this manual.
OM-216 869 Page 34
A complete Parts List is available at www.MillerWelds.com
4-11.
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
D M
G
E F
REMOTE
OUTPUT
CONTROL
A/V
803 900-A / 218 716-A
*The remaining sockets are not used.
Note: 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 35
A complete Parts List is available at www.MillerWelds.com
4-12.
Automation Connection (For 28-Pin Receptacle If Present)
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
Pin Information For 28-Pin Receptacle RC28
1
Start/Stop - Closure to pin 8 starts the weld cycle. Opening closure stops weld cycle. During 2T operation, a momentary closure
(greater than 100 ms, but less than 3/4 seconds) starts and stops weld output.
2
Output enable - functional only in automation modes - Closure to pin 8 must be maintained at all times. If the closure between pins 2
and 8 is broken, an output disable occurs, Postflow begins to time out, and AUTO STOP will be displayed on the meters.
3
Gas - Closure to pin 8 turns on gas. This input will override Postflow, but if a Preflow time is entered, the Preflow cycle will time out
before arc initiation.
4
Valid arc, collector - Output is on when the contactor is on and there is less than 50 load volts (see Section 4-15).
5
Voltage feedback - +1 volt DC per 10 volts w/reference to pin 11.
6
Current feedback - +1 volt DC per 100 amperes w/reference to pin 11.
7
Not used
8
IGND isolation common
9
Valid arc, emitter - Output is on when the contactor is on and there is less than 50 load volts (see Section 4-15).
10
Memory Select 2 - See Section 4-13.
11
Remote control circuit common
12
Chassis common
13
Pulse lockout, collector - Output is on when in Initial Amperage, Initial Slope, Final Slope, Final Amperage, and Pulsed Background
time when the pulse frequency is less than 10 Hz (see Section 4-15).
14
Pulse lockout, emitter - Output is on when in Initial Amperage, Initial Slope, Final Slope, Final Amperage, and Pulse Background
time, when the pulse frequency is less than 10 Hz (see Section 4-15).
15
Memory select 0 - See Section 4-13.
16
Memory select 1 - See Section 4-13.
17
Command signal from remote control - 0 to +10 volts DC input.
18
+10 volts DC
19
HF disable - Disables high frequency when connected to pin 8.
20
Automation enable 1 - See Section 4-14.
21
Amperage EN common - See Section 4-14.
22
Amperage EN command - See Section 4-14.
23
Final slope, collector - Output is on when in Final Slope (see Section 4-15).
24
Final slope, emitter - Output is on when in Final Slope (see Section 4-15).
25
Automation enable 2 - See Section 4-14.
26
Amperage EP command (Dynasty models only) - See Section 4-14.
27
Amperage EP common (Dynasty models only) - See Section 4-14.
28
Polarity (Dynasty models only) - See Section 4-14.
OM-216 869 Page 36
A complete Parts List is available at www.MillerWelds.com
4-13. Remote Memory Select Inputs (For 28-Pin Receptacle If Present)
28-Pin Receptacle RC28
Socket Designations 0 = No Connection /
3
Function
15
16
10
Off
0
0
0
Memory 1
1
0
0
Memory 2
0
1
0
Memory 3
1
1
0
Memory 4
0
0
1
Memory 5
1
0
1
Memory 6
0
1
1
Memory 7
1
1
1
1
8
4
9
14
15
20
25
21
28
26
1 = Connected To Ground (Pin 8)
4-14. Automation Selections (For 28-Pin Receptacle If Present)
28-Pin Receptacle RC28
3
Socket Designation 0 = No Connection / 1 = Connected To Ground (Pin 8)
1
8
X= Do Not Care
4
9
14
Pin
15
20
Function
25
21
28
26
20
25
No automation functions selected
0
0
Automation 1
1
0
X
1
Enables pin 2 function, Sequencer and weld timers
Automation 2
Enables pin 2 functions
Connected to pin 8 (EP)
Pin 22 to pin 21 - 0 to +10 volts DC EN amplitude
Pin 26 to pin 27 - 0 to +10 volts DC EP amplitude
Open (EN)
Pin 28
Pin 28 to pin 8 - EP polarity (Frequency and Balance)
Pin 28 not connected to pin 8 - EN polarity (Frequency and
Balance)
OM-216 869 Page 37
A complete Parts List is available at www.MillerWelds.com
4-15. Typical Automation Application
CR1
Coil resistance plus R
should be chosen to
limit current to 75 mA
CR1
To User Equipment
+
R
−
Typical 28-Pin Output
User supplied power
up to 27 volts DC peak
Collector
Emitter
4-16.
115 Volts AC Duplex Receptacle, Supplementary Protector CB1, And Power
Switch
3
1
AC Duplex Receptacle
Receptacle RC2 supplies 115 V 10
A of single-phase power.
1
2
2
Supplementary Protector CB1
CB1 protects duplex receptacle
from overload. If circuit breaker
opens, the receptacle does not
work. Press button to reset
protector.
3
Power On/Off Switch
803 901-A
OM-216 869 Page 38
A complete Parts List is available at www.MillerWelds.com
4-17.
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
4-18.
TIG HF Impulse/ Lift-Arct 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 4-11).
5
Gas In Connection
Connect gas hose from gas supply
to gas in fitting (see Section 4-17).
2
3
Tools Needed:
11/16 in, (21 mm for CE units)
803 915-A
OM-216 869 Page 39
A complete Parts List is available at www.MillerWelds.com
4-19.
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-A
6
Tools Needed:
GTAW Or Where
HF* Is Used
Application
3-1/2
Gal
Low Conductivity Coolant
No. 300 355**;
Distilled Or Deionized Water
OK Above 32° F (0° C)
Coolant
*HF: High Frequency Current
**Coolant 300 355, 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 40
11/16 in, (21 mm for CE units)
A complete Parts List is available at www.MillerWelds.com
4-20.
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.
2
3
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 4-11).
1
803 916-B
4-21.
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
3
2
− Weld Output Terminal
Connect work lead to negative (−) weld
output terminal.
3
Remote 14 Receptacle
If desired, connect remote control to Remote 14 receptacle (see Section 4-11).
1
803 916-B
OM-216 869 Page 41
A complete Parts List is available at www.MillerWelds.com
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.
NOTE: Green on nameplate indicates a TIG
function, Gray indicates a normal Stick function.
1 Encoder Control
2 Ammeter And Parameter Display
See Section 5-4.
3 Voltmeter And Selected Parameter
Display
See Section 5-5.
4 Polarity Control (Dynasty Only)
OM-216 869 Page 42
See Section 5-6.
10 AC Waveshape (Dynasty Only)
5
See Section 5-13.
Process Controls
See Section 5-7.
11 Amperage And Spot Time Control
6
For Amperage Control see Section 5-3.
Output Controls
See Section 5-9.
For Spot Time Control see Section 6-6.
7
12 Memory
Pulser Controls
See Section 5-10.
See Section 5-14.
8
13 Memory Display
Sequencer Controls
See Section 5-11.
Displays active memory.
9
14 Power Switch
Gas/DIG Controls
See Section 5-12.
Use switch to turn unit On/Off.
A complete Parts List is available at www.MillerWelds.com
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).
Note: See Section 5-13 for AC functions.
5-4.
Ammeter And Parameter Display
1
1
Ammeter
Ammeter displays actual amperage while welding. It also displays
adjustable parameters for all functions
OM-216 869 Page 43
A complete Parts List is available at www.MillerWelds.com
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 (Dynastyt 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
OM-216 869 Page 44
A complete Parts List is available at www.MillerWelds.com
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 4-18.
TIG Lift-Arc - 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 4-18.
1
Stick (SMAW) - This method can
be used with either AC or DC Stick
welding. Make connections according to Section 4-20.
5-8. Lift-Arc™ And HF TIG Start Procedures
Lift-Arc Start
When Lift-Arc 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 10-2) 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 45
A complete Parts List is available at www.MillerWelds.com
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 6-3A).
NOTE: 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.
OM-216 869 Page 46
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
6-3B).
NOTE: This switch function can be reconfigured for 3T, 4T, 4T Momentary, or Mini
Logic control See Sections 6-3C, 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
6-3G).
2
On LED
Blue On LED is lit whenever Output is on.
A complete Parts List is available at www.MillerWelds.com
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.
NOTE: Function is enabled, when LED is lit.
OM-216 869 Page 47
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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 48
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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 49
A complete Parts List is available at www.MillerWelds.com
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 50
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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 51
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5-15.
Factory Parameter Defaults And Range And Resolution For 350 Models
Parameter
Default
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 6-3)
(DYNASTY ONLY)
Range And Resolution
A MAIN / PEAK
(DYNASTY ONLY)
AC TIG
150 A
5 − 350 Amps
(DYNASTY ONLY)
AC STICK
110 A
5 − 350 Amps
DC TIG
150 A
5 − 350 Amps
DC STICK
110 A
5 − 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
5 − 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
5 − 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
5 - 350 Amps
EP Amps
150A
5 - 350 Amps
30 − 99 Percent
AC WAVESHAPE
BALANCE
75%
FREQUENCY
120 Hz
20 − 400 Hertz
EN/EP
Independent
Same/Independent
*TIG Start parameters for each program (1-9)
MAXSTAR:
Amperage
30 A
5 − 200 Amps
Time
3m
1 − 200 Milliseconds
Polarity
EN
EP / EN
Amperage
30 A
5 − 200 Amps
Time
3m
1 − 200 Milliseconds
DYNASTY:
DC:
AC:
Polarity
EP
EP / EN
Amperage
40 A
5 − 200 Amps
Time
40 m
1 − 200 Milliseconds
* Parameter adjusted using an Advanced Function configuration only (See Section 6).
** Parameter used with the automation option only.
OM-216 869 Page 52
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5-16.
Factory Parameter Defaults And Range And Resolution For 700 Models
Parameter
Default
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 6-3)
(DYNASTY ONLY)
Range And Resolution
A MAIN / PEAK
(DYNASTY ONLY)
AC TIG
500 A
5 − 700 Amps
(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
PEAK t
40%
5 − 95 Percent
BKGND A
25%
5 − 95 Percent
INITIAL A
20 A
5 − 700 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
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
30 − 99 Percent
(DYNASTY ONLY) AC WAVESHAPE
BALANCE
75%
FREQUENCY
120 Hz
20 − 400 Hertz
*EN/EP
Independent
Same/Independent
*TIG Start parameters for each program (1-9)
MAXSTAR:
Amperage
30 A
5 − 200 Amps
Time
3m
1 − 200 Milliseconds
Polarity
EN
EP / EN
Amperage
30 A
5 − 200 Amps
Time
3m
1 − 200 Milliseconds
DYNASTY:
DC:
AC:
Polarity
EP
EP / EN
Amperage
40 A
5 − 200 Amps
Time
40 m
1 − 200 Milliseconds
* Parameter adjusted using an Advanced Function configuration only (See Section 6).
** Parameter used with the automation option only
OM-216 869 Page 53
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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 6-8). 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 54
Rear Panel
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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 55
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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:
• Programmable TIG Start Parameters
(see Section 6-2) − Allows you to set
amps, time, and polarity to customize arc
starts for different tungstens.
OM-216 869 Page 56
• Output Remote Hold And Trigger Functions (see Section 6-3) − For reconfiguring RMT 2T Hold for 3T, 4T Momentary,
or Mini Logic
• AC Waveshape Selection with Dynasty
models only (see Section 6-4) − 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 6-5) −
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.
• Spot Enable (see Section 6-6) − Allows
you to turn the spot function on and be
available for all programs.
• Stick OCV Selection (see Section 6-7) −
Allows you to select either low or normal
ocv (open circuit voltage).
• Lockout Functions (see Section 6-8) −
Allows you to turn the lockout function on
and off and adjust the lockout levels.
• Meter Displays (see Section 6-9) − Allows you set meters to display actual
welding parameters, or for the meters to
be blank while pulse welding.
To exit advanced functions, press and hold
the Amperage (A) switch pad and then
press the Gas/Dig switch pad.
A complete Parts List is available at www.MillerWelds.com
6-2.
Programmable TIG Start Parameters
Each memory and polarity selection has their own programmable parameters.
A.
Changing Programmable TIG Start Amperage
3
2
STRT
20A
1
1 Amperage Switch Pad
2 Encoder Control
3 Amps Meter
To adjust TIG Start Amperage, press Am-
perage switch pad. Switch pad LED turns
on. If necessary, press Amperage switch
pad to scroll through the programmable
TIG start parameters until the current Start
Amperage is displayed on the amps meter.
The TIG start amperage can be adjusted
(see Section 5-15) by turning the Encoder
control.
B. Changing Programmable Start Time
3
TIME
2
10m
1
1
2
3
C.
Amperage Switch Pad
Encoder Control
Amps Meter
To adjust Programmable Start Time, press
Amperage switch pad. The current Start
Time is displayed on the amps meter, and
can be adjusted by turning the Encoder
control (see Section 5-15).
Changing Programmable TIG Start Polarity (Dynasty Models Only)
3
2
POL
En
1
1
2
3
Amperage Switch Pad
Encoder Control
Amps Meter
To adjust TIG Start Polarity, press Amperage switch pad. Switch pad LED turns on.
The current Start Polarity, [POL][En] or
[POL][EP] is displayed on meters, and can
be changed (see Section 5-15) by turning
the Encoder control.
OM-216 869 Page 57
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6-3.
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.
NOTE: 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
P/R = Push trigger and release. NOTE: If torch trigger is held more than 3 seconds, operation reverts to RMT STD (Remote Standard) mode.
OM-216 869 Page 58
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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 59
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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
NOTE: 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.
NOTE: 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 60
A complete Parts List is available at www.MillerWelds.com
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.
NOTE: When a remote switch is connected to the welding
power source, use the remote switch to control the weld
cycle. Amperage is controlled by the welding power source.
Application:
Use 4T Momentary trigger method when the functions of a
remote current control are desired, but only a remote on/off
control is available.
Current (A)
Main Amps
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
NOTE: For first torch trigger push & release, if trigger is held more than 3 seconds, trigger cycle ends
OM-216 869 Page 61
A complete Parts List is available at www.MillerWelds.com
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 62
Lift Tungsten
A complete Parts List is available at www.MillerWelds.com
6-4.
1
AC Waveshape Selection (Dynasty Models Only)
1
2
AC Soft
= Advanced Squarewave
= Sine wave
1 Memory Switch Pad
Each memory location can select any of
four wave shapes.
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].
Note: 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 6-5) as a reminder.
Application: Use advance squarewave
= Soft Squarewave
= Triangular wave
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 63
A complete Parts List is available at www.MillerWelds.com
6-5.
Independent Amplitude Selection
1
2
2
ENEP
6-6.
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.
6-7. 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 64
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.
A complete Parts List is available at www.MillerWelds.com
6-8.
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 6-8.
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.
NOTE: Before activating lockout levels, be sure that all procedures
and parameters are established. Parameter adjustment is limited
while lockout levels are active.
There are four lockout levels available. Turn Encoder control to select a lockout level (see Sections 6-8B for lockout level descriptions).
To turn On the lockout feature, proceed as follows:
1
2
Encoder Control
Amperage (A) Switch Pad
Once the desired three digits have been entered and a lockout level
selected, exit advanced functions mode (see Section 6-1).
To turn Off the lockout feature, proceed as follows:
Press Amperage (A) switch pad to toggle between the lock and code
displays. Toggle switch pad until code is displayed.
Use Encoder control to enter the same code number that was used
to turn on the lockout feature.
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.
OM-216 869 Page 65
A complete Parts List is available at www.MillerWelds.com
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
NOTE: Before activating lock out levels, be
sure that all procedures and parameters are
established. Parameter adjustment is limited while lock out levels are active.
Level 1
NOTE: Remote amperage control is not
available in level 1.
TIG Output Selection
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.
When parameter change or selection is limited by lock level 1, [LOCK][LEV1] is dis-
OM-216 869 Page 66
played as a reminder.
Level 2
NOTE: Remote amperage control is not
available in level 2.
Includes all the functions of level 1 plus
Memory, Polarity and Process Selection
(see Sections 5-6 and 5-7).
When parameter change or selection is limited by lock level 2, [LOCK][LEV2] is displayed as a reminder.
Level 3
NOTE: 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 4-11.
When parameter change or selection is limited by lock level 4, [LOCK][LEV4] is displayed as a reminder.
A complete Parts List is available at www.MillerWelds.com
6-9. Setting Unit So Meters Are Blank While Pulse Welding
2
METR
1 Encoder Control
2 Ammeter Parameters Select Display
Turn Encoder to change between voltage/
amperage [V/A] and [OFF] meter display.
1
V/A
When the [OFF] meter display feature is
active while pulse welding, [Puls][Weld] is
displayed, and the meter hold feature is
disabled.
The [OFF] meter display feature will not effect the normal amperage display or meter
hold capabilities when in a non-pulse welding mode.
OM-216 869 Page 67
A complete Parts List is available at www.MillerWelds.com
SECTION 7 − MAINTENANCE AND TROUBLESHOOTING
7-1. Routine Maintenance
!
Disconnect power before maintaining.
A. Welding Power Source
= Check
= Change
= Clean
* To be done by Factory Authorized Service Agent
Δ = Repair
= Replace
Every
3
Months
Labels
Weld Terminals
Gas Hoses
Every
3
Months
Δ
Cables And Cords
Every
6
Months
0.010
(0.254 mm)
:Durning heavy service, clean monthly.
*
Adjust or clean spark gap
B. Cooler
= Check
= Change
= Clean
* To be done by Factory Authorized Service Agent
Every
3
Months
Δ = Repair
= Replace
Blow out heat exchanger fins.
Check coolant level. Top off with
distilled or deionized water if necessary.
Coolant
Strainer,,
d i heavy
durning
h
service,
i
clean more frequently.
Every
6
Months
Hoses
Every
12
Months
Replace coolant.
OM-216 869 Page 68
Labels
Oil motor
A complete Parts List is available at www.MillerWelds.com
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-A
7-3. Coolant Maintenance And Oiling Motor
!
Disconnect input power before maintaining.
1
Coolant Filter
Unscrew housing to clean filter.
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 4-19).
1
2
2
Motor
Remove plugs and put about 15
drops of SAE 20 motor oil into each
oil port. Replace plugs.
If replacing hoses, use hoses
compatible with ethylene glycol, such as Buna-n, Neoprene, or Hypalon. NOTE:
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 69
A complete Parts List is available at www.MillerWelds.com
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 4-2). 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
4-2). 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 4-2).
Operation will continue when the unit has
cooled.
OM-216 869 Page 70
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 6-8).
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.
A complete Parts List is available at www.MillerWelds.com
B. Troubleshooting Table
Trouble
No weld output; unit completely
inoperative.
Remedy
Place line disconnect switch in On position (see Section 4-8).
Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 4-8).
Check for proper input power connections (see Section 4-8).
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 4-11).
Input voltage outside acceptable range of variation (see Section 4-7).
Check, repair, or replace remote control.
Unit overheated and [Over][Temp] is displayed. Allow unit to cool with fan On (see Section 4-2).
Erratic or improper weld output.
Use proper size and type of weld cable (see Section 4-10).
Clean and tighten all weld and gas connections.
No 115 volts ac output at duplex receptacle.
Reset circuit breaker CB1 (see Section 4-16).
Fan not operating. Note: 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 10-1).
Use properly prepared tungsten (see Section 10-2).
Reduce gas flow rate.
Tungsten electrode oxidizing and not re- Shield weld zone from drafts.
maining bright after conclusion of weld.
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 71
SECTION 8 − ELECTRICAL DIAGRAM
Figure 8-1. Circuit Diagram For Dynasty 350 Models
OM-216 869 Page 72
215 133-D
OM-216 869 Page 73
Figure 8-2. Circuit Diagram For Maxstar 350 Models
OM-216 869 Page 74
224 526-D
OM-216 869 Page 75
Figure 8-3. Circuit Diagram For Dynasty 700 Models (Part 1 of 2)
OM-216 869 Page 76
213 338-E
OM-216 869 Page 77
Figure 8-4. Circuit Diagram For Dynasty 700 Models (Part 2 of 2)
OM-216 869 Page 78
213 338-E
OM-216 869 Page 79
Figure 8-5. Circuit Diagram For Maxstar 700 Models (Part 1 of 2)
OM-216 869 Page 80
215 121-E
OM-216 869 Page 81
Figure 8-6. Circuit Diagram For Maxstar 700 Models (Part 2 of 2)
OM-216 869 Page 82
215 121-E
OM-216 869 Page 83
228 525-A
Figure 8-7. Circuit Diagram For Cooler
OM-216 869 Page 84
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 12/96 − S-0693
9-2. Incorrect Installation
Weld Zone
11, 12
50 ft
(15 m)
10
14
9
8
7
3
2
13
1
4
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
5
6
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 85
9-3. Correct Installation
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
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, 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 86
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
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.
Ground water pipes every 50 ft (15 m).
10 Windows and Doorways
7
Cover all windows and doorways with
grounded copper screen of not more than
1/4 in (6.4 mm) mesh.
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.
11 Overhead Door Track
Ground the track.
SECTION 10 − SELECTING AND PREPARING A
TUNGSTEN FOR DC OR AC WELDING WITH INVERTER
MACHINES
gtaw_Inverter_2007−05
Whenever possible and practical, use DC weld output instead of AC weld output.
10-1. Selecting Tungsten Electrode (Wear Clean gloves To Prevent Contamination Of Tungsten )
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 (Orange Band), 1.5% Lanthanum (Gray Band), Or 2% Thorium (Red Band) Alloy Tungstens
.010” (1 mm)
Up to 25
Up to 20
.020” (1 mm)
15-40
15-35
.040” (1 mm)
25-85
20-80
1/16” (1.6 mm)
50-160
50-150
3/32” (2.4 mm)
135-235
130-250
1/8” (3.2 mm)
250-400
225-360
5/32” (4.0 mm)
400-500
300-450
3/16” (4.8 mm)
500-750
400-500
1/4” (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.
10-2. 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
1
2-1/2 Times
Electrode Diameter
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.
3
Wrong Tungsten Preparation
4
Ideal Tungsten Preparation − Stable Arc
Flat
Diameter of this flat determines amperage
capacity.
4
Straight Ground
Grind lengthwise, not radial.
OM-216 869 Page 87
SECTION 11 − GUIDELINES FOR TIG WELDING (GTAW)
11-1. 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 10.
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 88
11-2. 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
11-3. 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 89
SECTION 12 − SETUP GUIDES FOR (GTAW) TIG WELDING
12-1. 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 216 896 Page 90
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-216 869 Page 91
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 92
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.
1
Workpiece
Make sure workpiece is clean before welding.
5
4
2
3
2
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).
3
6
1
7
4
5
6
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.
7
Slag
Use a chipping hammer and wire
brush to remove slag. Remove slag
and check weld bead before making another weld pass.
Tools Needed:
stick 2007−04 − ST-151 593
OM-216 869 Page 93
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
LOW
SMOOTH, EASY,
FAST
LOW HYDROGEN,
STRONG
7024
EP,EN
NI-CL
EP
FLAT
HORIZ
FILLET
ALL
308L
EP
ALL
USAGE
PENETRATION
EP
6011
AC
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*
450
400
350
300
AMPERAGE
RANGE
250
200
150
POSITION
6013
6010
ELECTRODE
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 − Scratch Start Technique
1
1
2
3
Electrode
Workpiece
Arc
Drag electrode across workpiece
like striking a match; lift electrode
slightly after touching work. If arc
goes out electrode was lifted to
high. If electrode sticks to workpiece, use a quick twist to free it.
2
3
S-0049
14-4. Striking an Arc − Tapping Technique
1
1
2
3
2
Electrode
Workpiece
Arc
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
S-0050
OM-216 869 Page 94
14-5. Positioning Electrode Holder
10°-30°
90°
90°
End View of Work Angle
Side View of Electrode Angle
GROOVE WELDS
10°-30°
45°
45°
End View of Work Angle
Side View of Electrode Angle
FILLET WELDS
S-0060
14-6. Poor Weld Bead Characteristics
1
2
3
4
5
Large Spatter Deposits
Rough, Uneven Bead
Slight Crater During Welding
Bad Overlap
Poor Penetration
1
2
4
3
5
S-0053-A
14-7. 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.
4
5
1
2
3
4
No Overlap
Good Penetration into Base
Metal
5
S-0052-B
OM-216 869 Page 95
14-8. 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
Drag
ELECTRODE ANGLE
Spatter
Normal
Too Short
Too Long
ARC LENGTH
Normal
Slow
Fast
TRAVEL SPEED
S-0061
14-9. Electrode Movement During Welding
Normally, 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.
1
2
1
2
3
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.
3
S-0054-A
OM-216 869 Page 96
14-10. Butt Joints
1
1
2
Tack Welds
Prevent edges of joint from drawing
together ahead of electrode by tack
welding the materials in position before final weld.
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°
4
3
Create 30 degree angle of bevel on
materials in V-groove welding.
4
Double V-Groove Weld
Good for materials thicker than 3/16
in (5 mm).
S-0662
14-11. Lap Joint
30°
Or Less
30°
Or Less
1
1
Single-Layer Fillet Weld
Electrode
Single-Layer Fillet Weld
Move electrode in circular motion.
3
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
1
2
Multi-Layer Fillet Weld
S-0063 / S-0064
14-12. Tee Joint
1
2
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.
1
2
45°
Or Less
Electrode
Fillet Weld
For maximum strength weld both
sides of upright section.
2
3
Multi-Layer Deposits
Weld a second layer when a heavier fillet is needed. Use any of the
weaving patterns shown in Section
14-9. Remove slag before making
another weld pass.
1
3
S-0060 / S-0058-A / S-0061
OM-216 869 Page 97
14-13. Weld Test
1
2
3
3
Strike weld joint in direction shown.
A good weld bends over but does
not break.
3
2 To 3 in
(51-76 mm)
1/4 in
(6.4 mm)
Vise
Weld Joint
Hammer
2 To 3 in
(51-76 mm)
2
2
1
1
S-0057-B
14-14. Troubleshooting − Porosity
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.
14-15. Troubleshooting − Excessive Spatter
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.
OM-216 869 Page 98
14-16. Troubleshooting − Incomplete Fusion
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.
Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before
welding.
14-17. Troubleshooting − Lack Of Penetration
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.
14-18. Troubleshooting − Excessive Penetration
Excessive Penetration − weld metal melting through base metal and
hanging underneath weld.
Excessive Penetration
Possible Causes
Excessive heat input.
Good Penetration
Corrective Actions
Select lower amperage. Use smaller electrode.
Increase and/or maintain steady travel speed.
OM-216 869 Page 99
14-19. Troubleshooting − Burn-Through
Burn-Through − weld metal melting completely through base metal resulting
in holes where no metal remains.
Possible Causes
Excessive heat input.
Corrective Actions
Select lower amperage. Use smaller electrode.
Increase and/or maintain steady travel speed.
14-20. Troubleshooting − Waviness Of Bead
Waviness Of Bead − weld metal that is not parallel and does not cover
joint formed by base metal.
Possible Causes
Unsteady hand.
Corrective Actions
Use two hands. Practice technique.
14-21. Troubleshooting − Distortion
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
Excessive heat input.
Corrective Actions
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 100
SECTION 15 − PARTS LIST
A complete Parts List is available on-line at www.MillerWelds.com.
http://www.millerwelds.com/service/replacementparts.html
Choose Genuine Select to review spare parts requirements such
as filters, spark plugs, and fuses.
Choose Service Parts to download complete parts listing.
Notes
OM-216 869 Page 101
Notes
Effective January 1, 2007
(Equipment with a serial number preface of “LH” 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
* Induction Heating Coils and Blankets, Cables, and
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to
Non-Electronic Controls
its original retail purchaser that new Miller equipment sold after
* APT & SAF Model Plasma Cutting Torches
the effective date of this limited warranty is free of defects in
* Remote Controls
material and workmanship at the time it is shipped by Miller. THIS
WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
* Accessory (Kits)
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
* Replacement Parts (No labor)
WARRANTIES OF MERCHANTABILITY AND FITNESS.
* Spoolmate Spoolguns
Within the warranty periods listed below, Miller will repair or
* Canvas Covers
replace any warranted parts or components that fail due to such
defects in material or workmanship. Miller must be notified in
writing within 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.
5 Years Parts — 3 Years Labor
2.
3 Years — Parts and Labor
*
*
*
*
*
*
*
*
*
3.
Original main power rectifiers
Transformer/Rectifier Power Sources
Plasma Arc Cutting Power Sources
Process Controllers
Semi-Automatic and Automatic Wire Feeders
Inverter Power Sources (Unless Otherwise Stated)
Water Coolant Systems (Integrated)
Intellitig
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by the
engine manufacturer.)
1 Year — Parts and Labor Unless Specified
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
Motor Driven Guns (w/exception of Spoolmate
Spoolguns)
Positioners and Controllers
Automatic Motion Devices
RFCS Foot Controls
Induction Heating Power Sources, Coolers, and
Electronic
Controls/Recorders
Water Coolant Systems (Non-Integrated)
Flowgauge and Flowmeter Regulators (No Labor)
HF Units
Grids
Spot Welders
Load Banks
Arc Stud Power Sources & Arc Stud Guns
Racks
Running Gear/Trailers
Plasma Cutting Torches (except APT & SAF
Models)
Field Options
(NOTE: Field options are covered under True Blue®
for the remaining warranty period of the product they
are installed in, or for a minimum of one year —
whichever is greater.)
Bernard-Branded Mig Guns (No Labor)
Weldcraft-Branded TIG Torches (No Labor)
Subarc Wire Drive Assemblies
4.
6 Months — Batteries
5.
90 Days — Parts
*
MIG Guns/TIG Torches and Subarc (SAW) Guns
Miller’s True Blue® Limited Warranty shall not apply to:
1.
Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, slip rings, relays
or parts that fail due to normal wear. (Exception:
brushes, slip rings, and relays are covered on Bobcat,
Trailblazer, and Legend models.)
2.
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.
3.
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 2007−01
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.
Replacement Parts
Training (Schools, Videos, Books)
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
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.
PRINTED IN USA
© 2007 Miller Electric Mfg. Co. 2007−01
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
European Headquarters −
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
www.MillerWelds.com
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